1. ROTARY LEAD RECYCLING VESSELS
APRIL 2013

5. SCRAP LEAD ACID BATTERIES PROCESSING
COKE ADDITION REDUCES LEAD SULPHATE TO PbS
AVOIDING EXCESSIVE SO2 POLLUTION
ADDITION OF CAST IRON (TURNINGS AND BORINGS)
REDUCES LEAD SULPHIDE TO METALLIC LEAD AND
IRON SULPHIDE.
SODA ASH ADDITION ALSO TO DESULPHURIZE
AND TO FLUIDIZE SLAG/MATTE BY-PRODUCT
(REFRACTORY LINING SENSITIVE TO EXCESS SODA)

6. Lead Sulphate reduced to Lead Sulphide with Coke
PbSO4 + 2C > PbS + 2CO2
Iron Sulphide produced by reaction with Iron
PbS + Fe > Pb + FeS
Sodium Sulphide created by reduction of soda ash
C + 2PbS + 2 Na2CO3 > 2 Pb + 2 Na2S + 3CO2

7. SEPARATORS (40 – 60% SILICA)
LEAD RESOURCE
RECOVERY BREAK-DOWN
LEAD PASTE ( % SULFUR)
POSTS AND GRIDS
SEPARATORS (40 – 60% SILICA)

8. Desulfurisation of Lead Sulfate PbSO4 + Na2CO3 PbCO3 + Na2SO4
BATTERY PASTE CONTENTS
PASTE CAN CONTAIN:
50-60% PbSO4
30-35% PbO2
10-15% PbO
% Sb (Antimony)
Desulfurisation of Lead Sulfate
PbSO4 + Na2CO PbCO3 + Na2SO4

9. Precipitated silica: Morphology
SEPARATORS
Precipitated silica: Morphology
REACTION STAGE
DRYING STAGE
Strong bonding
Weak bonding
Very weak bonding nm nm
1-50 µm µm
Agglomerate
Primary
particle
Aggregate
Agglomerate
(in slurry)
PULVERIZING
Bonding energy got during drying stage can be adjusted.
According the shear rate of the application
there is no need to pulverize micropearls to get
targeted particles size in the polymer matrix.
15-20 µm
Agglomerate
(Powder)

10. PROCESSING AND VESSEL LINING DESIGN
ISSUES IMPACTING REFRACTORY WEAR RATE
1. OXYGEN ENRICHED FUEL BURNERS
2. SODIUM LEVELS IN THE FEED
3. SILICA CONTENT OF THE FEED
4. MORTAR COMPOSITION
5. IRON CONTENT OF BRICK LINING
6. OPTIMIZATION OF HEAT FLUX THRU LINING

15. Magnesia: Production Process Steps
MgCl2+Ca(OH)2 --> Mg(OH)2+CaCl2
Mg(OH)2-->MgO+H2O
(app °C)
MgO
(caustic)
MgCl2
(from sea water or brines)
agglomeration
MgO
calcined and briquetted
sintering
(1700 up to 2100 °C)
MgO
sintered briquette

16. Chrome Ore (main component: chromite)
Chromite/ Serpentine (intergrown)
Chromite
Turkey
Groups (composition):
ores rich in Cr2O3
Türkey; Pakistan
Cr2O3 55 %
Fe2O3 16,4 %
Al2O3 10,0 %
SiO2 2,4 %
Chromite crystals
ores rich in iron
South Africa
typisch
Cr2O3 44,6 %
Fe2O3 28,2 %
Al2O3 14,7 %
SiO2 0,6 %
South Africa
ores rich in Al2O3
Kuba
Cr2O3 32,2 %
Fe2O3 14,8 %
Al2O3 26,2 %
SiO2 5,63 %
Grain size:
lump – fine concentrate

17. Fused Magnesia-Chrome: Production Process
The raw material magnesia/chrome is fused in an electric arc furnace at high temperatures (> 2800°).
material feed
3 independent moveable electrodes
Electric arc
Water cooled steel shell
molten material
furnace car

18. Fused Magnesia-Chrome: Production Process
cooling of steel shell after fusion process
electric arc furnace
crushing, grading and classing
further cooling after taking off the shell

19. 10mm.
NARMAG 60DB

20. 10mm.
SUPER NARMAG 145

21. 10mm.
SUPER NARMAG FG

28. TYPICAL ANALYSIS OF SRF “SLAG”

29. JCI GARCIA SLAG ANALYSIS

31. SODA ASH,COKE AND IRON METALLICS REACT WITH LEAD SULPHATE/OXIDE TO
REDUCTION OF LEAD SULPHATE TO ELEMENTAL
LEAD AND SODIUM/IRON SULPHIDE EUTECTIC
SODA ASH,COKE AND IRON METALLICS
REACT WITH LEAD SULPHATE/OXIDE TO
PRODUCE SODIUM AND FERROUS SULPHIDE
C + PbO + PbSO4 > Pb + PbS + CO2
PbS + Fe > Pb + FeS
C + 2PbS + 2 Na2CO3 > 2 Pb + 2 Na2S + 3CO2

33. A.P. Green, Harbison-Walker, NARCO