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zincoxgame changers

game changers

From its recycling plant in South Korea, ZincOx has captured the attention of the metal processing industry by utilising a revolutionary form of technology to recover zinc from electric arc furnace dust

ZincOx ResOuRces

written by: Will Daynesresearch by: Jeff abbott

It is estimated that 12 million tonnes of zinc is consumed across the world on an annual basis. While zinc and other raw materials provide the essential building blocks required by rapidly expanding economies to

achieve growth, we do live in a world of finite resources. It is for that reason that recycling has become an increasingly important component in the supply of commodities.

Initially formed as a Dutch company by Andrew Woollett and Noel Masson in 1997, ZincOx’s business today is the recycling of electric arc furnace dust (EAFD), a hazardous waste generated by the recycling of steel scrap. Initially set up to bring to account unconventional zinc ore deposits, ZincOx soon identified the potential benefits and uses of EAFD and in the last seven years has shifted its focus away from mining to recycling.

As a result of a decade of research and development, the company has adopted a game changing form of technology that has shown itself to be the best way of processing EAFD and recovering zinc. Throughout the world, steel scrap is recycled in electric arc furnaces using a simple remelting process. To protect steel objects from corrosion they are increasingly being galvanised by being coated in a thin layer of zinc metal. When scrap steel is recycled, the zinc from this galvanising process is driven off as a dust and caught up in the flue gasses. These fine particles are then filtered out and the resulting dusty material is collected.

For each tonne of steel produced by recycling, between 12 and 20 kilogrammes of EAFD is also created. This dust typically contains in the region of 18 to 24 percent zinc, a figure that is up to five times greater than that gained from DBQ & Dryer

ZincOx ResOuRces

the average zinc deposit. In addition to this zinc, EAFD also contains between 22 and 30 percent of iron and up to three percent of lead.

Historically, the recovery of zinc from EAFD has not been possible without a subsidy being provided by the steel industry. Indeed, because the cost of landfill in many developing countries is much less than the subsidy required, EAFD continues to find itself being landfilled. It is estimated that as much as seven million tonnes of EAFD is generated annually, of which only half is recycled.

ZincOx’s management recognised that a technology that would be able to recover all of the zinc and iron present

ZincOx ResOuRces

in EAFD would not only be energy efficient, and generate no waste, but would also enjoy higher margins that existing recyclers. This meant that it could be developed without having to rely on subsidies from the operators of electric arc furnaces. As such, the process represents a technically, economically and environmentally superior solution to the problem of EAFD.

Today, ZincOx’s technology is being demonstrated in South Korea, where its first recycling plant has recently been development and where the company holds ten year EAFD supply agreements that cover approximately 400,000 tonnes per annum. The plant itself is being designed in two

90,000

Tonnes of zinc in concentrate that the recycling plant will produce per annum

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A Leading EPCM Services Provider In the Nonferrous Metals Industry Armed with over fifty years of industry experience under Korea Zinc Group, and the foremost latest technologies for the nonferrous metals industry, Xmetech Corporation is a reputed international leader that can be trusted to bring out your company’s utmost potential, with custom tailored solutions in: • Engineering • Procurement • Construction Management • Project Control • Training & Commissioning Services

Excellence in EPCM capabilities for ZincOx EAF Dust Recycling Project.

www.xmetech.com

Address: 3F, Starwood Plaza, 5439-1, Sangdaewon 2-dong, Joongwon-Gu, Seongnam, Gyeonggi-Do, Republic of Korea, 462-819 TEL: +82-31-737-0620~0624 | FAX: +82-31-737-0607 | e-mail : marketing@xmetech.com

ZincOx Korea Recycling EPCM Project Construction Phase

Procurement – Filter Press Dalian UNi Utility Nickel EPC Project

phases, the first of which is now complete. This phase cost $110 million to bring to fruition and was fully financed by a combination of equity and debt.

Phase two of the plant development will shortly commence with all of the major infrastructure already installed. Estimated to cost around $100 million, phase two will be financed by a combination of bank debt, off-take finance and equity to be provided either by ZincOx or by the introduction of a partner into the project.

As the second largest scrap importer in the world, South Korea is the perfect location for ZincOx to launch its technology on a large scale. At present, the country generates about 380,000 tonnes of EAFD a year, with this figure expected to rise to 400,000 tonnes in short order. It was in June 2008 that the company entered into a Memorandum of Understanding with KOSA, the association representing the Korean steel sector, by which KOSA would assist ZincOx in obtaining EAFD supply commitments from various steel companies and in locating a suitable plant site. ghs area

ZincOx ResOuRces

“As the secOnd lARgest scRAp impORteR in the wORld, sOuth KOReA is the peRfect

lOcAtiOn fOR ZincOx tO lAunch its technOlOgy On A lARge scAle”

Xmetech corporation Xmetech corporation was presented with a unique ePcm challenge by ZincOx, for the Korea recycling Project. Through the expertise and knowledge of its specialist staff, Xmetech was not only able to successfully complete the first phase of construction of the electric arc Furnace Dust treatment facility in gyeongju, but also had firmly demonstrated effective operation utilizing a new technology, with great economic and environmental success. Preparations for the second phase are underway, and it is hoped that, with the introduction of a second rhF to the plant, the facility will bring even further fortune and recognition for all involved parties.enjepark@xmetech.com

ghs area

In April 2009, this resulted in the company entering into exclusive EAFD supply agreements with all of Korea’s most significant operators, including Hyundai Steel, Dongkuk Steel, Daehan Steel, YK Steel, Dongbu Steel, Hwanyoung Steel, Korean Iron and Steel Company, SeAH Besteel and Posco Speciality Steel.

At full capacity, ZincOx’s plant will be able to generate a concentrate containing 90,000 tonnes of zinc in concentrate a year, a figure equivalent to that recorded at the fifth largest zinc mine in China. At full capacity, the plant will also be able to produce approximately 180,000 tonnes of iron product per annum.

ZincOx’s work is now being increasingly recognised by leading figures throughout the industry, with its South Korean recycling plant project shortlisted for the2012 Financial Times and International Finance Corporation Sustainable Investment of the Year Award.

Having made a considerable impact with its work in Korea, the company intends to roll out its technology in other parts of the world in the coming years, with considerable progress having been made thus far in Thailand, Turkey and the United States. This work is all part of ZincOx’s long term objective of operating a network of recycling plants covering each of the world’s major steel recycling regions, all in pursuit of becoming the largest, most sustainable recycler of EAFD, and therefore zinc, in the world.

ZincOx ResOuRces

For more information aboutZincOx resources visit:www.zincox.com

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