Selection of alternative for zinc waste recycling

A Case Study

Carlos Alberto Chaves – EEIMVR / Universidade Federal Fluminense - UFF

Robisom Damasceno Calado – Universidade Federal Fluminense - UFF
Wainer da Silveira e Silva – Universidade Federal Fluminense - UFF
Marco Antonio Teixeira – Nexa Resources
Tone Takayama Filho – Nexa Resources

October, 3rd 2019

Objective of the study:

Develop a systematic approach (metodology) for the

preparation of projects aimed at reducing the

generation, treatment and proper disposal of

industrial waste, considering the issue from a

holistic and sustainable point of view.

Limits of Grow *

In 1972 the Club of Rome issued a report that

warned that the planet’s natural Resources (water,

materials and energy) are finite and at the rate we

were consuming them would inevitably lead to their

depletion. * Club of Rome, Aurélio Peccei – 1972.

World population: 2019
7,7 billions

Figura 1- World population and material consumption

Source: Stephen Keller, Our finite Mineral Resources, McGraw-Hill, 1976
Figure 2 – World population and material consumption (oil, steel, coper and diamond).
Sources: KESLER, S. E., 2015; Steel Production – Word Steel Association, 2015.
Alert from Club of Rome in 1972
Top five problems facing humanity at the
beginning of third millenium:

 Accelerated Industrialization; This

work
 Rapid demographic growth; focus
 Food shortage;
 Depletion of non-renewable resources;
 Deterioration of the environment (pollution).
The problem:
Zinc residue generated in Electric Arc Furnaces
dedusting systems (Electric Arc Furnace Dust - EAFD)
A Hazardous Waste, Class I, ABNT NBR 10004 ~
Generation from Brazilian Steelworks ~100,000 ton/year
(Zn content ~ 19%)

Consequence:
Proper waste treatment and disposal results in high cost and
affects the economic and environmental sustainability of the
business.
The problem:
The price of zinc concentrate (ZnS) tripled between 2005
and 2008 (USD 477.00 to 1,414.00!), jeopardizing the
economic sustainability of zinc business.
Current zinc price (USD 2,620.50 LME, June 2019)

Necessity:
Economic alternatives of raw materials for zinc
production process.
.
Photo 1 - Eletric Arc Furnace (EAF) – origin of EAFD. Source: Danieli
 EAFD supply for Zinc Smelter
at Juiz de Fora, MG
Favourable logistic
(~85% of total availability)

Figure 3- Brazilian Steel Works geography - Source: IABr and PWC, 2013 .
 Study Methodology
• Particular case study (Industrial Recycling
Investment)) seeking conclusions of general
Case Study principles that could be applied in similar projects
and adopted as GOOD SUSTAINABLE PRACTICE.

• Technical visits to the Zinc Industrial Plant (VSA/JF);

Researcch
• Interview with managers and Project participants;
Instrument
• Bibliographic Research.

• Aplication of Analytic Hierarquic Process (AHP) for

selection of best solution for treatment of the
hazardous zinc waste;
Data Analysis and
Interpretation
• Evaluation of Project Implementation Methodology in
the light of IPA, PMBOK and UNIDO methodologies.
 Perdas de energia

Gases,pós

Perdas materiais

Refugos (sucata)
Resíduos (escórias, lamas, etc.)

Figura 1: o conceito de perdas no processo de produção

Figure 4 – Concept of Losses in Production Process

The Case Study:

Votorantim Metais (Currently Nexa Resources) is a Zinc Smelter

Company located in Juiz de Fora, Minas Gerais State, Brazil.
VSA Group, the Holding Company, is a Centenary Brazilian
Company, present in 23 countries and business in:
• Metals (Al, Ni, Zn); . Mining;
• Energy ; . Cellulose;
• Cement; . Finance.
Aluminium: 430,000 t/y; Nickel: 25,000 t/y;
Zinc: 600,000 t/y (JF: 100,000); Zinc Oxide: 200,000 t/y.
3 R`s Philosophy

Consist in search for residues solutions before its

production .

• Reduction of the amount of waste generated in the

production process;
• Reuse of waste one or more times;
• Recycling of waste in the same or another industry.
Philosophy of 3R’s and 2E’s:

Recently 2E’s have been added to the 3R`s, meaning:

- Economy – activities of reuse and Recycling bring

economic return;

- Environment - activities of waste reuse and recycling

concurr to environment preservation;
Thus, 2E’s are the motivation for those responsable
rcorporate management to promote the reuse and recycling
activities.
 2/3 do ciclo do projeto é consumido na geração,
uso e transferência de informação de uma fonte para outra.

Estudo Conceitual
Autorização
FEL 2 & FEL 3

Projeto Executivo

Construção&Montagem

Partida

Apenas 1/3 do ciclo do projeto é consumido

na Construção & Montagem.
Figure 5 – Project Life Cycle
Source: MILROD, IPA Web Seminar, 2015.
 Estratégia do projeto
e estudo do mercado

Programa de vendas Matérias primas e Localização /

insumos Meio Ambiente

Engenharia e Tecnologia

Organização do Recursos Humanos Implementação do

Empreendimento Empreendimento

Avaliação Econômica e
Financeira

Figure 6 – Feasibility Study Flowsheet

Source : UNIDO
The Case Study:

Votorantim Metais (Currently Nexa Resources) is a Zinc Smelter

Company located in Juiz de Fora, Minas Gerais State, Brazil.
VSA Group, the Holding, is a Centenary Brazilian Company,
present in 23 countries and business in:
• Metals (Al, Ni, Zn); . Mining;
• Energy ; . Cellulose;
• Cement; . Finance.
Aluminium: 430,000; Nickel: 25,000;
Zinc: 600,000 (JF: 100,000); Zinc Oxide: 200,000 ton/y.
Photo 2 – Nexa Resources – Zinc Smelter and Polimetalic Plant, Juiz de Fora, MG
Source: TAKAYAMA, T. et al, Lead and Zinc, 2015.
Zn conc.: 49%
100 kt/a

Figure 7- Nexa Resources Juiz de Fora – Zinc Production Process Production Flowsheet
Source: TAKAYAMA, T. et al, Zinc and Lead, 2015
 Table 1- EAFD Chemical composition , %
Supplier Zn Fe Pb SiO2 CaO Cl F

1 19,12 28,79 2,09 3,30 13,79 na 0,43

2 21,49 25,68 2,27 2,85 15,57 2,62 0,39

3 20,17 33,61 1,68 2,81 6,74 1,65 0,43

4 20,22 36,85 1,41 2,79 4,92 1,36 0,47

5 19,50 35,14 1,35 3,67 6,61 1,50 0,44

6 18,05 36,29 1,22 2,95 8,01 1,25 0,46

7 17,10 35,96 1,37 3,70 7,79 1,64 0,46

8 17,02 31,40 1,28 2,75 13,61 1,59 0,45

9 17,93 34,73 1,35 3,47 8,03 1,51 0,44

10 18,60 34,90 1,4 2,70 5,90 1,88 0,42

Average 18,92 33,34 1,54 3,10 9,10 1,67 0,44

na: not available. Source: TAKAYAMA, T. et al, Zinc and Lead, 2015
 Table 2 – EAFD Grain size distribuition

Particle size diameter

0-0.7 0.7 – 7.0 7.0 – 80.0 >80.0
(μm)

% fraction 45 30 15 10

75% Ɵ < 7 microns !

Source: ANDONYEV, S.; FILIPYEV, O. , 1977

 Table 3 – EAFD possible treatment alternatives
Pyrometalurgical Hydrometalurgical
Confinement
Process Process

Co-processing Ezinex Vitrification (GI)

Waels Furnace Zincex Inorganic Recycling

International
Ausmelt Reactor ZincOx
Melting&Manufacturing

Imperial Smelting
Richland Molded Brick
Furnace (ISF)

Rotary Hearth
Ceramic
Furnace (RHF)

Tecnored Furnace Concrete

Source: D’Abreu&Noldin Jr, 2007; Southwick, 2010; Takayama&Magalhães , 2015; Buzin, Vilela e Heck, 2017.
Figure 8 - Waelz Process Flowsheet for EAFD recycling
Source: Votorantim Metals, 2013
Figure 9 - Waelz Rotary Furnace for EAFD recycling
Source: Doronin e Svyazhin, 2011
Figure 10 - Ausmelt Reactor Schematic (Outotec)
Source: Glinin et al., 2013
Figure 11- Imperial Smelting Furnace Schematic
Source: Schwab et al., 2005
Figure 12- Rotary Hearth Furnace (RHF)
Source: Maxwell, PUC - Rio, 2009
Photo 3- Rotary Hearth Furnace (RHF) - FASTMET Plant, Usina Kakogawa, Kobe Steel
Source: Southwick, 2010
Figure 13 - Tecnored Furnace – Tecnologos-Vale
Source: Noldin Jr. & Sanches, 2008
Photo 4- Tecnored Furnace – Demonstration Plant
Pindamonhangaba, SP - Tecnologos-Vale
Source: Noldin Jr. & Sanches, 2008
 Início

Definição do
Problema

Estruturação da
Hierarquia

Construção da
Matriz AHP

Julgamentos

Estabelecimento
de Prioridades

Realizar etapas
3,4,5 todos níveis

Vetor Geral de
Prioridades

Avaliação da N
Consistência
S
Fim

Figure 14 - Analytic Hierarquic Process (AHP) - Steps

Source: Saaty, 2012
 Figure 15 - Analytic Hierarquic Process - AHP
Best urban choice for Brandwyne River, PA, EUA
Surce: SAATY, 2012
Table 4 – Saaty’s Fundamental Scale for paired judgments

Verbal scale Numeric scale

Equality of preference (importance) 1

Weak preference 3

Moderate preference 5

Strong preference 7

Absolute preference 9

Source: Saaty, 2012; Costa, H.G. 2002.

 Table 5 – Hierarquic Structure for zinc waste problem solution

OBJECTIVE CRITERIA SUB-CRITERIA ALTERNATIVES

Adequate treatment/ Environmentally -Attend to ABNT ISO A)

disposition of zinc Sustentainable NBR 10004 Standard Pirometalurgical

containing waste Solution Process

  Economic -Economic Return B)

Solution Hydrometalurgical

Process
  Technically -Low operacional cost C)

viable Solution Confinement/

Vitrification
    -Raw material for other  

process
    -Sinergy with other  

Business Units
    - Favourable Logistics  
Table 6 – Performance of alternatives in the light of environmental criteria

Environmental Process Processo Confinamento/

Solution Pirometalúrgico Hidrometalúrgico Vitrificação

Processo Piro 1 2 5

Processo Hidro 1/2 1 3

Confinamento 1/5 1/3 1

Tabela 7 - Desempenho das alternativas à luz do critério logística favorável

Logística Processo Processo Confinamento/

Favorável Pirometalúrgico Hidrometalúrgico Vitrificação

Processo Piro 1 1 5

Processo
1 1 3
Hidro

Confinamento 1/5 1/3 1

 Tabela 8- Quadro Normalizado para o critério Solução Ambiental

Solução Processo Processo Confinamento/

Ambiental Pirometalúrgico Hidrometalúrgico Vitrificação

Processo Piro 0,59 0,60 0,56

Processo Hidro 0,29 0,30 0,33

Confinamento 0,12 0,10 0,11

Tabela 9 - Quadro prioridades médias locais para o critério Solução Ambiental

Confinamento Prioridade
Solução Processo Processo
/ Média
Ambiental Pirometalúrgico Hidrometalúrgico
Vitrificação Local

Processo Piro 0,59 0,60 0,56 0,58

Processo
0,29 0,30 0,33 0,31
Hidro

Confinamento 0,12 0,10 0,11 0,11

Soma 1,00 1,00 1,00 1,00

 Tabela 10 - Quadro prioridades médias locais (PML’s) -Resumo

QUADRO DE JULGAMENTOS NORMALIZADOS PIRO HIDRO CONFI

PRIORIDADE MÉDIA LOCAL PARA AS

ALTERNATIVAS À LUZ DO CRITÉRIO SOLUÇÃO PMLsas 0,58 0,31 0,11
AMBIENTAL
PRIORIDADE MÉDIA LOCAL PARA AS
ALTERNATIVAS À LUZ DO CRITÉRIO SOLUÇÃO PMLses 0,54 0,30 0,16
ECONÔMICA
PRIORIDADE MÉDIA LOCAL PARA AS
ALTERNATIVAS À LUZ DO CRITÉRIO SOLUÇÃO PMLsmc 0,58 0,31 0,11
MENOR CUSTO OPERACIONAL
PRIORIDADE MÉDIA LOCAL PARA AS
ALTERNATIVAS À LUZ DO CRITÉRIO SOLUÇÃO PMLsmp 0,59 0,33 0,08
MATÉRIA PRIMA
PRIORIDADE MÉDIA LOCAL PARA AS
ALTERNATIVAS À LUZ DO CRITÉRIO SOLUÇÃO PMLsun 0,49 0,44 0,08
SINERGIA COM OUTRAS UN's
PRIORIDADE MÉDIA LOCAL PARA AS
ALTERNATIVAS À LUZ DO CRITÉRIO SOLUÇÃO PMLslg 0,48 0,41 0,11
LOGÍSTICA FAVORÁVEL
 Table 11 – Global Priorities (GP’s)
Global
Priority
SAS SEC SMC SMP SUN SLG
Vector
(GP)
(0,31 x 0,58) + (0,25 x 0,54) + (0,22 x 0,58) + (0,12 x 0,59) +
GPpyro = (0,06 x 0,49) + (0,04 x 0,48)
0,181 0,133 0,126 0,073 0,030 0,018 0,562
(0,31 x 0,31) + (0,25 x 0,30) + (0,22 x 0,31) + (0,12 x 0,33) +
GPhydro = (0,06 x 0,44) + (0,04 x 0,41)
0,096 0,075 0,068 0,040 0,026 0,016 0,322
(0,31 x 0,11) + (0,25 x 0,16) + (0,22 x 0,11) + (0,12 x 0,08) +
GPconfi = (0,06 x 0,08) + (0,04 x 0,11)
0,034 0,040 0,024 0,010 0,005 0,004 0,117
1,001
Figure 16- AHP applied to Nexa Resource’s Case Study
Source: current study
Photo 5- Polimetalics Plant (zinc waste recycling), Nexa Resources, Juiz de Fora, MG
Source: Takayama, Magalhães andTeixeira, 2015
Photo 6- Polimetalics Plant – Waelz Furnace, Nexa Resources, Juiz de Fora, MG
Source: Takayama, Magalhães e Teixeira, 2015
Figure 17- Polimetalics Plant Process Flowsheet
Source: Takayama, Magalhães e Teixeira, 2015
 Conclusion
The reduction of zinc ore reserves lead to a
dramatic increase in concentrate prices, putting in
risk VSA’s zinc business sustainability;

The company searched for alternative raw

materials supply for zinc production, essential for
brazilian industry.
 Conclusion
A new material has shown to be economically
viable to use at VSA’s zinc production Unit. This
was the zinc containing dust (EAFD) generated in
Electric Arc Furnaces which contain, on average,
19% of zinc;

Various technological alternatives exist to treat

EAFD hazardous waste. After a detailed study
(technical, economic and environmental) VSA
chose the Waels Furnace Technology to recover
the zinc contained in the waste.
 Conclusion
The technological alternative chosen by VSA
resulted in the implementation of the Polymetalic
Plant Project, in Juiz de Fora, MG (Investment of
R$ 521 Million and capacity of 200,000 t/year).

This Research work used the Project of the

industrial plant of VSA as a Case Study to analyse
the reasons and criteria that the company came to
this decision.
 Conclusion

The study provided the development of a

methodology fo the evaluation of investments in
industrial waste, using the Analytical Hierarquic
Process (AHP) combined with a technical and
Economic Feasibility Study based on gates of
approval (FEL).
 AHP

EVTE
FEL1&2

FEL
3&4

Figure 18 – Project Methodology for treatment/Recycling of Industrial Wastes

 Obrigado!
Thank you!

cachaves@id.uff.br