Date: Thu, 20 Nov 1997 22:38:08 GMT Server: Stronghold/1.3.4 Ben-SSL/1.3 Apache/1.1.3 Content-type: text/html Content-length: 7177 Last-modified: Wed, 12 Nov 1997 15:47:16 GMT Company Profile

"The Largest Zinc Mine in the World"

In 1979, Honda imported the first automobile into the U.S. with a galvanized body. By 1987 nearly all of the cars produced in the world used galvanized metal to extend the life of the vehicle. At the same time the use of galvanized metal increased in other areas; appliances and structural as an example. As the amount of galvanized scrap increased the amount of black (non zinc containing) scrap decreased.

Through obsolescence, recycling, and the creation of prompt scrap from automobile stamping and other manufacturing operations, there is now a rapidly increasing amount of galvanized scrap. The zinc coating on this galvanized scrap causes pollution problems as well as decreased efficiency when melted to produce new iron or steel. Two solutions exist to this problem; either, use only black scrap, or, use mixed scraps containing some quantity of galvanized which requires the installation of costly equipment to minimize zinc pollution. As the cost of waste treatment and disposal continues to rise a cost effective method for changing galvanized to black scrap will become increasingly more important to the iron and steel industries.

This problem was foreseen by the American Iron and Steel Institute during the late 1980’s. The AISI in conjunction with the U.S. Department of Energy (DOE) established funding for a research project to investigate methods for the removal of zinc from galvanized scrap. The recipient of this funding was Argonne National Laboratories (ANL) and Metal Recovery Industries, Inc. Following some initial research at ANL; MRI, starting in 1991, undertook the dezincing of some 3,000 tonnes of scrap in the form of bales, clips, and shred. The process developed produces a high quality black scrap and high quality metallic zinc powder while generating no hazardous wastes.

From 1991 through 1995 work was done to further refine the process and its economic viability. A patent was applied for and is pending.

In 1995, MRI was purchased by Metal Recovery Technologies, Inc. (MRTI) which invested in a pilot plant to verify laboratory and early trial results. In 1996 construction was begun on the pilot plant in East Chicago, IN. In early 1997, with construction complete, this plant dezinced another 1,500 tonnes of galvanized steel scrap and produced approximately 5 tons of zinc powder. From the experience and information gained from this trial run, MRTI has gained the ability to expand the pilot plant to a 100,000 tpa production facility and to properly design other follow on facilities.

The environmental and economic costs associated with the enormous increases in galvanized scrap have generated a much greater degree of awareness and interest in the MRI(US) dezincing technology.

In February of 1997 MRTI received from General Motors Corporation an invitation to propose a 250,000 tpa facility for the dezincing of scrap produced by GM stamping plants in the Midwest. In April MRTI contracted with SSOE Engineering, the sixth largest Architectural and Engineering firm in the U.S., for the design of such a plant and an audit of the operating cost numbers formulated by MRTI. This work was completed in August, 1997. SSOE’s work confirmed to within less than 5% the accuracy of the MRTI cost projections.

The work initiated in 1991 was funded by a $1.1 million grant from the DOE. Today a contract exists with ANL for a grant of an additional $5.5 million. This money is to be spent over a three year period on various projects; including. the engineering and construction of a commercial plant of at least 200,000 tpa capacity, and research into improvements of the technology and its products.

Funded by MRTI the University of California, Berkeley is developing more efficient methods for the recapture of zinc from the MRTI process. This work, begun in 1996, is scheduled for completion in 1999 and will help to decrease the operating cost of the MRTI process. This new method may also have application in the recovery of zinc from natural ores.

Estimates provided by U.S. Government sources place 1996 production of galvanized steel sheet at 15.1 million tonnes. Estimates by automobile manufacturers place the amount of scrap at 30% of purchased. It is estimated that the dezincing of the approximate 5 million tonnes of scrap would yield savings of:

The same Government estimates place world wide production of galvanized sheet at 72 million tonnes. Already MRI(US) is in serious discussion with steel companies in Australia and Brazil and has fielded letters of inquiry from Europe and Asia.

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