zincox
game changers
www.zincox.com
game changers
ZincOx Resources 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
written by: Will Daynes research by: Jeff Abbott
I
t 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
ZincOx Resources
the average zinc deposit. In addition to this in EAFD would not only be energy efficient, and zinc, EAFD also contains between 22 and 30 generate no waste, but would also enjoy higher percent of iron and up to three percent of lead. margins that existing recyclers. This meant Historically, the recovery of zinc from EAFD that it could be developed without having to has not been possible without a subsidy being rely on subsidies from the operators of electric provided by the steel industry. Indeed, because arc furnaces. As such, the process represents a the cost of landfill in many developing countries technically, economically and environmentally is much less than the subsidy required, EAFD superior solution to the problem of EAFD. continues to find itself being Today, ZincOx’s technology landfilled. It is estimated that is being demonstrated in as much as seven million South Korea, where its first tonnes of EAFD is generated recycling plant has recently been development and where annually, of which only half is recycled. the company holds ten year Tonnes of zinc in ZincOx’s management EAFD supply agreements that concentrate that the recognised that a technology cover approximately 400,000 recycling plant will produce per annum that would be able to recover tonnes per annum. The plant all of the zinc and iron present itself is being designed in two
90,000
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
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Excellence in EPCM capabilities for ZincOx EAF Dust Recycling Project.
www.xmetech.com ZincOx Korea Recycling EPCM Project Construction Phase
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
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ZincOx Resources phases, the first of which is Xmetech Corporation now complete. This phase Xmetech Corporation was presented with a unique EPCM cost $110 million to bring challenge by ZincOx, for the Korea Recycling Project. Through to fruition and was fully the expertise and knowledge of its specialist staff, Xmetech financed by a combination of was not only able to successfully complete the first phase equity and debt. of construction of the Electric Arc Furnace Dust treatment Phase two of the plant facility in Gyeongju, but also had firmly demonstrated effective operation utilizing a new technology, with great economic and development will shortly environmental success. Preparations for the second phase commence with all of the are underway, and it is hoped that, with the introduction of major infrastructure already a second RHF to the plant, the facility will bring even further installed. Estimated to cost fortune and recognition for all involved parties. around $100 million, phase enjepark@xmetech.com two will be financed by a combination of bank debt, offtake 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 GHS area suitable plant site.
“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�
GHS Area
ZincOx Resources
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. For more information about ZincOx Resources visit: www.zincox.com
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