1

Integrated Battery Recycling atBERZELIUS Metall GmbH

Dr.-Ing. Reinhard PüllenbergManaging Director BERZELIUS Metall GmbH

2

PRIMARY SMELTER

Treatment of concentrates

QSL-Technology

Production:

140,000 t lead;

320,000 kg silver;

100,000 t sulphuric acid

BERZELIUS Metall GmbH - Smelters

SECONDARY SMELTER

Battery- and Polypropylene-Recycling

Production: 41,500 t lead; 33,000 t polypropylene

SECONDARY SMELTER Battery-Recycling

Incinerator Plant

Production:55,000 t lead, Waste Incinerator:18,200 t of hazardous waste

Berlin

München

Hamburg

ROLAND Batterieservice GmbH

Gelsenkirchen

BERZELIUS Logistik Service GmbH – BatteryCollectors

POPP Batterieservice GmbH

Kornwestheim

ERV Voggenthaler GmbH

Regensburg und Freiberg

Berlin

Hamburg

München

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Berzelius Metall

Input: • Lead Concentrates• Leach Residues

from Zinc Industry• Battery Paste

SECONDARY SMELTER PRIMARY SMELTER

Output:

• Battery Scrap• Scrap Lead• Production

Rejects

• Lead• Polypropylene• Battery Paste• Tin Alloys

• Lead• Silver• Sulphuric Acid• Cu Matte

Integrated Lead Recycling

Rotary FurnacesPaste

MRU Paste and GridsBreaker

BSB

Paste

Waste

BBH Stolberg

Polypropylene

QSL Reactor

Sulphuric Acid PlantSilver Plant

Rotary Furnaces

Primary Smelter

Secondary Smelters

BSB Braubach

Desulfurised Paste

Waste Incinerator

MRU Freiberg

Polypropylene Recycling

Desulfurisation MRU

Lead Acid

Battery

Scraps

Automotive Industry

Battery

Seculene®

Electricity

Slag

NA2 SO4

Lead

Sulphuric Acid

Silver

Copper matte

4

OverviewSecondary Smelters

Here it starts…Raw materials are scrap lead-acid battery and other lead-containing materials

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Battery Scrap Deliveries

Schematic Production Flow Sheet

BREAKER PLANT FURNACE PLANT REFINERY PLANTPaste

GridsBullion

Batteries

Otherraw

materials

Bullion

Paste

PP-chips

plasticw

aste

Slag

Bullion

Leadalloys

Acid

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Breaker BSB Plant

Batteries

(100 %)

STORAGE BREAKER SIEVING DRUM SEPARATION

Acid (10,5%)

WASHING

Paste (55%)Grids, Poles(26%)

PlasticWaste (3,5%)

Polypropylene-chips (5 %)

Breaker MRU plant

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Insight into Breaker BSB Plant

Modern Process Control Systems

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Wet Desulfurisation

Wet Desulfurisation

PbSO4 + 2NaOH=>PbO + Na2SO4 + H2O

H2SO4 + 2NaOH=> Na2SO4 + H2O

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Reduction

SHORT ROTARY FURNACE Bullion (70%)

Slag (30%)

Grids(30%)

Paste (10%)

OtherMaterials

(46%)

Fluxes(14%)

Reduction step: main reactions

PbO + C = Pb + CO

PbO + CO = Pb + CO2

PbO + Fe = Pb + FeO

PbS + Fe = Pb + FeS

Formation of lead-copper-matte (Cu2S; PbS; FeS)

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BSB Furnaces

Raw Lead (Bullion)

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Refinery

Dedrossing / decoppering

Alloying / CastingSofteningDetinning

Dedossed bullion

Lead alloys

Bullion

Refining steps

First step / First dedrossing:

Segregation with falling temperature (550°C down to 360°C) of NiS, CuS, PbS, PbO

Second step / Decopperizing (360°C):

Cu + S = CuS

Pb + S = PbS

PbS + 2 Cu = Pb + Cu2S

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Refining steps

Third step / Detinning (550°C):

2 Pb + O2= 2 PbO

Sn + PbO = SnO

2 SnO + O2 = 2 SnO2

Final detinning with NH4Cl

Sn + 2 NH4Cl = SnCl2 + 2 NH3+ H2

Fourth step / Removal of antimony (600 - 650°C):

Pb + O2 = 2 PbO

4 Sb + 5 O2 = 2 Sb2O5

Fifth step: Final de-oxidation with petcoke and alloying

Sixth step: Casting

Refining steps

13

Refinery

Casting

14

Casting Machine

Lead Alloys

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BSB Recycling GmbH

Secondary Lead Smelter with PP-Recycling

BSB Recycling GmbH

ANNUAL PRODUCTION (approx.):

20,500 tonnes lead (bars, slabs for rolling)17,000 tonnes lead bullion44,000 tonnes of paste1,000 tonnes tin alloys

40,000 tonnes Seculene® PP

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BSB Recycling GmbH

Bullion

Paste Grids

PP- Chips

PP productSECULENE

Batteries

PasteGypsum

SlagAdditives

Soft lead, hard leadLead alloys etc.

Refinery

Short Rotary Furnace

Breaker

Milling Plant

CompoundingAdditives

QSLBBH

Lead Scraps

Residues

Development of PP-Recycling

Automotive-industry

Extruder Shredder

Injectionmoulding

Sortation ofbumpers

Grinding-plant

Bumpers etc.

Bumpers out ofPP/EPDM

ChipsGrinded material

Seculene® PP

Fender linercable channels,filterbodies...

PP fromexternal partners

PP Chips fromSecondary Smelters

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Flow Sheet PP-Recovery

BREAKER PLANT MILLING PLANT EXTRUDER PLANTPP-Chips

PP interm. chips

PP/EPDM interm. ch

Batteries

PP-Chips

Master batch

Paste

Grids

Plasticw

aste

SeculenePP

Acid

Seculene® PP35.000 t/a

PP/EPDM

-Chips

OtherM

aterial

PP/EPDM

interm. ch.

PP interm. chips

Fillers

Stabilizers

Milling PlantPolypropylene-Chips(100 %

)

Wet cuttingmill

Washingtrays

CentrifugeDrying Cyclone Washed and milled

PP-Granulate97,6%98,1%99,3%

Metallics (0,7%)

Plastic, Wood (1,2%)

Wood, Rubber (0,5%)

MillingDust

(0,1%)

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Input material for production of compounds

raw granulated

Seculene-Production

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Compounding Process

Seculene® PP

Washed and milledPP-Granulate and additives

Double screwextruder Molten mass filter

Granulator

Drying

Seculene Production

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Raw material for the CompoundingPP granules

Seculene® PP-Applications

93 % Car Producers (7 % others)In the automotive industry, more than 80 % of the material is used for wheel-housecasing.

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Historical Development of Seculene® PP

1987 – 1990: Technology development F & E Frankfurt / Braubach1990: Initial startup of the production plant2000: Start of the second Extruder2006: Placing into operation the third Extruder

3.3004.600

6.5006.700

9.500

14.000

18.500

21.00022.600

25.900

29.700

35.750

0

5.000

10.000

15.000

20.000

25.000

30.000

35.000

40.000

1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007

[ to / a ]

Muldenhütten Recycling und Umwelttechnik GmbH (MRU)

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Muldenhütten Recycling und Umwelttechnik

ANNUAL PRODUCTION (approx.):55,000 tonnes lead/lead alloys5,000 tonnes sodium sulphate3,000 tonnes PP-chipsplus paste

Exploitation of 20,000 tonnes hazardouswastes in the incinerator plant

Secondary lead smelter with integratedincinerator for hazardous wastes

Muldenhütten Recycling und Umwelttechnik

Bullion

Paste Grids

PP chips

Paste

Sodium Sulfate

Slag

Soft leadLead Alloys etc.

Refinery

Short Rotary Furnace

Breaker +Desulfurisation

MillingBSB

QSLBBH

Plastic residues Incinerator Steam

Batteries

ResiduesAdditives

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Used Lead-acid batteries

Breaking

Separation

De-sulfurization

Crystallization

Lead and Lead-alloys

Smelting

Refining

Alloying

Casting

Bundling

Hazardous wastes

Incineration

Waste-watertreatment

Waste-water

Polypropylen

Na2SO4

Metallics

PasteLead-scrap

Oxides, Ashes

Sewage

Bullion

Fluedust

Steam

NaSO4

Products: Lead and Lead-alloys

By-products: Polypropylen,Sodiumsulfat

Wastes: Soda-slag / Incinerator-slag

Separators

Drosses

Fluedust

Silika-slag

SludgeSoda-slag

Flowsheet MRU

Natural gas / liquid wastes Waste to Rotary

Kiln

Measurementfor exhaust

gas emission

Steam/Condensate

Wastewater

Dust

Slag

Filter Chimney

Fluid-bed-reactor

Adsorbens

Air

Scrubber

NaOH

Feedwater

Electric filter

Steam

Waste-heat boiler

NBK

Bunker with crane

Rotary Kiln

Hopper

Tanks for liquid wastes

Gas

Turbine

X

Incinerator Plant

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Primary Smelter

BERZELIUS STOLBERG GmbH

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BERZELIUS STOLBERG Smelter Area

BERZELIUS STOLBERG GmbH

ANNUAL PRODUCTION (approx.):

150,000 tonnes lead/lead alloys

100,000 tonnes sulphuric acid

60,000 tonnes BERZELIT

6,000 tonnes copper/lead matte

300 tonnes silver

Primary Lead Smelter with QSL-Technology

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BERZELIUS STOLBERG GmbH - QSL ProcessConcentrates+ Secondaries

e.g. PasteLead sulfate

Oxygen

QSL - Reactor

Lead Bullion

Refinery

Lead +Alloys

Slag

Fluxese.g. Sand

IronCalcium Sulfate

Coal Dust

Silver Copper matte

Off gas Sulfuric Acid

SteamElectric Energy

Raw Material Storage Hall

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Raw Material Storage - inside

Raw Material Storage Hall - inside

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QSL Building

QSL Building

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Charging System to the QSL Reactor

QSL Reactor with Cooling Elements

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QSL Reactor with Cooling Elements

Sulfuric Acid plant

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Air Pollution ControlSO2 – Emission QSL Plant (Development 1985 – 2007)

6.113

4.164

533359 215

0

1.000

2.000

3.000

4.000

5.000

6.000

7.000

1985 1990 1995 2001 2007

t / a

Source: Berzelius Metall GmbH

Air Pollution ControlLead - Immission and Production (1990 – 2006)

0,38

0,40

0,56

0,53

0,45

0,60

0,53

0,35

0,59

0,43

0,37

0,52

0,32

0,450,

51

0,98

2,01

2,44

1,81

2,01

1,711,

80

1,49

1,32

1,16

0,93

0,61

0,90

0,52

0,45

0,41

0,39

0

0,5

1

1,5

2

2,5

1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004* 2005 2006 2007*

Imm

issi

on: µ

g / m

3

Thro

ughp

ut: 1

00.0

00 t

/ a* n

o Im

mis

sion

Dat

a av

aila

ble

Immission ThroughputSource: Berzelius Metall GmbH

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BERZELIUS LOGISTIC SERVICE GmbH (BLS)

BERZELIUS Logistik Service GmbH

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Economic Operator - Collection and Treatment § 8 (RL2006/66/EG, Battery Directive)

ERV- Regensburg +Freiberg/ CollectorERV- Regensburg +Freiberg/ Collector

RBS- Gelsenkirchen/Collector/ TreatmentRBS- Gelsenkirchen/Collector/ Treatment

PBS- Kornwestheim/CollectorPBS- Kornwestheim/Collector

• 45 employees• 25 trucks• Waste management facilities• Quality management system EN DIN ISO 9001ff, etc.• Environmental System EMAS and EN DIN ISO 14001ff

BERZELIUS Logistik Service GmbHNationwide collection- and treatment system for automotive,

industrial- and portable batteries; founded in 2007

Core Competence of BLS

Collection, transport, storage, treatment of car- and industrial batteries:

Lead batteries, Ni-Cd batteries, Alkali-batteries and electrolytes collected separated

• Container Management

• Dismantling of industrial batteries

• Consulting work in all logistic related questions

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A Closed Product Cycle

PRODUCT CYCLE

PRODUCTION WASTES

DISPOSAL

TREATMENTAND DISPOSAL

REFEEDING TO THEPRODUCT CYCLE

Consultations and Acquisition

Lead accumulator industry

Chemical industry

Electrical Industry

Tin processing industry

Automotive industry

used batteries,metallic wastes (lead, tin)

solids - pastes - dusts

Production of lead

lead alloysPP compounds

Proportional Share of Secondary Lead Production Western World (1970 – 2005)

2.376 2.3361.917 1.970 1.905

1.344

1.3201.793 2.594 2.818 3.197

3.400

0

1.000

2.000

3.000

4.000

5.000

6.000

1970 1980 1990 1995 2000 2005

1.00

0 t/a Secondary Lead

Primary Lead

Source: CRU Lead Quarterly, Industry and Market Outlook – February 2008

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Lead Consumption/Production Western World and Secondary Production (1960 – 2007)

0

1.000

2.000

3.000

4.000

5.000

6.000

West. World 2509 3696 4129 4511 4478 4578 4524 4581 4788 4790 4972 4911 4946 5102 4944 4922 4770 4596 4744 4763 4831

Secondary 930 1320 1793 2594 2542 2547 2493 2603 2818 2882 2985 2993 3020 3197 3167 3261 3262 3332 3400 3465 3850

Usage West. World 2523 3576 4038 4535 4474 4507 4603 4897 5117 5212 5280 5264 5405 5610 5431 5323 5287 5410 5452 5454 5378

1960 1970 1980 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007

[1.0

00 to

ns]

Source: CRU Lead Quarterly, Industry and Market Outlook – February 2008

CRU Forecast for Increase of Lead Consumption (2005 – 2020)

0

2.000

4.000

6.000

8.000

10.000

12.000

14.000

other consumption 1702 1712 1798 1682 1626

Ind. Batteries 2220 2991 3393 4259 5067

SLI OEM 719 792 860 1033 1243

SLI-After Sales Market 2974 3217 3385 3810 4255

2005 2008 2010 2015 2020

[1.000 tons]

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Possible Developmentof Lead Production (2005 – 2020)

0

2000

4000

6000

8000

10000

12000

14000

secondary 4126 4870 5580 6540 7680

primary 3410 3740 3950 4180 4330

Word Total 7536 8610 9530 10720 12010

2005 2008 2010 2015 2020

[1.000 tons]

Source: CRU

Battery Quantities deliveredfor Recycling in 2007

19.725

249.786

190.000

128.000

0

50.000

100.000

150.000

200.000

250.000

300.000

Germany Italy Great Britain Austria

tons

/a

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Lead Acid Battery Recycling

SeparatorsPolypropyleneCasing

Grid MetalPaste

Sulphuric Acid

SulphuricAcid 96

SecondaryLead

PP-Compounds Seculene

Seco

ndar

yLea

d

Lead Acid Battery Recycling

SeparatorsPolypropyleneCasing

Grid MetalPaste

Sulphuric Acid

SulphuricAcid 96

SulphuricAcid 96

SecondaryLead

SecondaryLead

PP-CompoundsSeculene

PP-CompoundsSeculene

Seco

ndar

yLe

adSe

cond

ary

Lead

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BERZELIUS Metall GmbH-Group

Recycling network of 1 primary- and 2 secondary-lead smelters, 1 incinerator plant and 3 collecting companies

• Nationwide biggest collector of car - and Industrial batteries• Leader in treatment and recycling of lead acid Batteries• State-of-the-art technologies• 420 employees in Germany • 5 of 6 companies are waste management facilities• Quality management according to EN DIN ISO 9001ff, etc.• Environmental management EMAS and EN DIN ISO 14001ff. • Works safety certification OHSAS 18001.