World of Metallurgy ERZMETALL 68 2015 No 3150 Paul B Queneau et al Recycling Lead and Zinc in the United States 2 Secondary lead In 2015 total North American lead production capacity is estimated to be 2 090 000 short tons st Primary lead production capacity in North America is projected to be 290 000 tons a decrease of 100 000 tons since 1997 Second ary sources are projected to total 1 800 000 st i e about 86 of lead production capacity Primary metal is that originating from ore a portion of a primary producer s out put is considered to be secondary production if old or new secondaries are included as feedstock Current operating rates are approximately 1 550 000 st or an 86 run rate 2 While 50 of lead production in 1980 came from second ary sources in 2015 this has increased to 86 In 2015 95 of the recycled lead will derive from spent lead acid batteries and drosses as compared to 70 in 1980 The secondary lead total also includes material derived from copper based cable solder scrap leaded glass contaminat ed soil manufacturing scrap residue ash and dust While many primary lead smelters have installed battery pro cessing facilities that dovetail with existing production operations in order to provide regional recycling services this represents only a small portion of their feed materials 2 1 Secondary lead production Table 1 lists the locations smelting technologies and nomi nal capacities of North American lead plants All are smelt ers However many now combine physical concentration and hydrometallurgical processing methods with pyrome tallurgy for optimum economic and environmental perfor mance During 2014 these plants collectively operated at 86 of capacity The 2014 representative costs were as follows unbroken batteries were purchased for about US 0 395 lb FOB the seller in 2014 The shipping of batteries to the smelter and the lead product to the customer added about 0 03 lb to the cost Soft lead lead free of alloying elements pro duced by these smelters sold for about 0 95 lb 3 not including a premium whereas hard lead containing 3 Sb and 0 05 Sn commanded a premium based on the value of the contained antimony above 2 5 Sb Credit was applied for the polypropylene by product or more commonly a return yield for polypropylene was specified Typical cash conversion costs for efficient U S secondary lead smelters were 0 20 lb Pb excluding lead purchase costs amortized production costs were at least 0 02 lb Pb higher American secondary lead smelters typically toll processed 40 to 70 of their feedstock with fees ranging from about 0 30 to 0 35 lb Pb 4 Tolling spent lead ac id batteries was therefore profitable for most operations The same was not true for lead produced from batteries purchased on the open market 2 2 Secondary lead processes The recyclability of the lead acid battery and the cra dle to cradle approach by that industry has rendered bat teries as the dominant consumer of lead in North America The past two decades have seen a remarkable improve ment in the utilization of the diverse components con Table 1 2015 North American smelting ca pacities short tons Country Company Location Furnace Type Primary Secondary Subtotal Canada Cominco Trail BC Kivcet 90 000 Xstrata Belledune NB Blast 80 000 Mexico Penoles Torreon Blast 120 000 290 000 USA BRC Arecibo PR Rotary idled 5 14 18 000 Doe Run Boss MO Reverb Blast 140 000 East Penn Lyons PA Reverb Blast 100 000 Exide Forrest City MO Blast 35 000 Muncie IN Reverb Blast 90 000 Vernon CA Reverb Blast idled 4 14 95 000 JCI Florence SC Rotary 120 000 Gopher Eagan MN Reverb Blast 130 000 Tampa FL Reverb Blast 110 000 RSR City of Industry CA Reverb Elec 120 000 Indianapolis IN Reverb Elec 120 000 Middletown NY Reverb Blast 120 000 Sanders Troy AB Blast 100 000 1 298 000 Canada Nova Pb Montreal QC Long Rotary 80 000 Tonnolli Toronto Ontario Rotary 45 000 125 000 Mexico JCI Cienega de Flores NL Rotary 125 000 Garcia NL Rotary 135 000 M3 Roynosa Rotary 30 000 Omega Planta Dr Gonzoles NL Rotary 25 000 Pipsa Garcia NL Rotary 25 000 Riasa St Caterina NL Rotary 35 000 375 000 Total 290 000 1 798 000 2 088 000

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