2. Eco-friendly Recycling ABU KHADER GROUP Battery Recycling System Presented by Eng. Mohammad Al Tarawneh Recycling Plant Manager

3. OUR BACKGROUND… Good ideas come from everywhere in the company. “ ”  Current Business Sectors :  Automotive spare parts,  Tyres,  Lubricants,  Vehicles,  Battery manufacturing,  Public transport,  Leasing and car rental,  Technology, education and real estate  Abu Khader group made its beginnings in the year 1937  The decentralized structure allows each company in the group to remain focused on its own strategy and enables it to stay close to its market segment and its customers.

4. LOCATION…  Abu Khader Group is among the leading business groups in Jordan and the region with operations in Palestine, Egypt, The United Arab Emirates and Lebanon  International Storage Battery Co. is located at Abdullah bin Al Hussein Industrial Estate (AIE)  AIE is an Industrial zone of 12 km south east of Amman, where ISBCO is manufacturing Lead Acid Batteries.  Industries include metals, packaging, pharmaceutical 7 machine industries employing more than 13,000 people JORDAN

5. International Storage Battery Company (ISBCO)..  International Storage Battery Company (ISBCO) has been established in the year 1994  Started operation in 1995 under license from Hoppecke GmbH, Germany We are specialized in the manufacturing, marketing and distribution of automotive batteries, in Jordan and the region “ ”

6. International Storage Battery Company (ISBCO)..  Ours is a professionally managed company with ISO-14001:2004 certification  ISBCO achieved a milestone in pursuit of quality by receiving the ISO-9001:2000 certification  Manufacturer of high quality batteries of DIN and JIS standards  ISBCO has adopted the backward integration manufacturing strategy - looking forward to establishing a Lead Battery Scrap Recycling Plant  Presently we are using 3000 MT / year of Pure Lead & Lead Alloys, which consists of 85-87% out of total Raw material cost to produce Batteries

7. WHY LEAD RECYCLING… Emissions during Recycling can be fully controlled by effective Pollution Control Equipments. “ ”  Lead Battery Scrap is a Hazardous waste and unsafe disposal creates heavy Environmental / Health problems.  Careful Recycling is essential, beneficial & cost effective in comparison to treatment & disposal cost.  The country do NOT have Eco-friendly recycling Plant to handle this hazardous waste generated locally.  Presently Battery Recycling operations in Jordan are being handled by un-organized Backyard Smelters.  Such illegal operations is serious threat TO OUR ENVIRONMENT.

8. BACKYARD SMELTERS & UNCONVENTIONAL SYSTEMS…  High Demand of Lead Metal Market - Leading to birth of Backyard Smelters.  Shortage of Supply - Way towards Small Unconventional / Backyard recycling Practices  Price Hikes in Metal Value - A Favorable condition for Business But Need of Eco – Friendly Recycling More then 85% of the total Lead Battery Scrap is required to be channelized properly for Eco - Environment “ ”

9. TRENDS OF LEAD METAL PRODUCTION…  Gap between the Production from Primary & Secondary Production has increased from 1990 to 2004  Secondary Production exceeds the Primary

10. LEAD METAL MARKET (GLOBAL)…

11. LEAD METAL MARKET…  The Trend of Primary & Secondary is exceptional in Oceania region because of Australia being a Mining Zone.

12. REFINED LEAD (PURE LEAD) METAL MARKET…

13.  Lead is a hazardous material used in many industries such as:- Paints. Additive for petrol. Lead Acid Batteries. Because of the high demand on lead bearing materials and pure lead for local industries, it is most essential to secure lead sources to be able to compete locally and internationally. In most of these industries lead can’t be retrieved, since it’s disseminated and causes pollution, how ever lead can be retrieved through lead acid batteries in substantial quantities for recycling. Due to the fact that lead can be collected from lead acid batteries, and then recycled nearly all lead can be retrieved, due to that fact most known manufacturers tend to have recycling plants for batteries, for dual purposes environmentally and economically. Lead acid batteries are a well established industry in Jordan, and for that industry to be able to compete in both arena’s locally and internationally building a recycling plant is a MUST if we want to enhance the economic and environmental factors. Overview

14. Introduction  Lead is the 4 th most widely used Metal on earth  Lead has highest rate of recycling among all Ferrous & Non-Ferrous Metals  Lead is the only metal on earth which retains its 100% Chemical & Physical properties, irrespective of any number of recycling  Worldwide production of recycled Lead is now about 3 times more than producing Prime Lead…

15. Component by weightPercent Metallic Lead35 Lead sulphates/oxides40 Plastic7 Acid15 Residuals3 TOTAL100 Grid plate Positive plate Micro porous separator Negative Plate Positive plate pack Positive cell connection Electrolyte-tight seaing ring Negative pole Negative cell connection Negative plate pack Valve adapter and valve Composition of Lead-Acid Battery Scrap

16. A Lead Scrap Material B Furnace Metal C Slag (Discard) D Finished Metal E Dross F Filter Dust 1.Rotary Furnace 2.After Chamber 3.Gas Cooler 4.Filter Plants 5.Blending/Refining Pots 6.Ingot Casting Machine 7.Exhaust Fans 8.Chimney 9.Scrap Loading Bay Flow Diagram of a Lead Recycling Plant

17. Plant Layout

19. ACID TREATMENT UNIT DRY DRAINED BATTERIES ACID TREATMENT TANK STAGE 1 – BATTERY TREATMENT SECTION CAUSTIC STORAGE TANK CHEMICAL A. Draining & Neutralization of Electrolyte  Several punches are made at the bottom of the scraped battery after removing the vent plugs to allow for maximum electrolyte draining and any lead suspended in the acid to be drained off in to a closed draining tank.  The acid is treated and neutralized in the tank with formation of Gypsum along with lead bearing powder \ compound which is finally fed in furnace as a charge.  The neutralization of acid makes water, who's PH is 7+ and further pumped as make up water for recirculation in the wet scrubber unit.  The generated fumes and effluent gases are captured and treated in the acid treatment unit. Main Stages of Lead Recycling Process

20. B.Breaking System & Separation of Components  Through an inclined conveyer (S.S) the batteries are transported.  Conveyor Band Saw Cutting machine is used.  The saw is designed with adjustable height in order to accommodate different types of batteries, after sawing the battery will be released and the lid will be removed manually, the lead plugs and anodes will be removed from the battery by applying a hammer. AS A RESULTE TWO TYPES OF MATERIALS ARE OBTAIND.  LEAD.  POLYPROPLENE. I. PP is crushed in to small chips then washed before being filled in to bags for further use either in remanufacturing of spacers used in batteries or to be dumped in to legal dumping site by coordinating with the MOE. DRY DRAINED BATTERIES SEPARATION OF LEAD BEARING MATERIAL & PP BOX EMPTY PP BOXES SENT TO PP CRUSHER CONTINUE IN NEXT SLIDE STAGE 1 – BATTERY TREATMENT SECTION Main Stages of Lead Recycling Process

21. PLASTIC CRUSHER PP Boxes are processed in colour batches PP Chips are produced Removed on regular intervals using Mini Excavator Machine Some Lead Bearing material; deposited at the base of Water tank Main Stages of Lead Recycling Process Polypropylene chips produced from polypropylene boxes STAGE 1 – BATTERY TREATMENT SECTION

22. STAGE 2 - SMELTING SECTION STAGE 2 - SMELTING SECTION  Mixing of Lead Bearing Materials with agents & charging into Furnace - Furnace charging Machine  Smelting Lead Bearing Materials - Rotary Furnace  Capturing of Effluent Gases - Pollution Control Equipments RAW MATERIAL POLLUTION CONTROL EQUIPMENTS JUMBO LEAD BLOCKS Main Stages of Lead Recycling Process

23.  Smelting  is the recovery and treatment of lead bearing material in used lead acid batteries.  The charge of furnace consist of lead bearing materials with agents.  Rotary furnace. our purchased RF is a well- designed and well equipped with modern accessories and pollution control systems. STAGE 2 - SMELTING SECTION STAGE 2 - SMELTING SECTION Main Stages of Lead Recycling Process

24. BlowerRotary FurnaceDust CollectorCyclone Cooling TowerBag HouseI D Blower Wet Scrubber STAGE 2 - SMELTING SECTION STAGE 2 - SMELTING SECTION Plant Layout for rotary furnace Main Stages of Lead Recycling Process

25. STAGE 3 – REFINING SECTION  Lead Refining Process - Refining Kettle  Our purchased kettle holds up to 20 MT of un pure lead.  The sequences at our refining unit means de-coppering, softening, de-zincing, de-tin and de-antimony. to allow for 99.97 purity of lead.  Lead Casting - Automatic Ingot Casting Machine  Capturing of Effluent Gases - Pollution Control Equipments HOT FLUE GASSES REFINED LEAD AUTOMATIC INGOT CASTING MACHINE REMELTED LEAD Main Stages of Lead Recycling Process

26.  Kettle: 10-20 Mt per charge capacity  F.O. / Gas Burner with Pre-heater  Steering System]  Hood with Pollution Control Equipment  Automatic Ingot Casting Machine (10 MT/hr) STAGE 3 – REFINING SECTION Main Stages of Lead Recycling Process

27. ElementsComposition in % Antimony (Sb)0.001% (max) Arsenic (As)0.001% (max) Tin (Sn)0.001% (max) Copper (Cu)0.001% (max) Bismuth (Bi)0.025% (max) Iron (Fe)0.001% (max) Nickel (Ni)0.001% (max) Silver (Ag)0.003% (max) Zinc (Zn)0.001% (max) Calcium (Ca)0.0005% (max) Sulphur (S)0.0005% (max) Aluminum (Al)0.0005% (max) Lead (Pb)99.970% (min) REFINED LEAD-(PURE LEAD)

28.  Pollution control plays an important part in the used Lead-Acid Battery Recycling.  Three types of waste and effluents are generated:-  Solids & Slugs.  Liquids.  Gases.  Treatment:-the following is provided to sustain a positive impact on the environment.  Dust collector.  Cyclone.  Cooling tower.  Spark arrestor.  Bag Filters.  Scrubber (wet ). Pollution Control

29.  All the processes and operations are aligned with environmental aims to ensure minimum level of emissions and waste material.  The plant is integrated with efficient pollution control modules, with the objective of widespread adoption of modern, eco-friendly designs and technologies  Slag accounts for (7-8)% of the input material fed in the rotary, whereas waste water is treated to guarantee that no liquid waste is produced.  Gases are treated as per the pollution norms with the help of pollution control equipments. Pollution Control

30.  The most critical part of ‘Lead Recycling Operation’ is Air Pollution Control  The plant is specifically designed to meet specific norms and environmental standards in terms of  Ambient Air Standard  Stack Emission Standard  Effluent Discharge Standard  Solid Waste Disposal Limits  Noise Levels  Occupational Exposure Pollution Control

31. AMBIENT AIR LIMIT (WHO Recommendations) Pollutant Averaging Time Gravita Plant follows Jordan Limit values Carbon Monoxide (CO) 8 hr.5-8.6 PPM9 PPM 1 hr.20-25.8 PPM26 PPM Sulphur Dioxide (SO 2 ) Annual0.018 – 0.02 PPM0.04 PPM 24 hr.0.047 – 0.09 PPM0.14 PPM Nitrogen Dioxide (NO 2 ) Annual0.02-0.035 PPM0.05 PPM 1 hr.0.1 – 0.15 PPM0.21 PPM Total Particulate Matter (TPM) 24 hr.100- 120 µg/m 3 120 µg/m 3 Lead (Pb)Annual/24 hr.0.5 / 1 µg/m 3

32. STACK EMISSIONS STANDARDS… Pollutant Our Plant follows Limit values Jordan Limit values Soot & Dust120-150 mg/Nm 3 - Carbon Monoxide (CO)800-930 mg/m 3 1000 mg/m 3 Sulphur Dioxide (SO 2 )5700-6390 mg/m 3 6500 mg/m 3 SmokeRinglemann 2- Lead (Pb) & it’s Compounds8-10 mg/Nm 3 as Pb20 mg/Nm 3 as Pb Particulates (SPM)–Furnaces.40-50 mg/Nm 3 50 mg/Nm 3 Particulates (SPM)-Pot Furnaces 7-10 mg/Nm 3 10 mg/Nm 3

33. Effluent Discharge Standards Parameter/ Substance Tolerance Limit Values Discharge into inland waters Discharge into coastal waters Discharge into public sewers Sensitive waters General waters pH6.0-8.56.0-9.05.5-9.05.5-10.0 Total Suspended Solids 20 mg/l max. 50 mg/l max. 150 mg/l max. 500 mg/l max. Lead (Pb) 0.1 mg/l max. 0.5 mg/l max. 1.0 mg/l max. 5.0 mg/l max. Pollution Control

34. Lead Contents Limits (Solid Waste Disposal on Land) Cumulative Limit Annual Limit Soil Concentration 1000 Kg/Ha33 Kg/Ha550 mg/Kg limit Maximum Permissible Noise Levels (At Plant Perimeter) Day Time (0600-1800 hrs) Night Time (1800-0600 hrs) 65db55db Pollution Control

35. LEAD EMISSIONS LIMITS (Major Countries)… CountryMaximum Lead Level (mg/m3) Date Operative Title of Legislation Current Status Controlling Authority CANADA Federal” 29a 14 1990Secondary Lead Smelter Regulations Canadian Environment Act LegalEnvironment Canada SOUTH AFRICA 50b1972Atmospheric Pollution Prevention Act (Act of 1965) LegalDepartment of Health and Welfare THAILAND301993Act on Control of Industrial Emission Quality LegalMinistry of Industry KORIA20c1991Smelting Furnace Refining & heat treatment facilities Air Quality Policy Division, Ministry of Environment UNITED KINGDOM 101985EC Directive on Lead in Air 82/994/EEC LegalDepartment of Environment  a. 29 mg/m3 limit applies to blast furnaces & Rotary Furnaces.  14 mg/m3, applies to holding furnaces, kettle furnaces  b. Emissions measured at ground level must not exceed 10 mg/m3.  c. Smelting Furnaces, Refining & heat treatment facility : 20mg/m3

36.  Proper plant design and engineering controls in order to protect workers from occupational exposure to Lead, including by control of process and fugitive emissions.  Appropriate codes of practice/policies/plant hygiene practices for the workforce and relevant management personnel  Required education & training to workforce about facilities and protective equipment Occupational Safety Health Standards

37.  Regular monitoring procedures including in-plant/perimeter environmental monitoring of Air Lead Levels  Screening of workforce Blood Lead Levels at 6 months interval  Advance planning of steps to be taken in case of crossing of prescribed action levels.  Remedial actions, which may include engineering and process corrections, job rotation of workers with High Blood Lead Levels to no-exposure work areas Occupational Safety Health Standards

38. SUMMERY …  Lead Acid Battery Scrap Recycling is essential for mankind as well as for Industry survival  Recent technological deployments made Lead Battery Scrap Recycling Operations as Environment-friendly Increasing Environmental Awareness makes this operation more professional & technical, which finally leads to highly economic viability “ ”

39. WE NEED TO STOP THEM

42. WHER DO WE START? Collection of Spent Batteries.

43. Acid Resistant Flooring

44. RF POURING ARRANGMENT

45. Refining Kettle

46. THE PRODUCT

47. The Plant

48. Plant Pictures Entrance Hanger (Upper View) Hanger (Side View) Transformer

49. LEAD ACID BATTERY RECYCLING ABU KHADER GROUP AbuKhader Bldg. #1, Mecca Str. P.O. Box 739, Amman 11118 Jordan Phone: +962-6-5803600 Fax: +962-6-5813896 Website : www.abu-khader.com E-mail : info@abu-khader.com