E-waste, battery and catalyst recycling

Electronic waste or WEEE (waste of electronic and electrical equipment) is the post-consumption waste from consumer and business devices such as mobile phones, computers, screens, and household appli­ances. In 2022, the world generated 62 million tons of e-waste, an average of 7.8 kg per capita.

The complexity of recycling WEEE stems from the diverse and functional combination of metals and other materials, such as plastics, ceramics, and organic compounds. More than 60% of WEEE consists of various metals, including ferrous metals, aluminum, copper, PGM (platinum group metals), magnesium, silver, antimony, and rare earth elements, to name just a few. Although WEEE contains only small quantities of these metals, recycling can be highly profitable due to the high market prices for certain rare technology metals. 

The TBRC combines smelting, converting and refining functions into a single, versatile reactor. An optional slag-treatment configuration further enhances metal recovery and waste minimization.

SMS group’s performance modules provide advanced solutions for injectors, burners, purging systems, and valves, aimed at boosting production and improving process control. The SIS Plus injector is versatile, facilitating accurate injection in steel and non-ferrous metal processes, and reducing natural gas consumption by up to 80%. It also serves as a burner, offering high efficiency in oxygen injection. The patented PROX burner allows for adjustable flame configurations and atmospheres, optimizing energy input in oxidizing and reducing environments. Purging systems enhance operations by reducing process time, preventing build-ups, and increasing vessel service life, particularly in anode furnaces and converters. These systems also improve slag management and lower fuel consumption. SMS group’s supersonic underbath injection system for Peirce Smith Converters is designed to prolong lining life in the tuyere zone and improve process efficiency. Simulation results show reduced refractory wear and better gas utilization, making it applicable to conventional converters without altering off-gas systems. 

As the global demand for batteries surges, SMS group is leading the charge in developing advanced recycling solutions that cater to a diverse range of battery types, including lead-acid batteries, batteries based on nickel or lithium, as well as alkaline batteries and flow batteries. Choosing the best recycling process for batteries and accumulators depends greatly on the amount and on the chemical and physical properties of the input material, as well as the location. The pyrometallurgical process route is best combined with hydrometallurgical steps, separating the individual metals from a multiple metals regulus to produce high-quality battery precursor material.

Pyrometallurgical technology such as the BlueSmelter, TBRC (top blown rotating converter), electric smelters, and the Kivcet furnace are typical melt production techniques. SMS group is also developing a solution that combines pyro- and hydrometallurgical steps for recycling complex metal-bearing materials, including lithium-ion batteries. The advantage of this new process route is that it offers more flexibility when processing rapidly changing battery chemistries.

The TBRC combines smelting, converting and refining functions into a single, versatile reactor. An optional slag-treatment configuration further enhances metal recovery and waste minimization.

Submerged arc furnaces excel in smelting ore concentrate, calcine, pre-reduced ores, and waste materials such as deposits, flue dust, slags, refractory breakout waste, and skulls. These units are highly versatile and tailored to specific input materials and product requirements.

Product portfolio:

• AC-based submerged arc furnaces (3- or 6-electrode systems; up to 140 MVA)
• Next-generation DC furnaces for niche processes (FeCr fines, TiO₂ slag, UG2, copper, PGM, recycling)
• Custom electric smelters for ferro-alloys, non-ferrous metals and specialty feedstocks