Discuss energy conservation and emission reduction in the metallurgy industry

I’m also looking to learn some information and knowledge on this topic; please those who are aware share their insights

For emission reduction, reference can be made to Chengdu West China’s \"ion liquid circulation method for the removal and recovery of SO2 from flue gas\" technology; sulfuric acid can be produced using the recovered SO2, which can generate certain economic benefits. It can also reduce the emission of acidic gases. As for energy conservation, from what I understand at the moment, heat pipe technology is used to recover heat as much as possible to generate steam for power production. To achieve energy savings.

Regarding the recycling of water, feel free to contact me for information on reuse treatment; I’ll share everything I know

Energy conservation mainly involves the reuse of various types of waste heat, while emission reduction focuses on the recovery of dust and the utilization of acidic gases.

Yuguang Development focuses on circular economy practices to reduce energy consumption and emissions. Henan Yuguang Gold and Lead Group Company is primarily engaged in the smelting of gold, silver, lead, and zinc; it is a resource-based enterprise, and the main constraint on its development is resources. Developing a circular economy is the fundamental way for enterprises to alleviate resource constraints, achieve energy conservation and emission reduction, and pursue sustainable and rapid development. In recent years, Yuguang Jinlian Group Company has leveraged its technological advantages, focusing on improving the efficiency of resource utilization. It has prioritized the development of recycled lead and enhanced comprehensive recycling, while taking environmental pollution control as a key point for progress. By doing so, it has steadily advanced structural adjustments and vigorously promoted a circular economy, thereby initially establishing a new industrial model characterized by resource conservation, clean production, and ecological protection. In June 2005, it was designated by the Henan Provincial Development and Reform Commission as one of the first batch of pilot enterprises for circular economy in the province. In October of the same year, it was recognized by the ** Development and Reform Commission as part of the first batch of pilot units for circular economy, becoming one of the six pilot enterprises in China in the field of waste metal recycling. Improving the utilization of renewable resources is an essential path to developing a circular economy. The recycling of renewable resources can reduce or even eliminate pollutant emissions, increase the efficiency of resource use, and protect increasingly scarce natural resources as well as the increasingly fragile ecological environment. It represents an important measure for safeguarding the environment and maintaining ecological balance, and it is also a necessary requirement for developing a circular economy and achieving sustainable development. Developing the recycled lead industry to achieve resource recycling is the only way for lead smelting enterprises to achieve sustainable development. Abroad, especially in the United States, the production of recycled lead accounts for over 70% of the total lead production. In contrast, the development of the recycled lead industry in China is relatively lagging behind; enterprises are scattered, management is lax, and the system for recycling used batteries is disorganized. As a result, recycled lead accounts for only about 21% of the total lead production in China. In 2000, Yuguang Jinlian Group Company began to develop the recycling of used non-ferrous metals; it manufactured its own equipment and adopted its own processing techniques for handling used lead-acid batteries, with its processing capacity gradually increasing from 20,000 tons to 60,000 tons. In 2004, leveraging its technical advantages and by introducing advanced foreign equipment, the company began construction of a 100,000-ton recycled lead project. This facility is capable of processing 150,000 tons of used lead-acid batteries per year, producing 40,000 tons of alloyed lead, 64,000 tons of lead sludge, and 8,000 tons of polypropylene, thereby generating an additional revenue of 960 million yuan. By adopting two internationally advanced new technologies—the CX integrated pretreatment technology and the oxygen-enriched bottom-blown oxidation-blast furnace reduction lead smelting technology—the process equipment features full sealing, full automation, a small footprint, a high degree of automation, and thorough separation of materials. Compared with domestic lead recycling enterprises that focus solely on recycling, it offers advantages such as lower overall energy consumption, better environmental protection performance, and higher metal recovery rates. The energy consumption per unit is reduced by 100 kilograms when expressed in terms of standard coal; the sulfur recovery rate reaches 97%, while the metal recovery rate is 98.5%. In order to leverage its comparative advantages and promote the healthy development of a circular economy, the company plans to increase the use of recycled resources further, aiming to make recycled lead account for 50% of the total lead production by 2010. Promoting industrial structure adjustment is an important aspect of developing a circular economy. A circular economy requires increased connections and interactions between industries, so as to achieve maximum recycling of materials and energy. An irrational industrial and product structure is a major cause of significant resource waste, high energy consumption, and severe environmental pollution; therefore, accelerating the adjustment of the industrial structure is a key factor in developing a circular economy. The mineralogical characteristics of lead-zinc symbiosis result in a large amount of zinc-containing materials being generated during lead smelting, while a large amount of lead-containing materials are produced during zinc smelting. Yuguang Jinlian Group Company used to be engaged only in lead smelting, resulting in a large amount of zinc-containing materials being discarded as waste slag. Later, based on the complementary properties of lead and zinc, the industrial structure was adjusted to establish a \"combined lead-zinc production model.\" The integrated processing process for the combined smelting of lead and zinc was improved, with the lead system being used to process the secondary materials generated by the zinc system, and vice versa. This creates a positive internal material cycle that not only allows lead and zinc materials to supplement each other as raw materials but also enables the centralized processing of valuable metals such as silver, indium, and cadmium that are concentrated in the lead and zinc systems. This approach helps reduce overall energy consumption and improves the level of comprehensive resource utilization. By establishing a complementary economic cycle for lead and zinc, Yuguang Group has laid a solid industrial foundation for the development of a circular economy. In the complementary cycle of lead and zinc, the by-products of these two systems—zinc monoxide and lead slag—serve as raw material supplements for each other; the products obtained from comprehensive recycling can also act as supplementary raw materials. This creates an industrial advantage through the complementarity of lead and zinc, enabling an internal circulation within the enterprise and thereby improving resource utilization efficiency. The products produced through smelting, namely electrolytic lead and electrolytic zinc, are not only sold in the market; some of them are further processed into alloys, lead salts, zinc powder, etc., which are used in power supply products such as batteries and headlamps. It improved resource utilization, increased the added value of products, avoided the market risks associated with a single product line, and achieved good economic and social benefits. By promoting industrial structure adjustment and improving the development model of a circular economy, Yuguang Gold and Lead Group has established numerous industrial chains. Currently, it is possible to recover more than 10 valuable elements from lead-zinc concentrate, including gold, silver, copper, iron, antimony, bismuth, indium, cadmium, and others. Through the treatment and recovery of flue gases in the lead-zinc smelting process, 380,000 tons of sulfuric acid are produced each year. Zinc is extracted from lead slag through smelting to produce zinc suboxide; part of this zinc suboxide is used as an exhaust gas absorbent to synthesize zinc sulfate or zinc oxide, while the remainder is sent to zinc oxide plants for further processing to yield active zinc oxide or nano-zinc oxide. In 2006, the comprehensive recovery revenue from the lead sector of Yuguang Lead Group accounted for 7.8% of the total revenue, while its profits accounted for 55.3% of the total profits. The comprehensive recovery revenue from the zinc sector accounted for 3.88% of the total revenue, with its profits making up 47.9% of the total profits. Establishing a green technology support system is a key factor in developing a circular economy. A circular economy is an ecological economy, and environmental protection is one of the core elements of such an economy. To overcome the drawbacks of the traditional resource-based economic development model and develop a circular economy, it is crucial to break through technical barriers and establish a green support system. Based on the development of high-tech, with an emphasis on developing technologies that enable ecological connections within the economic system, clean production techniques and processes that cause little or no harm should be actively adopted. Consumption of raw materials and energy should be drastically reduced, so as to achieve high output with minimal input and low pollution, and environmental pollutants should be eliminated as much as possible during the production process. Yuguang Group makes use of scientific and technological platforms such as postdoctoral research stations, industry-university-research bases for heavy non-ferrous metals, and engineering technology centers for lead-zinc smelting. It strengthens cooperation with universities and research institutions, continuously enhances its independent innovation capabilities, improves the level of lead-zinc smelting technologies and equipment, and strives to achieve a win-win situation in terms of economic benefits and environmental protection. In the domestic lead smelting industry, it was the first to adopt the technology of producing acid through the non-steady-state conversion of sulfur dioxide, the technology of lead smelting via oxygen-enriched bottom-blown oxidation and blast furnace reduction, as well as the fully wet-process gold refining technology. The adoption of the technology for acid production through the non-steady-state conversion of sulfur dioxide addresses the problem of sulfur dioxide pollution in traditional lead smelting processes. It not only purifies the waste gases generated during lead smelting but also increases economic benefits, enabling the production of 150,000 tons of sulfuric acid per year – representing a significant breakthrough for the traditional lead smelting industry. The oxygen-enriched bottom-blown oxidation-blast furnace reduction technique for lead smelting has been implemented on an industrial scale for the first time in China, effectively solving the problems associated with the difficult recovery and utilization of sulfur dioxide in traditional lead smelting processes as well as the poor environmental outcomes that resulted from this, allowing the sulfur dioxide concentration to be increased to around 14%. Sulfuric acid is then produced using a two-turn two-absorption process, enabling a total sulfur utilization rate of over 97%. Emissions of sulfur dioxide are effectively controlled, with the exhaust gas concentration being only 14 milligrams per cubic meter, thus achieving the best conversion and absorption efficiency for sulfur dioxide in China. By integrating this technology, Yuguang Jinlian Group Company has adhered to independent innovation, conducting research on the configuration and application of industrial systems for lead smelting via oxygen-enriched bottom-blown oxidation followed by blast furnace reduction, and has developed 15 patented technologies. According to evaluations by relevant experts, this process features reasonable assembly, reliable performance, high operational efficiency, significant environmental benefits, and a technical level that is at the international advanced stage. It serves as an excellent model for the technological transformation of lead smelting in China. At present, Yuguang Jinlian Group Company is carrying out semi-industrial experiments on the subsequent technology of direct reduction of liquid high-lead slag, which is part of the strategic plan based on patent technologies for lead smelting via oxygen-enriched bottom-blown oxidation and blast furnace reduction, and has achieved substantial progress. Once this mature technology is applied in industrial production, the energy consumption per ton of lead will be 30% lower than that of current blast furnace production, thereby significantly reducing the production costs associated with lead smelting. An innovative management concept is an essential requirement for the development of a circular economy. From the perspective of resource flows and the environmental impact of economic growth, there are two patterns of growth: the traditional growth model and the circular economy model. The circular economy model is a feedback-based cycle of “resources – products – waste – recycled resources”, which enables more efficient use of resources and environmental protection, thereby achieving the greatest possible economic and social benefits with the lowest possible resource consumption and environmental costs. The new economic model requires new management concepts and approaches to be maintained and developed. Yuguang Jinlian Group Company firmly upholds the concepts of \"no waste in the lead-zinc industry\" and \"eliminating waste without limits.\" It mobilizes all available resources to promote the development of a circular economy; by taking into account the actual conditions of its operations, it carries out innovative activities at various levels and in different aspects. This approach ultimately leads to the formation of an innovation system and model that progresses from individual elements to networks, from networks to larger areas, and from there to an overall framework, thereby effectively integrating, facilitating, and driving the healthy development of the circular economy. The company earnestly implements international management standards, fully carries out the certification process for comprehensive management systems in terms of quality, environment, and occupational health and safety, and uses these standards to organize its production and operational management. This has enabled the company to transition its management approach to a modern model characterized by comprehensive standardized management. Through activities such as Enterprise Management Years, intensive training for employees, refined management, and evaluation and rewards for scientific and technological achievements, the awareness among various functional departments and production units to conserve resources, reduce material consumption, and practice clean production is continuously enhanced, thereby ensuring that efforts to save energy and reduce emissions are put into practice. Adopting \"target management and cost veto\" as the basic model, it continuously improves the assessment mechanism that focuses on costs for performance evaluation and on consumption for bonus distribution. Technical indicators such as the recovery rates for lead and zinc processing, direct yield, energy consumption, and the lead content in slag are included in the target responsibility documents of various functional management departments and production units. Assessment is carried out through both economic responsibility systems and target management, as well as a system of eliminating those at the bottom of the performance rankings; rewards are given to those who perform well and penalties are imposed on those who perform poorly, thereby encouraging all units to improve their management practices, pursue technological innovation, save coal, coke, water, and electricity, and reduce processing costs. In 2006, the metal recovery rate in lead smelting reached 96.51%, and the electrolytic processing cost per ton of crude lead dropped to 170.33 yuan, achieving the best level in the industry. (Written by Yang Anguo) Actively promoting the development of a circular economy and striving to create resource-efficient and environment-friendly enterprises, Henan Yuguang Gold and Lead Group Co., Ltd. is a large-scale enterprise group that focuses on non-ferrous metal smelting while engaging in diversified business activities. It holds the qualifications for exporting silver, conducting overseas operations independently, and participating in overseas futures trading. Its main business activities cover various fields such as non-ferrous metals, precious metals, the chemical industry, coal machinery products, electricity, mining, services, and real estate. The company currently has 6,000 employees, 11 wholly-owned and controlled subsidiaries, 1 listed company, 1 Sino-foreign joint venture, and 22 manufacturing plants, with total assets amounting to 5 billion yuan. The production capacity of the company’s main products is as follows: 300,000 tons of electrolytic lead, 100,000 tons of electrolytic zinc, 380,000 tons of sulfuric acid, 3,000 kilograms of gold, 500 tons of silver, 1 million mining lamps, and 200,000 KVAH of batteries. In 2006, the company achieved a total industrial output value at current prices of 6.8 billion yuan, generated sales revenue of 6.88 billion yuan, made a profit of 340 million yuan, and earned tax revenues of 660 million yuan; it also generated $360 million in foreign exchange through exports. The company ranks second in the national lead-zinc industry and first in the lead smelting industry; its key performance indicators place it 17th among the top 100 key enterprises in Henan Province. I. Formulate strategies and goals for the development of a circular economy in order to promote a strategic transformation in the mode of economic growth. Utilizing its technological advantages, Yu Guang Jin Lead Group focuses on addressing environmental pollution resulting from lead smelting, emphasizes the development of recycled lead and improved comprehensive recycling practices, and takes enhancing resource utilization efficiency as a key approach. As a result, it has initially established a new path and model of industrialization characterized by resource conservation, clean production, and ecological protection, enabling the company to gradually become a resource-efficient and environment-friendly enterprise. In July 2005, the company was designated by the Henan Provincial Development and Reform Commission as one of the first batch of pilot enterprises for circular economy initiatives. In October of the same year, it was recognized by the National Development and Reform Commission and five other ministries as part of the first batch of such pilot enterprises, becoming one of the six pilot companies in China in the field of waste metal recycling. After being identified as one of the first pilot units for circular economy in Henan Province, the company, in accordance with the overall arrangements and requirements regarding circular economy pilot projects, as well as considering the current situation and characteristics of the industry and the actual conditions of the enterprise, prepared the \"Circular Economy Pilot Plan for Henan Yuguang Gold and Lead Group\". In April 2006, the company’s \"Pilot Plan for Circular Economy\" was reviewed in Beijing at a meeting dedicated to evaluating pilot implementation plans for circular economy in key national sectors ； In September 2006, the General Office of the National Development and Reform Commission issued a reply containing its evaluation opinions on the pilot implementation plan for circular economy in key areas, officially approving our company’s pilot plan. The company’s “Pilot Plan for Circular Economy” mainly includes: the development strategy for a circular economy. Adhering to the guidance of the scientific development concept, and following the principles of a circular economy based on reduction, reuse, and resource recycling, we emphasize technological innovation to enhance the core competitiveness of enterprises ； Implement lead-zinc complementarity to increase industry concentration ； Strengthen the development of the recycled lead recycling system, improve the comprehensive utilization rate of resources, transform the mode of economic growth, and achieve sustainable and coordinated development for enterprises. Near-term development goals. Without increasing the demand for raw resources, by the end of 2007 a scientific and standardized recycling network for used batteries was established. A fully automated production line for the disassembly and sorting of used batteries was set up, along with a corresponding smelting system, thus creating a new demonstration facility capable of processing 100,000 tons of recycled lead. Complementary comprehensive recycling production lines were also developed; the proportion of recycled lead in the raw materials increased to 30%, the rate of water recycling reached 95%, and the overall resource utilization rate reached 95%. Long-term development goals. By 2010, the capacity for producing 300,000 tons of electrolytic zinc and 300,000 tons of recycled lead was to be established. Technical upgrades were to be carried out in areas such as the development of recycling networks, pre-treatment, smelting, comprehensive recycling, and clean production, in order to create a comprehensive recycling model for lead. The following targets were to be achieved: the proportion of recycled materials was to increase to over 50%, the recovery rate of lead as the main metal was to reach 96%, the utilization rate of solid waste was to reach 95%, wastewater discharge was to be reduced to zero, and the overall energy consumption per ton of lead was to be lowered to 390 kg of standard coal. II. Rely on technological progress to intensify environmental governance. The circular economy is an ecological economy, and environmental protection is one of the core elements of it. The company continuously improves its smelting process technologies and equipment, increases investments in environmental protection, and strives to achieve a favorable situation where both social and economic benefits as well as environmental benefits are realized. The company is the first in China to develop the technology for non-steady-state conversion of sulfur dioxide, as well as the oxygen-enriched bottom-blown oxidation–blast furnace reduction smelting technology. The adoption of the technique for the non-steady-state conversion of sulfur dioxide solves the problem of direct emission of SO2 during traditional sintering processes, achieving a sulfur recovery rate of 85%. This not only purifies the exhaust gases generated in lead smelting but also increases economic benefits, representing a significant breakthrough for China’s traditional lead smelting industry ； Oxygen-enriched bottom-blown oxidation – blast furnace reduction smelting technology has been implemented on an industrial scale in China for the first time; it represents a revolution in China’s lead smelting technology. It effectively solves the problems associated with traditional lead smelting, such as the difficulty in fully recovering sulfur dioxide and the poor environmental impact, by raising the SO2 concentration to 14%. This allows for the use of a two-turn two-absorption process in sulfuric acid production, resulting in a total sulfur utilization rate of over 97%. SO2 emissions are effectively controlled, with exhaust gas concentrations reaching only 14 mg/m3, thereby achieving the best conversion and absorption efficiency in acid production processes in China. Oxygen-enriched bottom-blown oxidation in lead smelting – the blast furnace reduction smelting technology and its industrial installation configuration offer advantages such as a rational process flow, the ability to utilize recycled resources, and good environmental benefits. It has reached a level that is leading in China and advanced internationally, representing the direction of development in lead smelting technology in our country, and thus holds great potential for widespread application. This technology won the **Second Prize for Scientific and Technological Progress**, and the industrial installation configuration applied by our company also received the Second Prize for Scientific and Technological Progress in Henan Province. In 2006, the company formulated a patent strategy and plan, conducted classification and screening of scientific and technological achievement projects, and filed 15 patents. The company was involved in the drafting of 4 industry standards, including those related to \"Zinc Ingots\" and \"Energy Consumption of Products in Lead and Zinc Smelting Enterprises\", which significantly enhanced its voice and influence within the industry. Active efforts have been made to develop the direct reduction technology for liquid high-lead slag, and substantial breakthroughs have been achieved; design work for its industrial application has now begun. Once this process is matured and put into industrial use, the energy consumption per ton of lead produced will be reduced by 30% compared to that of the blast furnaces currently in use. This will significantly lower the production costs associated with lead smelting and help push the non-ferrous metals smelting industry to a new level. Having resolved environmental issues, the company stepped up efforts in 2006 to recycle exhaust gases and solid waste. First, a zinc oxide exhaust gas absorption project was implemented. In response to the fact that small amounts of flue gas from blast furnaces and acid production processes in the old system are still being emitted, a new technology utilizing self-produced zinc oxide powder to absorb oxidized SO2 is employed for waste gas treatment. This approach not only ensures that all of the company’s waste gases are discharged in compliance with regulations but also enables the comprehensive recovery and utilization of by-products such as zinc sulfate. The second is the comprehensive recycling project for kiln slag. Using magnetic separation to treat zinc system volatilization slag not only reduces dust generation from the waste residue storage but also alleviates the pressure on the slag storage area. Currently, 70,000 tons of kiln slag are processed annually, yielding 28,000 tons of iron ore with 58% iron content, as well as 14,000 tons of zinc-containing coking particles. The 28,000 tons of residue remaining are sold as brick slag to silicon factories. The annual output value is 13.58 million yuan, generating a profit of 5 million yuan. Third is the smelting zinc extraction project. Zinc is comprehensively recovered from blast furnace slag through sulfidation treatment, yielding the by-product zinc suboxide. Through technological upgrades in 2006, the zinc recovery rate was gradually increased, and the production of zinc oxide rose from 1,600 tons per month to 2,100 tons. Through technological innovation and a series of environmental protection measures, the company has largely achieved the goal of \"green smelting\". IV. Focus on developing the recycled lead industry to create a new model of circular economy in the lead industry. China’s recycled lead industry began in the 1950s, and significant progress has been made over the past decade, with production increasing rapidly; it has thus begun to take shape as an independent industry. However, overall, there are many small-scale recycled lead enterprises that consume large amounts of energy, cause severe pollution, use outdated industrial technologies, and have low rates of metal recovery and comprehensive utilization. There are nearly 300 lead-acid battery recycling plants for lead recovery across the country, with production capacities ranging from dozens of tons to over a thousand tons; those with capacities of more than 10,000 tons are very few. The processing techniques primarily involve traditional methods such as small reverberatory furnaces, blast furnaces, and cupolas for melting, with the grid and lead sludge being mixed together without any prior treatment processes ； Some small businesses and individual entrepreneurs even use primitive earthen kilns and furnaces for smelting ； The production of recycled lead is low, and there is still a significant gap compared to developed countries in the West. In those developed countries, recycled lead accounted for 63.3% of the total lead production in 2002, whereas in China it only accounted for 17% in 2004 ； At the same time, there are significant differences between primary lead and recycled lead in terms of smelting energy consumption, water usage, SO2 emissions, and solid waste discharge. It is evident that China’s recycled lead industry has good potential for market development and urgently needs to pursue improved growth. Since 2005, our company has focused on developing a 100,000-ton recycled lead project. This project consists of 3 sub-projects, mainly including: a 100,000-ton recycled lead separation project, an 80,000-ton crude lead technical upgrade project, and an 80,000-ton recycled lead refining project. The latter two projects were put into operation in March and September 2005, respectively. The 100,000-ton recycled lead separation project has introduced a world-class CX pretreatment integrated system from Italy; it is now operational. The facility is capable of processing 150,000 tons of used batteries per year, producing 40,000 tons of alloyed lead, 64,000 tons of lead sludge, and 8,000 tons of polypropylene. It generates annual sales revenue of 960 million yuan, while the processing cost per ton of crude lead is reduced by 20% compared to the existing level. Our company has technical advantages in the development of recycled lead. The company uses the CX integrated system for the production of recycled lead: pre-treatment and decomposition are carried out using this system, lead paste is melted through oxygen-enriched bottom-blowing, and electrolytic refining is employed to produce electric lead. Sulfur is recovered by using a \"double rotation double absorption\" process to produce acid, while grid materials are directly melted to yield alloy lead or processed into electric lead; this process is the first of its kind in China ； This process for treating used batteries not only solves the problem of sulfur-related environmental pollution but also provides a new approach for dealing with the lead paste waste from batteries. Pre-treatment system: The pre-treatment process for used lead-acid batteries makes use of the CX integrated system, which enables fully automatic pre-treatment, crushing, and separation. This process and its associated equipment are at the international forefront; it is the only process that meets environmental requirements as well as ensures the safety of workers. It is also the only process that guarantees the clean treatment of industrial batteries. It features the following advantages: largest scale, high processing capacity, and high production efficiency, capable of producing 150,000 tons per year, which facilitates intensive operation ； The system has a high degree of automation; only 6 people are required to operate it, which is different from the manual processing methods used in most current lead recycling plants ； The products are separated thoroughly, allowing lead paste, lead grids, and plastic to be sorted and reused effectively, resulting in a high overall utilization rate ； The system is fully enclosed, safe, and environmentally friendly; it features water recycling, produces no waste, and minimizes water consumption to the greatest extent possible. Lead paste, lead grid treatment. The smelting of lead paste employs oxygen-enriched bottom-blown furnace technology, in combination with the processing of raw ore, to produce electrolytic lead through electrolytic refining ； Sulfur recovery for the production of sulfuric acid ； The direct casting of lead grids to produce alloyed lead or processing it into electrical lead is a first in China. It has the following features: a) Classification-based processing leads to high product quality; the lead paste is processed to produce electric lead with a purity of 99.998%, making it a high-tech product in Henan Province. In contrast, most domestic manufacturers mix lead paste with lead grids during melting, which results in a lower quality of the final product ； At the same time, the lead grid is directly cast into alloy lead or processed into electrical lead, enabling direct further processing of the product and reducing production costs. b. Low comprehensive energy consumption. By utilizing the sulfur present in the primary lead concentrate, lead paste and the primary lead concentrate are mixed together and fed into an oxygen-enriched bottom-blown furnace for melting; pure oxygen is used to assist combustion along with the self-ignition of sulfur, eliminating the need for fuel and thus saving a large amount of energy. This process consumes 400 kg of standard coal per ton of Pb, which is 100 kg less than that of the traditional lead recycling process, and about 220 kg less than that of the conventional lead smelting process. The energy consumption for recycled lead is calculated to be 220 kg of standard coal per ton of Pb. c. It has excellent environmental protection effects, with a comprehensive sulfur utilization rate of 97%. The acid production system utilizing the exhaust gases from existing primary lead production systems is employed to recover sulfur dioxide gas generated during the smelting of recycled lead and convert it into acid; the SO2 content in the emitted exhaust gases is 360 mg/m3, which is lower than the standard value of 850 mg/m3, ensuring compliance with environmental regulations. It overcame the environmental pollution problem of sulfur not being recyclable, which plagues most domestic manufacturers. Most single lead recycling plants do not have specialized facilities for treating exhaust gases, and only a few have carried out desulfurization treatment. d. The metal recovery rate is high; the lead recovery rate reaches 97%, which is significantly better than the 85-90% achieved by traditional lead recycling processes. The 100,000-ton recycled lead comprehensive utilization project features process equipment that is fully sealed and fully automated, occupies a small area, has a high degree of automation, and ensures thorough separation of the products. The company uses its unique oxygen-enriched molten pool smelting process to process recycled materials, adopting a approach that combines primary lead with recycled lead, which facilitates the intensive production of recycled lead. Compared to domestic companies that focus solely on recycled lead, it offers advantages such as lower overall energy consumption (400 kg of standard coal per ton of Pb, which is 100 kg less than that of traditional processes), better environmental performance (a sulfur recovery rate of 97%, with SO2 emissions of 14 mg/m3; in traditional processes, the sulfur recovery rate is around 93%), and a higher metal recovery rate (98–98.5%, compared to 95% in traditional processes). Additionally, this approach helps to **reduce the pressure associated with purchasing raw ore. To fully leverage its comparative advantages, the company plans to increase its efforts in the production of recycled lead, aiming to raise the proportion of recycled lead from 20% to 50% by 2010, when the total lead production reaches 400,000 tons per year. The construction of the company’s recycled lead production facility will integrate clean production with the comprehensive utilization of resources, thereby creating a circular industrial chain of \"resources – products – recycled resources – recycled products\". Our company’s 100,000-ton recycled lead production project opens up a new path for the development of a circular economy in the lead smelting industry. At the same time, it will help to change the current situation in China’s recycled lead industry, where environmental pollution is severe, the level of technical equipment is low, and the rates of metal recovery and utilization are insufficient – conditions that are not in line with the principles of a circular economic development model. V. Strengthen comprehensive recycling to achieve complementarity between lead and zinc. The coexistence of lead and zinc results in the generation of large amounts of zinc-containing materials during lead smelting, while large amounts of lead-containing materials are produced during zinc smelting. Developing a combined lead-zinc production model not only allows lead and zinc materials to supplement each other as raw materials, but also enables the centralized treatment of metal elements such as silver, copper, indium, and cadmium that are concentrated in the lead-zinc system, thereby reducing the energy consumption associated with comprehensive recycling and improving the level of comprehensive resource utilization. To this end, the company invested 120 million yuan in the first phase of a 300,000-ton electrolytic zinc project, which was completed and put into operation on May 18, 2005. In 2006, the production volume of electrolytic zinc reached 100,000 tons, while that of sulfuric acid was 180,000 tons; profits and taxes amounted to 220 million yuan. In early 2007, the company began construction on the second phase of its 300,000-ton zinc electrowinning project. The total investment for the second phase is 1.2 billion yuan, with a production capacity of 100,000 tons of zinc oxide and 150,000 tons of sulfuric acid per year. By establishing a complementary recycling loop for lead and zinc, the company has laid a solid industrial foundation for the development of a circular economy. In the complementary lead-zinc cycle, the by-products of the lead and zinc systems—lead slag and zinc suboxide—serve as raw material supplements for each other; the products obtained from comprehensive recovery can also act as raw material supplements for one another. This creates an industrial advantage through complementarity between lead and zinc, enables a large-scale internal circulation within the enterprise, and improves resource utilization efficiency. In the recycling cycles for lead and zinc, the products obtained from smelting, namely electrolytic lead and electrolytic zinc, are, in addition to being sold abroad, partially processed further into alloys, lead salts, zinc powder, etc. The alloys are used in power supply products such as batteries and headlamps, which improves the efficiency of resource utilization, increases the added value of these products, helps to avoid the risks associated with a single market for these products, and thereby yields good economic and social benefits. The development model for circular economy has been improved, and structural adjustments have been made to achieve complementarity between lead and zinc, enabling the company to establish three main industrial chains: 1. Lead industry chain: exploration—extraction—mining—smelting—alloying—batteries (power sources)—recycling. 2. Zinc industry chain: exploration—mining—concentration—smelting—alloying (electroplating)—recycling. 3. Comprehensive recovery chain: During the smelting of primary lead and zinc concentrates as well as recycled lead, many valuable metals are generated as by-products. The company has made significant efforts to recover these valuable minor metals; it is now capable of extracting over 10 such elements from lead and zinc concentrates, including gold, cadmium, indium, silver, copper, iron, antimony, bismuth, etc. By treating the exhaust gases produced during lead and zinc smelting, the company is able to produce 380,000 tons of sulfuric acid each year ； By subjecting waste residue to smelting for zinc extraction to produce zinc monoxide, and using this zinc monoxide as an absorbent for exhaust gases to synthesize zinc sulfate or zinc oxide, the zinc monoxide is sent to zinc oxide factories as raw material to produce active zinc oxide and nano-zinc oxide, among others. Zinc sulfate is supplied to zinc processing companies as a raw material for the production of electrolytic zinc; cadmium and indium from the lead processing system are fed into the comprehensive recycling system for the zinc processing system, while silver slag and copper slag from the zinc processing system are sent to the comprehensive recycling system for the lead processing system, thereby enabling full utilization of these trace valuable metal resources. In 2006, a total of 790 tons of antimony metal, 834 tons of antimony white, 214 tons of bismuth metal, 2,576 tons of copper, 8.8 tons of indium metal, 40 tons of cadmium, and 15,496 tons of iron powder were recovered, achieving significant economic benefits. According to statistics, in 2006, the comprehensive recycling revenue from joint-stock companies accounted for 7.8% of the total revenue, while their profits accounted for 55.3% of the total profits ； Building on its existing operations for recovering valuable elements such as lead, copper, and sulfur, the zinc company invested in 2006 to set up facilities for the comprehensive recovery of resources like indium and germanium, crude cadmium, and silver through flotation. The income generated from these comprehensive recovery operations accounted for 3.88% of the total revenue, while the profits resulting from them made up 47.9% of the total profits. VI. Vigorously promote clean production and carry out effective work in energy conservation, consumption reduction, emission control, and pollution prevention. The company adheres to optimized management and focuses on implementing the strategy of “focusing on one aspect while promoting three others.” This means using energy conservation, consumption reduction, and emission control as key approaches to facilitate economic structure adjustment, a shift in the mode of growth, and improvements in quality and efficiency. Clean production is implemented comprehensively to achieve energy savings and increased efficiency. The company earnestly implements the international standard management system and comprehensively adopts standardized management. The company actively carried out the certification audit for its comprehensive management system for quality, environment, and occupational health and safety in 2006, and organized its production management in accordance with these standards. This provided a scientific management framework for achieving high quality, low costs, reduced consumption, minimal pollution, and safe production, enhanced the company’s scientific management capabilities, and facilitated a successful transition in its management approach to a scientific model characterized by comprehensive standardization. Actively carry out clean production audits. In 2006, it was the first in its industry to carry out clean production audits; as a result, the company’s material consumption levels were significantly reduced compared to before, and its various indicators were at the leading level in China, yielding clear economic and environmental benefits. During this round of clean production audits, the relevant units of the joint stock company developed 208 effective clean production plans, of which 5 were high-cost plans and 203 were medium or low-cost plans. 181 of these plans have been implemented, accounting for 91.4% of the feasible plans. Following the implementation of this round of cleaner production measures, the company recovered 153.5 tons of mineral powder, reduced coal consumption by 543.4 tons, saved 1.9 million kWh of electricity, decreased the emission of SO2 by 2,081 tons, reduced fresh water usage by 25,400 m3, cut waste residue emissions by 2,750 tons, and recovered 393 tons of lead dust. These actions generated annual economic benefits of 34.36 million yuan. The key points of the audit for Smelting Plant No. 2 showed that the comprehensive energy consumption for crude lead smelting decreased by 34.2 kg/t, the coke consumption for crude lead processing dropped by 4.94 kg/t, the recovery rate in crude lead smelting increased by 0.31%, the amount of fresh water used decreased by 0.31 t/t, the amount of wastewater generated decreased by 0.352 t/t, the wastewater reuse rate increased by 1.8%, the utilization rate of SO2 improved by 6.24%, the solid content in the exhaust dust decreased by 18 mg/m3, and the amount of waste residue produced decreased by 0.04 t/t. The company’s environmental management level has improved. In accordance with the requirements of the ISO14001 management system, the company has developed a detailed environmental management framework. It conducts regular monitoring of environmental protection facilities and emission points, standardizes all such facilities and emission points by installing clear signs, thereby improving its environmental management system. The quality of employees has improved significantly, and awareness of clean production has grown markedly. Through this round of clean production audits, the employees and staff have developed a strong awareness of clean production. Activities such as \"energy conservation at the work post,\" \"minor improvements and innovations,\" \"employee-driven technological innovation,\" and \"QC quality management\" are being carried out vigorously within the company, creating an overall atmosphere conducive to the implementation of clean production. By carrying out activities such as Enterprise Management Years, energy conservation and consumption reduction efforts, skill training at various positions, and evaluations and rewards for scientific and technological achievements, the company continuously enhances the awareness of all functional departments and production units to save resources, reduce material consumption, pursue innovation, and proactively extend the product lifecycle, thereby ensuring that maximum resource utilization is achieved in practice. While developing a range of energy-saving technologies such as oxygen-enriched bottom-blown melting technology, blast furnace oxygen-enriched melting technology, coal injection technology for reverberatory furnaces (as a replacement for traditional methods using large amounts of carbon or fuel), and gas ignition technology for sintering machines (as a replacement for heavy oil ignition), the company connected all waste heat boilers and steam drums together to supply waste heat uniformly for heating the refining system, the nano-zinc oxide distillation system, and residential heating in winter; as a result, several boilers were shut down. The company also actively organized and implemented a project for generating electricity from the waste heat of zinc smelting roasters; once completed, this project will enable the generation of over 40 million KWHR of electricity from such waste heat. In addition, the company includes technical indicators such as the direct recovery rate, recycling rate, energy consumption, and the lead and silver content in the slag from lead and zinc smelting within the target responsibility plans of the relevant functional departments and production plants. It employs both economic responsibility systems and target management, along with a system of eliminating those who perform worst, to assess performance and reward excellence while holding deficiencies accountable. This has encouraged various units to strengthen effective management, actively pursue technological improvements and innovation, reduce processing costs, and save coal, coke, water, and electricity, thereby achieving good economic and social benefits. In 2006, the company’s lead consumption per ton dropped to 380.8 kilograms, a decrease of 4.7% compared to the previous year. The metal recovery rate during the smelting of crude lead increased to 96.51%, while the electrolytic processing cost per ton of crude lead was 170.33 yuan, representing the best level in the industry. The company’s approach to developing a circular economy has received significant attention from all sectors of society. On December 1, 2006, Shi Jichun, the vice governor of Henan Province, issued important directives regarding our company’s approaches to developing a circular economy. He stated that \"a circular economy is the foundation for the development and growth of enterprises; Yuguang Jinlian has done an excellent job in this area – turning waste into valuable resources, improving efficiency, making comprehensive use of materials, and saving resources, thus forging a path with its own unique characteristics.\" ” VII. Existing Problems 1. The scale of recycled lead production still needs to be expanded. The company has made significant efforts to develop the production of recycled lead by using the oxygen-enriched bottom-blown smelting process, thus pursuing a path of circular economy development that combines recycled lead with primary lead. Through research and testing on processing technologies, the proportion of recycled lead that can be used can reach 60%; the current usage level in the company is far too low. To fully utilize the advantages of this technology, it is urgent to increase the scale of recycled lead use. 2. The recycling system needs to be strengthened. In line with the company’s plans for developing recycled lead, the establishment of a recycling system has become an important aspect in ensuring the company’s strategy for developing recycled lead. 3. There is still significant room for energy conservation and efficient use. The oxygen-enriched bottom-blown blast furnace reduction and smelting process currently used by our company is the most advanced one in China. However, this process relies on blast furnaces for the reduction stage, which results in the unused latent heat of the high-lead slag; as a result, a large amount of metallurgical coke is still required, and the energy consumption for smelting remains higher than international standards. Further efforts are needed to improve energy efficiency. 4. The comprehensive recycling process is not yet perfect. During the smelting of recycled lead and primary lead, many valuable metals are produced as by-products. The company has currently recovered some of these products; as the use of recycled materials increases, the variety and quantity of metals that can be recovered will change, and further improvements are needed to boost the recovery rates. VIII. Policy Recommendations (1) Financial support. According to the company’s pilot program plan, there are many projects that need to be carried out promptly, and **financial support is required for project development**. In particular, projects such as the construction of a recycling system, the 200,000 t/a recycled lead comprehensive utilization project, the direct reduction process for liquid high-lead slag, and the 100,000-ton recycled lead pretreatment project that is already in progress and nearing completion – all of which play an important role in helping the company develop a circular economy development model – deserve **priority support. (II) Policy support. 1. Improve laws and regulations by accelerating the formulation of relevant laws and regulations such as the Law on the Recycling of Recyclable Resources and the Technical Specifications for Pollution Control of Used Lead-Acid Batteries and Lead-Containing Materials, so as to ensure management in accordance with the law. Mandatorily bring the recycling of used lead-acid batteries and lead-containing waste under legal regulation. 2. **The market entry standards for lead recycling plants should be regulated; those small-scale lead recycling enterprises that lack adequate environmental protection facilities and use outdated production methods should be phased out within a set time frame, so as to create a favorable market environment for enterprises that meet the required conditions.** 3. **Priority should be given to supporting demonstration projects for clean and harmless processing technologies, in order to improve the technical management level of recycling in the recycled lead industry.** 4. **Consider formulating regulations for the mandatory collection of used batteries.** Adjust the taxes imposed on lead recycling enterprises to create a level playing field for them. 5. The direct reduction technology for liquid high-lead slag should be included in the national and provincial science and technology research programs, and support should be provided for it. Recently, the long-awaited **Development and Reform Commission’s ‘Access Conditions for the Lead and Zinc Industry’ were finally made public. This access regulation introduces new adjustments to projects related to lead and zinc mining, smelting, and recycling, raising the entry barriers for the lead industry. For the lead industry, a period of survival of the fittest and mergers and reorganizations is about to begin, leading to a monopoly situation dominated by a few large lead industry conglomerates in the country. With the introduction of this access system, the domestic lead industry will undergo a reshuffle, with a group of leading enterprises emerging as the winners first. At the same time, this access system is bound to accelerate the consolidation of the lead industry. Yuguang Jinlian is Asia’s largest electrolytic lead production facility, as well as the country’s biggest silver production site. With rising market demands, and thanks to the commissioning of 100,000 tons of recycled lead and the construction of the second phase of a 300,000-ton zinc production facility, Yuguang’s leading role in China’s lead-zinc industry will become even more prominent. We believe that, with the support and assistance of the Provincial Development and Reform Commission, and as the company’s circular economy continues to develop, Yu Guang Jin Lead, as a leader in China’s lead industry, will surely achieve even greater success and make further contributions to building a harmonious Central China. This post was last edited by hchyanan on 2008-1-20 18:04]

An effective measure for energy conservation and emission reduction is the implementation of a clean production audit system. However, in many places, such audit systems serve merely as a metric to improve performance ratings, without any real oversight mechanism; as a result, conducting audits or not makes no difference, and it all remains a formality. :handshake

For pyrometallurgy, pool melting should be strongly promoted to reduce waste gas emissions, and it is also beneficial for acid production.

Regarding energy conservation and emission reduction, what is practical at present is to continuously improve production processes, especially for us technicians. Since most of the existing production processes are already quite mature, it is rather unrealistic to develop a new one; the amount of manpower, resources, and funding required is beyond what an ordinary company can afford. Consideration can be given to the recycling of water, by focusing on every stage of the metallurgical process; it is important to control the operating conditions properly, improve the skills and competence of workers, further increase the level of automation, and link workers’ bonuses to factors such as energy consumption. Of course, it is also necessary to eliminate some outdated production methods, expand the scale of the factory, comprehensively recover valuable elements from the production process, and enhance the overall utilization of raw materials.

I agree with what was said on floor 8; last year we carried out audits, but they were basically just a formality. At present, there are **many requirements**, and it seems that various **departments** attach great importance to this matter; the Development and Reform Commission, the Industry Bureau, and the Science and Technology Bureau are all seeking projects. Are there that many projects? I think by changing the cooling method of smelting slag from water quenching to air cooling, and using hot air for hot-air melting, it should be possible to recover the residual heat from the slag. I’ve seen some information on it before, but it seems to be scarce. I’ve always thought it should be possible; what do others think? Furthermore, can the carbon dioxide contained in flue gas be used for carbon dioxide production, and is it economical? Do people think so?

By increasing the yield, the unit consumption can be reduced. Through a series of experiments here, we have reduced energy consumption by 1/3 and increased output by 30%. Many involve paying more attention to things that were overlooked before, in order to optimize the processes. For example, in the past we could only rely on two gas stoves to power production, all the way until recently. Through calculation, by operating the two locations that require gas intermittently and in a coordinated manner, one furnace is sufficient to solve the problem. It can also reduce the equipment failure rate by ~ and improve production efficiency. There may not be true technological breakthroughs, but the results are very good.

In heavy-colored industries, the treatment of exhaust gases primarily involves introducing and modifying production processes, improving management of leaks and spills, as well as optimizing the recovery processes for acid-producing exhaust gases. Desulfurization techniques such as the lime/limestone-gypsum method or the zinc oxide method can be employed to reduce the emission of harmful gases and to enhance the comprehensive utilization of resources； At the same time, efforts are being made to enhance the use of variable frequency speed control technology in pump products for energy savings and consumption reduction, as well as to promote and replace them with new, efficient, environmentally friendly, and energy-saving devices. Additionally, measures are being taken to optimize the use of electricity during peak and off-peak times for equipment that consumes a large amount of power.

In the current lead-zinc smelting process, an increasing amount of sulfur is directly recovered as sulfur itself. The market price of sulfur is now over 5,000 RMB per ton, which represents considerable profits; it also eliminates the need for the complicated process of producing sulfuric acid.

To achieve energy conservation and emission reduction, the first step is to manage the three types of waste. Among these, flue gas poses the greatest threat, followed by wastewater, and then waste residues. The most effective way to handle waste gases is to use advanced smelting equipment, such as top-blown AOD furnaces and EAFs, and to install comprehensive dust collection systems to reduce the levels of various harmful substances in the exhaust gases to levels below the specified standards. Common dust collection devices used in the non-ferrous metallurgy industry include dry types such as sedimentation chambers, surface coolers, cyclone collectors, bag filters, and electrostatic precipitators, as well as wet types such as scrubber towers, Venturi tubes, and desulfurization towers

I’m not sure if this is what everyone wants. . :lol

http://bbs.hcbbs.com/thread-203431-1-1.html

In the production of sulfuric acid from flue gases generated during the smelting of lead, zinc, and copper, equipment such as venturi tubes, power wave reactors, packed towers, foam towers, and scrubber towers in the flue gas purification section often requires the periodic discharge of a portion of the dilute acid. This is due, on the one hand, to an increase in the dust content in the circulating dilute acid, and on the other hand, to an increase in the levels of arsenic and heavy metal ions. Several manufacturers in Yunnan, Jiangxi and other regions use the DiJia membrane liquid filters produced by Shanghai DiJia Environmental Protection Engineering Co., Ltd.; these filters can remove dust from dilute acids, resulting in a colorless and transparent solution, and they also achieve a removal efficiency of over 60% for arsenic and heavy metal ions. The treated dilute acid can be reused in purification devices, or added to the desiccation section to prepare acid or for the production of phosphate fertilizers. It also solves the problem encountered by some manufacturers, where high impurity levels in the dilute acid cause frequent clogging of plate heat exchangers, thereby affecting production. In this way, the dilute acid that would otherwise have needed to be discharged is reused after treatment, which not only reduces emissions but also generates significant economic benefits. I believe that as technology continues to advance and new products keep emerging, some of the traditional, extensive production methods and outdated manufacturing processes will inevitably change, and energy conservation, emission reduction, and a circular economy will surely be achieved in practice.

In heavy-colored industries, the treatment of exhaust gases primarily involves introducing and modifying production processes, improving management of leaks and spills, as well as optimizing the recovery processes for acid-producing exhaust gases. Desulfurization techniques such as the lime/limestone-gypsum method or the zinc oxide method can be employed to reduce the emission of harmful gases and to enhance the comprehensive utilization of resources； At the same time, efforts are being made to enhance the use of variable frequency speed control technology in pump products for energy savings and consumption reduction, as well as to promote and replace them with new, efficient, environmentally friendly, and energy-saving devices. Additionally, measures are being taken to optimize the use of electricity during peak and off-peak times for equipment that consumes a large amount of power. The ammonia-based desulfurization technology used by Jiangsu Century Jiangnan Environmental Protection Co., Ltd. (formerly Zhenjiang Jiangnan Environmental Protection Engineering Construction Co., Ltd.) is superior to the lime/limestone-gypsum method. Principle of the process: The flue gas delivered by the pressure booster fan enters the desulfurization tower where sulfur dioxide is absorbed; thereafter, it goes into a reheater where it is heated to 70°C before being released through the chimney or discharged directly. 　　· The sulfurous acid an that is formed is oxidized to sulfuric acid an, and then it enters the ammonium sulfate system to produce commercial ammonium sulfate. Process schematic diagram

The traditional image of the metallurgical industry is one of high energy consumption and high pollution; however, many new technologies and processes are now being adopted, leading to significant improvements in energy efficiency and environmental protection. But **guidance and support are essential!**

Energy savings can be achieved through various methods: Process optimization for energy savings – achieving savings by adopting new processes through technical upgrades. Power savings: saving energy in lighting, using high-voltage frequency converters in fans, addressing electrolytic leakage issues, managing harmonics, employing efficient motors, shifting energy usage to off-peak times, and generating power from waste heat, among others. This post was last edited by Migratory birds fly by on 2008-7-15 at 15:44

It is hoped that **support will be provided to the industry; many manufacturers are reluctant to invest in mere environmental protection measures