When you are a galvanizer, you will face some waste to treatment includes Rinse water, Spend acid, Sludge, Dross, Ash...etc. Some of them are valuable like dross and Ash; some of them need to pay for treatment like spend acid or sludges. Today we would like to introduce our Ash recovery system, even ash is a valuable product but we still can get more add values.
The ash will be created each dipping than workers are skimming to the side for quality reason. When ash accumulate more and more, workers will scoop up ash from kettle to drum. This is the traditional practice, Some Asian countries will ask workers to re-fill ash on kettle then pushing till ash color changes, but it will create lots of fumes and it is hard jobs. So it was not easy to teach workers to scoop the ash from kettle, it needs experience accumulation and practices harder. Once you have a machine, you don't need to worry the worker creates money loss.
Our system is easy to operate. Worker scoops ashes into our drum directly beside the kettle. When the drum has 80% full (Max. 800kg/drum) then put the cover on and move it into our system by forklift. After 4 hours machine running, open the hole on the drum you can get the metal zinc back. Then let the drum cooling remove residues from it will complete a cycle.
The calculation:
If ash created 800 kg/day and recycle one drum per day.
Our average recovery rate is 70%
The zinc price base on USD 2,000 / ton for calculation as below:
- recycled zinc value：(0.8 ton × 70%) × USD 2,000 / ton = $ 1,120
- residues value：(0.8 ton × 30%) × USD 2,000 / ton × 10% = $ 48
- ash price：0.8 ton × USD 2,000 / ton × 40% = $ 640
- max fuel cost：16 m3/H × 4 H × 0,7 USD/m3 = $ 44.8
- worker/amortization：$ 40/drum. day
The BENEFIT = (1) + (2) - (3) - (4) - (5) = $ 443.2 per day
If your ash created 20 tons per month, then you can save $ 11,000 per month.
The system ROI will less than 6 months!!!
Below are some of our system photos.
▲the Zinc Ash Recovery system. (ZARS)
