AZR to restart for zinc recycling plant in North Carolina

American Zinc Recycling LLC, a Pittsburgh-based provider of environmental services to the U.S. steel industry, is restarting production at its updated facility in Mooresboro, Rutherford County, North Carolina. The facility, which is designed to produce special high grade (SHG) zinc using recycled steel mill dust has officially restarted and is producing SHG-grade zinc metal products. The site is expected to produce 155,000 tons of SHG zinc annually.

American Zinc Recycling Corp. (AZR) takes zinc-bearing steel mill dust, a hazardous waste that would otherwise be disposed of in landfills, and recycles it using its waelz kiln technology into waelz oxide (WOX), a zinc-based feed that it uses to produce zinc metal at the Rutherford County plant. According to a news release from AZR, the company expects to recycle more than 500,000 tons of dust across its four recycling facilities this year alone. 

AZR reengineered the Rutherford County plant, which had been idled since early 2016, with upgrades to its solvent extraction and metals refining technology, according to AZR. After an initial restart in April 2016, the Mooresboro facility experienced an accidental fire that caused damage to one area of production. The cause of the fire was investigated and, as a result, modifications were made in the plant design prior to restart.

“We investigated the causes [of the fire],” says Wayne Isaacs, board chairman of AZR. “Frankly, we effectively were not able to pinpoint exactly where its origin was, so to speak, but we have eliminated part of the process” that likely caused the fire, so he adds that it’s unlikely for another fire to occur.  

AZR’s Rutherford County plant will extend the recycling value chain by refining WOX into SHG zinc, which is used in products such as galvanizing steel for automobiles, various infrastructure applications, die cast components for appliances and toys. Zinc is also added to soil vitamin supplements and sunscreen. The Mooresboro facility is unique in that it produces zinc solely from recycled sources. 

“At American Zinc Recycling, our vision is to be the preferred partner in maximizing the recovery and reuse of valuable metals,” says Wayne Isaacs, board chairman of AZR. “The successful operation of our Rutherford County facility makes it possible for us to close the recycle loop and maximize the value chain through production of Special High-Grade zinc metal. AZR now has a unique position in the world, and we will continue to grow and generate value for all our stakeholders.”

Isaacs says the Rutherford County facility began to ramp up production in February. The facility is consuming steel mill dust from EAF producers across North America. He estimates it will be at full production of 155,000 tons per year by early 2021 at the latest.

“We want to be a one-stop shop for customers to close the zinc recycling loop,” Isaacs adds. “We take electric arc furnace dust from steel producers to help handle dust properly, and we make finished zinc metal. Those same steel producers on the front end are interested in receiving some of this metal back for their galvanizing lines. It closes the whole loop with zinc from start to finish with our customers.”

“I am extremely proud of the commitment and tenacity of our team who has worked tirelessly to get this facility back in full working order not once, but twice, and has now safely completed the restart of zinc production in a sustainable way,” adds Robert Williamson, vice president and general manager of the Rutherford County plant. “We are committed to operating the facility to the highest safety and environmental standards. The contributions and commitment of each employee cannot be overstated, and we are optimistic about the production we will see throughout the remainder of 2020 and beyond. This is a generational facility that will provide good sustainable jobs to the Rutherford County community for years to come.”