Located 43 miles north of Tulsa, the Bartlesville facility has been active since 1907. Formerly a primary zinc as a hydrometallurgical metals recovery facility processing poly-metallic concentrate that has been produced at our Palmerton facility. Bartlesville separates the concentrate into metal-bearing fractions and then sells it to smelters. The recovered zinc from the operation is returned to Monaca.

The Beaumont plant utilizes patented "Flame Reactor" technology developed in the 1980’s. The water-cooled, "flash-smelting" furnace processes EAF dust in an intensive oxy-fuel flame at temperatures in excess of 2000 degrees centigrade. This allows for a compact and highly automated plant, occupying less than 5 acres adjacent to the Gerdau-Ameristeel mini-mill in Beaumont. The plant can process over of zinc.

Horsehead's Calumet facility, located just south of Chicago on the Calumet River, operates two Waelz kilns and processes EAF dust. Built in 1940 to calcine coke and coal for the steel and aluminum industries, Horsehead purchased the plant in 1986 and began processing EAF dust on August 8, 1988.

Conveniently positioned with access to road, rail and river transportation, Horsehead’s Monaca plant operates as the country’s largest zinc smelter. Located 28 miles north of Pittsburgh, this electrothermic zinc smelter is the result of a company experiment conducted in the 1920's to produce zinc oxide. Since that time, the Beaver County operation has been expanded and modernized. Recognized as the world’s largest user of recycled zinc-bearing materials in its manufacturing process, Horsehead's Monaca location produces primarily zinc metal and zinc oxide.

The history of the Palmerton, Pennsylvania site dates all the way back to 1897. Located in a scenic valley along the Lehigh River 80 miles north of Philadelphia, it was named for the company president who guided the development of the site. Horsehead operates three Waelz kilns at the Palmerton location that produce concentrated zinc material that feeds our Monaca zinc smelting plant and other plants around the world. The plant also operates our only calcining kiln. In addition, the Palmerton facility produces powder metal in zinc alloys and copper-based alloys.

Located between Nashville and Knoxville, our Rockwood facility operates with fewer than 50 people, but processes nearly 100,000 tons of EAF dust annually in the creation of Crude Zinc Oxide (CZO) and Iron-Rich Material (IRM). Built in 1978 as a direct iron reduction plant, Horsehead purchased the facility in 1989 and started processing EAF dust in 1990.

With headquarters located in Monaca, PA, Horsehead Corporation.s operation consists of a multi-product manufacturing plant in Monaca, PA, a metal powder facility in Palmerton, PA, a hydrometallurgical metals recovery facility in Bartlesville OK, and four recycling facilities located in Beaumont, TX, Calumet, IL, Rockwood, TN, and Palmerton, PA.

Our facilities process hundreds of thousands of tons per year of electric arc furnace (EAF) dust generated by the steel industry. EAF dust is a listed hazardous waste. It contains approximately 20% zinc from galvanized scrap melted by steel mini-mills. Horsehead's Waelz kiln technology has been designated by the U.S. EPA as the "Best Demonstrated Available Technology" for processing EAF dust.