Japan s Technology for Metal Recycling

Transcription

1 ADEME-NEDO Workshop 2016 Circular Economy and Recycling Technology December 8, 2016 Japan s Technology for Metal Recycling Katsuaki ISHIDA, Director General Technology Strategy Center (TSC), Environment & Green Chemistry Unit New Energy and Industrial Technology Development Organization (NEDO)

2 Outline 1. History of Metal Recycling in Japan Government Policy R&D Projects Supported by Government 2. Current Situation of Metal Recycling in Japan Domestic Market Business Players Process Flow of Metal Recycling from Waste Products Problems to Be Solved 3. Challenges in Metal Recycling Technology 4. Future Development and New R&D Project 2

3 History of Major Issues and Legislation Related to Recycling in Japan (1/2) Japan s legislation with regard to recycling has been formulated in the advent of issues on public health and environmental conservation associated with economic growth. Basic legislation on promotion of recycling has been established since Relevant technologies have been developed alongside legislation on recycling of individual products. Phase Major Issues Laws & Strategies Improvement in Public Health Pollution Solutions, Protection of Living Environment, Addressing Landfill Shortage Promotion of Recycling Reduction of Toxic Substances Promotion of 3R (Reuse, Reduce & Recycling) Boosting a Transformation of Urban Mines into Raw Materials Feedstock Strengthening the Link between Arterial & Venous Industries Environmental Hygiene Public Cleansing Act (1954) Serious Pollution Problems Strengthening Measures against Shortage of Landfill Space Construction/Improvement of Waste Disposal Facilities Environmental Conservation Waste Reduction and Promotion of Recycling Establishment of Various Recycling Systems Measures against Dioxins and Other Toxic Substances Establishment of a Circulating Society Measures for Securing Resource Supply Recovery of Resources from Used Products Improvement in Resource Efficiency Information Sharing Platform Waste Management Act (1971) Law for Bay Area Marine and Environment Consolidation Centers (1981) Structure Guidelines of Waste Disposal Facilities Amended (1986) Act on the Promotion of Utilization of Recycled Resources (1991) Containers and Packaging Materials Recycling Law (1995) Home Appliance Recycling Law (1998) Law for Special Measures against Dioxins (1999) Construction Materials Recycling Law (2000) Food Matters Recycling Law (2000) Basic Act on Establishing a Sound Material-Cycle Society (2001) End-of life Vehicle Recycling Law (2002) Basic Plan on Establishing a Sound Material-Cycle Society (2003) Strategy for Ensuring Stable Supplies of Rare Metals (2009) Basic Energy Plan (2010) Strategy for Securing Natural Resources (2012) Small Electronic Appliances Recycling Law (2013) Basic Act on Establishing a Sound Material-Cycle Society Amended (2013) Japan Revitalization Strategy (2016) Source: NEDO TSC (2016) based on Ministry of the Environment (2015) History and Current State of Waste Management in Japan and other materials. 3

4 History of Major Issues and Legislation Related to Recycling in Japan (2/2) In recent years, countries around the world have been facing new problems with raw materials, for example, a shortage in raw metals supply and subsequent price rise. To address these problems, Japan is making a shift towards another phase of technology development, thereby boosting a transformation of urban mines (e-waste) into raw materials feedstock and strengthening the link between arterial and venous (i.e. recycling) industries. Phase Major Issues Laws & Strategies Improvement in Public Health Pollution Solutions, Protection of Living Environment, Addressing Landfill Shortage Promotion of Recycling Reduction of Toxic Substances Promotion of 3R (Reuse, Reduce & Recycling) Boosting a Transformation of Urban Mines into Raw Materials Feedstock Strengthening the Link between Arterial & Venous Industries Environmental Hygiene Public Cleansing Act (1954) Serious Pollution Problems Strengthening Measures against Shortage of Landfill Space Construction/Improvement of Waste Disposal Facilities Environmental Conservation Waste Reduction and Promotion of Recycling Establishment of Various Recycling Systems Measures against Dioxins and Other Toxic Substances Establishment of a Circulating Society Measures for Securing Resource Supply Recovery of Resources from Used Products Improvement in Resource Efficiency Information Sharing Platform Waste Management Act (1971) Law for Bay Area Marine and Environment Consolidation Centers (1981) Structure Guidelines of Waste Disposal Facilities Amended (1986) Act on the Promotion of Utilization of Recycled Resources (1991) Containers and Packaging Materials Recycling Law (1995) Home Appliance Recycling Law (1998) Law for Special Measures against Dioxins (1999) Construction Materials Recycling Law (2000) Food Matters Recycling Law (2000) Basic Act on Establishing a Sound Material-Cycle Society (2001) End-of life Vehicle Recycling Law (2002) Basic Plan on Establishing a Sound Material-Cycle Society (2003) Strategy for Ensuring Stable Supplies of Rare Metals (2009) Basic Energy Plan (2010) Strategy for Securing Natural Resources (2012) Small Electronic Appliances Recycling Law (2013) Basic Act on Establishing a Sound Material-Cycle Society Amended (2013) Japan Revitalization Strategy (2016) Source: NEDO TSC (2016) based on Ministry of the Environment (2015) History and Current State of Waste Management in Japan and other materials. 4

5 R&D Projects Supported by Government In the new phase, various projects have been promoted by government focusing on Rare metals recycling and reduction of rare metals usage Energy Saving and low-carbon recycling process NEDO Funded by Project Comment R&D Project of Rare Metals Substitute Material Development ( ) Demonstration Project of Energy-saving Resource Circulation System Introduction into Asian Countries (2016-) etc. Recent Major Projects for Metal Recycling Technology Supported by Government in Japan Reduction of Usage and Development of Alternative Materials for Rare Metals and Rare-Earth Metals Including Utilization of IT for Recycling System JOGMEC (Japan Oil, Gas and Metals National Corporation) R&D for Recycling Prior Rare Metals ( ) R&D for Recovering Rare Metals ( ) etc Recycling Prior 5 metals (Co, Ta, W, Nd and Dy) Waste Small Electronic and Electric Appliances METI (Ministry of Economy, Trade and Industry) Demonstration Project of Resource Circulation ( ) R&D Project of Alternative Materials and Purification Technology of Rare Metals and Rareearth Metals ( ) etc. Recycling of Cemented Carbide Tools and LIB Reduction of Usage and Development of Alternative Materials MOE (Minister of the Environment) Demonstration Project of Low-carbon 3RTechnology and System ( ) Promotion Project of CO 2 -saving Recycling Plant Introduction (2015-) etc. and Shredding of Automobiles CO 2 -saving for Whole Recycling Process of Used Products 5

6 Domestic Market (Trillion JPY) Current Situations of Metal Recycling in Japan: Domestic Market Domestic Market of Recycled Materials (Non-ferrous Metals) has been grown at an average annual growth rate of 4.5% since Present: 1.26 Trillion JPY (2013 actual) 10 Billion EURO Future: 1.97 Trillion JPY (2030 predicted based on Growth Scenario, GDP growth 1.6%/y) 1.43 Trillion JPY (2030 predicted based on Basic Scenario, GDP growth 0.6%/y) Predicted (Basic scenario) Predicted (Growth scenario) Actual 1.26 Trillion JPY 1.97 Trillion JPY Trillion JPY 0.5 Average 4.5%/y Growth Year Domestic Market of Recycled Materials (Non-ferrous Metals) Source: NEDO TSC (2016) based on MOE Report on market and employee in environmental industry (2015) 6

7 Current Situations of Metal Recycling in Japan: Business Players We have some business categories in venous industry to play metal recycling business based on applicable laws and regulations. Since business players are certified by individual local governments, most of the business scales are not large. Arterial Industry Waste Usage/ Consumption Delivery /Sales Manufacturing Resource/ Raw materials Collection/ Transport Intermediate Treatment Raw Materials Recovery Venous Industry Waste Disposal Business Category Collection/ Transport Intermediate Treatment Raw Materials Recovery Waste Disposal Business category and players in metal recycling business in Japan Number of Business Players General waste: 38,304 Industrial waste: 127,266 General waste: 2,229 Industrial waste: 10,741 Non-ferrous metal smelting: 84 General waste: 138 Industrial waste: 541 Players Business Scale Small/Medium Mainly: Small/ Medium, Partially: Large Medium/Large Medium/Large Source: NEDO TSC (2016) based on METI Investigative report on measures against global warming (Sophistication and efficiency of resource circulation) (2015). 7

8 Current Situations of Metal Recycling in Japan: Process Flow of Metal Recycling from Waste Products Physical Chemical Separation Waste Products Waste Stream Disassembly & Shredding & Crushing Scrap Metals Smelting Visual/Manual Inspection Sensor Manual Mechanical Shredding Crushing Hand sorting Classification by Shape Magnetic Separation Pyrometallurgy (Heating, Calcination, Oxidation, Hydrogen Reduction, Carbonization, Chlorination, Moltensalt Reduction, etc.) Electric Separation (Electrostatic/ Eddy Current) Gravity Separation (Hydro/Pyro) Hydrometallurgy (Acid/Alkali Leaching, Solvent Extraction, Precipitation, Deposition, Drying, Electrolysis, Microbial Treatment, etc.) Flowchart of raw metals recovery from waste products Source: NEDO TSC (2015) based on NEDO Data analyses and evaluation report for resource-efficient environmentally-friendly raw materials recycling project to establish rare earths and rare metals recycling system from used small home appliances (2010). 8

9 Current Situations of Metal Recycling in Japan: Problems to Be Solved (1/2): Mixed Materials Not Circulated in Japan Reused rates of waste products are statistically high (e.g. Home appliances: 81%). A substantial portion of reused metals is not of raw materials circulated in Japan. Exported: Mixed metal from motors, compressors, transformers, etc. Used as mixed materials not fully sorted into single materials such as roadbed materials: Slag from e-waste Outflowing mixed materials (estimated 20%) Mixed metal Disassembled by hand and sorted overseas Mixed plastic (recycled) Hand-sorted and made into lowergrade products overseas Weight ratio Metals Glass others Recycling rate: 81% Recycled single material plastic Mixed materials not fully sorted into single materials (estimated 20%) Substrates Noble metals & copper: recovered Resin: incinerated Rare metals: slag Mixed plastic (not recycled) Incinerated (heat utilization), landfill Not circulated in Japan Recycling of home appliances in Japan (Mixed materials not circulated in Japan) Source: NEDO TSC (2015) based on Council on Competitiveness-Nippon Sustainable manufacturing technology platform (2009). 9

10 Current Situations of Metal Recycling in Japan: Problems to Be Solved (2/2): Outflow of Scrap Resources An increasing amount of scrap has been exported to the countries with lower cost. Recycling cost depends on the quality of metal scraps. Not only low quality scraps but also medium or high quality scraps are exported. Consequently, the supply of scrap metals may fall short of demand, and this potentially affects domestic smelting businesses in our venous industries. Decline in scrap iron prices affects other scrap resources in Japan such as outflow of resources and decreased domestic recycling rate. Export > Import Cu, PGM (platinum group metals) Low quality scraps are exported. Al, Pb High quality scraps which can be economically recycled due to higher purchase prices in foreign countries. Source: NEDO TSC (2016) based on METI FY 2014 research report on global warming countermeasures for the initiative towards improved sophistication and efficiency of resources circulation (2015). 10

11 Challenges in Metal Recycling Technology: Physical Challenges in physical sorting technology Low-cost automated operation to replace manual operation Generalization of low-cost mechanical sorting Selective disassembly & dismantling Energy-saving in shredding & crushing Higher recovery yield in scrap metals sorting based on simulation and sensing technologies Physical Waste Products Waste Stream Visual/Manua l Inspection Sensor Disassembly & Manual Mechanical Shredding & Crushing Shredding Crushing Scrap Metals Hand Classification by Shape Magnetic Separation Expensive Automated-apparatus Manual Operation High Cost High Energy Consumption Electric Separation (Electrostatic/ Eddy Current) Gravity Separation (Hydro/Pyro) 11

12 Challenges in Metal Recycling Technology: Chemical Separation Challenges in chemical separation technology Low-cost small-quantity processing for metals used in small quantities such as rare metals Environmental loading reduction Energy-saving smelting technology Chemical Separation Smelting Pyrometallurgy (Heating, Calcination, Oxidation, Hydrogen Reduction, Carbonization, Chlorination, Molten-salt Reduction, etc.) Hydrometallurgy (Acid/Alkali Leaching, Solvent Extraction, Precipitation, Deposition, Drying, Electrolysis, Microbial Treatment, etc.) High temperature processing High energy consumption Slug product Expensive scale-up plant High Cost Waste of acid and alkali Multi-step process 12

13 Challenges in Metal Recycling Technology: Information Sharing Platform Venous industries can be more efficient and sophisticated with the help of information sharing platform. Metal Recycling Processes Manufacturing /Disposal Transportation Waste Stream Disassembly & Shredding & Crushing Scrap Metals Smelting Data Base of Product s Metal Contents Product Traceability by Grade Based on Product Structure Particle Size Optimization Concentration of Recovered Metals Controlled Extraction Image Analysis Data Base Management Individual Identification I o T Robotics Sensing AI Applicable Technology Elements as Information Sharing Platform Sophistication of metal recycling processes enabled by information sharing platform Source: NEDO TSC (2016) based on materials from Resource Circulation Network, Inc. (Takamasa Hayashi, 2016). 13

14 Future Development TSC Environment &Chemistry Our goal is to ensure low-cost recycling to play a significant role in consistent supply of various raw metals, and recycled metals to become readily usable feedstock for high-performance applications (i.e. value recovery). A flexible system is needed to deal with fluctuations in resource prices to cover increasingly complex products enabled by advancement of materials technology. Issue 1 Effective Scheme for Waste Collecting Improve the Operation of Legal and Other Systems Used Products Issue 4 Disposal Urban Mines e-waste Recovery Intermediate Treatment Eco-friendly Design Collaboration between Sales Arterial and Venous Industries Smelting Issue 2 Effective and Low-cost Process Technology Development Recycling Products Issue 3 Market Formation and Expansion Promote Standardization Recycled Materials Challenges and their solutions in raw metals value chain 14

15 New R&D Project METI has been requesting budget for a new national project Technology Development of Metal Recycling for High-Efficiency Resource Circulation System to be started in 2017FY. (Budget for 2017FY: 900 million JPY). Product designs do not meet recycling processes. Waste product Linkage of product and recycling processes Quantity and quality of recycled materials do not meet product requirements Urban mines (Electronic waste) and sorting Automatic dismantling and sorting technology Smelting Inefficient manual operation Insufficient valuable recovery Solution Recycled materials High-efficiency smelting technology Outline of new national project for metal recycling 15