Circular Material Conference Gothenburg May 11th-12th 2016

Transcription

1 Circular Material Conference Gothenburg May 11th-12th 2016 Gro Eide, Director R&D Technical Centre

2 ELKEM AT A GLANCE Founded in 1904 Owned by China National Bluestar since years of history as a technology provider Global research centers in Kristiansand and Lyon, with 370 R&D workers 21 plants world wide, headquarter in Oslo, Norway 3600 employees (of which 1350 in Norway) NOK 15 bn revenue in

3 YOU MEET OUR PRODUCTS EVERY DAY 3

4 ELKEM HAS FOUR OPERATING DIVISIONS Elkem Silicon Materials Global producer and supplier of silicon, microsilica and specialty products 3 plants in Norway Elkem Foundry Products Leading producer of ferrosilicon alloys for iron foundries and steel industry 5 plants in Norway, Iceland, Canada and China Elkem Carbon Leading producer of electrode paste and other carbon products 5 plants in Norway, Brazil, South Africa and China Bluestar Silicones One of the foremost fully integrated silicone manufacturers in the world 8 plant in France, Spain, UK, Italy, Germany, US, Brazil and China 4

5 CLOSE TO OUR CUSTOMERS ON ALL CONTINENTS 5

6 ELKEM TECHNOLOGY YOUR INDUSTRIAL R&D PARTNER 6

7 ELKEM R&D TECHNICAL CENTER: FROM IDEA THROUGH TESTS INTO RESULTS Plan Design Experiment Analyse 7

8 ELKEM PILOT PLANT Facilities: Hydro-metallurgical lab Bench scale pyro-metallurgical lab Pilot skale pyro-metallurgical facility m 2 area pilot facilities Projects: Pyro-metallurgical process development and verification «Waste to resources» Raw material testing and qualification Testing and verfication of process equipment Hydro-metallurgical treatment Product testing 8

9 WASTE 2 RESOURCE: ELKEM S FISKAA PLANT IN NORWAY CA. 1970

10 WASTE TO RESOURCE: HOW TO GET RID OF THE SMOKE? 1950: filtration trials with blankets 1951: the first application experiments with The Fiskaastuff (microsilica) 1953: Elkem give up construction of large-scale filters, too challenging 1966: Elkem invests in electrostatic precipitator. Failure. 1971: Elkem invests in US filtration technology. Failure. 1973: Elkem has success with own design 1974: Authorities requires cleaning of Norwegian smelting industry Elkem establishes business unit for filters the filtered smoke creates a huge disposal problem Elkem: First successful filter installation (1973) Full plant cleaning (1979) 10

11 WASTE 2 RESOURCE: WHAT A DIFFERENCE A GOOD FILTER MAKES Before After

12 ELKEM MICROSILICA : SUPPORTING INDUSTRIEAL PROCESSES GLOBALLY Concrete Fibre Cement Ceramite Polymer Applications Well Drilling Ceramics Refractories Filters & equipment 12

13 UPGRADING OF BY-PRODUCTS: SOME EQUIPMENT EXAMPLES EAF with top and bottom electrodes kw, V, AC or DC Volume l EAF with two top electrodes 150 kw, V (1,5 V steps) Volume l Rotary kiln furnace Length 8750mm Dia 640mm, slope 4% Capacity kg/h Connected to 800kW EAF Pelletizing equipment 1500mm dia, variable slope Disc feeder and adjustable liquid nozzles Induction furnace kw, 4kHz Volume 35 l Hydraulic tilt, lip axis movement Bricquetting equipment Capacity kg/h Pillow or almond rollers 13

14 VORTAIR- 3 PROCESS STEPS IN ONE The Vortair technology Creates a vortex with higly adjustable caracteristics Coarse fraction leaves the bottom of the Vortair, while dry, fine fraction is collected from the bag house filter jhg Suggested uses Drying & pulverization of waste sludges Separation of metal/ oxide fines mix Surface cleaning of materials Applicable for metals, oxides, biomass, plastics, rubber and other materials Separation Particle separation based on density, size and/ or hardness Effective particle surface cleaning Vortair advantages 60% energy savings proven against thermal drying benchmark No moving parts, automated operation Low CapEx Adjustable processing performance 14

15 EYDE CLUSTER Founded core companies 21 suppliers (SMEs) 24 mrd. NOK (turnover) 7900 employees Norwegian Centre of Expertise (NCE) 2015

16 2013: EYDE ZERO WASTE MAPPING OF ALL MATERIALS PRODUCED AT 7 COMPANIES Company X

17 WASTE 2 RESOURCE: YESTERDAYS SPL LANDFILL

18 EYDE WASTE 2 VALUE Business case Recover metals from Fe- and SiMn sludges Utilize carbon from the Hall Herault waste streams Minimize need for future waste deposit Slag prosess FeMn(Ni)- alloy production Non leaking slag- Several possible uses Pre- reduction Direct reduction Mn- sludge: Return to customer process Fe(Ni)-/ FeMn(Ni)- sinter for steel industry Cryolite: Return to customer process Fe(Ni)(Mn)- alloy for iron and steel industry Results so far Single step drying/ milling ~0,14 kwh/ kg sludge «Ready to ship» quality on pre- reduced Fe- sludge «Return to process» quality on SiMn sludge Several alternative product routes detected 18

19 SEPARATION OF SI FROM SCULLS Business case 9wt% of the Si- units produced are lost post taphole Campaign objective: To establish a recovery route for Simet Program Small scale re- melting tests Pilot scale verification tests IR sorting (thermal conductivity) Vortair separation tests on scull fines Results Melting process >90% Si- recovery IR sorting tests successful in lab scale. Confirmed in automated industrial scale setup Fines separation in Vortair still ongoing with good results so far 19

20 FROM FLY ASH TO FOAM GLASS MSWI Fly Ash Land fill Foam glass Road building Floor insulation 20

21 FROM WASTE TO NICKEL PIG IRON Nickel production Iron sludge waste Underground deposit Coke and additives Nickel Pig Iron 21

22 EU-PROJECT SPIRE REE4EU Elkem Technology is responsible for the pilot part in REE4EU Pilot scale set-up and operation of the integrated recycling prosess of Rare Earth Elements for permanent magnets and Ni-hydrid batteries The process is an integrated high temperature electrolysis and Ion Liquid Extraction 22

23 RECYCLING OF BATTERIES Gas treatment Separation Copper Aluminium Plastic Co/Ni 23

24 CARBON NEUTRAL METAL PRODUCTION 24