Metallurgical infrastructure:

Transcription

1 Prof. Dr. Dr. h.c.. Markus A. Reuter I I Metallurgical infrastructure: A key enabler of a circular economy Markus Reuter

2 Agenda: Illustrated by various industrial examples Circular Economy: Opportunities & Limits? Metallurgical infrastructure is a pillar of a Circular Economy Product Centric Recycling Roots in minerals thinking, which the basis of metal production Material Centric & Element Flow thinking may limit innovation as it reveals limited process metallurgical resolution? Metallurgical Infrastructure Importance & Criticality Metal Criticality is also dependent on metallurgical know-how and it s available infrastructure & robustness/flexibility Approaches should enable innovation i.e. techno-economical feasibility of metal and by-products production should form the foundation Page 5

3 Complex minerals: Metallurgical Infrastructure key From: Raw materials of strategic economic importance for high-tech made in Germany: BMBF research and development programme for new raw material technologies Page 6

4 Recoverying metals from minerals and residues Two industrial examples: Require complex flowsheets and deep knowledge Feeds Zn Concentrates Washed/roasted secondaries fumes (e.g. EAF dust) Fume (Zn rich, Pb, In, Ge) Residue Feeds Pb Concentrates Pb Secondaries (e.g. battery) Ag Concentrate Fume Leaching Plant Ag Concentrate Fume Zn/Pb (In/Ge..) H 2SO 4 H 2SO 4 Direct Zn (TSL 2 stage) Zn Solution Zn Plant Various configurations (Figure 2) H 2SO 4 Pb Residue Rotary Kiln (low Pb) Horizontal Bath (QSL, KIVCET, SKS 2 stage) Fume BULLION Vertical Bath (TSL 1,2 & 3 stage) Horizontal Bath (SKS 1 stage) (high Pb) Pb/Speiss To lead plants Fume Zn/Pb (In/Ge..) Jarosite Goethite (old ponds / production) Other residues Cu Speiss Circuit Boards etc. Cu Dross Cu Removal BULLION Blast Furnace Cu TSL Processing BULLION Pb Refinery Pb Slime Fumer Waelz Kiln Zn-Fumers Zn-Plasma Fumers 1 or 2 TSL(s) Leached Residue Precious Metal Refinery Cu Speiss Discard Zn & Refinery Products By-products: In, Ge etc. Discard and Steam Soda Refinery Cu, PMs, PGMs, various others Refinery Pb, Sn, Sb, Te, Se, In Refinery Au, Ag, Cu, Sb, As, Ge Discard Page 7

5 Recoverying metals from minerals and residues Identify holes in the system for complex minerals Focus on them and integrate metallurgy (multi-layer knowledge required) Feeds Zn Concentrates Washed/roasted secondaries fumes (e.g. EAF dust) Fume (Zn rich, Pb, In, Ge) Residue Feeds Pb Concentrates Pb Secondaries (e.g. battery) Ag Concentrate Fume Leaching Plant Ag Concentrate Fume Zn/Pb (In/Ge..) H2SO4 H2SO4 Direct Zn (TSL 2 stage) Zn Solution Zn Plant Various configurations (Figure 2) H2SO4 Pb Residue Rotary Horizontal Bath (QSL, KIVCET, SKS 2 Kiln stage) (low Pb) Fume BULLION Vertical Bath (TSL 1,2 & 3 stage) Horizontal Bath (SKS 1 stage) (high Pb) Pb/Speiss To lead plants Fume Zn/Pb (In/Ge..) Jarosite Goethite (old ponds / production) Other residues Cu Speiss Circuit Boards etc. Cu Removal Cu Dross Focus Cu TSL Processing BULLION Pb Refinery BULLION Pb Slime Blast Furnace Fumer Waelz Kiln Zn-Fumers Cu Speiss Zn-Plasma Fumers 1 or 2 TSL(s) Leached Residue Precious Metal Refinery Secondary Feeds (Low & high-grade Cu, circuit boards, metal containing residues, ASR etc.) Discard Zn & Refinery Products By-products: In, Ge etc. Discard and Steam Soda Refinery Cu, PMs, PGMs, various others Refinery Pb, Sn, Sb, Te, Se, In Refinery Au, Ag, Cu, Sb, As, Ge Discard Reductant Flux Fuel Air (Oxygen) 1-3 Stage TSL Discard (Construction Material) Raw / Anode Copper Dust/Fume Intermediate Pb-rich Phases Fumes (Zn-rich) Gypsum Slimes Precipitates Zn Recycle (Pb/Sn-rich) Pb/Sn/Bi Products Te, Se etc. Slimes PGMs PMs Slimes Electrowinning & Refining Cathode Copper Page 8

6 Recognizing complexity of EoL minerals Most geological minerals are complex and require complex flowsheets to recover all metals, so what about flowhseets for EoL products? Page 9

7 Thermodynamics & technoeconomics of separation Test ideas first with thermodynamic tools. Support fundamental thermodynamic data measurement not just MFAs Page 10

8 Technology and System Options Understand technology systems to inform simpler element flow analysis Secondary Copper Feeds Fuel, Air (Oxygen) (Low-grade Cu) Reductive Smelt Reductant Flux Dust/Fume Zn rich, Pb/Sn To further processing Various High- & Low-Grade Cu Scrap TSL Discard (Construction Material) Dust/Fume To further processing - Zn rich, Pb/Sn Dust Fume Sn rich, Pb Fuel, Air (Oxygen) Black Copper Secondary Copper Feeds (High-grade Cu) Flux Discard Reduction Furnace (Optional) Copper Alloy To further processing Kaldo Oxidative Convert (Optional) Raw Copper (+PMs & PGMs) To Refining Converting can also take place in TSL in two-stage process Page 11

9 Technology and System Options Understand industry & technology SiO Al 2 2O 3 V 2O 5 MgO SrO SrO WO 3 FeO CaO CaO REOs KCl CaF x 2 BaO MgO TiO 2 ZrO 2 In 2O 3 Al 2O 3 Na K P Cd Ga 2O 3 Hg F ThO BaO 2 Cl Na REOs Hg As Ag Bi Pb P Ta 2O 5 K Nb 2O 5 Pb Cd Au Sn Zn CaF 2 Ti Zn Sb Sb Cr Br Ta Fe Mn REs Si Ni Nb Mg V Th Al 2O 3 Co W Sn Ni Cu Cr Cu Ti Au V Nb Pd Pd Ag Mo Si Cr Pt Cl SiO 2 Pb Rh Sn Pt Fe Al Mo Zr Si Zn Al Al Remelt Ti REs Th CaO Steel (BOF&EAF) Refine Pyro F Fe Si Metallurgy Mn Remelt Zr Al FeO x Mg Cl TRIP Steel Hydro Metallurgy Ni Austenitic Remelt Zn MgO Fe Ni/Cr Li Cr Stainless Hydro&Pyro Steel Cu Pt Bi Smelt Refine Various High- & Low-Grade Au Ge Cu Sn Scrap Cu/Ni Dust/Fume To further processing - Zn rich, Pb/Sn Al 2O 3 Co CaO SiO 2 Ag In As Te Zn RLE/Fume Pb Ga Smelt/Refine Sb Au Cd Pt Ag Se Th Pd Ni Rh Pb Te REs As Mo FeO x Hg Br Zn Co Ni Sb V 2O 5 In Bi Cd In 2O 3 F TiO 2 Sn P Na Ga 2O 3 Ta 2O 5 SrO Ge Nb 2O 5 Cl MgO K ZrO 2 MnO WO 3 Al 2O 3 BaO SiO 2 FeO x REOs CaO Cu 2O NiO ThO 2 EoL Products Residues Sn Smelt/Refine Sb Ag Zn metallurgy RE Hydrometallurgy RE Special Battery Recycling As Pb Cu Co Secondary Copper Feeds Fuel, Air ZrO 2 TiO 2 (Oxygen) Ni Bi MnO RE(O)s In MgO Nb 2O 5 In CaO 2O 3 Ta V 2O 5 2O 5 TiO 2 SiO 2 Al 2O 3 van Schaik WO 3 Reuter K ZrO 2 P REOs Li 2O AlX y In FeO x REOs B SiO 2 Sb 2O 3 Ga/As SiX y Al 2O 3 F/Cl Br Cu CaX y FeO x K/Na P MgO MnO MgO SrO CaO P 2O 5 SiO 2 CaO Al 2O 3 FeO x Dust Fume Sn rich, Pb Fuel, Air (Oxygen) (Low-grade Cu) Reductive Smelt TSL Black Copper Reductant Flux Dust/Fume Zn rich, Pb/Sn To further processing Discard (Construction Material) Secondary Copper Feeds (High-grade Cu) Flux Discard Reduction Furnace (Optional) Copper Alloy To further processing Kaldo Oxidative Convert (Optional) Raw Copper (+PMs & PGMs) To Refining Converting can also take place in TSL in two-stage process Page 12

10 Technology & System Options: Companies doing it (65) Page 13

11 Technology & System Options: Companies doing it 3 Stage lead smelting, cleaning: YTCL (China) WEEE, ewaste, Cu scrap, Residues: Dowa (Japan) Cu, slimes, ewaste etc.: Boliden (Sweden) Cu-scrap, internal residues: Guixi (China) Lead Battery Recycling: Recylex (Germany) WEEE, Cu Recycling, cleaning: GRM (S. Korea) Zn-Residue processing: Young Poong Corporation (S. Korea) cleaning: Mitsui, Hachinohe (Japan) Page 14

12 Thermodynamics & techno-economics of separation Compare Outotec: technologies HSC on Sima rigorous basis (Shown PE-International: Pb&Zn smelting) GaBi BAT, Flow Sheets & Recycling System Maximizing Resource Efficiency Benchmarks $US / t Product (CAPEX & OPEX) Recyclability Index (based on system simulation of whole cycle) Energy: GJ & MWh / t Product (source specific) Exergy: GJ & MWh / t kg CO 2 / t Product kg SO x / t Product g NO x / t Product m 3 Water / t Product (including ions in solution) kg Residue / t Product (including composition) kg Fugitive Emissions / t Product kg Particulate Emissions / t Product Etc. M.A. Reuter, A. van Schaik and J. Gediga (2015): Simulation-based design for resource efficiency of metal production and recycling systems, Cases: Copper production and recycling, ewaste (LED Lamps), Nickel pig iron, International Journal of Life Cycle Assessment, Vol. 20(5), pp Page 15 Environmental Indicators based on BAT Driving Benchmarks of Industry ReCiPe (and similar) Endpoint estimation Global Warming Potential (GWP) Acidification Potential (AP) Eutrification Potential (EP) Human Toxicity Potential (HTP) Ozone Layer Depletion Potential (ODP) Photochemical Ozone Creation Potential (POCP) Aquatic Ecotoxicity Potential (AETP) Abiotic Depletion (ADP) Water footprint (Green, Blue, Grey) Etc...

13 Thermodynamics & technoeconomics of separation Compare technologies on a rigorous basis (Shown for Pb&Zn smelting) Page 16

14 Ag Al Al2O3 Au BaO Ba Bi C (C5O2H8)n C6H12Cl3O4P C15H12Br4O2 (C25H30O4N)n C12H12O4n CaO Co Cr Cu Fe Mg MgO Mn Ni Pb Pd Ru REEs Silicone Si SiO2 Sn SrO TiO2 Ti V Zn TOTAL RECOVERY % Total Recovery (%) after Physical Recyclingand Process Metallurgy Design for Recycling and Sustainability Simulation based Recyclability index: Knowing where all metals flow to Product Design Recycling process simulation models Recycling Index Recovery rate calculations of all elements Environmental Assessment % 46% 41% 48% 38% LED Design A LED Design B LED Design C LED Design D LED Design E Page 17

15 Recyclability Index Inform consumer Rigorous simulation based evaluation produces a low recycling rate: 30-40% Non-process metallurgy based approaches calculate RR >> 60% [Source: M.A. Reuter, A. van Schaik and J. Gediga (2015): Simulation-based design for resource efficiency of metal production and recycling systems, Cases: Copper production and recycling, ewaste (LED Lamps), Nickel pig iron, International Journal of Life Cycle Assessment, Vol. 20(5), pp ] Page 18

16 Summary Digitalizing the Circular Economy Quantify TRUE resource efficiency by a detailed simulation based understanding of the process This enables rigorous digitalization i.e. Internet of Metallurgical Things Metallurgical infrastructure key to a circular economy Maximizes metal recovery in dynamically changing conditions System Innovation Key Understanding the system and process metallurgy will help to maximize resource efficiency Inform Policy & Consumer with simple results as the Recycling Index based on rigorous (simulation) engineering methods Page 19