Advancements in Handheld XRF Technology Improve Scrap Sorting and Segregation

Transcription

1 Advancements in Handheld XRF Technology Improve Scrap Sorting and Segregation Jonathan Margalit, Ph.D Business Development Manager Metals Thermo Scientific Portable Analytical Instruments 20 th International Recycled Aluminium Conference, 2012 Salzburg, Austria 1 The world leader in serving science

2 Is It Aluminum or Aluminium? Take the Quiz.. Element number 13 (Al) was named by: A B C A B C Co-developer of the Hall-Héroult process, Charles Martin Hall The English Chemist, Sir Humphry Davy The Danish discoverer of the element, Hans Christian Ørsted Sir Humphry Davy s initial spelling of the element was: Aluminum (US) Aluminium (Rest of world) None of the above None of the above! He first spelled it Alumium (1807) Then changed it to Aluminum And finally settled on Aluminium (1812) 2

3 Presentation Outline Introduction Key Developments in the Al-Industry Handheld XRF-Basics and Developments The Value Proposition: Manufacturers Scrap Yards Conclusion 3

4 We Are the World Leader in Serving Science We are the leading provider of analytical instruments, equipment, reagents and consumables, software and service for research, analysis, discovery and specialty diagnostics Global Scale 39,000 employees in 40 countries $12 billion in annual revenues Unparalleled commercial reach Unmatched Depth Innovative technologies Applications expertise Laboratory productivity partner Leading Brands We enable our customers to make the world healthier, cleaner and safer 4

5 Portable Analytical Instruments Molecular analysis Leading field-deployed analytical instruments for human health and public safety, delivering lab-accurate analysis at the point of need Elemental analysis The pioneer in x-ray fluorescence (XRF) analysis, bringing the lab to the field with speed, accuracy, and ease of use Stats: More than 400 employees worldwide Headquartered near Boston, USA Analyzer excellence recognized globally Molecular More than 6,000 instruments deployed since 2005 Elemental More than 35,000 analyzers deployed since

6 Key Developments in the Aluminum Industry 6 The world leader in serving science

7 Key Developments in The Aluminum Industry 1) Increased demand for aluminum Industrialization in emerging markets Automotive: increased build rates and increasing light content (energy efficiency) Aerospace Consumption is up by 9.2% in Jan-Aug 2012 over Jan-Aug 2011* 2) Primary production constraints Growing demand growing profits Oversupply (10 mill. t stockpiled 150,000 Boeing 747s) Capacity shut down, non-profitable operation 3) Strong push to incorporate scrap as a raw material Financial: 95% energy savings Environmental: 95% green house emissions reduction Regulatory compliance (LEED, CAFE) Growing environmental awareness Aluminum is 100% recyclable with no loss of quality * Shipments of aluminum extruded products, The Aluminum Association 7

8 Novelis: An Example for Higher Scrap Integration 100 Content of Recycled Materials % from postconsumer scrap From Novelis website, red arrow added by author Benefits to Aluminum Manufacturers: Reduce dependence on mining and primary production Reduce carbon footprint Increase profitability Scrap Trends: Higher recycling content Higher post-consumer scrap content Cross sector competition for scrap 8

9 The Challenge: Replacing Alumina with Scrap as a Feed Material Feed Material: Norsk Hydro Information availability about: Manufacturer Composition Lot Information Country of Origin Knowledge of Hazardous Materials With XRF???????? 9

10 Portable XRF Technology Overview 10 The world leader in serving science

11 Handheld XRF Technology Overview 1. Primary x-ray ejects K-shell electron 2. Electrons from higher shells fill in the gaps 3. Differential energy state is released as fluorescence x-rays (element-specific) 4. The x-ray energies are analyzed and compared with a built-in alloy library 5. Output: - Spectra - Positive grade identification - Elemental composition - Match level (0-4) 11

12 12 Detectable Elements Using Handheld XRF Then

13 Handheld XRF Technologies Improvements Technology Improvements Advantages Value Large Silicon Drift Detector (SDD) Small anode capacitance DC operation Low leakage current Higher count rate No detector dead-time Higher resolution at low temp Improved signal-to-noise ratio 3x improvement over Si-PIN Light element (Al, Si, Mg) detection in air Higher sensitivity (trace elements) 50 kv X-ray Tubes Maximize fluorescent x-rays 2x improvement over 40 kv Improved Limits of Detection (LODs) Faster measurements Optimized Detector-Tube- Sample Geometry Primary x-rays Maximize fluorescent x-rays 2x improvement No/minimal sample preparation Detector Sample Improved confidence level 13

14 14 Detectable Elements Using Handheld XRF Now

15 The Result: New Alloy Separation Capabilities: Based on Light Element Content*: Si Fe Cu Mn Mg Min Max Min Max Min Max Min Max Min Max Based on Trace Element Content*: Cr Zr Cu Zn Mg Min Max Min Max Min Max Min Max Min Max *Not all elements shown

16 The Value Proposition Scrap Yards Al-Manufacturers Photo: Norsk Hydro 16

17 The Value Proposition - Manufacturers Handheld XRF used to: Examples: Value Proposition: Direct Impact on: Savings Compliance Safety Block undesired elements/alloys from entering the melt Enforce desired elements/alloys into the melt Contaminant prevention Melt feedstock optimization Raw material sourcing optimization Ensure furnace integrity Extend furnace service life Prevent equipment downtime Ensure end-product specs Monitor melt properties Select most cost-effective melt feedstock Minimize the need to purchase additives 17

18 Application Example: Contaminants Prevention Example 1) 6033 (Pb, Bi) 6262 (Pb, Bi) Example 2) 7xxx (Zn) 6xxx Bi/Pb free alloys 6061,

19 Application Example: Melt Feedstock Optimization 3105 can be made by using various alloy combinations: A B C n % 37% 30% % 37% 51% % 26% 19% Within 3105 Spec? 3105 Relative Material Cost: 1X 1.08X 1.11X Most Cost-Effective Combination 19

20 Application Example: Raw Material Sourcing Option $ Option 2 Alloy A Alloy B Mg Alloy C Alloy D Mg Note: element proportions have been exaggerated to illustrate the principle

21 The Value Proposition Scrap Yards Handheld XRF can be used to: Value Proposition Direct Impact on: Profitability Credibility Competitiveness Segregate between high and low-value alloys Increase lot value Deliver consistent chemistry Avoid lot downgrade or rejection Identify in-family grades Provide value-added services to their customers (secondary manufacturers) 21

22 What a Difference a Grade Makes Maximizing Profitability 6061 or 6063? 4 cm Annual Turnover ( ooo tons) Potential Cost Savings as a Result from Correct Grade Identification Price Difference ( ) USD/lb $0.05 $0.07 $ $2.6 M $3.7 M $5.2 M 12 $1.3 M $1.8 M $2.6M 6 $0.6 M $0.9 M $1.2M 22

23 Conclusion Key developments within the aluminum industry are creating an increased demand for scrap: Increased aluminum consumption Primary aluminum capacity constraints Attractiveness of scrap Replacing alumina with scrap as a raw material brings new challenges (material identification, hazardous elements). Thanks to technological advancements in handheld XRF, light element measurement capabilities (Mg, Al, Si, P, S) have improved significantly. Handheld XRF is a value-added tool, currently used by aluminum manufacturers and scrap yards operators to determine alloy grade and chemical composition. 23

24 Thank You Q&A The metal in old Canadian cars and trucks goes to Asia for recycling. Its circle route as it makes its way through the global recycling economy is a Mad Max world of metal dealers and desperate people mining civilization's infrastructure. Excerpted from "American Scrap: an old-school industry globalizes" by John Seabrook Jonathan Margalit Thermo Fisher Scientific jonathan.margalit@thermofisher.com Tel.: +1 ( 978)