Recycling to Recycling 4.0 Metallurgy & its infrastructure are key enablers Markus A. Reuter (Extract from 2016 TMS EPD Distinguished Lecture, February 17 th, 2016, Nashville, USA.) Helmholtz Institute Freiberg for Resource Technology I www.hzdr.de/hif
Overview: Metallurgy enables the CE CE: Circular Economy Energy and materials: Product Centric Recycling Circular Economy within a Corporation SIMP: System Integrated Metal Production Metallurgical infrastructure & knowledge of key importance Internet-of-Metallurgical-Things Web of Metals CEE: Circular Economy Engineering Recycling 4.0 Digitalized link of all stakeholders Quantification of resource efficiency Informing society in an understandable CE-paradigm Page 2
Some recent background literature to this talk http://www.unep.org/resourcepanel/portals/50244/publications/metal_recycling-full_report_150dpi_130919.pdf Page 3
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Circular Economy CE Recycling 4.0 understands and quantifies entropy in the CE http://www.europarl.europa.eu/news/en/news-room/20151201sto05603/circular-economy-the-importance-of-re-using-products-and-materials Page 5
CE: Harmonizing energy and materials Page 6
CE: A key issue? Sorting into the correct routes with minimum designed losses Au Cu Ta Page 7
Is sustainable considering both energy and materials for LED lamp designs? M.A. Reuter, A. van Schaik (2016): Strategic metal recycling: adaptive metallurgical processing infrastructure and technology are essential for a Circular Economy, RESPONSABILITÉ & ENVIRONNEMENT - AVRIL 2016 - N 82, pp. 62-66. Page 8
CE: Complexity & creating entropy Recycling 4.0 requires detail of particles to be able to optimize and & simulate Ferrous recyclate PCB recyclate Plastics recyclate Residue fraction Different appearances of PCB in (PCB) recyclates Page 9
CE: Understanding complexity and entropy System optimization key to Recycling 4.0 Page 10
CE: Understanding scrap & process metallurgy Simulation key to Recycling 4.0 Page 11
Decision variables produced during optimization, subject to market, EoL feed mix, etc. M.A. Reuter, A. van Schaik, O. Ignatenko (2006): Fundamental limits for the recycling of end-of-life vehicles, Minerals Engineering, 19(5), 433-449. UNEP, 2013: Reuter (LEAD AUTHOR), United Nations Environmental Protection (UNEP) Report Metal Recycling: Opportunities Limits Infrastructure report: http://www.unep.org/resourcepanel/publications/metalrecycling/tabid/106143/default.aspx
M.A. Reuter, A. van Schaik, O. Ignatenko (2006): Fundamental limits for the recycling of end-of-life vehicles, Minerals Engineering, 19(5), 433-449. UNEP, 2013: Reuter (LEAD AUTHOR), United Nations Environmental Protection (UNEP) Report Metal Recycling: Opportunities Limits Infrastructure report: http://www.unep.org/resourcepanel/publications/metalrecycling/tabid/106143/default.aspx
CE: Metallurgical infrastructure a key enabler https://www.youtube.com/watch?v=0we72hb7asy Page 14
System Integrated Metal Production - SIMP GEOLOGICAL MINE Geological Minerals (Au containing) URBAN MINE Designer Minerals and Functional Materials (Au containing) Market & Stocks Collection, Dismantling, Shredding Unaccounted Losses & Theft Product Complexity Losses Product Design Remanufacture Recycling Index Physical Separation Particle Properties Controls Losses Multi-material Recyclates Stocks & Losses Functional Metal & Material Combinations Pyro- & hydrometallurgy, Refining) Complex Linkages/Connections Losses & Stocks Losses Page 15
SIMP: The limits of the system? How much entropy creation (e.g. dilution of elements) can the system deal with? Page 16
SIMP: Complex minerals Reuter et al., United Nations Environmental Protection (UNEP) Report (2013) Metal Recycling: Opportunities Limits Infrastructure report: http://www.unep.org/resourcepanel/publications/metalrecycling/tabid/106143/default.aspx From: Raw materials of strategic economic importance for high-tech made in Germany: BMBF research and development programme for new raw material technologies Page 17
SIMP: Product Centric Recycling Reuter et al., United Nations Environmental Protection (UNEP) Report (2013) Metal Recycling: Opportunities Limits Infrastructure report: http://www.unep.org/resourcepanel/publications/metalrecycling/tabid/106143/default.aspx. Page 18
SIMP: Multi-metal Web of Metals Understanding dynamic interactions key to Recycling 4.0 Page 19
SIMP: Multi-metal Web of Metals Page 20
SIMP: Metallurgical System Optimization 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 Slag (low Pb) Horizontal Bath (QSL, KIVCET, SKS 2 stage) Fume BULLION Vertical Bath (TSL 1,2 & 3 stage) Horizontal Bath (SKS 1 stage) Slag (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 Slag Slag Zn & Refinery Products By-products: In, Ge etc. Discard Slag and Steam Soda Slag Refinery Cu, PMs, PGMs, various others Refinery Pb, Sn, Sb, Te, Se, In Refinery Au, Ag, Cu, Sb, As, Ge Discard Slag Page 21
SIMP: Resource efficient metallurgical systems Feeds Zn Concentrates Washed/roasted secondaries fumes (e.g. EAF dust) Ç Fume Leaching Plant Ag Concentrate Fume Zn/Pb (In/Ge..) Fume (Zn rich, Pb, In, Ge) Residue Feeds Pb Concentrates Pb Secondaries (e.g. battery) Ag Concentrate H 2SO 4 H 2SO 4 Direct Zn (TSL 2 stage) Pb/Speiss To lead plants Fume Zn/Pb (In/Ge..) Zn Solution Zn Plant Various configurations (Figure 2) H 2SO 4 Jarosite Goethite (old ponds / production) Zinc-Metallurgy Pb Residue Other residues Rotary Kiln Ç Slag (low Pb) Horizontal Bath (QSL, KIVCET, SKS 2 stage) Cu Speiss Circuit Boards etc. Cu Dross Fume BULLION Cu Removal BULLION Vertical Bath (TSL 1,2 & 3 stage) Lead-Metallurgy Horizontal Bath (SKS 1 stage) Blast Furnace Slag (high Pb) Cu TSL Processing BULLION Pb Refinery Pb Slime Fumer Waelz Kiln Zn-Fumers Cu Speiss Zn-Plasma Fumers 1 or 2 TSL(s) Leached Residue Copper-Metallurgy Precious Metal Refinery Discard Slag Slag Zn & Refinery Products By-products: In, Ge etc. Discard Slag and Steam Soda Slag Refinery Cu, PMs, PGMs, various others Refinery Pb, Sn, Sb, Te, Se, In Refinery Au, Ag, Cu, Sb, As, Ge Discard Slag Page 22
SIMP: Recovering metals from minerals & residues Lead Concentrates & Zinc residues Nyrstar (Zürich) installing TSL at Port Pirie, Australia 2016 (Outotec) Page 23
A selection of Outotec s 65 TSL and 18 Kaldo references Page 24
SIMP: Recovering metals from minerals & residues (65) Page 25
SIMP: Understanding metal distributions M.A.H. Shuva, M.A. Rhamdhani, G. Brooks, S. Masood, M.A. Reuter (2016) Thermodynamics data of valuable elements relevant to e-waste processing through primary and secondary copper production - a review, J. Cleaner Production (in press). Page 26
SIMP: Understanding and innovating technology TSL - Smelting Slag Fuming P- subarc smelting (60MW) Al-scrap salt-slag Pigiron & slag though coke bed Page 27
SIMP: Big data analysis Page 28
SIMP: Big data analysis Page 29
SIMP: Big data analysis Page 30
SIMP: Understanding complex recyclate feeds to metallurgical reactors we recycled 1153 ELVs Page 31
SIMP: Understanding metal recovery from complex feeds 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 Slag (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 Slag Reduction Furnace (Optional) Slag 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 32
Circular Economy Engineering - CEE I. Rönnlund, M.A. Reuter, S. Horn, J. Aho, M. Päällysaho, L. Ylimäki, T. Pursula (2016): Sustainability indicator framework implemented in the metallurgical industry: Part 1-A comprehensive view and benchmark, Part 2-A case study from the copper industry, International Journal of Life Cycle Assessment (both in press). Page 33
Circular Economy Engineering - CEE Outotec: HSC Sim PE-International: 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. Page 34 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) Etc... M.A. Reuter, A. van Schaik, 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, 20(5), 671-693.
CEE: Measuring particle properties and estimating resource efficiency through simulation Page 35
CEE: Big data analysis creating fuzzy models Page 36
CEE: Link CAD & Smelter to Recycling Index Traditional Design for Recycling does not provide detail nor reveal the limits! M.A. Reuter, A. van Schaik, 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, 20(5), 671-693. Page 37
CEE: Comparing solutions relative to baseline Rönnlund, M.A. Reuter, S. Horn, J. Aho, M. Päällysaho, L. Ylimäki, T. Pursula (2016): Sustainability indicator framework implemented in the metallurgical industry: Part 1-A comprehensive view and benchmark, Part 2-A case study from the copper industry, International Journal of Life Cycle Assessment (in press). A + A ++ A A +++ G Recycling Index CE System 1 CE System 2 B C F D E MARAS B.V. I Page 38
CEE: Rigorous comparison of options Ni-Pigiron M.A. Reuter, A. van Schaik, 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, 20(5), 671-693. Page 39
CEE: Geographic comparison of technology - FeCr Page 40
CEE: Recycling vs Energy-Index, 3 LED Redesigns A + A ++ A A +++ G Recycling Index 10-50% B C F D E LED 1 LED 2 MARAS B.V. LED 3 Page 41
Is sustainable? Page 42
CEE: Recycling 4.0 Page 43
Summary and some thoughts Digitalizing the Circular Economy: Recycling 4.0 Maximize Resource Efficiency: Energy vs. Material Efficiency Simulation, measurement, control, Internet of Metallurgical Things Metallurgical infrastructure key to circular economy Maximizes metal recovery in dynamically changing conditions Ensure that CE system is robust and agile in its technologies Circular Economy Engineering: Metallurgy s contribution Simulation basis to estimate economics and environmental impact Inform Policy & Consumer in a simple but rigorously based manner Limits of a Circular Economy? Is CE the answer or must we simply consumer less? CAPEX & OPEX of CE system? Page 44