CENTER FOR RESOURCERECOVERY & RECYCLING

An NSF Industry/University Cooperative Research Center

Diran ApelianHowmet Professor of EngineeringDirector of Metal Processing InstituteWPI – Worcester, MA 01609 USA

dapelian@wpi.edu508 831-5992 office508 380-1203 mobile

Metal Processing InstituteWPI, Worcester, MA 01609 USA

• CONTEXT & SOCIETAL NEED• VISION AND APPROACH• WHO ARE THE PLAYERS?• SCOPE OF CENTER

Next Steps

OUTLINE

Importance of Materials Recycling

Recycling iron and steel saves 74% of energy and 86% of emissions compared with primary production

Other Energy savings are: 95% for aluminum 85% for copper 65% for lead 60% for zincOver 80% for plastics

Credit: C. Meskers - Umicore

Consumer products are increasingly complex

* based on 2008 sales, Gartner 2.3.2009 1 20 g Li-ion battery 2 Li-ion batteries is used in >90% of laptops

Cell phones*:

1300 Million units x 250 mg Ag ≈ 325 t Ag

x 24 mg Au ≈ 31 t Au

x 9 mg Pd ≈ 12 t Pd

x 9 g Cu ≈ 12,000 t Cu

x 3.8 g Co1 ≈ 4900 t Co

PC & laptops*:

300 Million units x 1000 mg Ag ≈ 300 t Ag

x 220 mg Au ≈ 66 t Au

x 80 mg Pd ≈ 24 t Pd

x ≈ 500 g Cu ≈ 150,000 t Cu

≈140 M batteries2 x 65 g Co ≈ 9100 t Co

Ag, Au, Pd… (precious metals)

Cu, Al, Ni, Sn, Zn, Fe, Bi, Sb, In… (base & special metals)

Hg, Be, Pb, Cd, As… (metals of concern!)

halogens (Br, F, Cl...)

plastics & other organics

Glass, ceramics

These devices represent a considerable metal stock in society

© Umicore

Growing Material Use(Ayres, Ayres & Moore 2006)

When waste is produced, the costs Are all additive …+

Raw materials used to produce waste Processing raw materials into waste Waste treatment Trade waste fees or disposal charge Lost opportunity by not recycling Waste-related maintenance

Policy and Economic Issues

Regulations, e.g.:

Mandate by municipalities to segregate

“Bottle Bill Law” for beverage containers

ELV legislation, “cradle-to-grave” (Europe)

Economic Incentive, e.g.: Need for materials segregation, or sortation

Contamination reduces (and can eliminate) value of recycled materials

EDUCATION POLICY

INVESTMENTSR&D

THREE KEY PILLARS

Why Is CR3 Important and Needed?

Reduce: waste of scarce resources materials going to landfills (finite capacity) emissions of greenhouse gases demand for energy

Develop: engineering talent policy for a sustainable future

CR3 Vision

To be the premiere industry-university alliance serving consortium members’ needs, by establishing the needed knowledge base, and by educating future leaders of the industry. We are dedicated to the Sustainable Stewardship of our Earth’s Resources.

The Industry/University Cooperative Research

Center (I/UCRC) on Resource Recovery and Recycling engages in the development of technologies and their transfer to industry with the goal of achieving materials sustainability. Resource productivity and societal sustainability demand that materials recovery and recycling be included from initial product design through manufacture to end-of-life disposition in a manner that yields both energy savings and profitability.

Approach

• CONTEXT & SOCIETAL NEED• VISION AND APPROACH• WHO ARE THE PLAYERS?• SCOPE OF CENTER

Next Steps

OUTLINE

Management Organization Chart

Academic

Policy

CommitteeCENTER

EVALUATOR

project

project

WPI Faculty and

Industrial

Representation

project

project

project

project

project

project

project

project

project

CSM Faculty and

Industrial

Representation

Purdue Faculty and

Industrial

Representation

NSF

Industries

across the

United

StatesCenter

Director

At WPI

INDUSTRIAL

ADVISORY

BOARD

Dean’s

office

•Each cluster carries its own weight

•Multiple companies provide interaction capabilities

project

WPI

www.wpi.edu/+mpi

A Little Bit of History

• Founded in 1865 by Boynton & Washburn

Worcester Free Institute of Industrial Science

• First graduate degree in 1898

• First women admitted in 1968

• “WPI Plan” adopted in 1970

20

WPI Innovations (a few of them)

Stainless Steel (Elwood Haynes, 1911)

First Liquid-Fueled Rocket

(Robert H. Goddard, 1926)

Negative Feedback Principle in Electronics

(Harold Black, 1927)

Area Rule for transonic flight, supercritical wing, winglets

(Richard Whitcomb)

Airbag Safety Systems (Carl Clark, mid 1960s, for aircraft)

Catalytic Converter (Robert C. Stempel, 1973)

First Portable Drug Infusion Pump (Dean Kamen, early 1970s)

Segway Human Transporter (Dean Kamen, 2001)

21

Recognition for WPI

Ranked No. 68 among all national, doctoral universities by U.S. News & World Report

WPI’s part-time MBA ranked #1 in the Nation by Business Week

WPI ranked 9th in the nation by Forbes.com in “Top Colleges for Getting Rich”

22

Engineering is about creating our physical world and as our environment changes, we may have to learn new skills and adopt new attitudes. To do so we need to understand the broader role of engineering in shaping our civilization

Engineering as a discipline

Commodity Engineers

Entrepreneurial Engineers

What is Engineering?

Knows Everything— Or rather, can find any information

quickly and knows how to evaluate and use those

information.

Can do Anything — Understands the basics to the degree

that he or she can quickly understand what needs to be

done and acquire the tools needed

Collaborates— Has the communication skills, team skills,

and understanding of global and current issues to work

with anybody anywhere

Innovates— Has the entrepreneurial spirit and the

managerial skills to identify needs, come up with new

solutions, and see them through

The Entrepreneurial Engineer

Source: Tryggvason and Apelian, Journal of Metals, V.58, No.10, pp. 14-17 (2006)

Metal Processing Institute

Advanced Casting Research Center (ACRC)

Consortium established in 1984

Educational home for Metalcasting Industry

Center for Heat Treating Excellence (CHTE)

Consortium established in 1991

Educational home for Heat Treating Industry

Resource Recovery and Recycling Center (CR3)

Consortium established in 2010

Center for Imaging and Sensing (CIS) - A dedicated facility for NDE and imaging

Diran Apelian Dan Backman

Rick Sisson Makhlouf Makhlouf Reinhold Ludwig

Metal Recovery via Automated Sortation

Optoelectronic Sensing of Molten Metal Composition

Development of an Alloy Recyclability Index and Strategies for Tagging to Facilitate Downstream Processing

WPI Research Projects

Development of Aluminum-Dross Based Materials for Engineering Applications:Reduce land filling and energy usage to recover Al

28

Alloy Grouper Concept

Concept of ChipSort™ Technology

29

Laser Induced Breakdown Spectroscopy (LIBS)

“Remote” LIBS for High Temperature Alloys

Laser

CR3 at the Colorado School of Mines

Established in 1874, Colorado School of Mines ranks 29th in the Top 50 Public National Universities and 72nd among Best

National Universities according to the 2011 edition of America’s Best Colleges by U.S. News and World Report.

Metallurgical & Materials Engineering

Functional Materials

RESEARCH ACTIVITIES [$6.5 MM/YR]

• Advanced Coatings & Surface Engineering Laboratory (ACSEL)– Funding: Approximately $1million/year: 20 company consortium + NSF, DOE

• Advanced Steel Processing & Products Research Center (ASPPRC)– Funding: Approximately $1.8 million/year: 25 company consortium + NSF,

DOE

• Center for Welding, Joining & Coating Research (CWJCR)– Funding: Approximately $1.2 million/year: DOD, + industry

• Colorado Center for Advanced Ceramics (CCAC)– Funding: Approximately $1.5 million/year: NSF, EPA, DOE

Home of CR3

The Kroll Institute for Extractive Metallurgy - KIEM

Department of Metallurgical and Materials

Engineering

Colorado School of Mines

www.mines.edu

KIEM

KIEM - Kroll Institute for Extractive Metallurgy

Patrick R. Taylor

Director, KIEM

G.S. Ansell

Distinguished

Professor of

Chemical

Metallurgy

EXPERTISE

Mineral Processing

Extractive

Metallurgy

Recycling

Waste Treatment &

Minimization

Thermal Plasma

Processing of

Materials

Thermal Plasma

Processing of Wastes

Brajendra Mishra

Associate Director

KIEM, Professor of

Metallurgical and

Materials Engineering

EXPERTISE

Pyrometallurgy

Electrochemistry

Materials synthesis

Waste Processing

Recycling

Molten Salt

Processing

Oxidation

Reactive &

radioactive metals

Glove box processing

Corby G. Anderson

Harrison Western

Professor of Metallurgical

and Materials

Engineering

EXPERTISE

Extractive Metallurgy

Mineral Processing

Recycling

Waste Treatment &

Minimization

CR3

Recovery of Rare Earth Metals from Phosphor Dust

Project Objectives:•Develop processes for the recovery of rare-earth metals from phosphor dust. Phosphor dust is generated from fluorescent light bulb wastes after glass and mercury have been removed.

•Only 30% of the lamps sold per year are recycled (2400 tons per year of phosphor powder). The total market for phosphor dust in US is currently 8000 tons per year.

•The dust contains economically recoverable amounts of rare earth metal oxides, estimated at 9.0-12.5 % of phosphor powder.

•Assess the dust physically and chemically, and based on valuable metal content, develop innovative RE recovery technologies.

•Recovery technologies will be divided into: (a) concentration of metal by physical beneficiation, (b)electrometallurgical processing and (c) pyrometallurgical processing.

Beneficiation of Photovoltaic (and other) Functional Coatings

Project Objectives:

•Evaluate and develop innovative PV recycling technologies. Recycling technologies might be divided into three general categories: physical beneficiation, hydrometallurgical processing and pyrometallurgical processing.

•Critically evaluate the use of physical and chemical beneficiation on PV scrap. The project will evaluate delamination of thin films and the utilization of pyrometallurgical approaches to recycling PV scrap.

Recovery of Binder and Silica from Bag-

House Dust

Project Objectives:

• Victaulic foundries currentlyproduce a bag-house dustbyproduct that contains potentiallyrecoverable amounts of silica andbinder material.

•Liberate and separate more usefulfractions of the bag-house dustfrom other, less recoverable,components such that a maximumamount of material is re-used inthe foundry process and aminimum amount of material mustleave the facility as a byproduct.

US AffiliatePurdue UniversityWest Lafayette IN

Prof. Carol Handwerker

Results of Legislation

Starting with EU Reduction of Hazardous Substances (RoHS) - 1999

Materials banned: Lead (Pb)Mercury (Hg)Cadmium (Cd)Hexavalent chromium (Cr6+)Brominated flame retardants:

Polybrominated biphenyls (PBB) Polybrominated diphenyl ether (PBDE)

Just the beginning of bans and restrictions

new materials sets, manufacturing processes, product designs, global interactions needed from global sustainability perspective

42

Lead ban, e-waste, and packaging law

27 states draft e-waste bills

E-waste & packaging laws

E-waste

Battery law

E-waste , Dfe product &Packaging

E-waste

EuP

REACH

E-waste & Energy

E-waste

China RoHS

Energy law

Energy E-waste, RoHS

Packaging

21 Mercury bans

IPP25 EU States –WEEE & RoHS

RoHS study

E-waste, RoHS

E-waste, RoHSDraft Dfe, Take-back,

Packaging

Draft RoHS, Battery

iNEMI Analysis:Global Environmental Regulatory Landscape - 2007

Purdue University working with iNEMI to realize the

iNEMI Environmental Vision

To move towards Environmentally Conscious Electronics

• We will take the initiative to fully leverage the iNEMI roadmap and aggressively drive the key environmental gaps and opportunities in and through the mfg electronics supply chain

– Focused collaborative research with universities and key governmental labs working in sync with industry.

– Proactive member led environmental improvement projects that close the technology gaps.

– Strengthen ties with policy decision makers. Ensure sustainable solutions are put in place.

• Problems will be attacked with scientific depth and rigor and the solutions implemented will be far reaching and sustainable.

43

Purdue University in Sustainable Electronics:Research Domains

• Sustainable materials, including development of new polymeric materials and synthesis of materials that can be recovered and recycled

•Sustainable product design, manufacturing, and global supply chain practices

•Product recovery and recycling/remanufacturing practices and reverse logistics

•Policies, legislation, and reward systems affecting the sustainability of electronics industry

44

Purdue’s response to iNEMI needs:

45

Purdue’s response to iNEMI needs:

I/UCRC Center for Resource Recovery and Recycling – Purdue University

In discussion with:Alcatel-Lucent, Celestica, Chemtura, Cisco, Cookson, Dell, Hewlett Packard, IBM, Intel, Lockheed Martin

Current iNEMI projects with:Alcatel-Lucent, Albermarle, Celestica, Cisco, Dell, Delphi Electronics, HP, Huawei, IBM, Intel, NIST, Tyco Electronics and others….

Thrust A: Sustainable Materials: Polymer Solutions

Problem

Polymers comprise a large volume of modern consumer microelectronics, yet there is a lack of recycling and reuse of this polymeric component

Currently, much e-waste is either land-filled, or shipped to developing countries for disassembly and/or recovery of precious metals by hazardous and non-green methods to remove the polymers

Issues

o Thermoplastics such as ABS, HIPS, PC etc. are recyclable, yet non-technical barriers such as supply chain, lack of demand for lower grades, etc., prevent such efforts

o Thermosets such as FR-4 fiberglass/epoxy, phenolic, etc. lack recyclability due to technological barriers as they cannot be reprocessed.

oMany factors must be considered: thermal, mechanical, economic, life-cycle, etc.

Approach

– While supply chain and economic barriers are explored in other thrusts, here the focus will be on innovative, but technically feasible materials solutions for casings, circuit boards, packaging.

– To lower risk in research, a range of technological readiness levels (TRL) are explored: off-the-shelf materials (PLA, etc) unexplored in these uses to innovative polymers with superior properties and new capabilities will be explored to provide a range of solutions.

– Innovative designs to maximize recovery of current materials and/or to minimize environmental impact upon disposal will be explored.

– Research will be integrated with life-cycle analysis to determine if research end-products would produces the intended impact

Thrust B: Product Design through EOL

ProblemUp to 80% of environmental impacts of a product are determined by design. Design for entire life cycle (i.e. from raw material extraction to end of life management) is critical for sustainable product realization. However, an integrated, quantitative design for the life cycle tool is not available yet.

Life Cycle Analysis (LCA)Does not reflect rapid advances in technology. Not easy to update. More impact categories needed to reflect sustainability.

ManufacturingProcess improvements needed. Life cycle inventory needed for all processes. Comparison of specific process used vs. average process gives very different answers. Standards and metrics for green processing needed.

End-of-life managementFate of used electronics products not well known. Barriers for product reuse needed to be understood in the context of business models and legislation. Best strategies would result from that analysis.

Ecodesign toolsNeeded to support conceptual design. Must be easy to use (by SMEs), have identified objective criteria, be more than a checklist to move from compliance to proactivity incorporate “life cycle” design along the supply chain.

Critical Gaps and Areas for Research

Thrust C: Expanding the Scope of Closed Loop Supply Chain for Sustainable Electronics

Problem

How should a company drive sustainable electronics or other supply chain improvements with a business justification ?

Approach

• Develop cases focused on Purchasing Manager-driven sustainability initiatives that decreased Cost of Goods Sold (COGs)

• Focus on sustainable design alternatives that could decrease costs to the company

• Recycled material procurement requires design, technology, legislative, community and economic issues to be understood

• Create sustainable supply chain prototypes from communities

• Success can be measured as lower Cost of Goods Sold, with lower emissions and energy usage

• Develop mathematical models that can be used as decision support systems

European AffiliateKatholieke University (KU)Leuven, Belgium

Prof. Bart Blanpain

Benefits and Cost

Center membership gives “ownership” to CR3; direct and influence direction of research

Royalty free IP rights Pre-Competitive Research available to CR3 members; in addition,

members can sponsor a specific project that will be proprietary Two meetings per year to review results Access to Faculty and Students; access to industrial internship

program Join a “Learning Organization” and be a founding member of the

nation’s first Center dedicated to resource recovery and recycling of materials

Cost: $30K/year (flexible payment plans available)

Pre-competitive fundamental research funded by the members

Large-scale projects funded by the federal government or foundations leveraging the research agenda of the centers

Specific and proprietary researchconducted for consortium members

Research Programs

Alcoa • Apogee Technology • Argonne National Laboratory • ERCo • First

Solar, Inc.• GE Global Research • GM • H.C. Starck • Keywell • MolycorpMinerals • Surface Combustion • Schnitzer • Tosoh SMD • Veolia •

Victaulic • wTe

Founding Members

• CONTEXT & SOCIETAL NEED• VISION AND APPROACH• WHO ARE THE PLAYERS?• SCOPE OF CENTER

Next Steps

OUTLINE

THANK YOU. GRACIAS. SHOUKRAN. MERCI. TAK TAK. AFKHARISTO. GRAZZIE. DANKE