chancen und grenzen einer circular economy · prof. dr. dr. h.c. markus a. reuter helmholtz...
TRANSCRIPT
Prof. Dr. Dr. h.c.. Markus A. Reuter I Director: Helmholtz Institute Freiberg for Resource Technology© I www.hzdr.de/hif
Chancen und Grenzen einer Circular Economy(from 2016 TMS EPD Distinguished Lecture, Nashville, USA)
Markus Reuter
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
Page 2
Overview
• Circular Economy - SIMP– System integrated metal production – SIMP
– Rigorous quantification of Resource Efficiency (RE)
• Digitalization - Recycling 4.0– Internet-of-Metallurgical-Things
– Link all stakeholders in material cycle
• Circular Economy Engineering - CEE– Metallurgical infrastructure & deep knowledge key
– Inform society in an understandable manner
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
Page 3
∆" = ∆$%
Linear Energy vs. Circular Material Systems
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
Page 4
System Integrated Metal Production – SIMPMetals play key role, economics as well
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
Page 5
System Integrated Metal Production – SIMPhttps://www.youtube.com/watch?v=0WE72HB7asY
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
Page 6
SIMP: Quantifying Resource Efficiency (RE)Minimize entropy creation, maximize resource efficiency
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
Page 7
SIMP: System optimizationS. Sudhölter, M.A. Reuter and J. Krüger (1996): Eco-techno-economic synthesis of process routes for the production of zinc using combinatorial optimisation, Metallurgical Transactions B, Vol. 27(6), pp. 1031-1044.
Slag (low Pb)
BULLION
Horizontal Bath(QSL, KIVCET, SKS 2
stage)
Discard Slag and Steam
Fume Leaching Plant
FeedsPb Concentrates
Pb Secondaries (e.g. battery) Ag Concentrate
RefineryCu, PMs, PGMs, various others
Pb Residue
FumeZn/Pb (In/Ge..)
JarositeGoethite
(old ponds / production)
Fume
RefineryPb, Sn, Sb, Te, Se, In
Vertical Bath(TSL 1,2 & 3 stage)
1 or 2 TSL(s)
Cu TSL Processing
Zn-Fumers
Cu Speiss
ZnSolution
Cu Removal
RefineryAu, Ag, Cu, Sb, As, Ge
Zn & Refinery ProductsBy-products: In, Ge etc.
Cu SpeissCircuit Boards
etc.
Precious MetalRefineryLeached
Residue
Pb Refinery
BULLION
BULLIONCu Dross
Pb Slime
Residue
AgConcentrate
Horizontal Bath(SKS 1 stage)
Blast Furnace
Waelz Kiln
Slag
FumeZn/Pb (In/Ge..)
Fumer
Fume (Zn rich, Pb, In, Ge)
Slag(high Pb)
DiscardSlag
H2SO4
H2SO4H2SO4
DiscardSlag
Zn PlantVarious configurations
(Figure 2)
Direct Zn(TSL 2 stage)
FeedsZn Concentrates
Washed/roasted secondaries fumes (e.g. EAF dust)
Pb/SpeissTo lead plants
Rotary Kiln
Soda Slag
Zn-Plasma Fumers
Other residues
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
Page 8
Slag (low Pb)
BULLION
Horizontal Bath(QSL, KIVCET, SKS 2
stage)
Discard Slag and Steam
Fume Leaching Plant
FeedsPb Concentrates
Pb Secondaries (e.g. battery) Ag Concentrate
RefineryCu, PMs, PGMs, various others
Pb Residue
FumeZn/Pb (In/Ge..)
JarositeGoethite
(old ponds / production)
Fume
RefineryPb, Sn, Sb, Te, Se, In
Vertical Bath(TSL 1,2 & 3 stage)
1 or 2 TSL(s)
Cu TSL Processing
Zn-Fumers
Cu Speiss
ZnSolution
Cu Removal
RefineryAu, Ag, Cu, Sb, As, Ge
Zn & Refinery ProductsBy-products: In, Ge etc.
Cu SpeissCircuit Boards
etc.
Precious MetalRefineryLeached
Residue
Pb Refinery
BULLION
BULLIONCu Dross
Pb Slime
Residue
AgConcentrate
Horizontal Bath(SKS 1 stage)
Blast Furnace
Waelz Kiln
Slag
FumeZn/Pb (In/Ge..)
Fumer
Fume (Zn rich, Pb, In, Ge)
Slag(high Pb)
DiscardSlag
H2SO4
H2SO4H2SO4
DiscardSlag
Zn PlantVarious configurations
(Figure 2)
Direct Zn(TSL 2 stage)
FeedsZn Concentrates
Washed/roasted secondaries fumes (e.g. EAF dust)
Pb/SpeissTo lead plants
Rotary Kiln
Soda Slag
Zn-Plasma Fumers
Other residues
SIMP: Circular Economy within a corporationMetallurgy key to enable Circular Economy
Copper-Metallurgy
Lead-Metallurgy
Zinc-Metallurgy
Ç√
Ç√
KCM – Bulgaria: New TSL SmelterLead primary and residues
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
Page 9
Recovering metals from minerals & residuesNyrstar (Basel) Port Pirie Redevelopment in Australia
From: Watts (2015): Nyrstar Port Pirie Redevelopment
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
Page 10
SecondaryFeeds(Low&HighgradeCumaterials&alloys,WEEE-PMs(Au)&PGMscontainingresidues&scrap,shredderresidue)
Raw/AnodeCopper
FuelAir(Oxygen)
DiscardSlag(ConstructionMaterial)
Dust/Fume
ReductantFlux
CathodeCopper
Pb/Sn/Bi/AgProducts
Zn
PGMsPMs
Gypsum
Te,Seetc.
IntermediatePb-RichPhasesFumes
Slimes
SlimesPrecipitates
(Pb/Snrich)
(Znrich)
Slimes
1-3 Stage TSL
Electrowinning & -RefiningPrecious Metal Refining
Smelting/RefiningLeaching
Offgas treatment
Leaching
SIMP: Deep knowledge & technology
DOWA, JapanN.Huda,J.Naser,G.Brooks,M.A.Reuter,R.W.Matusewicz (2012):ComputationalFluidDynamicModeling ofZincSlag FumingProcess inTop-Submerged LanceSmelting Furnace,Metallurgical Transactions B,43B(1),39-55.A.Anindya,D.R.Swinbourne,M.A.Reuter,R.W.Matusewicz (2013):Distributionofelements between copper andFeOx-CaO-SiO2 slags during pyrometallurgical processingofWEEEPart2– Indium,Mineral ProcessingandExtractiveMetallurgy (Trans.Inst.Min Metall.C),123(1)43-52.
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
Page 11
SIMP: Measuring fundamental data!!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 (submitted).
ReductiveSmelt
OxidativeConvert(Optional)
RawCopper(+PMs&PGMs)ToRefining
‘Black’
Copper
Fuel,Air(Oxygen)
DiscardSlag(ConstructionMaterial)
Dust/FumeZnrich,Pb/SnTofurtherprocessing
ReductantFlux
Slag
DustFumeSnrich,Pb
FluxFuel,Air(Oxygen)
SecondaryCopperFeeds(High-gradeCu)
ReductionFurnace(Optional)
DiscardSlag
CopperAlloyTofurtherprocessing
SecondaryCopperFeeds(Low-gradeCu)
Dust/FumeTofurtherprocessing-Znrich,Pb/Sn
Converting can also take place in TSL in two-stage process
TSL
Kaldo
VariousHigh-&Low-GradeCuScrap
???
???
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
Page 12
Recycling 4.0: Optimization, Simulation, Big-dataReal-time data and evaluation of the complete chain
Product Design
Remanufacture
Functional Metal &
Material Combinations
Multi-material Recyclates
Losses
Losses & Stocks
Losses
Complex Linkages/Connections
Unaccounted
Losses & Theft
Stocks & Losses
Particle Properties Controls
Losses
URBAN MINEDesigner ”Minerals” and Functional Materials (Au containing)
GEOLOGICAL MINEGeological Minerals (Au containing)
Fe
C Ca
Al Cr
V SiMg Ti
W H/O
Li
Zr Ta NbAs
P
K
REE
Ce
U
Mn
CuZn Sn Pb
Co
Ni
Mo
AuPt
Ga Ge AgIn TeSe
Os
Ru Bi
Sb
Ru Pd Ir RhCd
Collection, Dismantling, Shredding
Recycling
Index
Physical Separation
Pyro- & hydrometallurgy, Refining)
Product Complexity
Market & Stocks
GeologicalMinerals DesignerMinerals
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
Page 13
Recycling 4.0: Optimization, Simulation, Big-dataReal-time data and evaluation of the complete chain
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
Page 14
Recycling 4.0: Simulation & exergy analysis
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
Page 15
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 CO2 / t Product kg SOx / t Productg NOx / t Product
m3 Water / t Product (including ions in solution)kg Residue / t Product (including composition)
kg Fugitive Emissions / t Productkg Particulate Emissions / t Product
Etc.
Environmental Indicators based on BATDriving Benchmarks of IndustryReCiPe (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...
Recycling 4.0: Rigorous estimation of RE!
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
Page 16
Rigorous comparison
Finland
China
South Africa
0
1
2
3
4
5
6
7
8
CASE 1: 60% concentrate, 40%
lump ore/fines, open furnace
CASE 2: 70% pellets, 30% lump
ore, closed furnace, preheated
CASE 3: 100% pellets, closed
furnace, preheatedCASE 4: 100% concentrate,
prereduced with coke, hot charge
GW
P: k
g CO
2-eq
/kg
liqui
d Fe
Cr(5
0% C
r)
Copper
HC FeCrZinc
Nickel Pig Iron
Lead
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
Page 17
Recycling 4.0: Link CAD to Recycling IndexM.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. 671-693.
Productdesign
LifeCycleAssessment(LCA)
0
20
40
60
80
100
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
TOTALRECOVERY%
TotalRecovery(%)
afterP
hysic
alRecyclingand
ProcessM
etallurgy
LEDDesignA LEDDesignB LEDDesignC LEDDesignD LEDDesignE
38%
48%
41%
46%
15%
PhysicalRecyclingSimulationModels
CalculationofElementRecoveriesRecyclingIndex
ProcessModels
Remanufacture
Traditional Design for Recycling: Does not provide detail!
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
Page 18
Circular Economy EngineeringLinear vs Circular System Analysis & Quantification for 5 LED designs
©MARASB.V.
A+++ GF
EA D
CB
A+
A++
RecyclingIndex
10-50%
LED Design 5
LED Designs 2 to 4
LED Design 1
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
Page 19
Summary• Digitalizing the Circular Economy: Recycling 4.0
– Business models
– Internet of Metallurgical Things – Linking it with software
– Maximize Resource Efficiency: Energy vs. Material Efficiency
• Processing infrastructure key to circular economy– Digitalization platform key!
– Ensure that system is robust with its suite of technologies
• Circular Economy Engineering– Engineering basis to estimate economics & environmental impact
• Inform Policy & Consumer in rigorously based approach– Quantify limits of consumption?
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology
Page 20
Markus A. ReuterDr. h.c. (Liege), D.Eng.(ZA), Dr. habil. (Aachen), PhD (ZA)• Industry
Ø Ausmelt-Outotec (Director Technology Management: Outotec, Finland (2010-2015)& Technical Director: Ausmelt, Australia (2006-2010 - taken over by Outotec 2010))
Ø Leader furnace control group: Mintek, South Africa (1994-1996)Ø Process Metallurgist: Anglo American Corporation, South Africa (1984-1985)
• AcademicØ Helmholtz Institute Freiberg for Resource Technology, Germany (2015 →)Ø Adjunct & Honorary Professor: Aalto University Helsinki (2012→)Ø Guest Professor: Central South University Changsha, China (2012→)Ø Professor and Professorial Fellow: University Melbourne, Australia (2005→) Ø Professor & Emeritus: TU Delft, Netherlands (1996-2012)Ø Adjunct Professor: Stellenbosch, South Africa (1999-2007)
DegreesØ Dr. h.c. Honorary Doctorate University of Liege (2015: Belgium)Ø D. Eng. & PhD: University of Stellenbosch (1991 & 2006: South Africa)Ø Dr. habil.: RWTH Aachen (1995: Germany)
Recent Awards, Publications, Interests, Patents, etc.Ø 2016: TMS EPD Distinguished LectureØ 2016: SME Henry Krumb LecturerØ 2015: Doctor honoris causa, Honorary Doctorate, University Liège, BelgiumØ 2014: 1st Prize Publication Award: International Solid Waste Association for “Handbook of Recycling” (http://www.iswa.org/)Ø 2014: TMS Science Award: Best paper in Metallurgical Transactions B (2013)Ø 2013: Outotec Technology Award - Awarded to individuals that enhance the commercial success of OutotecØ 2013: Lead author of a 2nd report on recycling for United Nations Environmental Protection (UNEP): Metal Recycling:
Opportunities, Limits, Infrastructure (400,000 downloads April 2013 to September 2015) http://www.unep.org/resourcepanel/Portals/50244/publications/Metal_Recycling-Full_Report_150dpi_130919.pdfand http://www.ubraintv.com/watch.php?id=842
Ø H-Factor: ISI=20; Scopus=21, Google Scholar=29Ø >400 Publications: Book / Chapters in Encyclopedias / Journal / Conference / Patents (see ResearchGate and other links)
Various patent families (pending or awarded e.g. Japanese Patent 2014-517328:TOP SUBMERGED INJECTING LANCES)
http://fi.linkedin.com/pub/markus-reuter/11/195/90https://www.researchgate.net/profile/Markus_Reuter3?ev=prf_highl
http://scholar.google.co.uk/citations?user=5cLC8VEAAAAJ&hl=en&oi=aohttp://www.researcherid.com/rid/D-2839-2015