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Japan’s Technology for Metal Recycling

Katsuaki ISHIDA, Director General

Technology Strategy Center (TSC), Environment & Green Chemistry Unit

New Energy and Industrial Technology Development Organization (NEDO)

ADEME-NEDO Workshop 2016

“Circular Economy and Recycling Technology”

December 8, 2016

TSC Environment &Chemistry

Outline

1. History of Metal Recycling in Japan

Government Policy

R&D Projects Supported by Government2. Current Situation of Metal Recycling in Japan

Domestic Market

Business Players

Process Flow of Metal Recycling from Waste Products

Problems to Be Solved3. Challenges in Metal Recycling Technology4. Future Development and New R&D Project

2


Japan‘s legislation with regard to recycling has been formulated in the advent of issues on public health and environmental conservation associated with economic growth.

Basic legislation on promotion of recycling has been established since 1991. Relevant technologies have been developed alongside legislation on recycling of individual products.

History of Major Issues and Legislation Related to Recycling in Japan (1/2)

3

Phase Major Issues Laws & Strategies

・Environmental Hygiene ・Public Cleansing Act (1954)

・Serious Pollution Problems・Strengthening Measures against Shortage of Landfill Space

・Waste Management Act (1971)

・Construction/Improvement of Waste Disposal Facilities

・Environmental Conservation

・Law for Bay Area Marine and Environment Consolidation Centers (1981)・Structure Guidelines of Waste Disposal Facilities Amended (1986)

・Waste Reduction and Promotion of Recycling

・Establishment of Various Recycling Systems

・Measures against Dioxins and Other Toxic Substances

・Act on the Promotion of Utilization of Recycled Resources (1991)・Containers and Packaging Materials Recycling Law (1995)・Home Appliance Recycling Law (1998)・Law for Special Measures against Dioxins (1999)・Construction Materials Recycling Law (2000)・Food Matters Recycling Law (2000)

・Establishment of a Circulating Society

・Basic Act on Establishing a Sound Material-Cycle Society (2001)・End-of life Vehicle Recycling Law (2002)・Basic Plan on Establishing a Sound Material-Cycle Society (2003)

・Measures for Securing Resource Supply

・Recovery of Resources from Used Products

・Strategy for Ensuring Stable Supplies of Rare Metals (2009)・Basic Energy Plan (2010)・Strategy for Securing Natural Resources (2012)・Small Electronic Appliances Recycling Law (2013)

・Improvement in Resource Efficiency

・Information Sharing Platform

・Basic Act on Establishing a Sound Material-Cycle Society Amended (2013)・Japan Revitalization Strategy (2016)

Reduction of Toxic

SubstancesPromotion of Recycling

Promotion of 3R (Reuse, Reduce &

Recycling)

Improvement in Public Health

Pollution Solutions, Protection of Living

Environment, Addressing Landfill Shortage

Boosting a Transformation of Urban Mines into Raw Materials

Feedstock

Strengthening the Link between Arterial & Venous

Industries

Source: NEDO TSC (2016) based on Ministry of the Environment (2015) “History and

Current State of Waste Management in Japan” and other materials.


In recent years, countries around the world have been facing new problems with raw materials, for example, a shortage in raw metals supply and subsequent price rise.

To address these problems, Japan is making a shift towards another phase of technology development, thereby boosting a transformation of urban mines (e-waste) into raw materials feedstock and strengthening the link between arterial and venous (i.e. recycling) industries.

History of Major Issues and Legislation Related to Recycling in Japan (2/2)

4

Phase Major Issues Laws & Strategies

・Environmental Hygiene ・Public Cleansing Act (1954)

・Serious Pollution Problems・Strengthening Measures against Shortage of Landfill Space

・Waste Management Act (1971)

・Construction/Improvement of Waste Disposal Facilities

・Environmental Conservation

・Law for Bay Area Marine and Environment Consolidation Centers (1981)・Structure Guidelines of Waste Disposal Facilities Amended (1986)

・Waste Reduction and Promotion of Recycling

・Establishment of Various Recycling Systems

・Measures against Dioxins and Other Toxic Substances

・Act on the Promotion of Utilization of Recycled Resources (1991)・Containers and Packaging Materials Recycling Law (1995)・Home Appliance Recycling Law (1998)・Law for Special Measures against Dioxins (1999)・Construction Materials Recycling Law (2000)・Food Matters Recycling Law (2000)

・Establishment of a Circulating Society

・Basic Act on Establishing a Sound Material-Cycle Society (2001)・End-of life Vehicle Recycling Law (2002)・Basic Plan on Establishing a Sound Material-Cycle Society (2003)

・Measures for Securing Resource Supply

・Recovery of Resources from Used Products

・Strategy for Ensuring Stable Supplies of Rare Metals (2009)・Basic Energy Plan (2010)・Strategy for Securing Natural Resources (2012)・Small Electronic Appliances Recycling Law (2013)

・Improvement in Resource Efficiency

・Information Sharing Platform

・Basic Act on Establishing a Sound Material-Cycle Society Amended (2013)・Japan Revitalization Strategy (2016)

Reduction of Toxic

SubstancesPromotion of Recycling

Promotion of 3R (Reuse, Reduce &

Recycling)

Improvement in Public Health

Pollution Solutions, Protection of Living

Environment, Addressing Landfill Shortage

Boosting a Transformation of Urban Mines into Raw Materials

Feedstock

Strengthening the Link between Arterial & Venous

Industries

Source: NEDO TSC (2016) based on Ministry of the Environment (2015) “History and

Current State of Waste Management in Japan” and other materials.


Funded by Project Comment

NEDO

• R&D Project of Rare Metals Substitute Material Development (2010-2015)

• Demonstration Project of Energy-savingResource Circulation System Introduction into Asian Countries (2016-) etc.

• Reduction of Usage and Development of Alternative Materials for Rare Metals and Rare-Earth Metals

• Including Utilization of IT for Recycling System

JOGMEC (Japan Oil, Gas and Metals National Corporation)

• R&D for Recycling Prior Rare Metals (2007-2015)

• R&D for Recovering Rare Metals (2008-2012) etc

• Recycling Prior 5 metals (Co, Ta, W, Nd and Dy)

• Waste Small Electronic and Electric Appliances

METI (Ministry of Economy, Trade and Industry)

• Demonstration Project of Resource Circulation(2013-2014)

• R&D Project of Alternative Materials and Purification Technology of Rare Metals and Rare-earth Metals (2010-2012) etc.

• Recycling of Cemented Carbide Tools and LIB

• Reduction of Usage and Development of Alternative Materials

MOE (Minister of the Environment)

• Demonstration Project of Low-carbon 3RTechnology and System (2014-2016)

• Promotion Project of CO2-saving Recycling Plant Introduction (2015-) etc.

• Dismantling and Shredding of Automobiles

• CO2-saving for Whole Recycling Process of Used Products

In the new phase, various projects have been promoted by government focusing on– Rare metals recycling and reduction of rare metals usage– Energy Saving and low-carbon recycling process

R&D Projects Supported by Government

5

Recent Major Projects for Metal Recycling Technology Supported by Government in Japan


1.43 Trillion JPY

1.26 Trillion JPY

1.97 Trillion JPY

0.0

0.5

1.0

1.5

2.0

2.5

2000 2005 2010 2015 2020 2025 2030

Dom

esti

c M

arke

t (T

rilli

on J

PY)

Year

Predicted (Basic scenario)

Predicted (Growth scenario)

Actual

Domestic Market of Recycled Materials (Non-ferrous Metals) has been grown at an average annual growth rate of 4.5% since 2000. – Present: 1.26 Trillion JPY (2013 actual) ≒ 10 Billion EURO– Future: 1.97 Trillion JPY (2030 predicted based on “Growth Scenario”, GDP growth 1.6%/y)

1.43 Trillion JPY (2030 predicted based on “Basic Scenario”, GDP growth 0.6%/y)

Current Situations of Metal Recycling in Japan: Domestic Market

6Source: NEDO TSC (2016) based on MOE “Report on market and employee in environmental industry” (2015)

Domestic Market of Recycled Materiaｌs (Non-ferrous Metals)

Average 4.5%/y Growth


We have some business categories in venous industry to play metal recycling business based on applicable laws and regulations.

Since business players are certified by individual local governments, most of the business scales are not large.

Current Situations of Metal Recycling in Japan: Business Players

7

Business Category

Number of Business Players

Players’Business Scale

Collection/Transport

General waste: 38,304Industrial waste: 127,266

Small/Medium

Intermediate Treatment

General waste: 2,229Industrial waste: 10,741

Mainly: Small/Medium,

Partially: Large

Raw Materials Recovery

Non-ferrous metal smelting: 84

Medium/Large

Waste Disposal

General waste: 138Industrial waste: 541

Medium/Large

Waste

Business category and players

in metal recycling business in Japan

Raw Materials

Recovery

Collection/

Transport

Intermediate

Treatment

Waste

Disposal

Arterial

Industry

Venous

Industry

Manufacturing

Delivery

/Sales

Usage/

Consumption

Resource/

Raw materials

Source: NEDO TSC (2016) based on METI “Investigative report on

measures against global warming (Sophistication and efficiency of

resource circulation)” (2015).


Current Situations of Metal Recycling in Japan: Process Flow of Metal Recycling from Waste Products

8

Source: NEDO TSC (2015) based on NEDO “Data analyses and evaluation report for resource-efficient environmentally-friendly

raw materials recycling project to establish rare earths and rare metals recycling system from used small home appliances” (2010).

Smelting

Pyrometallurgy(Heating, Calcination, Oxidation, Hydrogen

Reduction, Carbonization,

Chlorination, Molten-salt Reduction, etc.)

Hydrometallurgy(Acid/Alkali Leaching,

Solvent Extraction, Precipitation,

Deposition, Drying, Electrolysis, Microbial

Treatment, etc.)

Chemical Separation

Waste Products

Waste StreamSorting

Visual/Manual Inspection

Sensor Sorting

Disassembly & Dismantling

Manual Dismantling

Mechanical Dismantling

Shredding & Crushing

Shredding

Crushing

Scrap MetalsSorting

Hand sorting

Classification

Sorting by Shape

Magnetic Separation

Electric Separation

(Electrostatic/Eddy Current)

Gravity Separation(Hydro/Pyro)

Physical Sorting

Flowchart of raw metals recovery from waste products


Current Situations of Metal Recycling in Japan: Problems to Be Solved (1/2): Mixed Materials Not Circulated in Japan

Reused rates of waste products are statistically high (e.g. Home appliances: 81%). A substantial portion of reused metals is not of raw materials circulated in Japan.

– Exported: Mixed metal from motors, compressors, transformers, etc. – Used as mixed materials not fully sorted into single materials such as roadbed materials:

Slag from e-waste

9Recycling of home appliances in Japan (Mixed materials not circulated in Japan)

Source: NEDO TSC (2015) based on Council on Competitiveness-Nippon “Sustainable manufacturing technology platform” (2009).

Not circulated in Japan

others

Recycling rate: 81%

Weight ratio

Mixed plastic (not recycled)

Recycled single material plastic

Substrates

Mixed metal

Incinerated (heat utilization), landfill

Disassembled by hand and sorted overseas

Hand-sorted and made into lower-grade products overseas

Outflowing mixed materials(estimated 20%)

Mixed materials not fully sorted into single materials

(estimated 20%)Noble metals & copper: recoveredResin: incineratedRare metals: slag

Metals Glass

Mixed plastic (recycled)


Current Situations of Metal Recycling in Japan: Problems to Be Solved (2/2): Outflow of Scrap Resources

An increasing amount of scrap has been exported to the countries with lower cost.– Recycling cost depends on the quality of metal scraps. Not only low quality scraps but

also medium or high quality scraps are exported.– Consequently, the supply of scrap metals may fall short of demand, and this potentially

affects domestic smelting businesses in our venous industries.– Decline in scrap iron prices affects other scrap resources in Japan such as outflow of

resources and decreased domestic recycling rate.

Export > Import– Cu, PGM (platinum group metals)

• Low quality scraps are exported.– Al, Pb

• High quality scraps which can be economically recycled due to higher purchase prices in foreign countries.

10

Source: NEDO TSC (2016) based on METI “FY 2014 research report on global warming countermeasures for

the initiative towards improved sophistication and efficiency of resources circulation” (2015).


Challenges in physical sorting technology– Low-cost automated operation to replace manual operation– Generalization of low-cost mechanical sorting– Selective disassembly & dismantling– Energy-saving in shredding & crushing– Higher recovery yield in scrap metals sorting based on simulation and sensing technologies

Challenges in Metal Recycling Technology: Physical Sorting

11

Manual OperationHigh Energy

Consumption

ExpensiveAutomated-apparatus

Waste Products

Waste StreamSorting

Visual/Manual Inspection

Sensor Sorting

Disassembly & Dismantling

Manual Dismantling

Mechanical Dismantling

Shredding & Crushing

Shredding

Crushing

Scrap Metals Sorting

Hand Sorting

Classification

Sorting by Shape

Magnetic Separation

Electric Separation

(Electrostatic/Eddy Current)

Gravity Separation

(Hydro/Pyro)

Physical Sorting

High Cost


Challenges in chemical separation technology– Low-cost small-quantity processing for metals used in small quantities such as rare metals– Environmental loading reduction– Energy-saving smelting technology

Challenges in Metal Recycling Technology: Chemical Separation

12

High temperature processing High energy consumption

Slug product

Waste of acid and alkaliMulti-step process

High CostExpensive

scale-up plant

Smelting

Pyrometallurgy(Heating, Calcination, Oxidation,

Hydrogen Reduction, Carbonization, Chlorination, Molten-salt Reduction, etc.)

Hydrometallurgy(Acid/Alkali Leaching, Solvent Extraction,

Precipitation, Deposition, Drying, Electrolysis, Microbial Treatment, etc.)

Chemical Separation


Sophistication of metal recycling processes enabled by information sharing platformSource: NEDO TSC (2016) based on materials from Resource Circulation Network, Inc. (Takamasa Hayashi, 2016).

Challenges in Metal Recycling Technology: Information Sharing Platform

Venous industries can be more efficient and sophisticated with the help of information sharing platform.

13

Applicable Technology Elements as Information Sharing Platform

I o T Robotics Sensing AI SortingIndividual Identification

Data Base Management

ＩmageAnalysis

Manufacturing/Disposal

TransportationWaste Stream

SortingDisassembly &

DismantlingShredding &

CrushingScrap Metals

SortingSmelting

Data Base of Product’s

Metal Contents

Product Traceability

Sorting by Grade

Dismantling Based on Product

Structure

Particle Size Optimization

Concentration of Recovered

Metals

Controlled Extraction

Metal Recycling Processes


Future Development

Our goal is to ensure low-cost recycling to play a significant role in consistent supply of various raw metals, and recycled metals to become readily usable feedstock for high-performance applications (i.e. value recovery).

A flexible system is needed to deal with fluctuations in resource prices to cover increasingly complex products enabled by advancement of materials technology.

14Challenges and their solutions in raw metals value chain

【Issue 4】Eco-friendly Design→ Collaboration between

Arterial and Venous Industries

Products

【Issue 2】Effective and Low-cost Process→ Technology

Development

Used Products

Recycled Materials

【Issue 3】Market Formation and Expansion→ Promote Standardization

Sales

Recycling

Urban Mines（e-waste）

Intermediate Treatment

Smelting

Disposal Recovery

【Issue 1】Effective Scheme for Waste Collecting→ Improve the Operation of

Legal and Other Systems


New R&D Project

15

Wasteproduct

Recycledmaterials

• Inefficient manual operation

• Insufficient valuable recovery

Linkage of product

and recycling

processes

Dismantlingand sorting Smelting

Product designs do not meet

recycling processes.

Quantity and quality of recycled materials do not meet product

requirements

Urban mines(Electronic waste)

Automatic dismantling

and sorting technologyHigh-efficiency

smelting technology

Solution

Outline of new national project for metal recycling

METI has been requesting budget for a new national project “Technology Development of Metal Recycling for High-Efficiency Resource Circulation System” to be started in 2017FY.(Budget for 2017FY: 900 million JPY).

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