recycling to recycling 4 · (qsl, kivcet, sks 2 stage) discard slag and steam fume leaching plant...

Helmholtz Institute Freiberg for Resource Technology I www.hzdr.de/hif

Prof. Dr. Dr. h.c. Markus A. Reuter

Recycling to Recycling 4.0Metallurgy & its infrastructure are key enablers

Markus A. Reuter

(Extract from 2016 TMS EPD Distinguished Lecture, February 17th, 2016, Nashville, USA.)

Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©

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


Some recent background literature to this talk

http://www.unep.org/resourcepanel/Portals/50244/publications/Metal_Recycling-Full_Report_150dpi_130919.pdf

http://www.unep.org/resourcepanel/Portals/50244/publications/Metal_Recycling-Full_Report_150dpi_130919.pdf


http://www.europarl.europa.eu/news/en/news-room/20151201STO05603/Circular-economy-the-importance-of-re-using-products-and-materials

Circular Economy – CERecycling 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


CE: Harmonizing energy and materials


Au

Cu

Ta

CE: A key issue?Sorting into the correct routes with minimum

designed losses


Is sustainable considering both energyand 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.


Different appearances of PCB in (PCB) recyclates

CE: Complexity & creating entropyRecycling 4.0 requires detail of particles to be able to optimize and & simulate

Ferrous recyclate PCB recyclate Plastics recyclate Residue fraction


CE: Understanding complexity and entropySystem optimization key to Recycling 4.0


CE: Understanding scrap & process metallurgySimulation key to Recycling 4.0

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

Decision variables produced during optimization,subject to market, EoL feed mix, etc.

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 enablerhttps://www.youtube.com/watch?v=0WE72HB7asY

https://www.youtube.com/watch?v=0WE72HB7asY


System Integrated Metal Production - SIMP

Product DesignRemanufacture

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)

Collection, Dismantling, Shredding

RecyclingIndex

Physical Separation

Pyro- & hydrometallurgy, Refining)

Product Complexity

Market & Stocks


SIMP: The limits of the system? How much entropy creation (e.g. dilution of elements) can the system deal with?


SIMP: Complex minerals

From: Raw materials of strategic economic importance for high-tech made in Germany: BMBF research and development programme for new raw material technologies

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



SIMP: Product Centric RecyclingReuter 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

.



SIMP: Multi-metal Web of MetalsUnderstanding dynamic interactions key to Recycling 4.0


SIMP: Multi-metal Web of Metals


SIMP: Metallurgical System Optimization

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 Speiss

Circuit Boards

etc.

Precious MetalRefineryLeached

Residue

Pb Refinery

BULLION

BULLIONCu Dross

Pb Slime

Residue

Ag

Concentrate

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


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 Speiss

Circuit Boards

etc.

Precious MetalRefineryLeached

Residue

Pb Refinery

BULLION

BULLIONCu Dross

Pb Slime

Residue

Ag

Concentrate

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: Resource efficient metallurgical systems

Copper-Metallurgy

Lead-Metallurgy

Zinc-Metallurgy

Ç√

Ç√


SIMP: Recovering metals from minerals & residuesLead Concentrates & Zinc residues – Nyrstar (Zürich) installing TSL at Port Pirie,Australia 2016 (Outotec)


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SIMP: Recovering metals from minerals & residues


SIMP: Understanding metal distributionsM.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).


SIMP: Understanding and innovating technology

TSL - Smelting

Slag Fuming

P- subarc smelting (60MW)

Al-scrap salt-slag Pigiron & slag though

coke bed


SIMP: Big data analysis


SIMP: Understanding complex recyclate feeds to metallurgical reactors – we recycled 1153 ELVs


SIMP: Understanding metal recovery from complex feeds

Reductive

Smelt

Oxidative

Convert

(Optional)

Raw Copper (+PMs & PGMs)

To Refining‘B

lac

k’

Co

pp

er

Fuel, Air

(Oxygen)

Discard Slag

(Construction Material)

Dust/Fume

Zn rich, Pb/Sn

To further processing

Reductant

Flux

Slag

Dust Fume

Sn rich, Pb

FluxFuel, Air

(Oxygen)

Secondary Copper Feeds

(High-grade Cu)

Reduction

Furnace

(Optional)

Discard

Slag

Copper Alloy

To further processing

Secondary Copper Feeds(Low-grade Cu)

Dust/Fume

To further processing - Zn rich, Pb/Sn

Converting can also take place in TSL in two-stage process

TSL

Kaldo

Various High- & Low-Grade Cu Scrap


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).


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)Etc...

Circular Economy Engineering - CEE

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


CEE: Big data analysis – creating fuzzy models


CEE: Link CAD & Smelter to Recycling Index


Traditional Design for Recycling does not provide detail nor reveal the limits!


© MARAS B.V.

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RecyclingIndex

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CEE: Comparing solutions relative to baselineRönnlund, 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).

CE System 1 CE System 2


CEE: Rigorous comparison of options – Ni-Pigiron



CEE: Geographic comparison of technology -FeCr


CEE: Recycling vs Energy-Index, 3 LED Redesigns

© MARAS B.V.

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RecyclingIndex

10-50%

LED 1

LED 3

LED 2


Is sustainable?


CEE: Recycling 4.0


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?

recycling to recycling 4 · (qsl, kivcet, sks 2 stage) discard slag and steam fume leaching plant...

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