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©
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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
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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Some recent background literature to this talk
http://www.unep.org/resourcepanel/Portals/50244/publications/Metal_Recycling-Full_Report_150dpi_130919.pdf
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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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
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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CE: Harmonizing energy and materials
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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Au
Cu
Ta
CE: A key issue?Sorting into the correct routes with minimum
designed losses
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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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.
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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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
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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CE: Understanding complexity and entropySystem optimization key to Recycling 4.0
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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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.
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
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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CE: Metallurgical infrastructure a key enablerhttps://www.youtube.com/watch?v=0WE72HB7asY
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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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
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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SIMP: The limits of the system? How much entropy creation (e.g. dilution of elements) can the system deal with?
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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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
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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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
.
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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SIMP: Multi-metal Web of MetalsUnderstanding dynamic interactions key to Recycling 4.0
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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SIMP: Multi-metal Web of Metals
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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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
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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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√
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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SIMP: Recovering metals from minerals & residuesLead Concentrates & Zinc residues – Nyrstar (Zürich) installing TSL at Port Pirie,Australia 2016 (Outotec)
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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A s
ele
cti
on
of
Ou
tote
c’s
65 T
SL
an
d 1
8 K
ald
ore
fere
nces
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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(65)
SIMP: Recovering metals from minerals & residues
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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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).
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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SIMP: Understanding and innovating technology
TSL - Smelting
Slag Fuming
P- subarc smelting (60MW)
Al-scrap salt-slag Pigiron & slag though
coke bed
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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SIMP: Big data analysis
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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SIMP: Big data analysis
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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SIMP: Big data analysis
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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SIMP: Understanding complex recyclate feeds to metallurgical reactors – we recycled 1153 ELVs
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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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
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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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).
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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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.
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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CEE: Measuring particle properties and estimating resource efficiency through simulation
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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CEE: Big data analysis – creating fuzzy models
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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CEE: Link CAD & Smelter to Recycling Index
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.
Traditional Design for Recycling does not provide detail nor reveal the limits!
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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© MARAS B.V.
A+++ G
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A D
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RecyclingIndex
I
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
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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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.
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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CEE: Geographic comparison of technology -FeCr
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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CEE: Recycling vs Energy-Index, 3 LED Redesigns
© MARAS B.V.
A+++ G
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A+
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RecyclingIndex
10-50%
LED 1
LED 3
LED 2
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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Is sustainable?
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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CEE: Recycling 4.0
Prof. Dr. Dr. h.c. Markus A. ReuterHelmholtz Institute Freiberg for Resource Technology©
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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?
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