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Helmholtz Institute Freiberg for Resource Technology I www.hzdr.de/hif Prof. Dr. Dr. h.c. Markus A. Reuter Metallurgical Internet-of-Things m-IoT Markus A. Reuter

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Page 1: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

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

Metallurgical Internet-of-Thingsm-IoT

Markus A. Reuter

Page 2: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 2

Metallurgy enables the CE – An opportunity

• CE: Circular Economy

– “Circular Economy within a Corporation”

• m-IoT: Metallurgical Internet-of-Things

– Metallurgical infrastructure and knowhow are of key

importance

• CEE: Circular Economy Engineering

– Digitalized linking of stakeholders

– Quantifying resource efficiency

– Informing society in an understandable CE-paradigm

Page 3: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 3

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

Circular Economy: CEUnderstanding & quantification of entropy in the CE

Page 4: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 4

(65)

CE: Product Centric Recycling

Page 5: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 5

©MARASB.V.

A+++ GF

E

A DCB

A+

A++

RecyclingIndex(c)MARAS

LED1

LED3

LED2

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, RESPONSABILITE & ENVIRONNEMENT - AVRIL 2016 - N°82, pp. 62-66.

Page 6: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 6

Au

Cu

Ta

CE: A key issue of recycling

Page 7: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 7

Different appearances of PCB in (PCB) recyclates

CE: Complexity & creating entropyRequires detail of particles to be able to optimize and & simulate

Ferrous recyclate PCB recyclate Plastics recyclate Residue fraction

Page 8: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Page 9: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 9

CE: Optimization, Simulation, Big-dataReal-time data and evaluation of the complete chain

Page 10: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 10

CE: Processing infrastructureSecondary Feeds

(Low & High grade Cu materials & alloys, WEEE - PMs (Au) & PGMs containing residues & scrap, shredder residue)

Raw / Anode Copper

FuelAir (Oxygen)

Discard Slag (Construction Material)

Dust/Fume

ReductantFlux

Cathode Copper

Pb/Sn/Bi/Ag Products

Zn

PGMsPMs

Gypsum

Te, Seetc.

Intermediate Pb-Rich PhasesFumes

Slimes

SlimesPrecipitates

(Pb/Sn rich)

(Zn rich)

Slimes

1-3 Stage TSL

Electrowinning & -RefiningPrecious Metal

Refining

Smelting/Refining

Leaching

Offgas treatment

Leaching

Page 11: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 11

CE: Processing infrastructure Lead concentrates and residues YTCL (China) & KCM (Bulgaria)

Page 12: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 12

Page 13: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 13

CE: Metallurgy a key enablerhttps://www.youtube.com/watch?v=0WE72HB7asY

EU Supported Event in Brussels October 2015

Page 14: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 14

Metallurgical Internet-of-Things: m-IoT

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 AgInTeSe

Os

Ru Bi

Sb

Ru Pd Ir RhCd

Collection, Dismantling, Shredding

Recycling

Index

Physical Separation

Pyro- & hydrometallurgy, Refining)

Product Complexity

Market & Stocks

Page 15: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 15

M-IoT: Metallurgical Internet-of-Things

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..)

Jarosite

Goethite

(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

Zn

Solution

Cu Removal

RefineryAu, Ag, Cu, Sb, As, Ge

Zn & Refinery ProductsBy-products: In, Ge etc.

Cu Speiss

Circuit Boards

etc.

Precious Metal

RefineryLeached

Residue

Pb Refinery

BULLION

BULLION

Cu Dross

Pb Slime

Residue

Ag

Concentrate

Horizontal Bath

(SKS 1 stage)

Blast

Furnace

Waelz Kiln

Slag

Fume

Zn/Pb (In/Ge..)

Fumer

Fume (Zn rich, Pb, In, Ge)

Slag(high Pb)

Discard

Slag

H2SO4

H2SO4H2SO4

Discard

Slag

Zn PlantVarious configurations

(Figure 2)

Direct Zn(TSL 2 stage)

FeedsZn Concentrates

Washed/roasted secondaries

fumes (e.g. EAF dust)

Pb/Speiss

To lead plants

Rotary

Kiln

Soda Slag

Zn-Plasma

Fumers

Other

residues

Page 16: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 16

m-IoT: Recovering metals from residues, scrap etc.Lead Concentrates & Zinc residues – Nyrstar (Zürich) installing TSL at Port Pirie,

Australia 2016 (Outotec) – 65th Top Submerged Lance furnace

Page 17: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 17

m-IoT: Zinc Residue processingXing’an China

Metals

Recovered

Zn

Pb

Ag

Cu

In

Ge

Ga

Sb

Etc.

Page 18: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 18

M-IoT: 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).

Page 19: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 19

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).

Page 20: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 20

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.

Productdesign

LifeCycleAssessment(LCA)

0

20

40

60

80

100

Ag

Al

Al2O3

Au

BaO Ba Bi C

(C5O

2H8)n

C6H

12Cl3O4P

C15

H12

Br4O2

(C25

H30

O4N

)n

C12H

12O4n

CaO Co Cr

Cu

Fe Mg

MgO Mn Ni

Pb

Pd

Ru

REE

s

Silico

ne Si

SiO2

Sn

SrO

TiO2 Ti V

Zn

TOTA

LREC

OVER

Y%

TotalR

ecove

ry(%)

afterPhysicalRecyclingandProcessMetallurgy

LEDDesignA LEDDesignB LEDDesignC LEDDesignD LEDDesignE

38%

48%

41%

46%

15%

PhysicalRecyclingSimulationModels

CalculationofElementRecoveriesRecyclingIndex

ProcessModels

Remanufacture

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

Page 21: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 21

© MARAS B.V.

A+++ GF

E

A DCB

A+

A++

Recycling

Index

CEE: Comparing solutions relative to baselineI. 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 (online).

CE Product 1 CE Product 2

Page 22: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 22

CEE: Real-time optimization & simulation

Advanced Analysis

vAnalytics & big data analysis platform

vSimulation and optimization platform

vLink back to product design – key innovation

Multi-SensorArray

Multi-SensorArray

Multi-SensorArray

Multi-SensorArrayMulti-SensorArray

Multi-SensorArray

Multi-SensorArray

Multi-SensorArray

Multi-SensorArray

Page 23: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 23

Is sustainable in a CE

©MARASB.V.

A+++ GF

E

A DCB

A+

A++

RecyclingIndex(c)MARAS

Page 24: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 24

Summary

• Digitalizing the CE

• Metallurgical Internet-of-Things

– Metallurgical infrastructure key

• Circular Economy Engineering

– Metallurgy’s contribution

• Quantified limits of a Circular Economy?

Page 25: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 25

m-IoT: Metallurgical Internet-of-Things

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..)

Jarosite

Goethite

(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

Zn

Solution

Cu Removal

RefineryAu, Ag, Cu, Sb, As, Ge

Zn & Refinery ProductsBy-products: In, Ge etc.

Cu Speiss

Circuit Boards

etc.

Precious Metal

RefineryLeached

Residue

Pb Refinery

BULLION

BULLION

Cu Dross

Pb Slime

Residue

Ag

Concentrate

Horizontal Bath

(SKS 1 stage)

Blast

Furnace

Waelz Kiln

Slag

Fume

Zn/Pb (In/Ge..)

Fumer

Fume (Zn rich, Pb, In, Ge)

Slag(high Pb)

Discard

Slag

H2SO4

H2SO4H2SO4

Discard

Slag

Zn PlantVarious configurations

(Figure 2)

Direct Zn(TSL 2 stage)

FeedsZn Concentrates

Washed/roasted secondaries

fumes (e.g. EAF dust)

Pb/Speiss

To 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..)

Jarosite

Goethite

(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

Zn

Solution

Cu Removal

RefineryAu, Ag, Cu, Sb, As, Ge

Zn & Refinery ProductsBy-products: In, Ge etc.

Cu Speiss

Circuit Boards

etc.

Precious Metal

RefineryLeached

Residue

Pb Refinery

BULLION

BULLION

Cu Dross

Pb Slime

Residue

Ag

Concentrate

Horizontal Bath

(SKS 1 stage)

Blast

Furnace

Waelz Kiln

Slag

Fume

Zn/Pb (In/Ge..)

Fumer

Fume (Zn rich, Pb, In, Ge)

Slag(high Pb)

Discard

Slag

H2SO4

H2SO4H2SO4

Discard

Slag

Zn PlantVarious configurations

(Figure 2)

Direct Zn(TSL 2 stage)

FeedsZn Concentrates

Washed/roasted secondaries

fumes (e.g. EAF dust)

Pb/Speiss

To lead plants

Rotary

Kiln

Soda Slag

Zn-Plasma

Fumers

Other

residues

Copper-Metallurgy

Lead-Metallurgy

Zinc-Metallurgy

Ç√

Ç√

Page 26: Metallurgical Internet-of-Things m-IoT - Leibniz Institut · Metallurgical Internet-of-Things m-IoT ... Metallurgical Internet-of-Things Slag (low Pb) BULLION Horizontal Bath (QSL,

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

Helmholtz Institute Freiberg for Resource Technology©

Page 26

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 Product

g NOx / t Product

m3 Water / t Product (including ions in solution)

kg Residue / t Product (including composition)

kg Fugitive Emissions / t Product

kg Particulate Emissions / t Product

Etc.

Environmental Indicators based on BAT

Driving 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.