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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-Thingsm-IoT
Markus A. Reuter
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
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
Prof. Dr. Dr. h.c. Markus A. Reuter
Helmholtz Institute Freiberg for Resource Technology©
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(65)
CE: Product Centric Recycling
Prof. Dr. Dr. h.c. Markus A. Reuter
Helmholtz Institute Freiberg for Resource Technology©
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©MARASB.V.
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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.
Prof. Dr. Dr. h.c. Markus A. Reuter
Helmholtz Institute Freiberg for Resource Technology©
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Au
Cu
Ta
CE: A key issue of recycling
Prof. Dr. Dr. h.c. Markus A. Reuter
Helmholtz Institute Freiberg for Resource Technology©
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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
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. Reuter
Helmholtz Institute Freiberg for Resource Technology©
Page 9
CE: Optimization, Simulation, Big-dataReal-time data and evaluation of the complete chain
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
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)
Prof. Dr. Dr. h.c. Markus A. Reuter
Helmholtz Institute Freiberg for Resource Technology©
Page 12
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
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
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
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
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.
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).
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).
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!
Prof. Dr. Dr. h.c. Markus A. Reuter
Helmholtz Institute Freiberg for Resource Technology©
Page 21
© MARAS B.V.
A+++ GF
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A DCB
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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
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
Prof. Dr. Dr. h.c. Markus A. Reuter
Helmholtz Institute Freiberg for Resource Technology©
Page 23
Is sustainable in a CE
©MARASB.V.
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RecyclingIndex(c)MARAS
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?
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√
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.