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TRANSCRIPT
Dr. Lisa O’Donoghue – Coordinator
EIP Raw Materials Commitment
Value ChainMining
Refining & smelting
Recycling and recovery
Construction Gov. Agency
Research
Environmental
Objectives• To boost the innovation capacity of the aluminium
value chain with respect to secondary raw materials recovery
• To foster international co-operation among 40 key players across the aluminium value chain
• The creation of new value chains for the recovered raw materials from by-products
• To test the viability of solutions via pilot actions
• To mobilise a significant part of the aluminium value chain to increase the impact of research
• To promote socially acceptable, environmentally responsible and economically viable technologies
Challenges
Industry Challenges• Process: Bauxite - alumina - aluminium
• 140 millions tonnes of bauxite residue produced 2014*
(K.Evans)o Landfilled
o Sea or river disposal
• Highly alkaline
• Contains heavy metals & traces radioactive substances
• Variation in composition depending on the ore
• EU: Cost, transportation and legislation challenges for
both management and reuse
*European Aluminium Association
Industry Challenges• In spite of increasing global demand, since 2003 it was
reported that plants closing in EU
• Costs/ Safe environmental management (Ajka Alumina plant
accident, Hungary)
• “Restoring the aluminium industry to competitiveness is an
urgent issue” Commissioner Tajani
• European competitiveness in this sector is imperative to:
o both stabilise and reduce EU dependence on imports,
o promote production and
o protect jobs
From problem to opportunity
Drivers:
• Environmental drive
• Management costs
• Safety and Best practices
• IAI Technology Roadmap
• Residue Strategic Goal
o Develop sustainable storage without the need for ongoing management;
o Remediate all residue using various means including process-generated
o Utilise 20% of residue by 2025;
o Reduce soda trapped in mud sent to residue storage.
Addressing Challenges
Research
Innovation
BRAVO
Activities
Cooperation
Al-Ore
Al-Source
Al-Build
Al-Chain
Al-Aware
BRAVO Modules
Al-Ore
• Optimisation to reduce waste residues, increase their subsequent processabilty and reduce their environmental impact.
• Evaluated at process level such statistical techniques ; VMEA
• Explore optimised and alternative processing techniques• Input from BRAVO partners along the value chain will be
key to the success of such tests, specifically as the output of one step is the input to the another step in the chain.
• Effect of materials composition variations per plant. • Pilot output data will include BR volume per alumina
tonne, composition, pH and grain size.
Al-Source
• Al-source focuses on using the bauxite residue as a source of critical raw materials including gallium, titanium, selium, germanium, dysprosium and cerium.
• The residue contains high value metals in small fractions combined with a low grade bulk component composed of iron oxides.
• Al-Source will assist partners developing a holistic and optimised n integrated metallurgical system (including pyro-, hydro-, bio-, electro-chemistry) for the metal recovery by-products.
• The effect of varying composition due to differing sources of materials (composition and grain size) and processing parameters will also be quantified.
• This will be done via the expertise of the BRAVO commitment (involving academia, industry and technology suppliers) in metallurgy.
Al-Build• Innovations is the use of the bulk
material w for the construction sector.
• Assist partners with technologies for a
series of complex and integrated
solutions to convert residue wastes to
raw materials and products.
• Al-build will focus on the remaining bulk
low grade residue, exploring
techniques and processes from
alternative industries including the
construction sector.
Al-Chain• The Al-Chain project focuses on both policy, co-operation across
the aluminium value chain and the creation of innovation across the chain.
• Al-Chain focuses on the Innovation and Commercialisation activities of the BRAVO commitment and support the co-operation activities including the following:
• Policy development/ Best practices/ Dissemination days
• Knowledge exchange
Al-AwareAl-Aware focuses on both :
o public awareness ;
o skills, educations and knowledge within the
European aluminium value chain and
internationally.
• Al-Aware will pre-dominantly undertake the
cooperation activities of the BRAVO commitment
previously detailed.
Technology Templates
Technology MappingAl-Ore
•Partner 1 (TRL4)
•Partner 2 (TRL2)
•Partner 3 (TRL5)
Al-Source
•Partner 1 (TRL3)
•Partner 2 (TRL4)
•Partner 3 (TRL1)
•Partner 4 (TRL2-3)
•Partner 5 (TRL3)
•Partner 6 (TRL4)
•Partner 7 (TRL1)
•Partner 8 (TRL2-6)
•Partner 9 (TRL2)
Al-Build
•Partner 1 (TRL1)
•Partner 2 (TRL5)
•Partner 3 (TRL2)
•Partner 4 (TRL4)
•Partner 5 (TRL5-6)
•Partner 6 (TRL 1)
•Partner 7 (TRL4)
•Partner 8 (TRL4)
Sharing Best Practices• Best practices regarding Residue Management available
• State of art technologies innovation to utilise the residue
and achieve targets
• Present 3 partner innovations that are under
development;
o Zaak Technologies and Rio Tinto
o Rusal - Aughinish Alumina
o Fraunhofer Institute IWKS
Bauxite Residue
Oil & Gas
Building & Construction
Others
Red Mud Slurry Additives Slurry
No drying of red mud slurry
Bauxite Residue to Smart Spheres – The Approach
Smart Spheres
Patent pending technology, proven by outsourcing sub-process to
vendors
Zaak Technologies
Construction material
Tech. MortarPlaster/Rende
rConcrete
Other applications
Horticulture Moulding
Ke
y
US
Ps
Price
Thermal
insulation
Lightweight
Purity
Performance
Oil &
Gas
Proppants Paints
Sintered Spheres - Applications
AVAR
The advancement in state of the art in this project is to develop a combined process for the
removal on vanadium in tandem with gallium recovery at a purity of 6N. There is currently
no industrial process which removes vanadium and gallium in a single step process at this
level of purity. This project will for the first time combine vanadium and gallium recovery
processes in one single industrial system.
The ground breaking nature of AVAR is three-fold: a) the development of a novel Ga and V
recovery process from Bayer liquors for the first time including the hand to hand
development of specialized equipment b) recovery of high value 6 N purity gallium and
vanadium c) overall process integration and optimization with the main Bayer production
process
Bildquellen: © Fraunhofer ISC; © flickr
Innovative Separation-Technologies
Development of physical, chemical and biological methods
for the recovery of materials
Selective recovery of materials by gas phase reactions
Source: © Fraunhofer ISC
Opened System
DepositionCondensation
A(s), e. g. Powder, contaminated
T1
A(s) + B(g) C(g)
B(g)
T2
C(g)
Thank You• If you are interested in any of these technologies or
projects, or the activates of the BRAVO EIP, please contact us.
www.BRAVOEIP.eu
Dr. Lisa O’Donoghue
Design & Manufacturing Technology,
University of Limerick
Ireland