chancen und grenzen einer circular economy · prof. dr. dr. h.c. markus a. reuter helmholtz...

Prof. Dr. Dr. h.c.. Markus A. Reuter I Director: Helmholtz Institute Freiberg for Resource Technology© I www.hzdr.de/hif

Chancen und Grenzen einer Circular Economy(from 2016 TMS EPD Distinguished Lecture, Nashville, USA)

Markus Reuter

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

Overview

• Circular Economy - SIMP– System integrated metal production – SIMP

– Rigorous quantification of Resource Efficiency (RE)

• Digitalization - Recycling 4.0– Internet-of-Metallurgical-Things

– Link all stakeholders in material cycle

• Circular Economy Engineering - CEE– Metallurgical infrastructure & deep knowledge key

– Inform society in an understandable manner


∆" = ∆$%

Linear Energy vs. Circular Material Systems


System Integrated Metal Production – SIMPMetals play key role, economics as well


System Integrated Metal Production – SIMPhttps://www.youtube.com/watch?v=0WE72HB7asY


SIMP: Quantifying Resource Efficiency (RE)Minimize entropy creation, maximize resource efficiency


SIMP: System optimizationS. Sudhölter, M.A. Reuter and J. Krüger (1996): Eco-techno-economic synthesis of process routes for the production of zinc using combinatorial optimisation, Metallurgical Transactions B, Vol. 27(6), pp. 1031-1044.

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 SpeissCircuit Boards

etc.

Precious MetalRefineryLeached

Residue

Pb Refinery

BULLION

BULLIONCu Dross

Pb Slime

Residue

AgConcentrate

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 SpeissCircuit Boards

etc.

Precious MetalRefineryLeached

Residue

Pb Refinery

BULLION

BULLIONCu Dross

Pb Slime

Residue

AgConcentrate

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: Circular Economy within a corporationMetallurgy key to enable Circular Economy

Copper-Metallurgy

Lead-Metallurgy

Zinc-Metallurgy

Ç√

Ç√

KCM – Bulgaria: New TSL SmelterLead primary and residues


Recovering metals from minerals & residuesNyrstar (Basel) Port Pirie Redevelopment in Australia

From: Watts (2015): Nyrstar Port Pirie Redevelopment


SecondaryFeeds(Low&HighgradeCumaterials&alloys,WEEE-PMs(Au)&PGMscontainingresidues&scrap,shredderresidue)

Raw/AnodeCopper

FuelAir(Oxygen)

DiscardSlag(ConstructionMaterial)

Dust/Fume

ReductantFlux

CathodeCopper

Pb/Sn/Bi/AgProducts

Zn

PGMsPMs

Gypsum

Te,Seetc.

IntermediatePb-RichPhasesFumes

Slimes

SlimesPrecipitates

(Pb/Snrich)

(Znrich)

Slimes

1-3 Stage TSL

Electrowinning & -RefiningPrecious Metal Refining

Smelting/RefiningLeaching

Offgas treatment

Leaching

SIMP: Deep knowledge & technology

DOWA, JapanN.Huda,J.Naser,G.Brooks,M.A.Reuter,R.W.Matusewicz (2012):ComputationalFluidDynamicModeling ofZincSlag FumingProcess inTop-Submerged LanceSmelting Furnace,Metallurgical Transactions B,43B(1),39-55.A.Anindya,D.R.Swinbourne,M.A.Reuter,R.W.Matusewicz (2013):Distributionofelements between copper andFeOx-CaO-SiO2 slags during pyrometallurgical processingofWEEEPart2– Indium,Mineral ProcessingandExtractiveMetallurgy (Trans.Inst.Min Metall.C),123(1)43-52.


SIMP: Measuring fundamental data!!M.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 (submitted).

ReductiveSmelt

OxidativeConvert(Optional)

RawCopper(+PMs&PGMs)ToRefining

‘Black’

Copper

Fuel,Air(Oxygen)

DiscardSlag(ConstructionMaterial)

Dust/FumeZnrich,Pb/SnTofurtherprocessing

ReductantFlux

Slag

DustFumeSnrich,Pb

FluxFuel,Air(Oxygen)

SecondaryCopperFeeds(High-gradeCu)

ReductionFurnace(Optional)

DiscardSlag

CopperAlloyTofurtherprocessing

SecondaryCopperFeeds(Low-gradeCu)

Dust/FumeTofurtherprocessing-Znrich,Pb/Sn

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

TSL

Kaldo

VariousHigh-&Low-GradeCuScrap

???

???


Recycling 4.0: Optimization, Simulation, Big-dataReal-time data and evaluation of the complete chain

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 AgIn TeSe

Os

Ru Bi

Sb

Ru Pd Ir RhCd

Collection, Dismantling, Shredding

Recycling

Index

Physical Separation

Pyro- & hydrometallurgy, Refining)

Product Complexity

Market & Stocks

GeologicalMinerals DesignerMinerals


Recycling 4.0: Optimization, Simulation, Big-dataReal-time data and evaluation of the complete chain


Recycling 4.0: Simulation & exergy analysis


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)Water footprint (Green, Blue, Grey)

Etc...

Recycling 4.0: Rigorous estimation of RE!


Rigorous comparison

Finland

China

South Africa

0

1

2

3

4

5

6

7

8

CASE 1: 60% concentrate, 40%

lump ore/fines, open furnace

CASE 2: 70% pellets, 30% lump

ore, closed furnace, preheated

CASE 3: 100% pellets, closed

furnace, preheatedCASE 4: 100% concentrate,

prereduced with coke, hot charge

GW

P: k

g CO

2-eq

/kg

liqui

d Fe

Cr(5

0% C

r)

Copper

HC FeCrZinc

Nickel Pig Iron

Lead


Recycling 4.0: Link CAD to Recycling IndexM.A. Reuter, A. van Schaik and 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, Vol. 20(5), pp. 671-693.

Productdesign

LifeCycleAssessment(LCA)

0

20

40

60

80

100

Ag

Al

Al2O3

Au

BaO

Ba Bi C

(C5O2H8)n

C6H12Cl3O4P

C15H12Br4O2

(C25H30O4N)n

C12H12O4n

CaO

Co

Cr

Cu

Fe

Mg

MgO

Mn

Ni

Pb

Pd

Ru

REEs

Silicone Si

SiO2

Sn

SrO

TiO2

Ti

V

Zn

TOTALRECOVERY%

TotalRecovery(%)

afterP

hysic

alRecyclingand

ProcessM

etallurgy

LEDDesignA LEDDesignB LEDDesignC LEDDesignD LEDDesignE

38%

48%

41%

46%

15%

PhysicalRecyclingSimulationModels

CalculationofElementRecoveriesRecyclingIndex

ProcessModels

Remanufacture

Traditional Design for Recycling: Does not provide detail!


Circular Economy EngineeringLinear vs Circular System Analysis & Quantification for 5 LED designs

©MARASB.V.

A+++ GF

EA D

CB

A+

A++

RecyclingIndex

10-50%

LED Design 5

LED Designs 2 to 4

LED Design 1


Summary• Digitalizing the Circular Economy: Recycling 4.0

– Business models

– Internet of Metallurgical Things – Linking it with software

– Maximize Resource Efficiency: Energy vs. Material Efficiency

• Processing infrastructure key to circular economy– Digitalization platform key!

– Ensure that system is robust with its suite of technologies

• Circular Economy Engineering– Engineering basis to estimate economics & environmental impact

• Inform Policy & Consumer in rigorously based approach– Quantify limits of consumption?

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

Markus A. ReuterDr. h.c. (Liege), D.Eng.(ZA), Dr. habil. (Aachen), PhD (ZA)• Industry

Ø Ausmelt-Outotec (Director Technology Management: Outotec, Finland (2010-2015)& Technical Director: Ausmelt, Australia (2006-2010 - taken over by Outotec 2010))

Ø Leader furnace control group: Mintek, South Africa (1994-1996)Ø Process Metallurgist: Anglo American Corporation, South Africa (1984-1985)

• AcademicØ Helmholtz Institute Freiberg for Resource Technology, Germany (2015 →)Ø Adjunct & Honorary Professor: Aalto University Helsinki (2012→)Ø Guest Professor: Central South University Changsha, China (2012→)Ø Professor and Professorial Fellow: University Melbourne, Australia (2005→) Ø Professor & Emeritus: TU Delft, Netherlands (1996-2012)Ø Adjunct Professor: Stellenbosch, South Africa (1999-2007)

DegreesØ Dr. h.c. Honorary Doctorate University of Liege (2015: Belgium)Ø D. Eng. & PhD: University of Stellenbosch (1991 & 2006: South Africa)Ø Dr. habil.: RWTH Aachen (1995: Germany)

Recent Awards, Publications, Interests, Patents, etc.Ø 2016: TMS EPD Distinguished LectureØ 2016: SME Henry Krumb LecturerØ 2015: Doctor honoris causa, Honorary Doctorate, University Liège, BelgiumØ 2014: 1st Prize Publication Award: International Solid Waste Association for “Handbook of Recycling” (http://www.iswa.org/)Ø 2014: TMS Science Award: Best paper in Metallurgical Transactions B (2013)Ø 2013: Outotec Technology Award - Awarded to individuals that enhance the commercial success of OutotecØ 2013: Lead author of a 2nd report on recycling for United Nations Environmental Protection (UNEP): Metal Recycling:

Opportunities, Limits, Infrastructure (400,000 downloads April 2013 to September 2015) http://www.unep.org/resourcepanel/Portals/50244/publications/Metal_Recycling-Full_Report_150dpi_130919.pdfand http://www.ubraintv.com/watch.php?id=842

Ø H-Factor: ISI=20; Scopus=21, Google Scholar=29Ø >400 Publications: Book / Chapters in Encyclopedias / Journal / Conference / Patents (see ResearchGate and other links)

Various patent families (pending or awarded e.g. Japanese Patent 2014-517328:TOP SUBMERGED INJECTING LANCES)

http://fi.linkedin.com/pub/markus-reuter/11/195/90https://www.researchgate.net/profile/Markus_Reuter3?ev=prf_highl

http://scholar.google.co.uk/citations?user=5cLC8VEAAAAJ&hl=en&oi=aohttp://www.researcherid.com/rid/D-2839-2015

chancen und grenzen einer circular economy · prof. dr. dr. h.c. markus a. reuter helmholtz...

Documents