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© Outotec - All rights reserved Review of Metal Recycling End-of-Life Products, Residues, Wastes, Slags, Design for Sustainability, Eco-Labeling Markus A. Reuter Director – Technology Management Outotec Oy, Finland Adjunct Professor Aalto University Helsinki Guest Professor Central South University China Professorial Fellow University Melbourne Australia Sustainable use of Earth’s natural resources
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Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

May 03, 2018

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Page 1: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

Review of Metal Recycling End-of-Life Products, Residues, Wastes, Slags, Design for Sustainability, Eco-Labeling

M a r k u s A . R e u t e rDirector – Technology Management Outotec Oy, FinlandAdjunct Professor Aalto University HelsinkiGuest Professor Central South University ChinaProfessorial Fellow University Melbourne Australia

Sustainable use of Earth’s natural resources

Page 2: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

Ranked Globally 12th most Sustainable Corporationhttp://corporateknights.com/report/9th-annual-global-100Knowledge in the processing of >60 elements>130 Non-ferrous smelters (58 Flash, 56 TSLs, 17 Kaldo)• 2013 Flash Milestones

• Tongling>400,000tpa & Fanchenguang>400,000tpa• ca. world 50% Cu , >30% Sn in TSL , large % PGM matte converting

(AngloPlatinum)

650 sulfuric acid plants• World’s largest metallurgical based, Zambia and largest in Ma’aden

Minerals Processing / Hydrometallurgy• 1100 grinding mills

• 28MW worlds’ largest saving around 15% energy

• >10000 flotation units (reaching 500m3)• 1800 thickeners / >3500 filters

Ironmaking and Ferroalloys• 20 pelletizing and sintering plants for chromites (ferroalloys),• 13 ferroalloy smelters• 340 iron ore sintering plants• 93 iron ore pelletizing plants

Light metals / Roasting / Waste to Energy• 290 fluidized bed roasting plants / alumina calcining

World’s largestpellet plant

(7.5 million tpy) Samarco; Brazil

Grinding mills LKAB Sweden

Xiangguang Copper highest environmental award for

its smelter project from the Chinese Government.

4/2/2013

Outotec in Brief

2 Third International Slag Valorisation Symposium

Page 3: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

Resource Efficient Metal Production More than 130 Outotec smelters around the world

3

Flash Smelting Technology (58)Ausmelt TSL (56)Kaldo (17)

Flash Smelting Technology (58)Ausmelt TSL (56)Kaldo (17)

4/2/2013 Third International Slag Valorisation Symposium

Page 4: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

To achieve Resource Efficiency…Mineral Processing and Metallurgy – Foundation• The link Minerals to Metal has been optimized through the years

including economic and technological consideration and a deep physics understanding of various processes.

• There is a good understanding between all actors from rock to metal – also an understanding of slag chemistry.

Product Centric vis-à-vis Metal Centric Recycling• Designer Minerals (e.g. cars, mobiles etc.) are far more complex

than geological minerals; complicating recovery, requires rigorous system design taking all elements into consideration.

• To “close” the loop requires a deep understanding and harmonization between all actors of the system than is the case presently.

• Slag valorization, recovery of elements from it and understanding its properties is crucial for Product Centric recycling.

UNEP report on recycling with above message to appear April 24th 2013.

4 4/2/2013 Third International Slag Valorisation Symposium

Page 5: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

Geological vis-à-vis Urban Mine “Minerals”“Mineral Centric” from classical mining equivalent to “Product Centric” in Urban Mining

5 4/2/2013

Chalcopyrite CuFeS2and >20 minors e.g. Au, As, Ag, Se etc.

Designer Copper “Minerals”>40 elements complexly linked

Third International Slag Valorisation Symposium

Material combinations and Designed Consumer “Minerals”

Material connections

Joined Materials

Page 6: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

State-of-Art Copper Smelters (>400,000 tpa)Design for Sustainability, it is happening already through Outotec…

6 4/2/2013

Precious MetalsKaldo

Third International Slag Valorisation Symposium

Page 7: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

State-of-Art Copper Smelters

7 4/2/2013 Third International Slag Valorisation Symposium

Page 8: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

Resource Efficient Metal ProductionEconomic and multi-physics understanding key to “closing” loop

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Page 9: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

The physics and design of separation…Understand the economics, physics…

9 4/2/2013

Material CentricBulk recyclates well liberated with

relatively little impurities – easier to recycle

Product CentricComplex products create poorly liberated complex recyclates, these are the losses, inefficiencies, the true challenge of recycling and “closing the loop”

Slag Chemistry is a Key.

Third International Slag Valorisation Symposium

Page 10: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

The physics of separation…

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Page 11: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

11 4/2/2013

Understanding the complete system

Third International Slag Valorisation Symposium

Page 12: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

Controlling the FurnaceControlling the slag…

12 4/2/2013 Third International Slag Valorisation Symposium

0246

810

1214

0

20

40

60

80

100

120

100010

25105010

75110011

25115011

75120012

25125012

75130013

251350

% L

iqiu

id S

lag

Temperature (oC)

% Slag Liquid: Fe/SiO2=1.4 : %CaO=5: log(pO2)=-6

% Al2O3

FACTSage 6.2/Reuter

0246

810

1214

0

20

40

60

80

100

120

100010

25105010

75110011

25115011

75120012

25125012

75130013

251350

% L

iqiu

id S

lag

Temperature (oC)

% Slag Liquid: Fe/SiO2=1.2 : %CaO=5: log(pO2)=-6

% Al2O3

FACTSage 6.2/Reuter

0246

810

1214

0

20

40

60

80

100

120

100010

25105010

75110011

25115011

75120012

25125012

75130013

251350

% L

iqiu

id S

lag

Temperature (oC)

% Slag Liquid: Fe/SiO2=1 : %CaO=5: log(pO2)=-8

% Al2O3

FACTSage 6.2/Reuter

0246

810

1214

0

20

40

60

80

100

120

100010

25105010

75110011

25115011

75120012

25125012

75130013

251350

% L

iqiu

id S

lag

Temperature (oC)

% Slag Liquid: Fe/SiO2=1.4: %CaO=5: log(pO2)=-10

% Al2O3

FACT Sage 6.2/Reuter

Page 13: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

13

+ Recycling / E-waste

+ Recycling

4/2/2013

The physics and technology of separation…Understand the physics in the context of technology and economics (Video)

Third International Slag Valorisation Symposium

Page 14: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

Understanding the deportation of elementsElement distributions

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FLOGEN

Page 15: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

Secondary Smelting Processes

Copper Recycling GRM DanyangSmelter TSL (S. Korea)

E-Waste and Copper Recycling Dowa TSL (Japan) Lead Battery Recycling

Recylex TSL (Germany)

Xiangguang Yanggu SmelterKaldo (China)

Boliden – Rönnskår SmelterKaldo (Sweden)

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Page 16: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

Outotec Ausmelt TSL

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DOWA Mining• Process: E-Waste Recycling and Residue Processing

• Capacity: 140,000 tpa feed

• Commissioned: 2008

2/04/2013 Third International Slag Valorisation Symposium

Page 17: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

Outotec® Ausmelt Converting

17

Anglo Platinum• Process: Continuous nickel-copper matte converting

• Capacity: 210ktpa feed throughput

• Commissioned: 2002

Electric

Smelting Furnace

Concentrates

Electric Slag

Cleaning Furnace

Granulated Matte

Molten Slag

Outotec® Ausmelt

Converting Furnace

High-grade Ni-Cu Matte

2/04/2013 Third International Slag Valorisation Symposium

Page 18: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

Zn Residue ProcessingKorea Zinc applications of Outotec TSL Technology

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Page 19: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

Design for Resource Efficiency

19 4/2/2013

Precious MetalsKaldo

Third International Slag Valorisation Symposium

Page 20: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

Measuring Sustainability, Resource Efficiency

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Page 21: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

Design for Resource Efficiency

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Page 22: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

Urban Mining, Ecodesign, OEMsRecyclability Index

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Bill of MaterialsChemical contentFull Material DeclarationStructural product data / exploded viewsEtc.

Product compositional data

Simulated Recycling & Recovery rates Resource Efficiency

Environmental analyses recycling = Recyclability Index

Page 23: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

Third International Slag Valorisation Symposium23 2/04/2013

Design for Recycling & Metal Recoverability

Page 24: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

In summary…Mineral Processing and Metallurgy – Foundation• The link Minerals to Metal has been optimized through the

years including economic and technological consideration and a deep physics understanding of various processes.

• There is a good understanding between all actors from rock to metal – also an understanding of slag chemistry.

Product Centric vis-à-vis Metal Centric Recycling• Designer Minerals (e.g. cars, mobiles etc.) are far more

complex than geological minerals; complicating recovery, requires rigorous system design taking all elements into consideration.

• To “close” the loop requires a deep understanding and harmonization between all actors of the system than is the case presently.

• Slag valorization, recovery of elements from it and understanding its properties is crucial for Product Centric recycling.

24 4/2/2013 Third International Slag Valorisation Symposium

Page 25: Review of Metal Recycling - Slag Valorisation Symposium · Review of Metal Recycling End-of-Life Products, Residues, ... Director – Technology Management Outotec Oy, Finland ...

© Outotec - All rights reserved

Sustainable use of Earth’s natural resources

www.outotec.comwww.outotec.com/sustainability