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Metal Recycling: Opportunities, Limited, Infrastructure
Metal Recycling: Opportunities, Limited, Infrastructure
Recycling
Opportunities, Limits,
Infrastructure
Acknowledgments
Editor: International Resource Panel, Working Group on the Global Metal Flows
Lead author: Markus Reuter
Authors: Markus Reuter, Outotec Oyj, Finland and Aalto University, Finland; Christian Hudson, DIW, Germany; Antoinette van Schaik,
MARAS, Netherlands; Kari Heiskanen, Aalto University, Finland; Christina Meskers, Umicore, Belgium and Christian Hagelken, Umicore,
Germany.
Contributors (Alphabetical): Helmut Antrekowitsch, University Leoben, Austria; Diran Apelian, WPI, USA; Bo Bjorkman, Lule University of
Technology, Sweden; Bart Blanpain, Leuven University, Belgium; Franoise Bodenan, BRGM, France; Mieke Campforts, Umicore, Belgium;
Amlia Enrquez, UNEP, Brazil; Bernd Friedrich RWTH Aachen, Germany; Stefan Gssling-Reisemann, University of Bremen, Germany;
Daniel Froelich, ENSAM, Chambry, France; Tom Jones, Leuven University, Belgium; Yasushi Kondo, Waseda University, Japan; Jinhui Li
Tsinghua University, China; Hans-Rainer Lotz, Volkswagen, Germany; Stefan Luidold, University Leoben, Austria; Elisabeth Maris, ENSAM,
Chambery, France, Kazuyo Matsubae, Tohoku University, Japan; Nourredine Menad, BRGM, France; Shinsuke Murakami, Tokyo University,
Japan; Kenichi Nakajima, NIES, Japan; Tetsuya Nagasaka, Tohoku University, Japan; Shinichiro Nakamura, Waseda University, Japan;
Sheraz Neffati, ICDA, France; Shuji Owada, Waseda University, Japan; Jim Petrie, University of Cape Town, South Africa; Georg Rombach,
Hydro Aluminium, Germany; Susanne Rotter, University of Berlin, Germany; Mathias Schluep, EMPA, Switzerland, Guido Sonnemann, University of Bordeaux, France, Philip Strothmann, UNEP, France; Pia Tanskanen, Nokia, Finland; Karel van Acker, Leuven University, Belgium;
Jacques Villeneuve, BRGM, France; Harro von Blottnitz, University Cape Town, South Africa; Patrick Waeger, EMPA, Switzerland; Philippe
Wavrer, BRGM, France; Rolf Widmer, EMPA, Switzerland; Patrick Wollants, Leuven University, Belgium and Guomei Zhou, Ministry of Environmental Protection, China.
We would like to thank Christian Hudson and Marinus Kluijver for providing scientic and English editorial support for the full report.
The report went through several rounds of peer-review coordinated in an efcient and constructive way by Patrice Christmann together with
the International Resource Panel Secretariat. Valuable comments were received from several anonymous reviewers in this process. The
preparation of this report also beneted from discussions with many colleagues at various meetings.
Special thanks go to Ernst Ulrich von Weizscker and Ashok Khosla as Co-Chairs of the International Resource Panel for their continuing
support and encouragement, as well as to the members of the International Resource Panel and its Steering Committee for their dedication
and commitment and additional helpful comments.
Special thanks go to Anu Ketel (Aalto University, Finland) for her support during the nal stages of the document preparation. Shaoyi Li,
Janet Salem, Thomas Marques and Philip Strothmann, UNEP, provided valuable input and comments; the International Resource Panels
Secretariat coordinated the preparation of this report. Sybille Schmidtchen and the team from 3f design were instrumental in creating and
editing the gures and graphics.
The main responsibility for errors remains with the authors.
Copyright United Nations Environment Programme, 2013
The report should be referenced as follows:
UNEP (2013) Metal Recycling: Opportunities, Limits, Infrastructure, A Report of the Working Group on the Global Metal Flows to the International Resource Panel. Reuter, M. A.; Hudson, C.; van Schaik, A.; Heiskanen, K.; Meskers, C.; Hagelken, C.
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Metal
Recycling
Opportunities, Limits,
Infrastructure*
Foreword
The challenge of sustainable development at
the beginning of the 21st century has become
a systemic one, with environmental, social
and economic dimensions on an equal footing. UNEP and the UNEP-hosted International Resource Panel consider that our contributions also need to be systemic, for example
through the promotion of resource efficiency,
improved materials recycling and life-cycle
thinking. This report from the Panel, Metal Recycling - Opportunities, Limits, Infrastructure, provides unrivalled science to inform policy makers about how the recycling
of metals can be optimized on an economic
and technological basis along product life cycles in the move towards sustainable metals
management.
The report shows that sustainable metals
management requires more than improving recycling rates of selected materials. We
need to change thewhole mindset on recycling of metals, moving away from a Material-Centric approach to a Product-Centric approach. Recycling has become increasingly
difficult today and much value is lost due to
the growing complexity of products and complex interactions within recycling systems.
While common commodity metals like steel,
magnesium and copper can be recovered relatively easily, as these are often used in relatively simple applications, the small amounts
of metals in, for example, electrical and electronic waste can be harder to recover because they are often just one among up to
50 elements. As an example, a mobile phone
can contain more than 40 elements including
base metals such as copper and tin, special
metals such as cobalt, indium and antimony, and precious and platinum-group metals including silver, gold, palladium, tungsten
and yttrium. Fluorescent lamps contain various materials and elements which include a
range of Rare Earth elements, and other critical metal resources. And a modern car contains nearly all metals available, as it is a
2
quantity of metal stocks and on metal recycling rates outlined the so-far untapped
This is why thefocus needs to be on optimizing the recycling of entire products at their
end-of-life instead of focusing on the individual materials contained in them. The global
mainstreaming of a product-centric view on
recycling will be a remarkable step towards
efficient recycling systems, resource efficiency, and a green economy in the context of
sustainable development and poverty eradication.
Such a transition will depend on the mobilization of everyone in the value chain, from
operators in the primary production of metals
and metal-containing products to the recycling and collection industry to the consumers. Industry can be the source of driving innovation that maximizes resource efficiency
when policy makers draw on their expertise
and tools. Experts from the extraction industry, for example, can make a crucial contribution through their knowledge of metal streams and Best Available Techniques
(BATs) for the separation and recovery of different components of a product. Moreover,
the manufacturing industry plays a key role
in the design of products that facilitate recycling, leading to a substantial increase in recycling efficiency. However, making so-called
urban mines valuable through recycling
can only happen if consumers dispose waste
products at collection points operated according to BAT and decide against informal or
illegal disposal.
As populations in emerging economies adopt
similar technologies and lifestyles as currently used in OECD countries, global metal needs will be 3 to 9 times larger than all
the metals currently used in the world. This
poses a significant call for increased secondary production of metals. Two former reports
from the International Resource Panel on the
Achim Steiner
UN Under-Secretary General and
Executive Director UNEP
Nairobi, Kenya
Preface
The increasing demand for metals in the course
of the last century, putting permanent pressure
on natural resources, has revealed that metals are a priority area for decoupling economic
growth from resource use and environmental
degradation. The imperative of decoupling will
become even more pressing in the future with
a global demand for metals on the rise: In developing countries due to rapid industrialization
and in developed countries due to modern, metal intensive technologies that are crucial not
only but especially for the transformation towards green technologies. Ensuring appropriate
levels of supply while reducing the negative environmental footprints will therefore be essential on our way towards a global green economy.
In this regard, recycling and thus resource efficiency plays a crucial role, as it decreases the
necessity to fulfil the demand by exploiting our
natural resources further. Using secondary resources temporarily locked up in so-called urban mines hence decreases not only the environmental impacts associated with mining,
but also decreases the release of partly toxic
wastes into the environment. Taking into account that most modern technologies rely on
critical elements, which are not abundant in
nature, it is of crucial importance to preserve
and reuse them as much as possible.
The International Resource Panels working
group on Global Metal Flows contributes to the
promotion of an international sound materialcycle society by providing a series of six scientific and authoritative assessment studies on
the global flows of metals. To achieve best scientific results, it cooperates with a number of
actors, including metal industry associations.
The present, report builds on the findings of the
two previously published assessments of metal stocks in society and recycling rates, which
came to the conclusion that despite huge metal
mines above ground, recycling rates remain
low. It aims at leveraging secondary production
of metals through a close analysis of the necessary conditions and enablers of recycling.
The report identifies a number of shortcomings in current recycling policies but also shows
ways for their improvement. It emanates from
the report that recycling systems need to adjust
to the fact that recycling has become increasingly difficult due to the rising complexity of
products. Raising metal-recycling rates therefore needs realignment away from a materialcentric towards a product-centric approach. A
focus on products discloses the various tradeoffs between for example achieving weightbased policy targets and the excessive energy
consumed in efforts to meet these targets. Recycling objectives that go beyond what is thermodynamically possible, thus rather hinder
than promote recycling. Appropriate recycling
goals, which draw on the expertise and tools
available within the recycling industry, are a
better way to enhance recycling of metals.
The present report responds to the pressing
need to optimize current recycling schemes
with the help of a better understanding of the
limits imposed by physics, chemistry, thermodynamics and kinetics, as well as by the technological, economic and social barriers and inefficiencies encountered. Much is at stake when
thinking about how to improve recycling systems: closing loops, reducing related environmental impacts, safeguarding the availability of
metals, minimizing metal prices, and promoting
meaningful and safe jobs for poor people in developing countries.
We are very grateful to the lead author Markus
Reuter and principal contributors Christian
Hudson, Antoinette van Schaik, Kari Heiskanen,
Christina Meskers and Christian Hagelken for
having generated such a thorough and valuable
report.
Preface
Metal recycling is increasingly promoted as
an effective way to address resource scarcity
and mitigate environment impacts associated
with metal production and use, but there is
little systemic information available regarding recycling performance, and still less on
the true recycling rates that are possible and
how to do better considering the system in its
totality. The former topic was the subject of
an earlier report from the International Resource Panel (Recycling Rates of Metals: A
Status Report, 2011). In the present report,
the second topic is addressed.
This new report discusses the benefits and
necessity of approaching recycling from products, considering them as complex designer
minerals with typical structures and joinings. This Product Centric approach therefore
takes account of the complexities of modern
products (which are often much more complex than geological minerals), and the ways
in which non-traditional mixtures of elements
are now common. The approach gains much
useful perspective from experience in classical minerals and metallurgical processing.
All contained metals in all streams can be
tracked by revealing the mineralogies of the
material particles, thereby allowing a more
detailed and deeper understanding of these
complex systems.
The complementary Material Centric recycling view point, as presented in the first report, has the capability to answer the question of how much is recycled but does not
pretend to answer why and what should be
done to improve recycling of metals. This new
report sheds light on how to improve the recovery of especially those critical technology
elements that were shown to have low recycling rates.
The report concludes with a number of tools
that can aid decision-makers in arriving at
improved recycling approaches. This provides
a physics basis for performing Design for Recycling and Sustainability, Eco-labeling, and
quantifying resource efficiency, as well as estimating the opportunities, limits, and infrastructure of recycling.
Table of Contents
Prefaces
_________________________________________________________________________ 2
List of Figures
Figure 1:
Figure 2:
Figure 3:
Product-Centric recycling A schematic diagram of the life cycle of metalcontaining products going through recycling, showing the inevitable losses. Design for resource efficiency covers all details of the figure in order to
minimize losses__________________________________________________________ 27
Figure 4:
The Metal Wheel, based on primary metallurgy but equally valid for metals recycling reflects the destination of different elements in base-metal
minerals as a function of interlinked metallurgical process technology. Each
slice represents the complete infrastructure for base- or Carrier-Metal refining. As there are so many different combinations of materials in End-ofLife products, only physics-based modelling can provide the basis for valid
predictions. In essence, primary metallurgy is situated in a segment a complete processing plant, while the complexity of consumer product mineralogy requires an industrial ecological network of many metallurgical production infrastructure to maximize recovery of all elements in end-of-life products (Reuter and van Schaik, 2012a&b; Ullmanns Encyclopaedia, 2005). __________ 30
Figure 5:
Example of existing software for flowsheet design, based on compositional data for a product (here LCD screens), which lead to simulated resource
efficiency data that, in turn, lead to a recyclability index based on environmental analysis a metallurgical processing infrastructure is prerequisite
(Reuter 1998). ___________________________________________________________ 31
Figure 6:
Figure 7:
Figure 8:
Gold ore grades between 1830 and 2010 (Source: UNEP 2011c, p.24). ___________ 44
Figure 9:
Figure 11: The ever-increasing use of complex mixtures of metals in products has a
key effect on the recyclability of metals (Adapted by Reuter from Achzet
and Reller, 2011)._________________________________________________________ 53
Figure 12: Example of alloying elements affecting copper-alloy properties ranging
from strength, wear resistance to corrosion resistance (Copper Development Association, 2012). __________________________________________________ 54
Figure 13: The changing weights of cars over the years (International Aluminium Institute, 2007). ____________________________________________________________ 55
Figure 14: Various REEs and their application in electric vehicles._________________________ 60
Figure 15: The Metal Wheel, based on primary metallurgy but equally valid for metals recycling reflects the destination of different elements in base-metal minerals as a function of interlinked metallurgical process technology.
Each slice represents the complete infrastructure for base- or CarrierMetal refining. As there are so many different combinations of materials in
End-of-Life products, only physics-based modelling can provide the basis
for valid predictions. In essence, primary metallurgy is situated in a segment a complete processing plant, while the complexity of consumer product mineralogy requires an industrial ecological network of many metallurgical production infrastructure to maximize recovery of all elements in
end-of-life products (Reuter and van Schaik, 2012a&b; Ullmanns Encyclopaedia, 2005). ____________________________________________________________ 62
Figure 16: Material efficiency vis--vis energy efficiency (Allwood et al., 2011) in a
context of Material and Product-Centric Recycling. ___________________________ 63
Figure 17: Schematic overview of the historic and (potential) future evolution of waste
management. (Jones, 2008; Jones and DeMeyere, 2009; Jones et al. 2012).______ 65
Figure 18: Mean number of items out of 11 that are being recycled (Damanhuri, 2012). ______ 66
Figure 19: Typical material fractions in WEEE (Ongondo et al., 2011).______________________ 67
Figure 20: Metals found in printed circuit boards. ______________________________________ 72
Figure 21: Plant solutions based on commodity-metals production technology best
handle the, often low-volume, critical-element recycling. The above Korea
Zinc flowsheet not only creates no ponded residue, but also recovers many
valuable elements associated with zinc minerals, such as indium, which
are critical to flat-panel TV technology (Hoang et al., 2009). ____________________ 76
Figure 22: Conventional phosphorus flow through chemical and iron & steel industries and possible new flow (grey arrows) when P-recovery technology from
steelmaking slag comes on stream. Arrow width corresponds to quantity of
flow (Yoshida et al., 2012).__________________________________________________ 78
Figure 23: Critical levels of some elements (U.S. Department of Energy, 2010). _____________ 80
Figure 24: Primary carbon footprint of selected elements in WEEE goods (EU, 2010)
(AppendixF: Physics of Extractive Metallurgy). _____________________________ 84
9
Figure 25: Main WEEE recycling activities in China and India, types of produced emissions and general environmental pathways. (Seplveda et al., 2010). ____________ 85
Figure 26: Study of developing and developed markets about what people did with
their previous cell phone (Damanhuri, 2012)._________________________________ 88
Figure 27: Asian e-waste traffic who gets the waste? (Baker et al., 2005). ________________ 89
Figure 28: The link between joined particles, their shredding or dismantling into
groups, and their subsequent separation into economically valuable recyclates (van Schaik and Reuter, 2012; Reuter and van Schaik, 2012a&b). __________ 94
Figure 29: Impure quality recyclates created during physical separation of shredded
cars (Reuter et al., 2005). __________________________________________________ 95
Figure 30: Groups of components best sorted by hand for producing the cleanest recyclates (van Schaik and Reuter, 2010b)._____________________________________ 96
Figure 31: Characteristics of connection types related to their specific degree and
non-randomness of liberation behaviour after a shredding operation (van
Schaik and Reuter, 2007a&b; van Schaik and Reuter, 2012).____________________ 98
Figure 32: Example of recycling cars, a complex network of processes and interconnected material flows. Separation processes are of key importance in
producing suitable recyclates for processing in a metallurgical plant (van
Schaik and Reuter, 2012, HSC Sim 19742013). _____________________________ 100
Figure 33: Generic separator using the laws of physics and material properties for
separating materials.____________________________________________________ 101
Figure 34: Separation-efficiency curve for an arbitrary material during physical separation (Heiskanen, 1993; King, 2001). ______________________________________ 102
Figure 35: Maximum grade-recovery curve (left) for liberation characteristics of scrap
(right)._________________________________________________________________ 105
Figure 36: Maximum grade-recovery curve (left) for liberation characteristics of scrap
(right) (Heiskanen, 1993). _________________________________________________ 105
Figure 37: Typical WEEE material composition (European Topic Centre on Sustainable
Consumption and Production, 2009)._______________________________________ 106
Figure 38: Design for resource efficiency showing the destination of elements from an
end-of-life material. If a WEEE product falls in the copper and Zn/Pb slices, many metals can be recovered, but if it falls in the incorrect slice, e.g.
the steel cycle, the metals may be lost, diminishing the resource efficiency.
Policy should thus pay particular attention to the complete infrastructure
and systems. ___________________________________________________________ 108
Figure 39: Electric Arc Furnace (EAF) for smelting steel scrap (Krger et al., 2005;
SMS-Siemag: www.sms-siemag.com). _____________________________________ 109
Figure 40: Technologies used in aluminium recycling for various scrap types, including salt-slag smelting for producing cast aluminium from scrap (Boin and
Bertram, 2005; Bertram et al., 2009). ______________________________________ 111
10
Figure 41: The effect of scrap surface area (left) on recovery (right) of two scrap types
recovery is held back by inactive alumina coating scrap, so scrap with a
higher surface area/volume ratio (upper picture) has lower recovery rates
than larger pieces (bottom set) (Xiao and Reuter, 2002). ______________________ 112
Figure 42: The flow of elements associated with copper production (hydro- and pyrometallurgy) showing the link between primary production and recycling.
Gangue minerals are not included. (Nakajima et al., 2008; 2009; 2011; Nakamura and Nakajima, 2005; Nakamura et al., 2007). This flowsheet fits
into the copper segment of the Metal Wheel (Figure 15). ______________________ 113
Figure 43: Weight and material composition of the SuperLightCar light-weight BIW
concept (SuperLightCar, 20052009; Goede et al., 2008; Krinke et al., 2009)._____ 114
Figure 44: Metal-production flowsheet integrating copper and lead hydro- and pyrometallurgy for maximizing metal recovery from Bolidens operating facility (Outotec, 2012; NewBoliden, 2012), fitting into the Pb and Cu segment of
the Metal Wheel (Figure 15).______________________________________________ 115
Figure 45: The Umicore flowsheet based on copper and lead hydro- and pyro-metallurgy, using a TSL furnace for copper and a blast furnace for lead, which
permits the processing of slag, matte, speiss, slimes, sludges, dross, etc.
(Hagelken et al., 2009) This flowsheet fits in the two Pb&Cu segments of
the Metal Wheel (Figure 15). ______________________________________________ 116
Figure 46: The Kayser Recycling System for recycling copper metal and other copper
containing residues. This flowsheet fits into the Cu segment of the Metal
Wheel (Figure 15). _______________________________________________________ 117
Figure 47: Various smelters for the recycling of a wide range of materials including
copper, lead, zinc, critical elements, e-waste, slimes, batteries, scrap, etc.
All with high environmental standards as they are all located in or next
to towns._______________________________________________________________ 117
Figure 48: The link between the Iron and the zinc cycles for galvanized steel, a Material (& Metal)-Centric view (Reuter et al., 2005).______________________________ 118
Figure 49: Process steps of EoL product treatment with indicators of economic gain/
cost (Tanskanen and Takala, 2006)._________________________________________ 120
Figure 50: Steel scrap prices following iron ore prices (USGS, 2011). _____________________ 121
Figure 51: Past and projected growth in available EoL appliances with LCD screens in
EU25 (Salhofer et al., 2011)._______________________________________________ 123
Figure 52: Recycling efficiency between a common formal system in Europe and the
informal sector in India for the gold yield from printed wire boards._____________ 125
Figure 53: Metal recycling rates predicted by the recycling model for different metals for disassembled Printed Wire Boards (PWBs) either directly fed into a
copper smelter or shredded with varying intensity. Note the low recovery
of gold and copper for shredding and the high recycling values if the PWBs
are directly recycled to furnace without shredding (van Schaik and Reuter,
2010a). ________________________________________________________________ 126
11
Figure 54: The various stakeholders of recycling in a two dimensional simplified representation of a multi-dimensional complex product centric approach
(Harro von Blottnitz, 2011).________________________________________________ 131
Figure 55: Ratio of scrap recovered and domestic consumption (%) 2009 (The Aluminium Association www.abal.org.br).______________________________________ 139
Figure 56: Recycling rates for beverage cans (Sources: Brazilian Aluminium Association, ABAL, who collected data from: Brazilian Association of Highly Recyclable Cans, The Japan Aluminium Can Recycling Association, Camara Argentina de la Industria del Aluminio y Metales Afines, The Aluminium Association, and European Aluminium Association).____________________________ 139
Figure 57: Features affecting consumer recycling behaviour (Mkel, 2011). ______________ 141
Figure 58: Manual dismantling in the informal sector in China.__________________________ 142
Figure 59: Product-Centric recycling of EoL goods with a networked structure of technologies for dealing with the various streams.This Figure shows the complex network of technologies that can be applied to manage resource efficiency (van Schaik and Reuter, 2004a; 2004b; 2007; 2010a; 2010b; van
Schaik and Reuter, 2012; van Schaik, 2011; Reuter et al., 2005; Reuter,
2009; Ignatenko et al., 2008). ______________________________________________ 143
Figure 60: A key message concerning Product-Centric recycling: Product design
must be linked to liberation, separation efficiency, and quality of both recyclate and of final output streams, based on the thermodynamic limits of
recycling (Reuter et al., 2005; Reuter and van Schaik, 2008, 2012a&b; van
Schaik and Reuter, 2012). ________________________________________________ 145
Figure 61: LCA of a personal computer (Choi et al., 2006). ______________________________ 147
Figure 62: All functions in a company play an important role in Life Cycle Management (adapted from UNEP, 2007a)._________________________________________ 148
Figure 63: Life-cycle management within ALCAN, engaging and collaborating with
stakeholders in the value chain (Balkau and Sonnemann, 2010)._______________ 149
Figure 64: Element radar chart for metallurgical processing of selected metals,
showing element distribution in metal, slag, and gas phases based on
thermodynamic analysis and metallurgical data of specific single reactors.
(Nakajima et al., 2008; 2009; 2011; Nakamura and Nakajima, 2005; Nakamura et al., 2007). The copper Peirce Smith converter of Figure 44 represents the Cu (Converter) segment here.____________________________________ 152
Figure 65: Water cycle connected to metal and sludge processing, showing that recycling is not linear but complexly interlinked (van Schaik and Reuter, 2010b;
Fagan et al., 2010). ______________________________________________________ 157
Figure 66: Linking design with sophisticated recycling tools drives innovation and
improves resource efficiency through DfR for the SuperLightCar project
(Goede et al., 2008; SuperLightCar, 20052009). ____________________________ 159
12
Figure 67: LCA visualization of the SuperLightCar concept (Goede et al., 2008; Krinke
et al., 2009)._____________________________________________________________ 160
Figure 68: Total life cycle impact of a CFRP body in white (BIW) compared to a conventional steel BIW. Only the difference in fuel consumption is considered in
the use phase (van Acker and Verpoest, 2011; Duflou et al., 2008, 2012)._________ 162
Figure 69: Rough cost-breakdown for a typical shredder, where manual dismantling
contributes up to 80% of the ELV recyclate (Ferro and Amaral, 2006).__________ 166
Figure 70: Schematic explanation of the stakeholders obligations according to Swiss
WEEE legislation ORDEE (Widmer et al., 2008).______________________________ 171
Figure 71: A Material (&Metal)-Centric view of recycling: Linear and sequential representation of recycling for non-complex metal applications such as in construction, packaging etc. (UNEP, 2011b). This recycling-rate definition is
one-dimensional and lacks the required non-linear predictive qualities for
successfully driving a recycling system. ____________________________________ 172
Figure 72: Sensor based automatic sorting for metal particles from a mixture of
glass, polymer, stone, etc. (from HSC Sim 19742013)._______________________ 181
Figure 73: Eddy Current physics: light grey highly conductive and light, white nonconductive, and black slightly magnetic. Magnetic field strength, rotation
speed, and positioning of the two splitters, among others, determine recyclate purity (from HSC Sim 19742013).____________________________________ 182
Figure 74: Rising-current separator using a rising water flow in a column to recover a
light floating fraction from a feed also containing heavy material that drops
to the bottom of the water column._________________________________________ 182
Figure 75: A hydrocyclone separating feed into light and a heavy fractions. _______________ 183
Figure 76: The heavy-medium separator separates feed into a heavy fraction that
sinks to the bottom of a rotating drum that lifts it to the top where it discharges onto a conveyor belt. The light fraction floats on the separating
medium (water, FeSi slurry, etc.) and is collected and discharged via the
floats conveyor belt. Cleaning of the float medium creates a sludge that
has to be processed. _____________________________________________________ 184
Figure 77: Different process routes for steelmaking. A comparison of the energy requirements (GJ/t) of the different routes are given on p. 80 (World Steel,
2013). _________________________________________________________________ 185
Figure 78: The technology of stainless-steel production (Johnson et al., 2008). ____________ 186
Figure 79: Primary and recycling copper production (Outotec).__________________________ 187
Figure 80: Dedicated copper-smelting production (Outotec).____________________________ 187
Figure 81: The share of various technologies for processing zinc-containing residues
(Outotec)._______________________________________________________________ 189
Figure 82: Waelz kiln for the processing of EAF dust (Ullmanns, 2005).___________________ 190
13
Figure 83: The main reactions in a Waelz kiln (International Zinc Association,
20012002).____________________________________________________________ 191
Figure 84: Red mud production and inventory (Klauber et al., 2011a, b). __________________ 193
Figure 85: Various patents for the processing of red mud (Klauber et al., 2011a; 2011b).____ 193
Figure 86: Dry granulation of slag with heat recovery shown here for blast-furnace
slags (Jahanshahi et al., 2011). ____________________________________________ 195
Figure 87: Simplified view of a recycling plant (including extensive PST processing)
where 1153 cars were recycled, showing a generalized composition of a
fluff after extensive treatment (Reuter et al., 2005; Reuter and van Schaik,
2012a&b). ______________________________________________________________ 196
Figure 88: Economy-wide flow of phosphorus in Japan for the year 2000 (kt-P) (Matsubae-Yokoyama et al., 2009&2010). _______________________________________ 201
Figure 89: EPMA image of dephosphorization slag (FetO=19%, CaO/SiO2=4.4%,
P2O5=2.8%) (Matsubae-Yokoyama et al., 2009&2010). ________________________ 202
Figure 90: Recrystallized slags with minerals.________________________________________ 203
Figure 91: Flowsheets for the zinc process (left) and the coldstream process (right)
(Lassner and Schubert, 1999). ____________________________________________ 205
Figure 92: Flowsheets for the reclamation of niobium and tantalum from different
sources (Habashi, 1997).__________________________________________________ 207
Figure 93: A schematic overview of the cutting and physical sorting of lamps (European Lamp Companies Federation, 2012). ____________________________________ 209
Figure 94: Production of yttrium oxide from xenotime (McGill, 2010)._____________________ 210
Figure 95: A scheme for recycling manufacturing scrap, but EoL scrap can be mixed
with other types thus complicating matters. (First Solar, Inc., 2012). ___________ 211
Figure 96: Materials in a mobile phone (UNEP, 2009).__________________________________ 221
Figure 97: Worldwide battery market in 2010 HEV is mostly Ni/MH, while large rechargeable includes Ni/Cd and Ni/MH, created with data from May (2011)._______ 227
Figure 98: General composition of a battery (Umicore)._________________________________ 227
Figure 99: Schematic overview of Li-ion battery recycling processes. ____________________ 230
Figure 100: Process flowsheet for Umicore Battery Recycling (2010).______________________ 231
Figure 101: Dependency on natural resource categories for recycled (A) and primary
material (B) to fill the Co and Ni requirement of a Li-ion cathode (Dewulf
and van Langenhove, 2005). ______________________________________________ 233
Figure 102: Processing of NiMH batteries (Mller and Friedrich, 2006; Pietrelli et al.,
2002). _________________________________________________________________ 234
Figure 103: Flowsheet of the IME-ACCUREC recycling concept. __________________________ 235
14
Figure 104: The demand for Lithium for 50% market penetration of electric vehicles
(EU, 2010; Schler et al., 2011).____________________________________________ 237
Figure 105: The use of Ni, REs, Co and Li in batteries in the EU and the use of the metals relative to total production (HEV: Hybrid Electric Vehicle; EV: Full Electric Vehicle) (Eurometaux, 2010) (also EU Critical Metals).___________________ 238
Figure 106: Reasons for not recycling a mobile phone (Damanhuri, 2012).__________________ 239
Figure 107: Recycling envelope for mobile phone.______________________________________ 240
Figure 108: Product-Centric multi-level dynamic process simulation models that predict recyclate quality, grade, and recovery levels linked to product design
(Reuter and van Schaik, 2012a&b; van Schaik and Reuter, 2012a&b).___________ 243
Figure 109: Dynamic recycling-performance calculations of an e-waste product as a
function of time, showing different recycling rates due to distributed properties, such as material liberation, complex interlinked materials in products due to functionality, quality distribution of recyclates, distribution of
analyses, range of products and changing designs (van Schaik and Reuter,
2012). _________________________________________________________________ 245
Figure 110: Dynamic recycling rates per material (total recycling rates given in Figure 109) as a function varying product weights, composition and plant input
over time (van Schaik and Reuter, 2012). ___________________________________ 246
Figure 111: Post-shredder technology plant for ELVs as operated by ARN (2013). ___________ 247
Figure 112: Bandwidth of various produced recyclate streams (van Schaik and Reuter,
2012). _________________________________________________________________ 247
Figure 113: Quality of ferrous recyclate stream including the quantification and specification of the composition and contamination of the recyclate streams it is
obvious that the 3.1% copper in the top figure is not good for steel quality
(van Schaik and Reuter, 2012). ____________________________________________ 248
Figure 114: Quality of (a) ferrous and (b) aluminium recyclate streams, including quantification and specification of the composition/contamination of recyclate
streams (c) and (d) respectively for ferrous and aluminium fraction (presented as bandwidths as a function of changes in input, recycling routes,
etc.) (Reuter et al., 2005; SuperLightCar, 20052009). ________________________ 249
Figure 115: Dynamic recycling models that include also the convolution integral, and
hence permitting the simulation as a function of standard deviation of all
analyses and flows of the system for products and mixture of products (van
Schaik and Reuter, 2004a).________________________________________________ 253
Figure 116: Design for Resource Efficiency Designer Mineral to Metal (The effect of
Aluminium in WEEE on Slag and Metal Properties in Smelter). Metal recovery as a function of process technology, thermodynamics and transport processes, here showing the effect of liberated and un-liberated steel
on the recycling quality of aluminium and slag (Reuter et al., 2005; Reuter,
2011a). Products with high aluminium content, which oxidizes during processing, have a disruptive effect on processing and hence on resource effi15
Figure 128: A simplified SiO2-FeO-CaO phase diagram showing the area that is molten
at 1300C with an industrially safe range of Fe/SiO2 as shown (FACT Sage).______ 275
Figure 129: A simplified SiO2-FeO-CaO phase diagram showing the area that is molten
at 1250C and the operating point (FACT Sage).______________________________ 276
Figure 130: A simplified SiO2-FeO-CaO phase diagram showing the area that is molten
at 1300C with the operating point well within the molten slag area
(FACT Sage).____________________________________________________________ 277
Figure 131: General flowsheet of the Mintek Enviroplas process (Input flows are in
green, output flows in red) (Denton et al., 2005).______________________________ 281
Figure 132: Phase relationship in molten metal alloy and multi-oxide slag (ternary diagram) (FACT Sage; Castro et al., 2004; Castro et al., 2005; Reuter, 2011a;
Reuter, 2009).___________________________________________________________ 283
Figure 133: The effect of different alumina levels (from aluminium in e-waste) on the
slag liquidus temperature, on solids in solution as a function of temperature, and on oxygen partial pressure of a typical slag (FACT Sage; Reuter et
al., 2011b).______________________________________________________________ 284
Figure 134: The stability of some of tin (Sn) and indium (In) oxides under different operating conditions: (a, left) shows more reducing conditions while (b, right)
shows more oxidizing conditions (HSC Chemistry 7, 19742013; Outotec)._______ 284
Figure 135: The distribution of indium and copper between metal and slag as a function of lime addition at 1300 oC, Fe/SiO2=1.1-1.2 and log(pO2)=-7 (Anindya
et al., 2011)._____________________________________________________________ 285
Figure 136: Ellingham Diagram for the Stability of various compounds in e-waste the
bottom compounds being the most stable (HSC Chemistry7, 19742013;
Outotec)._______________________________________________________________ 285
Figure 137: Eh-pH diagram for an aqueous electrolyte showing the behaviour of different dissolved elements, which are subsequently recovered by various refining processes (HSC 19742013).___________________________________________ 286
Figure 138: Using computational fluid dynamics for optimizing conditions within furnaces (which can be 1040 m high) this drives process understanding to
its limits and maximizes resource efficiency (Huda et al., 2012).________________ 287
Figure 139: Manipulating conditions within a TSL to achieve desired metal production
and energy recovery, recycling and waste processing (www.outotec.com)._______ 288
Figure 140: Recycling lithium-ion batteries (Recupyl SAS)._______________________________ 289
17
List of Tables
18
Table 1:
Table 2:
Rare Earth Elements, their estimated supply and demand in 2016, and projected shortfalls (Lynas Corporation, 2011).__________________________________ 42
Table 3:
Growth in element use projected to 2030. The 2006 and 2030 indicators
show the proportion of ETRD compared to 2006 production, e.g. Ga: Indicator 2006 = 28/152 = 0.18 and Indicator 2030 = 603/152 = 3.97)
(EU, 2010; BGR, 2010)._____________________________________________________ 43
Table 4:
The scrap value of office equipment and a simplified cost breakdown for a
PC with value of about 11001/tonne, including the weight and value of various parts, in 2012 (Hieronymi, 2012).________________________________________ 46
Table 5:
Table 6:
Some average data for petrol and diesel vehicles (Nemry et al., 2008).___________ 56
Table 7:
Average composition of a car (Nemry et al., 2008) and changing aluminium content (International Aluminium Institute, 2007) to mitigate the weight
gain of vehicles.__________________________________________________________ 57
Table 8:
Table 9:
Table 10:
Table 11:
Examples of composition of mobile phones, PCs and laptops and the impact on metal demand based on 2010 sales (UNEP, 2009; Hagelken and
Corti, 2010).______________________________________________________________ 73
Table 12:
Table 13:
The use of rare earth elements (REE) in 2012 and projected demand and
growth by 2016 (Lynas Corporation, 2011).___________________________________ 81
Table 14:
Table 15:
Table 16:
A brief overview of earnings and costs for a 1000tpa NiMH battery recycling facility (Mller and Friedrich, 2006).___________________________________ 120
Table 17:
19
Table 18:
Various recovery rates for end-of-life vehicles (ELVs) depending on the objective function of the system optimization model (Ignatenko et al., 2008)._______ 129
Table 19:
Table 20:
Table 21:
Compatibility matrix for materials in a car, showing compatible and incompatible metals in terms of recovery (Castro et al., 2004, 2005; Reuter et al.,
2005).__________________________________________________________________ 158
Table 22:
Table 23:
Table 24:
Average composition of zinc concentrates obtained in flotation also showing the mineralogical and thermodynamic basis for the Metal-Wheel (see
Zn-pie) (Grant, 1993)._____________________________________________________ 189
Table 25:
Typical Zn and Pb containing recycled raw materials (Schneider et al., 2000).____ 190
Table 26:
Table 27:
Table 28:
Composition of ASR light and heavy fluff for different operators (Numbers
in brackets refer to references in Vermeulen et al. 2011).______________________ 196
Table 29:
A typical cost breakdown of an ELV dismantler (Ferro and Amaral, 2006)._______ 198
Table 30:
Table 31:
World reserves, demand for EEE, mine production and the amount by
weight (g) of metals in different WEEE categories (Ongondo et al., 2011).________ 212
Table 32:
Percentage of printed wire board (PWB) and precious-metal contents in diverse electrical equipment (Chancerel et al., 2009; Chancerel and Rotter,
2009a; United Nations University, 2007; Wecycle, 2011; Witik et al., 2011)._______ 213
Table 33:
Table 34:
Table 35:
Table 36:
Table 37:
Table 38:
Table 39:
20
Table 40:
Table 41:
Summary of data and calculated amount of REOs per lamp (Van Schaik, 2011).___ 225
Table 42:
Table 43:
Production, demand and use of REOs in 2010 (Van Schaik, 2011 based on
data by United Nations University, 2007; European Lamp Companies Federation, 2009; Hoek van den et al. 2010).____________________________________ 226
Table 44:
Table 45:
Table 46:
Table 47:
Common compounds in a slag and their melting points (HSC Chemistry 7).
Note that due to various crystalline forms of SiO2 a lower value of 1600C
is given. For CaO a value of 2572C is reported showing some variations in data._ 274
Table 48:
Common compound mixtures in a slag (see Figure 128 and Figure 129) and
their melting points and Fe/SiO2 ratios (HSC Chemistry 7).____________________ 274
List of Boxes
21
Box 1:
Alloys __________________________________________________________________ 54
Box 2:
Box 3:
Box 4:
Box 5:
Box 6:
Box 7:
Box 8:
Box 9:
Box 10:
Box 11:
Box 12:
Box 13:
Box 14:
Recycling of aluminium in Brazil income generation as the main motivation ___ 138
Box 15:
Box 16:
Box 17:
Box 18:
Box 19:
Box 20:
Box 21:
Box 22:
Iron recovery from Basic Oxygen Furnace (BOF) steel slags ___________________ 203
Box 23:
Box 24:
How to build improved models for aluminium recycling Multi-level simulation _ 258
Box 25:
Box 26:
Box 27:
Box 28:
Recycling of gallium-arsenide on a printed wire boards vis--vis steel beverage can recycling ______________________________________________________ 286
Box 29:
A final example recovery of all constituents from a cup of coffee _____________ 289
Box 30:
Geological
Designed
Copper Mineral
Chalcopyrite CuFeS2
Copper Mineral
More than
More than
15 Minors e.g.
40 Elements
Geological
Linkages
Figure 1:
Product Centric Recycling: Application of
economically viable technology and methods
throughout the recovery chain to extract metals
from the complex interlinkages within designed
minerals i.e. products, gleaning from the deep
know-how of recovering metals from complex
geological minerals.
22
Material
Connections
Joined
Materials
Executive Summary
Metal recycling is a complex business that
is becoming increasingly difficult! Recycling
started long ago, when people realized that it
was more resource- and cost-efficient than
just throwing away the resources and starting
all over again. Until recently, such relatively straightforward recycling concentrated on
specific materials, including metals, as most
products were relatively simple; this form
of recycling follows the so-called Material
(&Metal)-Centric (MMC) approach.
23
Figure 2:
The best footprint
of sustainability
and resource
efficiency may
be achieved
by reducing
losses during
processing by
bringing together
the various
stakeholders,
thus minimizing
the use of
resources in their
widest sense.
No society can
truly achieve a
closed-loop
status; there
will always be
some loss and
economic growth
implies more
raw-material
needs; therefore,
Figure 2 shows
how this footprint
is affected by the
various activities
of transforming
raw materials.
24
Three interrelated factors determine the success of recycling and maximize resource efficiency:
1. The recycling processes and the major
physical and chemical influences on the
metals and other materials in the processing stream.
2. The collection and pre-sorting of waste.
3. The physical properties and design of
the end-of-life products in the waste
streams.
While reading this document consider the
three points above and consider the technological and economic challenge of producing pure water, sugar, milk and coffee from
a cup of coffee a consumer product. This
illustrates the complexity of recycling, the effect of dissolution of metals in each other and
then separating them into pure or alloy products of economic value as shown by Figure 2.
Crushing
Comminution
Thickening
Resource
Materials
Residues | Sludges | Plant Footprint | Water
Energy | Materials etc.
Concentration
Water Recycling
Reagents
Plant Footprint etc.
Recycling
It is impossible to optimize one factor without considering the others. To get the best
results out of recycling, product designers,
collectors and processors must know what is
happening in the other parts of the system,
which requires a multi-faceted approach that
considers all metals, compounds, and other
materials.
Recycling saves resources, as it strengthens the primary supply from primary mining
by using the resources temporarily locked up
in urban minesa. Especially critical elements, not abundant in nature, must be preserved and reused as much as possible.
An added advantage is that the energy consumption of metal recovery from recycled
sources is usually less than that of primary
production, as recycling often only involves
the re-melting of metals. In addition, a resource-efficient system minimizes water use
and maximizes the quality of wastewater before discharge.
The basic assumption of recycling is that the
value of the recovered (and other materials) has to pay for all collection, dismantling,
sorting and other recycling activities. The
economics of such recycling is based on estimating the true value of recyclates from the
best recovery of refined metals, alloys and
compounds.
Recycling is thus driven by the value of the
recovered metal (and material). In any case,
all metallurgical plants always try to recover
all valuable elements. If there is an economic
incentive, recovery will happen.
a The word urban mine has been used for some years and
has been registered since many years e.g.
25
Table 1:
Compatibility
matrix as a
function of
metallurgical
recovery (van
Schaik and
Reuter, 2012;
Reuter and van
Schaik, 2012a&b)
(PMs: precious
metals; PGMs:
platinum group
metals).
Recoverability
per application
PMs
Ag
PGMs
Au
Pd
Pt
Other
Sb
Eu
Other
Co
In
Ga
Ta
Recovery possible
If separatly recovered and/or if there is appropriate technology and recovery available.
Washing machine
Large Hh Appliance
Video recorder
DVD player
Hifi unit
Radio set
CRT TV
Mobile telephone
Fluorescent lamps
LED
LCD screens
Batteries (NiMH)
No separate Recovery
Pure recovery not possible. Lost in bulk recyclates during separation and/or during metallurgy into different non-valuable phases.
Washing machine
Large Hh Appliance
Video recorder
DVD player
Hifi unit
Radio set
CRT TV
Mobile telephone
Fluorescent lamps
LED
LCD screens
Batteries (NiMH)
Depending on the process route followed, high recovery rates as well as high losses are possible. Hence a careful attention to design, infrastructure,
legislation etc. is necessary. This is especially possible for metals closely linked where one metal can be recovered while the other due to this selection
of recovery then goes lost. This is driven by thermodynamics, technology, design etc.
Losses
Consumer, Collection
Losses
Losses
Market & Stocks
Functional Element
Combinations
Production
Linkages, Economics
Collection &
Dismantling
Product Design
Unaccounted
Losses
Theft
Air Fill
Landfill
Physical
Separation
Metals back to
consumer Production
Dynamic Complex
Product-Centric
Recycling
Losses
Multi-material
Recyclate Grades
Stocks
Infrastructure
Metal & Energy
Recovery
27
MODELLING: Physics-based-modelling
and simulation of how products recycle
can help designing a product that facilitates recycling, based on how products and
their constituents break up and separate
in BAT recycling processes. Such design
goes beyond design for disassembly and
design for recycling, to become design
for resource efficiency. Here disassembly
breaks down complex products into components or subassemblies that then can
be directed into more suitable recycling
processes, such as the easy removal of a
circuit board from a plastic, aluminium or
steel housing.
28
BAT: EoL, waste, and residue streams destined for recycling must be processed by
Best Available Technique (BAT), according to specific performance standards and
being mindful of environmental and social
costs and benefits. These BATs can differ
between products and regions, and do not
need to be high technology per se. They
may include hand sorting in the earlier
steps of the recycling chain, thus creating
jobs. Where waste streams enter uncontrolled flows or less suitable processes,
value will be lost and the environmental
impact may be severe.
POLICY: Targets must align with the economic drivers of a complete system. With
so many operators in the collection and
recycling industry, enforcing regulations
is unlikely to be sufficient for steering the
destination of metal-containing waste
streams. Policy must create the economic incentives for waste to be handled by
registered BAT operations, rather than by
grey recycling, or even improper practice.
Economic drivers must align with longterm economic goals, such as conserving
critical metal resources for future applications, even if their recovery currently is
uneconomic. Policy targets should consider the loss of metals due to a complex
recyclate composition. Policies should neither exceed what is physically and thermodynamically possible, nor prioritize one or
two metals at the inadvertent expense of
other metals found in the input stream.
29
Life Cycle Management, LCM, is a business approach that can help companies
achieving sustainable development. It
helps reducing, for instance, a products
carbon, material and water footprints, as
well as improving its social and economic
performance. LCM is about making life-cycle thinking and product sustainability operational for businesses that aim for continuous improvement.
Figure 4:
The Metal
Wheel, based on
primary metallurgy but equally
valid for metals
recycling reflects
the destination of different
elements in basemetal minerals
as a function of
interlinked metallurgical process
technology. Each
slice represents
the complete
infrastructure for
base- or CarrierMetal refining.
As there are so
many different
combinations of
materials in Endof-Life products,
only physicsbased modelling
can provide the
basis for valid
predictions. In
essence, primary
metallurgy is
situated in a segment a complete
processing plant,
while the complexity of consumer product
mineralogy
requires an industrial ecological network of
many metallurgical production
infrastructure
to maximize
recovery of all
elements in endof-life products
(Reuter and van
Schaik, 2012a&b;
Ullmanns Encyclopaedia, 2005).
30
El
El
El
WO3
TiO2
ThO2
In2O3
BaO
Ga2O3
REOs
Pb
Zn
Al2O3
Cu
SiO2
Pt
Al
CaO
Fe
FeOx
MgO
Cl
Mn
Fe
Cr
Pd
Rh
Pt
Ni/Cr
Au
Ge
Ga
Cd
Hg
TiO2
Ta2O5
Nb2O3
Ni
Au
Cu
Pd
Pt
Cu/Ni
Sb
Au
Se
In
In2O3
REs
Br
Zn
Bi
SrO Ga2O3
ZrO2
Sn
MgO
WO3
Cd
Ge
MnO
BaO
Smelt/Refine
Pt
Rh
Mo
Th
Te
Co
Cr
Sn
Nb
V
Mo
Zr
Metallurgy
Remelt
REs
Th
Zr Al
Mg
Al2O3
Cl
Zn
Si
Al
Ti
Pyro
Remelt
Refine
FeOx
MgO
Si
F/Cl
Br
Li
RE
AIXy
RE(O)s
RE
Special Battery
P
Cl
NiO
ThO2
The usual basis for any bankable feasibility study at the heart of all process design is
a thorough description of the Product-Centric
recycling system. This requires rigorous simulation, including closure of all mass balances
of not only the bulk materials, but also of the
elements contained in organic and inorganic compounds and alloys. The energy balance
has to be closed as well, showing the details
As
ZrO2
MnO
Ta2O5
WO3
SiO2
CaO
Bi
Zn
TiO2
SiXy
SrO
Li2O
Pb
In
In2O3
CaXy
FeOx
K
Cu
Sb
Ga/As
Al2O3
MgO
REOs
Ag
Na
SiO2 FeOx
CaO Cu2O
Co
Cu
Sb2O3
In
P
Ni
As
P2O5
MnO
Hydro-Metallurgy
Sn
CaO
K/Na
Hydro&Pyro
metallurgy
Smelt/Refine
Pd
Sb
Al2O3
REOs
SiO2
Recycling
Sn
Pb
V2O5
Ag
TiO2
Zn
Sn
ZrO2
Na
Ti Sb Cr
Fe Mn
Si Mg
Smelt
Refine
Ag
CaO
FeOx
An
EoL
Product
Pb
Bi
Al2O3
Hydro Metallurgy
Remelt
Zn
In
Pb
Al
Steel (BOF&EAF)
RLE/Fume
Cu
Ti
Cr
Fe
Stainless Steel
Co
SiO2
V
W
Tr
Cd Hg
TRIP Steel
Austenitic
Ni
Zn
Al2O3
Ta
Nb
Ni
Co
Mo Si
Pb
Au Sn
Sb
REs
Bi
Ag
As
Cd
Br
Na
Cl
Hg
Ta2O5
Nb2O3
CaF2
Al2O3
V2O5
MgO SiO2
SrO
CaO
KCl
CaO REOs
FeO
x
BaO
CaF2
MgO
ZrO2
SrO
CaO
Al2O3
REOs
FeOx
MgO
Nb2O5
V2O5
SiO2
Standardize systems on the basis of physics and economics, for discussing sustainability and CleanTech.
Figure 5:
Example of
existing software
for flowsheet
design, based on
compositional
data for a
product, which
lead to simulated
resource
efficiency data
that, in turn, lead
to a recyclability
index based on
environmental
analysis a
metallurgical
processing
infrastructure
is prerequisite
(Reuter 1998).
31
Product
Composition
Design & functionality
Detailed composition
of all materials
Dismantling &
Physical Separation
Metallurgical
Recovery
= Recyclability
Index & Rate
Thermodynamics,
technology & economics
Sum of recovery
of all elements
& materials
A final observation: true Design for Recycling can only take place with tools that are
based on a rigorous application of physics,
thermodynamics and process technology, as
reflected by, for example, Figure 6.a
Figure 6:
Resource cycles
are linked by
flowsheeting and
simulation tools
(Reuter 1998&
2011) based on
rigorous physics
before interactively linking
them to environmental-impact
assessment
software (HSC
Sim and GaBi).
th
a 7 Principle of the Earth Charter (www.earthcharterinaction.org): Adopt patterns of production, consumption, and
reproduction that safeguard Earths regenerative capacities, human rights, and community well-being.
1. Reduce, reuse, and recycle the materials used in production and consumption systems, and ensure that residual waste can be assimilated by ecological systems.
2. Act with restraint and efficiency when using energy, and
rely increasingly on renewable energy sources such as
solar and wind.
32
3. Promote the development, adoption, and equitable transfer of environmentally sound technologies.
4. Internalize the full environmental and social costs of
goods and services in the selling price, and enable consumers to identify products that meet the highest social
and environmental standards.
5. Ensure universal access to health care that fosters reproductive health and responsible reproduction.
6. Adopt lifestyles that emphasize the quality of life and material sufficiency in a finite world.
Policy recommendations
Many of the worlds existing recycling policies have grown out of environmental policy,
and are often still under the jurisdiction of
environmental ministries. This duly reflects
the potential environmental benefits from
increased recycling as well as the potential harm from insufficient waste treatment.
However, it can also obscure the fact that
recycling is primarily an economic industrial activity with a strong environmental and
social implication, and is strongly affected,
for better and for worse, by all policies that
influence the costs and benefits of recycling.
Waste- and recycling policies directly affect
the cost of recycling processes (e.g. where
environmental requirements change such
processes) as well as the cost of alternatives
to recycling, such as waste disposal. These
policies also influence the availability and
composition of waste streams for recycling.
Relevant, too, are trade restrictions on waste
or metals, and all policies regulating industrial activity such as taxation, labour regulation and energy costs. Governments should
be conscious, in crafting and implementing
such policies, of their impact on sustainable
development.
Defining the system boundaries for which
targets are stipulated is of critical importance. Furthermore, weight-based targets
hinder rather than promote recycling of the
many critical elements in complex products,
usually present in very low concentrations.
In addition, priorities have to be set for different metals, such as base metals, special
metals, critical-technology metals, etc. This
further highlights the dilemma of defining recycling targets for metals that are present in
small quantities in products. Targets that go
beyond what is thermodynamically possible
for recycling are likely to fail and might lead
to excessive energy consumption in efforts to
meet the recycling target. Policy makers can
set appropriate targets from a life cycle perspective and by drawing on the expertise and
tools available within the recycling industry.
33
General perspectives
34
35
36
37
It may be counter-productive to use material-based recycling-performance output standards, such as mass or percentage of a single metal in a waste stream.
They can ignore the complexity of recycling
and its inherent trade-off between outputs
of different recycled metals from mixed
waste streams. This may lead to wasting
of valuable metals. For example, a system
focused on increasing recycled iron output may lose valuable metals with complex
links to iron, such as vanadium.
We must reconsider the current practice
of using recycling rates of single metals,
or of percentages of product mass, as the
Key Performance Indicator (KPI) of a recycling system. Approaches based on the
understanding of recycling physics can improve MMC indicators to render them more
Product-Centric, especially if they include
economics-based indicators.
Economics-based and environmentally
benign KPI processes should be considered as a BAT. Rather than industry having
to achieve a mandated performance target,
policy and industry need to create the conditions and incentives that facilitate high
performance. This, however, requires policy actions across the system to overcome
the bottlenecks that currently hold back
optimized recycling.
38
1. Brief Overview of
Factors affecting
Recycling
The Green Economy Initiative set up by United
Nations Environmental Programme (UNEP),
spearheads the transformations needed
to create a viable future for generations to
come. Its aim is to shape an economy that
results in improved human well-being and
social equity, while significantly reducing environmental risks and ecological scarcities.
In its simplest expression, a green economy
can be thought of as one which is low carbon, resource efficient and socially inclusive
(UNEP, 2011a).
This is one reason why metals and metal recycling are central in the work of UNEPs
International Resource Panel (IRP) and its
Global Metal Flows Working Group. Another
reason is that, while some studies exist on
the local impact of mining, the environmental
effects of recycling, or geological and anthropogenic metal stocks, no global and comprehensive overview of scientific data existed until now. To fill this gap, the Metal Flows
Working Group commissioned several Status
Reports of which this report is one.
We prepared the present report, following
the one on Recycling Rates, as a response
to several significant trends in societys ever
more complex use of metals. We briefly discuss some aspects of anthropogenic metal flows and cycles, covering issues around
39
40
ucts containing metals such as steel, aluminium, copper etc., a point that is addressed in
the following pages.
Due to the scale of their use, iron, steel and
aluminium are included in the lists of materials that the International Resource Panel
has prioritized for the decoupling of global prosperity from environmental depletion.
However, many of the other metals used in
smaller quantities have much higher energy
and environmental impacts per kilogramme
produced (UNEP, 2010a, p.12). A tonne of
gold, for example, has a typical CO2 footprint
more than 5,000 times larger than the footprint of a tonne of copper; however, as much
more copper is produced, in the end the copper industry emits about 1.3 times more CO2
per annum than gold production (Hagelken,
2012). A recent report discussed the economic benefits of recycling, putting forward
a clear positive economic case for a Circular
economy (Ellen McArthur Foundation, 2012).
While water recycling is not the topic of this
report, its relationship to metal production
Figure 7:
Past exponential
growth of
different battery
technologies
(Eurometaux,
2010).
Billion Cells
3.0
2.0
Li-Polymer
1.0
Li-Ion
Ni-MH
Ni-Cd
0
1970
41
1980
1990
2000
2010
Table 2:
Rare Earth
Elements,
their estimated
supply and
demand in 2016,
and projected
shortfalls (Lynas
Corporation,
2011).
metals and their compounds used in emerging (sustainable) technologies; its final column shows how 2030 demand for such metals compares to 2006 demand and 2006 production for all uses.
Global
Global
ROW@35%
145,000 t
50,000 t
165,000 t
52,500 t
60,000 t
4,250 t
1,500 t
6,000 t
1,000 t
1,350 t
14,500 t
5,000 t
7,000 t
300 t
750 t
42
ROW
Table 3:
Growth in
element use
projected to
2030. The
2006 and 2030
indicators show
the proportion
of ETRD
compared to
2006 production,
e.g. Ga: Indicator
2006 = 28/152 =
0.18 and Indicator
2030 = 603/152 =
3.97) (EU, 2010;
BGR, 2010).
Raw
material
Production 1)
(t)
Gallium
5)
152
Indium
581
Germanium
100
ETRD 2006
(t)
ETRD 2030
(t)
Indicator
2006
Indicator
2030
28
603
1)
0,18
3,97 1)
234
1.911
1)
0,40
3,29 1)
28
220
1)
0,28
2,20 1)
Neodymium 6)
16.800 4.00
27.900
1)
0,23
1,66 1)
Platinum 7)
345
Tantalum
1.384
Silver
1)
1,35
1)
0,40
1,02 1)
551
1.410
19.051
5.342
15.823
1)
1)
0,28
0,83
Cobalt
62.279
12.820
26.860
1)
1)
0,21
0,43
Palladium 7)
267
23
77
1)
1)
0,09
0,29
Titanium
7.211.000 3)
15.397
58.148
0,08
0,29
Copper
15.093.00
1.410.000
3.696.070
0,09
0,24
Ruthenium 7)
4)
29
0,03
Niobium
44.531
288
1.410
0,01
0,03
Antimony
172.223
28
71
<0,01
<0,01
Chromium
19.825.713 2)
11.250
41.900
<0,01
<0,01
6)
rare earth
2)
Chromite
7)
43
3)
Ore concentrate
4)
Consumption
5)
Figure 8:
Gold ore grades
between 1830
and 2010 (Source:
UNEP 2011c,
p.24).
Canada
South Africa
USA
Brazil
40
30
20
10
0
1835
44
1850
1870
1890
1910
1930
1950
1970
1990
2010
more readily available and collectable for recycling than those in private hands.
On average, the metal stocks used in moredeveloped countries equate to between ten
and fifteen metric tonnes per citizen. Of this
amount, five metals iron, aluminium, copper, zinc, and manganese make up more
than 98%. UNEPs report on Metals Stocks
in Society (UNEP, 2010b) reviewed 54 studies on metal stocks, finding that reliable estimates for in-use stocks exist for only four
of those metals: aluminium, copper, iron and
lead.
Table 4:
The scrap
value of office
equipment and
a simplified cost
breakdown for
a PC with value
of about 11001/
tonne, including
the weight and
value of various
parts, in 2012
(Hieronymi, 2012).
down for a PC given in the right three columns. Without this material value, recycling
will not happen.
Simply said, if EoL recyclates have sufficient
economic value, they will be recycled when
the appropriate technological infrastructure exists for recovering their contained elements, but not all EoL goods have a high
value. Therefore, an economics- and physicsbased policy should be careful to provide a
framework and business model that breathes
life into recycling systems. This will balance
their performance in a system that sometimes has to cope with negative costs, due to
the low value of some EoL goods.
While economics drive the system (Edwards
and Pearce, 1978), local and global policy should promote the use of certified Best
Available Techniques (BAT) in the global recycling system, to ensure that resource efficiency is driven to a maximum.
WEEE Item
Value (3/t)
Desktop PC
~1100
Laptop
~1800
Revenue
(3)
5241
1.41
Printer (consumer)
~120
448
4.03
Printer/Copier
(commercial)
~330
397
1.39
Flatscreen
~900
68
2.55
Hard-disk drive
598
0.45
Cables
198
0.28
444
0.27
122
0.03
226
-0.02
-0.00
3 min
-1.50
7742
8.61
Weight
(g)
Sector
Recovery rate
2007 (%)
Estimated
Recovery rate
2050 (%)
Construction
85
90
4070
Automotive
85
90
715
Machinery
90
95
1020
50
65
410
83
90
N/A
UNEPs report on Recycling Rates of metals (UNEP, 2011b) reported ranges for various recycling rate metrics for sixty metals as
summarized by Figure 9, which uses simple
one-dimensional recyclate rate definitions.
These are, however, limited in their use for
single metals and do not reflect the use of
a variety of metals in complex products (van
Schaik and Reuter, 2004a, 2010), i.e. these
recycling-rate definitions exclude non-linear
physical interactions in the complete recycling chain and therefore have a limited theoretical basis and little predictive value.
47
Life cycle
in years
Figure 9:
Various
definitions
of recycling
rates and
corresponding
data for elements
in the periodic
table (UNEP,
2011b).
1
H
2
He
3
Li
4
Be
5
B
6
C
7
N
8
O
9
F
10
Ne
11
Na
12
Mg
13
Al
14
Si
15
P
16
S
17
Cl
18
Ar
19
K
20
Ca
21
Sc
22
Ti
23
V
24
Cr
37
Rb
38
Sr
39
Y
40
Zr
41
Nb
42 43
Mo Tc
55
Cs
56
Ba
72
Hf
73
Ta
74
W
87
Fr
88
Ra
**
104 105 106 107 108 109 110 111 112 113 114 115 116 117 118
Rf Db Sg Sg Hs Mt Ds Rg Uub Uut Uug Uup Uuh Uus Uuo
> 50%
> 2550%
25 26
Mn Fe
75
Re
27
Co
28
Ni
29
Cu
30
Zn
31
Ga
32
Ge
33
As
34
Se
35
Br
36
Kr
44
Ru
45
Rh
46
Pd
47
Ag
48
Cd
49
In
50
Sn
51
Sb
52
Te
53
I
54
Xe
76
Os
77
Ir
78
Pt
79
Au
80
Hg
81
Tl
82
Pb
83
Bi
84
Po
85
At
86
Rn
* Lanthanides
57
La
58
Ce
59
Pr
60
Nd
61 62 63
Pm Sm Eu
** Actinides
89
Ac
90
Th
91
Pa
92
U
93
Np
64
Gd
65
Tb
66
Dy
67
Ho
68
Er
69 70
Tm Yb
71
Lu
95 96 97
Am Cm Bk
98
Cf
99
Es
> 1025%
110%
< 1%
94
Pu
EoL-RR for sixty metals: The periodic table of global average EoL (post-consumer) functional recycling (EoL-RR) for sixty metals. Functional recycling is recycling in which the physical and chemical properties that made the material desirable in the
first place are retained for subsequent use. Unfilled boxes indicate that no data or estimates are available, or that the element
was not addressed as part of this study. These evaluations do not consider metal emissions from coal power plants.
48
1
H
2
He
3
Li
4
Be
5
B
6
C
7
N
8
O
9
F
10
Ne
11
Na
12
Mg
13
Al
14
Si
15
P
16
S
17
Cl
18
Ar
19
K
20
Ca
21
Sc
22
Ti
23
V
24
Cr
37
Rb
38
Sr
39
Y
40
Zr
41
Nb
42 43
Mo Tc
55
Cs
56
Ba
72
Hf
73
Ta
74
W
87
Fr
88
Ra
**
104 105 106 107 108 109 110 111 112 113 114 115 116 117 118
Rf Db Sg Sg Hs Mt Ds Rg Uub Uut Uug Uup Uuh Uus Uuo
> 50%
> 2550%
< 1%
75
Re
27
Co
28
Ni
29
Cu
30
Zn
31
Ga
32
Ge
33
As
34
Se
35
Br
36
Kr
44
Ru
45
Rh
46
Pd
47
Ag
48
Cd
49
In
50
Sn
51
Sb
52
Te
53
I
54
Xe
76
Os
77
Ir
78
Pt
79
Au
80
Hg
81
Tl
82
Pb
83
Bi
84
Po
85
At
86
Rn
* Lanthanides
57
La
58
Ce
59
Pr
60
Nd
61 62 63
Pm Sm Eu
** Actinides
89
Ac
90
Th
91
Pa
92
U
93
Np
> 1025%
110%
25 26
Mn Fe
94
Pu
64
Gd
65
Tb
66
Dy
67
Ho
68
Er
69 70
Tm Yb
71
Lu
95 96 97
Am Cm Bk
98
Cf
99
Es
The periodic table of global average recycled content (RC, the fraction of secondary [scrap] metal in the total metal input to
metal production) for sixty metals. Unfilled boxes indicate that no data or estimates are available, or that the element was
not addressed as part of this study.
49
1
H
2
He
3
Li
4
Be
5
B
6
C
7
N
8
O
9
F
10
Ne
11
Na
12
Mg
13
Al
14
Si
15
P
16
S
17
Cl
18
Ar
19
K
20
Ca
21
Sc
22
Ti
23
V
24
Cr
37
Rb
38
Sr
39
Y
40
Zr
41
Nb
42 43
Mo Tc
55
Cs
56
Ba
72
Hf
73
Ta
74
W
87
Fr
88
Ra
**
104 105 106 107 108 109 110 111 112 113 114 115 116 117 118
Rf Db Sg Sg Hs Mt Ds Rg Uub Uut Uug Uup Uuh Uus Uuo
> 50%
> 2550%
< 1%
75
Re
27
Co
28
Ni
29
Cu
30
Zn
31
Ga
32
Ge
33
As
34
Se
35
Br
36
Kr
44
Ru
45
Rh
46
Pd
47
Ag
48
Cd
49
In
50
Sn
51
Sb
52
Te
53
I
54
Xe
76
Os
77
Ir
78
Pt
79
Au
80
Hg
81
Tl
82
Pb
83
Bi
84
Po
85
At
86
Rn
* Lanthanides
57
La
58
Ce
59
Pr
60
Nd
61 62 63
Pm Sm Eu
** Actinides
89
Ac
90
Th
91
Pa
92
U
93
Np
> 1025%
110%
25 26
Mn Fe
94
Pu
64
Gd
65
Tb
66
Dy
67
Ho
68
Er
69 70
Tm Yb
71
Lu
95 96 97
Am Cm Bk
98
Cf
99
Es
OSR for sixty metals: The periodic table of global average old scrap ratios (OSR, the fraction of old [post-consumer] scrap in
the recycling flow) for sixty metals. Unfilled boxes indicate that no data or estimates are available, or that the element was
not addressed as part of this study.
50
The first of the three periodic tables of Figure11 is based on one-dimensional recycling-rate definitions and thus provides the
EoL recycling rate, i.e the metal percentage
from EoL products that returns to the manufacture of new products. The second table
shows Recycled Content, or the share of recycled metal of the total metal produced. The
last table shows the share of post-consumer recycled metal in the total recycled metal
flow.a
Considering the complexity of recycling, remarkable accomplishments have been
achieved in recycling the most common
mostly bulk and simple commodity metals.b
Ingenuity in BAT metallurgy has helped industry pushing the recycling efficiency of ferrous and base metals, e.g. (stainless) steel,
aluminium, copper, zinc, lead, nickel, tin, always closer to the limits permitted by physics
and thermodynamics, although the industrys
continuing use of non-BAT technology leaves
room for improvement.
Yet, despite the resulting benefits from an environmental, economic and social perspective, current recycling rates are still rather
low for most metals. High scrap-recycling
rates seem to exist only for metals mainly
used for simple (bulk) products, such as iron
and nickel in carbon- and stainless steels,
and for precious metals (mostly jewellery and
similar simple products). It is also worth noting that there is often a long delay before the
recovery of steel and other metals from their
use, for example in buildings and other infrastructure, which markedly affects how much
metal can be recycled.
51
Current situation
Max. Recycling
Max. metal recycling
Max. recycling and recovery
Max. recycling and recovery (recovery <10%)
Recycling+recovery Rate
Recycling Rate
Recovery Rate
Produced Waste
0,0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
52
1700
53
1800
1900
2000
BOX 1:
Alloys
Alloying of metals is done to achieve better strength, workability and for better welding, to
name a few reasons. Different alloys improve different properties (Figure 12). An alloy typically contains a major component and several other components in much smaller concentrations. Not all alloys of the same main components will be compatible from a recycling
point of view, as is shown by the three examples below:
Steel: There are about 5000 carbon-steel alloys, from simple construction steel to ultra-high-strength steel, in addition to steels for high-temperature and high-wear uses.
Stainless steels also come in six major alloy groups.
Aluminium is alloyed into seven main wrought alloy groups with varying properties, suitable for making such different products as airplane frames, beverage cans, engines,
electrical cables and foils. Aluminium is also used in several types of cast-alloy grades.
Copper alloys fall in eight main groups, the most common ones being with zinc (brass)
and tin (bronze), and together as gunmetal. Copper alloys have moved from the age-old
bronze and brass to more than four hundred alloys, with different alloying metals (Figure 12) creating different properties of the Cu-alloys.
Figure 12:
Example of
alloying elements
affecting copperalloy properties
ranging from
strength, wear
resistance
to corrosion
resistance
(Copper
Development
Association,
2012).
Strength
Zn
P
Cr
Corrosion Resistance
Fe
Zr
Sn
Ni
Si
Mn
Al
Wear Resistance
Be
Machinability
Colour
Al
Zn
Sn
Ni
Sn
Ag
Ni
Mn
Fe
Si
Pb
Te
S
Zn
Al
Si
Cd
Ag
Sn
thin films, and creating nanoparticle structures. Functionality is often further enhanced
by coatings for improving wear, corrosion or
fire resistance, for safety and for improving
aesthetic aspects.
BOX 2:
reasons, dictates the physical and chemical properties of the materials available for
recycling. In addition, the combining of such
different materials also changes from simple rivets or nuts and bolts, to welding, gluing
and molecular deposition, dictated by functionality and production cost.
Car recycling
The average weight of a vehicle in the EU has increased substantially (Figure 13 and as
documented by van Schaik and Reuter, 2004a) from 856kg in 1981 to 1207kg in 2001.
Figure 13:
The changing
weights of cars
over the years
(International
Aluminium
Institute, 2007).
Opel Astra
VW Golf
Toyota Corolia
General Trend
kg
1550
1450
1350
1250
1150
1050
950
850
750
650
55
1970
1974
1978
1982
1986
1990
1994
1998
2002
2006
BOX 2_c:
The mass of vehicles has increased further, also reflecting the power and capacity changes (Nemry et al., 2008).
Table 6:
Some average
data for petrol
and diesel
vehicles (Nemry
et al., 2008).
Petrol
Average lifespan (years)
12.5
12.5
EURO4
EURO4
16900
19100
211250
238750
1585
1 905
78
83
1240
1463
Saloon
Saloon
Body model
56
Diesel
BOX 2_d:
Table 7:
Average
composition of
a car (Nemry
et al., 2008)
and changing
aluminium
content
(International
Aluminium
Institute, 2007)
to mitigate the
weight gain of
vehicles.
Table 7 provides details on the composition of an average vehicle and, for example, the
changing aluminium content of a car over time (Nemry et al., 2008; International Aluminium Institute, 2007).
Materials (kg)
Petrol
Diesel
819
1040
500
633
242
326
742
959
Aluminium primary
42
43
Aluminium secondary
26
29
68
72
Copper
Magnesium
0.5
0.5
Platinum
0.001
0.001
Palladium
0.0003
0.0003
Rhodium
0.0002
0.0002
Glass
40
40
Paint
36
36
Polypropylene (PP)
114
114
Polyethylene (PE)
37
37
Polyurethane (PU)
30
30
Polyamide (PA)
Other
27
27
23
23
57
BOX 2_e
Materials (kg)
Petrol
Diesel
Tyres
Rubber
Carbon black
Steel
Textiles
0.4
0.4
Zinc oxide
0.1
0.1
Sulphur
0.1
0.1
Additives
Sub-total (4 units)
31
31
Lead
PP
0.7
0.7
Sulphuric acid
PVC
0.3
0.3
Sub-total
14
14
Transmission fluid
Engine coolant
12
12
Engine oil
Petrol/diesel
23
25
Brake fluid
Refrigerant
0.9
0.9
Water
0.5
0.5
Sub-total
50
52
1240
1463
Battery
Fluids
Total weight
58
BOX 2_f
Component
Aluminium form*
Europe*
2002
kg/car
2002
kg/car
2006
kg/car
Japan
2006
kg/car
2002
kg/car
2006
kg/car
Engines
Castings
42.0
51.6
36.6
40.3
44.5
45.8
Transmission and
driveline
Castings
28.1
31.5
15.4
16.3
20.5
21.8
Chassis, suspension
and steering
Castings/Forgings/
Extrusions/Sheets
6.2
10.1
8.2
12.5
2.9
3.7
22.4
23.6
14.2
17.7
17.8
18.9
Heat exchanger
Sheets/Extrusions
14.5
14.5
11.0
12.3
12.0
13.6
Brakes
Castings/Forgings
2.5
3.5
2.7
3.7
1.7
3.4
Closures
Sheets/Extrusions/
(Castings)
2.0
2.5
2.4
4.0
0.3
1.6
0.5
0.5
1.8
2.8
0.1
0.2
Heat shields
Sheets
1.7
1.8
1.2
1.4
0.5
1.0
Bumper beams
Extrusions
0.6
0.8
1.4
2.8
0.8
0.8
4.1
4.1
3.9
3.9
2.8
3.2
124.6
144.6
98.8
117.6
103.9
114.0
Total
59
North America
BOX 2_g
The recycling of old cars and vans End-of-Life vehicles (ELVs) already plays an important role in closing resource cycles for a variety of critical commodity materials. Yet the
modern car is ever more complex, with increasing electronics and other gadgets that render it an extremely complex product. This will become even worse for electric cars; several critical materials including Rare Earths Elements (REEs) and Platinum Group Metals
(PGMs) in fuel cells will be needed in vehicles such as shown in Figure 14.
Figure 14:
LCD Screen
Europium
Yttrium
Cerium
UV Cut
Glas
Cerium
Diesel Fuel
Additive
Lanthanum
Cerium
Hybrid Electric
Motor and Generator
Neodymium
Praseodymium
Dysprosium
Terbium
Hybrid NiMH
Battery
Lanthanum
Cerium
25+ Electric Motors
Throughout Vehicle
Neodymium (NdFeB) Magnets
Catalytic
Converter
Cerium/Zirconium
Lanthanum
Figure 15:
The Metal
Wheel, based on
primary metallurgy but equally
valid for metals
recycling reflects
the destination of different
elements in basemetal minerals
as a function of
interlinked metallurgical process
technology. Each
slice represents
the complete
infrastructure for
base- or CarrierMetal refining.
As there are so
many different
combinations of
materials in Endof-Life products,
only physicsbased modelling
can provide the
basis for valid
predictions. In
essence, primary
metallurgy is
situated in a segment a complete
processing plant,
while the complexity of consumer product
mineralogy
requires an industrial ecological network of
many metallurgical production
infrastructure
to maximize
recovery of all
elements in endof-life products
(Reuter and van
Schaik, 2012a&b;
Ullmanns Encyclopaedia, 2005).
62
El
El
El
Al2O3
V2O5
MgO SiO2
SrO
CaO
KCl
CaO REOs
WO3
FeO
x
BaO
CaF2
MgO
ZrO2
SrO
TiO2
ThO2
In2O3
BaO
Ga2O3
REOs
Hg
Ta2O5
Nb2O3
Pb
Zn
CaF2
Al2O3
Cu
SiO2
Pb
Mo Si
Pt
Fe
FeOx
MgO
Cl
Mn
Fe
Cr
Pd
Rh
Pt
Au
Ge
Ga
Cd
CaO
TiO2
Ta2O5
Nb2O3
Ti Sb Cr
Fe Mn
Si Mg
Ni
Ag
Au
Cu
Pd
Pt
Cu/Ni
Sb
Au
Se
In
In2O3
REs
Br
Zn
Bi
SrO Ga2O3
ZrO2
Sn
MgO
WO3
Cd
Ge
MnO
BaO
Smelt/Refine
Pt
Rh
Mo
Th
Te
Co
Cr
Sn
Nb
Mo
Zr
Al
Pyro
Metallurgy
Remelt
REs
Mg
Th
Zr Al
Al2O3
Cl
Zn
Si
FeOx
MgO
Si
F/Cl
Br
RE
AIXy
RE(O)s
RE
Special Battery
P
Cl
SiO2 FeOx
NiO
Cu
Sb
ThO2
SiXy
SrO
SiO2
CaO
Li2O
Bi
Pb
Zn
In
In2O3
CaXy
FeOx
K
As
Ga/As
Al2O3
MgO
REOs
Ag
Na
K
CaO Cu2O
Ni
Cu
Sb2O3
In
Co
As
P2O5
MnO
Hydro-Metallurgy
Sn
CaO
K/Na
Li
Hydro&Pyro
metallurgy
Smelt/Refine
Pd
Sb
Al2O3
REOs
SiO2
Ti
Remelt
Refine
TiO2
Recycling
Sn
Pb
Hg
V2O5
Zn
Sn
ZrO2
Na
Smelt
Refine
Ag
FeOx
An
EoL
Product
Pb
Bi
Al2O3
Hydro Metallurgy
Remelt
Zn
In
Pb
Al
Fe
RLE/Fume
Cu
Ti
Cr
Steel (BOF&EAF)
Ni/Cr
Stainless Steel
Co
SiO2
V
W
Tr
Cd Hg
TRIP Steel
Austenitic
Ni
Zn
Al2O3
Ta
Nb
Ni
Co
Al
CaO
Au Sn
Sb
REs
Bi
Ag
As
Cd
Br
Na
Cl
ZrO2
REOs
MnO
FeOx
MgO
Nb2O5
CaO
V
2O5
Ta O
TiO2 2 5
SiO2
WO3
Al2O3
BOX 3:
Material-Centric Approaches
Allwood et al. (2011) discussed a Material-Centric perspective. This refers more to alloys
and very simple products within the constraints and confines of a Carrier Metal segment, which is also mainly the basis for the data on Figure 4. This approach usually works
well for bulk materials and alloys, but not for the more than 50 elements in many of our
modern products. These are not concentrated in, for example, an alloy to impart a specific
function, but are rather a complex mixture of alloys, compounds, metals, etc., that collectively imparts a functionality to the product. Often, these elements are thermodynamically
incompatible, thus requiring them to be glued, riveted or bolted together.
Figure 16:
Property improvement
Carbon capture
Component re-use
Producers
Material
efficiency vis-vis energy
efficiency
(Allwood et al.,
2011) in a context
of Material and
Product-Centric
Recycling.
Process
efficiency
Fuel
switching
Yield improvement
Energy/CO2
efficiency
Modularity | upgrade
Users
Recycling
Landfill
mining |
waste use
Remanufacture
Use-for-longer
Re-sale
Increased Producer
Responsibility
Material
efficiency
Dematerialisation
Designers
Substitution
Light-weightening
Doing without | with less
This complexity of connections and products means that parts, functional groups and sections cannot just simply be remanufactured, repaired, etc., as shown in Figure 16, leading
to material efficiency. Any one element or part can affect the whole and its material efficiency. While dematerialization is an important avenue to resource efficiency, this will affect the economics of recycling materials from complex products. Furthermore, the move
to nano-technology as an extreme case of dematerialization will irrecoverably dissipate
valuable materials, although it can be argued that these are small amounts that will have
no effect on the overall materials balance.
63
Design for Resource Efficiency not only requires detailed knowledge on the total flow of
materials and recyclates, but it also requires
these data as (statistical) standard-deviation and average-distribution values for each
flow. The shape of this distribution (Normal,
Weibull, or even multi-modal) must be known
as well. In addition, as the metals contained
in recyclates are the economic target, their
average and standard-deviation distributions
in the input recyclates should be known as
well.
64
Figure 17:
Past
1980s
1990s
Uncontrolled
dumping
Controlled
landfilling
Controlled
landfilling
Incineration
without
E-recovery
Prevention
Prevention
Recuperation
Re-use
(glass, paper)
(industrial
ecology)
Incineration
Incineration
E-recovery
with
E-recovery
Incineration
E-recovery
Landfilling
Landfilling
Increasing
Temporary
storage
EPR
Prevention
IW:
Industry Waste
Re-use
LFM:
Landfill
Management
Uncontrolled
dumping
Controlled
landfilling
ELFM:
Enhanced Landfill
Management
(industrial
ecology, CtC)
Incineration
IW
Landfilling
as a final
solution
ELFM
ELFM
Material
recovery
Recycling legislation for EoL home appliances, especially for the larger ones (air-conditioners, refrigerators, TV sets or washing
machines), now exists in various parts of the
world (e.g. European Commission). In Japan, EoL legislation has been effective since
April 2001. Though this law had more an endof-life-management motivation, the Japanese government now has implemented various recycling policies for securing resources. This has been one of the four important
approaches in Japanese mineral resource
policy: securing stable supplies from (mostly overseas) mines, material substitution,
stockpiling and recycling.
65
Prevention
Recuperation
Controlled
landfilling
MSW:
Municipal Solid
Waste
EPR:
Extended Producer
Responsibility
Future
(glass, paper)
without/with
EWM:
Enhanced Waste
Management
2000+
EMW
MSW
Schematic
overview of the
historic and
(potential) future
evolution of waste
management.
(Jones, 2008;
Jones and
DeMeyere, 2009;
Jones et al. 2012).
LFM
Energy
recovery
As a result of such legislation, the recycling of products made of one material type,
such as newspapers, glass or plastic bottles, or metal cans, is already common practice in many countries, and becoming more
so. More complicated products, such as cars,
batteries and electronic products, are now
slowly entering the recycling stream as well.
These, however, require a careful policy rethink for maximizing resource efficiency. Figure 18 shows how the recycling of 11 products (paper/cardboard, plastic bottles, cans,
glass, metals, clothes/shoes, cell phones,
batteries, television sets, refrigerators and
computers) varies for various countries,
showing that there is much room for increasing resource efficiency.
Figure 18:
Mean number
of items out
of 11 that are
being recycled
(Damanhuri,
2012).
Finland
7.8
UK
6.5
USA
5.8
China
4.4
Germany
7.4
Spain
7.2
India
3.8
Nigeria
1.8
UAE
1.6
Indonesia
1.8
Argentina
2.4
66
2. Recycling
Opportunities
Recycling can greatly increase the amount
of available metals for society, provided the
potential sources and recycling technologies
exist. The opportunities described below indicate why increased recycling is one of the
important ways that the global economy can
continue to sustain itself in the future.
Figure 19:
Typical material
fractions in WEEE
(Ongondo et al.,
2011).
67
Box 4:
Table 8:
The use of
different metal/
elements in EEE.
Metal/Element
Ferrous metal
Aluminium
Magnesium
Copper
Cables, connectors
Gold
Silver
Antimony
Alloying element, additive for flame retardants, soldering element, semiconductor technology and photocells Transparent Conductive Oxide
(ATO), Antimony oxide as additive in cathode ray tube glass
Gallium
Germanium
Photovoltaic cells, glass fibre, optical glasses glass fibre, semi-conductive chips
Indium
Cobalt
Tantalum
Capacitors
Beryllium
Tellurium
Tungsten
Tungsten carbide, electrodes, cables and electrical components, additives in cathode ray tube glass
Niobium
Tin
(Neodymium, Dysprosium,
Scandium, Lanthanum and
Yttrium)
68
Country
Generation
(tonnes/year)
Germany
1,100,000 (2005)
Reported discarded
items
Collection and
treatment routes
13.3
Domestic WEEE
PWMA, retailers
takeback
940,000 (2003)
15.8
Domestic WEEE
66,042 (2003)
Diverse range of
WEEE
SWICO, S.EN.S,
SLRS
2,212,000 (2007)
1.7
India
439,000 (2007)
0.4
Japan
860,000 (2005)
6.7
12,500 (200106)
Mobile phones
chargers and batteries
Informal
7,350 (2007)
0.2
Informal
59,650 (2007)
1.2
UK
Switzerland
China
Nigeria
Kenya
South Africa
69
Table 9_b
E-waste
generation
in different
countries
(Ongondo et al.,
2011).
Country
Reported discarded
items
Collection and
treatment routes
Argentina
100,000
2.5
Excludes white
goods, TVs and
some consumer
electronics
Small number of
takeback schemes,
municipal waste services
Brazil
679,000
3.5
2,250,000 (2007)
7.5
86,000 (2002)
2.7
Computers, TVs,
mobile phones and
fluorescent lamps
USA
Canada
Australia
WEEE:
TV:
PWMA:
DTS:
PCS:
SWICO:
S.E.N.S:
SLRS:
70
Generation
(tonnes/year)
Weight-share
Monitor-board
Fe
Al
Cu
plastics
Au (ppm)
Pd (ppm)
30%
15%
10%
28%
280
20
10
PC-board
7%
5%
18%
23%
900
200
80
Mobile phone
7%
3%
13%
43%
3000
320
120
Portable audio
23%
1%
21%
47%
150
10
DVD-player
62%
2%
5%
24%
115
15
Calculator
4%
5%
3%
61%
260
50
Value-share
Fe
Al
Cu
Sum
PM
Ag
Au
Pd
Monitor-board
4%
14%
35%
47%
7%
33%
7%
PC-board
0%
1%
13%
86%
5%
69%
12%
Mobile phone
0%
0%
6%
93%
11%
71%
11%
Portable audio
3%
1%
73%
21%
4%
16%
3%
DVD-player
15%
3%
30%
52%
5%
42%
5%
Calculator
1%
4%
10%
85%
6%
76%
3%
71
Ag (ppm)
Figure 20:
Metals found in
printed circuit
boards.
Cu
Fe
Si
Al
Br
Ti
V
Sn
Pb
Ca
Ni
Zn
Ba
Mn
Sb
Mg
Ag
Cl
Na
Cr
Zr
Be
Pd
Au
S
Bi
Mo
Ce
Ta
Cd
Co
K
P
La
Sr
Pt
As
Hf
Th
Sc
Hg
Cs
Eu
Se 1,0
1
10
100
1,000
10,000
100,000
1,000,000
g/t
72
Table 11:
Examples of
composition of
mobile phones,
PCs and laptops
and the impact on
metal demand
based on 2010
sales (UNEP,
2009; Hagelken
and Corti, 2010).
x 250 mg Ag
400 t Ag
x 1000 mg Ag
350 t Ag
3 %
x 24 mg Au
38 t Au
x 220 mg Au
77 t Au
5%
x 9 mg Pd
14 t Pd
x 80 mg Pd
28 t Pd
9 g Cu 14,000 t Cu
x ~500 g Cu 175,000 t Cu
3.8 g Co 6100 t Co
65 g Co 11,700 t Co
Fluorescent lamps also contain various materials and elements, including Rare Earths,
e.g. yttrium, lanthanum, cerium, europium,
terbium and gadolinium (USGS, 2002; 2010a;
2010b; 2010c) in phosphorescent or fluorescent powders, while LEDs also contain an interesting suite of elements and compounds.
Other critical resources, such as indium,
gallium and tungsten (van den Hoek et al.
2010) are also present, while germanium
is found in the fluorescent powder of highpressure mercury lamps. In summary, lamps
contain various amounts of metals (W, K, Th,
Re, Mo, Fe, Cr, Cu, Nb, Na, Hg, Zr, Al, Ba, Ni,
Ta, Al, Zn, REE, In, Ga) (van den Hoek et al.
2010; Franz et al., 2010; McGill, 2010).
The recycling of lamps, LEDs, batteries and
other WEEE is further discussed in AppendixA: "Details on Recovery of Metals from
Recyclates".
73
Cu: 16 M t/a
1%
74
75
is needed for recycling and residue processing. It provides all the technology for dealing
with elements that are associated and work
thermodynamically with Cu, Zn and Pb metallurgy. In this respect, we should also highlight metal recovery from foundry sands and
other contaminated sands.
to 75% of the aluminium comes from packaging, much of which will oxidize. Pruvost
(2011) estimated that residual MSW in the
EU-27 in 2006 contained about 1684 kt of aluminium, of which 533 kt went to WtoE plants.
These numbers and thus the potential
vary from country to country, depending on
Figure 21:
Plant solutions based on
commoditymetals production technology
best handle the,
often low-volume,
critical-element
recycling. The
above Korea Zinc
flowsheet not
only creates no
ponded residue,
but also recovers
many valuable
elements associated with zinc
minerals, such as
indium, which are
critical to flatpanel TV technology (Hoang et al.,
2009).
Feeds
Pb Secondary
Residues
Ag & Pb
Concentrates
Residue
High
Pb Slag
Fume
Leaching
Plant
QSL
Zn/Pb Fume
Ag
Slag
Concentrates
Zn
Plant
Ausmelt TSL
Residue
Fumers
Ausmelt TSL
QSL Fumers
Cu
Removal
Cu
Dross
Cu Ausmelt
TSL
Bullion
Pb Refinery
Pb Slime
Bullion
PMR
Cu
Speiss
Zn & other
By Poducts
Leached
Residues
Discard
Slag
Steam &
Energy
76
Pb Ausmelt
Plant
Bullion
Cu
Speiss
Pb Residue
Goethite
Ausmelt TSL
Zn Fumers
Fume
Cu
Pb
Box 5:
77
Figure 22:
Conventional
phosphorus flow
through chemical
and iron & steel
industries and
possible new flow
(grey arrows)
when P-recovery
technology from
steelmaking slag
comes on stream.
Arrow width
corresponds to
quantity of flow
(Yoshida et al.,
2012).
More and better recycling holds great economic rewards: from the sale of metal that
would otherwise be lost, including various
valuable and scarce elements, and from recycling processes that reduce energy use in
metal production. Substantial savings are
also possible in Greenhouse Gas emissions
and other environmental benefits.
2.4.1 Value of recovered metals
Metal prices directly or indirectly influence
the financial rewards of recovery. These are
related to the physics of primary and recycled
recovery of a metal, to the relative abundance
of the various elements in primary minerals,
and to the demand for greater sustainability and other services provided by the metal. Table 12 shows the economic potential of
world (mine) production compared to electrical and electronic equipment (EEE) demand,
estimating the value of metals going into EEE
in billions of dollars. This is a strong incentive for setting up profitable recycling sys-
Reduction of
Environmental Burden
During Mining
Phosphate Rock
Manganese Ore
Chemical
Industry
Reduction of Use of
Ferro-Manganese
Iron Ore
Coke
Phosphorus
Fertilizer
Agricultural
Soil
Steelmaking
Slag
High Phosphorus
Iron Ore
Fume
Plant
Reduction of
Emission
New Iron
Source
Conventional Flow
New Flow
78
Slag
Recycling
The (precious) metal content of various devices can do much to boost the economic recycling of WEEE products. For instance, the
metal value of used rechargeable batteries is
Table 12:
World mine
production,
electrical and
electronic
equipment
(EEE) demand
and application
relative to mine
production for
several critical
elements.
Values exceeding
100% are due to
recycling. Metal
prices from Metal
Bulletin, Mine
production from
USGS (Ru from
Johnson-Matthey,
2011), (see some
recent metal
prices Sept/Oct
2011 a reflecting
the large possible
changes).
a Metal prices from
Metal Bulletin
7/9/2011 pp. 3541
($/kg): Ag 972; Au
58,546; Pd 24,981;
Pt 59,253; Re
4,800; Ru 5,626; Rh
60,282; Cu 9 (down
lately to 7); Sn 24;
Sb 15; Co 35; Bi 29;
Se 136; In 785 (others not in table Ga
850; Ge 1,650; Ni
22; Pb 2.5; Te 380;
Zn 2.2; W 470)
79
Important
EEE
metals
World mine
production
EEE
demand
t/a
t/a
EEE
demand/
mine
production
Metal
price
Value of
EEE
use
$/kg
billion $
Silver Ag
22,200
7,554
34%
$ 649
$ 4.90
Gold Au
2,500
327
13%
$ 39.443
$ 12.90
Palladium Pd
229
44
19%
$ 16.948
$ 0.74
Platinum Pt
188
4%
$ 51.811
$ 0.37
29
21
72%
$ 5.069
$ 0.11
16,200,00
7,174,000
44%
$8
$ 54.08
Tin Sn
261,000
129,708
50%
$ 20
$ 2.65
Antimony Sb
135,000
67,500
50%
$9
$ 0.61
88,000
16,470
19%
$ 45
$ 0.75
Bismuth Bi
7,600
1,216
16%
$ 20
$ 0.02
Selenium Se
2,260
185
8%
$ 82
$ 0.02
574
717
125%
$ 566
$ 0.41
Total
$ 77.56
Ruthenium Ru
Copper Cu
Cobalt Co
Indium In
Figure 23:
Critical levels of
some elements
(U.S. Department
of Energy, 2010).
Li
1
(low)
Ce La
Eu
In
Nd Te
Co
Nd
Ga
El
Not Critical
In
Li
Eu
Yt
Te
Dy
Te
Ce Co
Pr
Yt
La Pr
1
(low)
Sa
1 (low)
80
4
(high)
Dy
Te
Near Critical
4
(high)
Ga
Critical
El
El
4 (high)
Supply risk
Sa
1 (low)
4 (high)
Supply risk
Table 13_a:
The use of rare
earth elements
(REE) in 2012 and
projected demand
and growth by
2016 (Lynas
Corporation,
2011).
Forecast Global Rare Earths Demand in 2012 (t REO 15%) (source: IMCOA and Rare
Earth Industry Stakeholders)
Application
Catalysts
China
Japan &
NE Asia
USA
Others
Total
Market
Share
12,000
2,000
5,000
2,000
21,000
18%
5,500
1,000
500
500
7,500
7%
Polishing
15,000
2,000
1,000
1,000
19,000
16%
Metal Alloys
16,000
4,000
1,000
1,000
22,000
19%
Magnets
18,000
3,500
500
500
22,500
20%
7,000
1,500
500
500
9,500
8%
Ceramics
2,500
2,000
1,500
500
6,500
6%
Other
3,500
1,500
1,500
500
7,000
6%
Total
79,500
18,000
11,500
6,500
115,000
100%
69%
16%
10%
5%
100%
Glass
Phosphors
(including Pigments)
Market Share
81
Table 13_b:
Forecast Global Rare Earths Demand in 2016 (t REO 15%) (source: IMCOA and Rare
Earth Industry Stakeholders)
Application
Catalysts
China
Japan &
NE Asia
USA
Others
Total
Market
Share
14,500
2,500
6,500
1,500
25,000
15%
6,000
1,000
1,000
1,000
9,000
6%
Polishing
19,000
2,000
3,000
1,000
25,000
15%
Metal Alloys
20,000
2,500
2,000
1,500
26,000
16%
Magnets
28,000
4,500
2,000
1,500
36,000
22%
9,000
2,000
1,000
500
12,500
8%
Ceramics
4,000
2,000
2,000
1,000
9,000
6%
Other
6,500
3,500
8,000
2,000
20,000
12%
107,000
20,000
25,500
10,000
162,500
100%
66%
12%
16%
6%
100%
Glass
Phosphors
(including Pigments)
Total
Market Share
For example, the scarcity issue linked to battery recycling revolves mainly around Co, Li
and rare earths, each of which presents its
own challenges. Cobalt is seen as the main
metal with scarcity concerns, but at least
there is an economic incentive for its recycling and it can be substituted by nickel and
manganese, both of which are less scarce.
Lithium, on the other hand, has no foreseeable substitute and presents geopolitical concerns with 80% of its world resources based
in Chile, Bolivia and Argentina.
Although the list of today's critical elements may change as applications and technology change, prudent safeguarding of these
materials, e.g. the recovery of these critical
resources from consumer products such as
cars and WEEE, will play an important role in
the sustainable development of our society.
82
83
Figure 24:
Primary carbon
footprint
of selected
elements in
WEEE goods
(EU, 2010)
(AppendixF:
"Physics of
Extractive
Metallurgy").
Au
Pt
10,000
Ru
Pd
200
In
Ag
Sn
Co
Cu
0
84
Demand for
EEE
CO2
emissions
t/a
Mt/a
Au Gold
16,991
327
5.56
Pt Platinum
13,954
0.11
Ru Ruthenium
13,954
16
0.22
Pd Palladium
9,380
30
0.28
Au Silver
144
4,917
0.71
In Indium
142
717
0.10
16
129,708
2.09
Co Cobalt
16,470
0.13
Cu Copper
7,174,000
24.39
33.58
Sn Tin
10
Primary
production intensity
t CO2/t
metal
Integrated recycling that extracts more metals from residues also is better suited for
dealing with potentially toxic elements, thus
avoiding or minimizing their release into the
environment, and rendering the final smelting or processing product benign. It commonly liberates land as existing residue
ponds are processed and eliminated. This
also has practical direct benefits for recycling
operations, as environmental regulators increasingly stop the licensing for new residue
ponds, decreasing the scope for potential expansion of primary production.
Figure 25:
Air
Subject to long distance transport
Material transport
between informal
treatment
FA
FP
Uncontrolled Dumping
Main WEEE
recycling
activities in China
and India, types
of produced
emissions
and general
environmental
pathways.
(Seplveda et al.,
2010).
L
SM
Dismantling | Shredding
SM
FP
CP
By-Products
SM
FA
F
WW
SM
WW
SM
Particles
within air
Original
Substances
Auxiliary
Substances
Biota
L
CP
BA
Soil
Surface Water
Biota
Sediments
Groudwater
Emission | Wastes
L
WW
Leachates
Wastewater
CP Coarse
particles
SM
FP Fine
particles
FA Fly
ashes
BA Bottom
ashes
Fumes
Effluents
Solid matter
85
86
3. Limiting Factors
in Recycling
This chapter looks at the factors that currently, and for the near future, constrain our
ability to achieve higher recycling rates of
metals. At the base are the limitations set by
nature, such as physics, chemistry, metallurgy and thermodynamics. These dictate the
outcome of a given input into a recycling process, the constraints of nature tying together
the use of energy, metal recovery, and quality and quantity of the inevitable losses. The
more complex a multi-material recyclate input is, the more metal will be lost in the metallurgical system. Where recycling uses less
sophisticated metallurgical technology, mixed
waste will be even more of a limitation.
Different processing routes give different
outcomes and thus different recycling rates.
Pre-processing technology, using mainly physical separation for preparing suitable
fractions for further processing, influences
the quality and quantity of the input streams.
However, several thermodynamic, technical,
economic and environmental issues must be
considered as well. A limiting factor at this
stage is the relationship between quality and
recovery of a given metal or metals. Though
their quantity depends upon the policies and
actions governing materials collection, the issue becomes more complex when discussing the quality of the streams to be pre-processed. A large variation in stream properties will adversely affect product quality and
recovery, thus increasing losses at this stage.
The streams may even become economically
unviable for processing.
87
Box 6:
Figure 26:
Study of
developing
and developed
markets about
what people
did with their
previous
cell phone
(Damanhuri,
2012).
Kept as spare
Given to friend/family
Sold/traded for a new phone
Lost/stolen/broken
Recycled
Other
Developing
Developed
0
20
40
60
80
100
According to the 2011 survey, 9% of respondents claimed to have recycled their last cell
phone, a 6% increase over 2007. The developed market leads in this, although strong
growth has been seen in India and China since 2007.
cling possibilities. Taking products to collection sites or facilities is felt as an inconvenience, leading to low collection volumes and
mixed waste streams with different compositions. This is even seen for ELVs, but more for
small electronic appliances, batteries, small
toys, packaging, etc.
88
89
90
Box 7:
At the individual firm level, managers must seek much higher efficiency through the
3Rs of cleaner production, reduced resource consumption, reduced emission of pollutants and waste, reuse of resources, and recycling of by-products.
The second level is to reuse and recycle resources within industrial parks and clustered or chained industries, so that resources will circulate fully in the local production
system.
The third level is to integrate the different production and consumption systems in a region, so that the resources circulate among industries and urban systems. This level requires development of municipal or regional by-product collection, and of storage, processing, and distribution systems.
Efforts at all three levels include the development of resource recovery and cleaner production enterprises and public facilities for implementing the CE concept. This adds a
strong economic-development dimension through investment in new ventures and job creation. As a result, the Circular Economy opens opportunities for both domestic and foreign
enterprises with regards to properly treating waste, including e-waste, in China.
91
Most Indian e-waste is generated domestically. Imports still account for a substantial
amount of WEEE, but their share is decreasing. The main sources of WEEE are government institutions, public and private sector
institutions, product and component manufacturers, and individual households. Concerning imported e-waste, a study by koPol
prepared for the German Federal Environment Agency assessed that 80% of the waste
is imported from the US and the remaining
20% mainly from the EU (Sander and Schilling, 2010).
Up to 2011, a patchwork of regulations covering e-waste had been in place, which ham-
pered effective WEEE regulation and enforcement (Sinha-Khetriwa et al., 2006). With the
introduction of the new E-Waste (Management and Handling) Rules 2011 that entered into force on May 1st, 2012, India introduced comprehensive legislation addressing
the issue of e-waste, which resembles the
EU WEEE Directive and follows the principle
of Extended Producer Responsibility (EPR)
(Ministry of Environment and Forests, Government of India, 2011). It remains to be seen
whether the legislation will be effectively enforced.
While some formal recycling facilities already
exist in India, they have significant problems
of receiving enough e-waste for operating
at an economically viable level. So far, informal recyclers handle up to 20 times as much
e-waste as formal recyclers. The new rules
intend to change this ratio in order to decrease the environmental impact of e-waste
recycling, which is significantly larger in the
informal sector. In addition to environmental
impact, the use of child labour and the exposure of workers to far higher toxin levels than
in the formal sector, provide a further incentive of enforcing the new rules (Skinner et al.,
2010).
3.1.2 Policy responses addressing waste
flow
Metal recycling is a highly complex process,
relying on various steps that need to be followed in order to ensure an environmentally sound recycling process. One of the most
challenging aspects concerning the recycling
of consumer goods, is to ensure that end-oflife products end up in the right facilities. Unfortunately, several studies have shown that
waste is often, and mostly illegally, shipped
to locations where this aspect is not ensured
(e.g. Sander and Schilling, 2010). For metals,
the problem of illegal waste-streams mostly
concerns mobile goods, e.g. cars or waste of
electrical and electronic equipment (WEEE).
92
ing with the Convention lies with the exporter and requires the take-back of waste, for
instance in cases of illegal transports (Basel Convention, Article 9). According to List
A of Annex VIII (A1180), WEEE is considered
hazardous and thus generally covered by the
Conventions jurisdiction. However, the convention only addresses transboundary shipments between OECD and non-OECD states,
and does not regulate waste shipments between non-OECD states for example (SinhaKhetriwa et al., 2006).
In 1997, the EU decided to implement the
Basel Ban a 1995 amendment to the Basel Convention that has not yet been ratified
through an amendment to its Waste Shipment Regulation. Not only does the EU ban
the export of hazardous (and e-waste) to nonOECD countries, but it has also introduced
the WEEE- and RoHS Directives that, respectively, force producers and resellers to implement take-back systems and to phase-out
hazardous materials in electrical and electronic equipment (EEE) (European Commission, 2008).
The policies concerning e-waste earlier had
a strong emphasis on hazardous environmental effects. However, as the volume of
e-waste increases, the increased and effective recovery of metals in sophisticated plants
using BAT technology will have to be stressed
as well.
93
Design
Dismantling
Shredding
Physical separation/sorting
Imperfect
separation
Recyclate 1
Imperfect
liberation
Recyclate 2
94
Recyclate 3
95
Mechanical sorting commonly produces imperfect recyclates (Figure 28) and society is
probably best suited to discern between the
vast combinations of materials, to produce
the highest grade of recyclates possible. Typical recyclates created through dismantling
are shown in Figure 30.
Figure 30:
Groups of
components best
sorted by hand
for producing
the cleanest
recyclates (van
Schaik and
Reuter, 2010b).
Coils
Cu, Fe3O4,
Copper,
Ceramics,
Plastics,
PVC,
Copper wire
[-C3H6-]n, PbO,
Wires
Cu, [-C2H6Cl-]n
SiO2
Copper, PVC
Getters
Glass, W, Plastics
W, BaO, CaO,
Al2O3, SrO, PbO,
SiO2
Wood Housing
Fe, [-C3H6-]n
Steel (staples),
Plastics
Plastic Housing
Plastics, Steel (bolts
etc.)
96
PWBs
[-C3H6-]n,
[-C11H22H2O4-]n,
Cl, Br, Sb2O3
CRT
Metal
Fe
Steel
Box 8:
97
The type of the material joints and connections (e.g. bolted, rivet, shape, glue, surface
coating).
Characteristics of the connection/joint, e.g. size of the connections in relation to particle size distribution after shredding.
Box 8_b:
Connection types
(design)
Before
shredding
After
shredding
Liberation
behaviour
Bolting/riveting
High liberation
High randomness
Gluing
Medium liberation
Medium randomness
Coating/Painting
Low liberation
Low randomness
of liberation
Foaming
Medium liberation
Medium randomness
Figure 31:
Characteristics
of connection
types related
to their specific
degree and
non-randomness
of liberation
behaviour after
a shredding
operation (van
Schaik and
Reuter, 2007a&b;
van Schaik and
Reuter, 2012).
98
Connected
materials/
components of
different levels
of complexity
High/medium
liberation from
structure
High/medium
randomness
(both depending
on joint type
and connected
materials)
Heterogeneous/
high number of
connections per
surface area
Low liberation
on component
Low randomness
Material
properties,
low complexity,
low number
of joints
High liberation
High/medium
randomness
(depending
on joint type
and connected
materials)
Figure 32:
Example of
recycling cars, a
complex network
of processes and
interconnected
material flows.
Separation
processes are of
key importance
in producing
suitable
recyclates for
processing in a
metallurgical
plant (van Schaik
and Reuter,
2012, HSC Sim
19742013).
100
Figure 33:
Feed
Generic separator
using the laws
of physics
and material
properties for
separating
materials.
Separating force
No effect
reject
101
Positive response
recyclate
pH of fluid
probability to sinks
100
50
p
0
2800
3000
3200
density [kg/m3]
102
Table 14:
The selection
of technology
in various
recycling plants
(Vermeulen et al.,
2011).
Separation techniques
Argonne
Galloo
Magnetic separation
Air classification
Screening
Trommel separation
MBApolymers
Salyp
process
Optical sorting
Stena
R-plus
(WESASLF)
x
x
x
x
Drying
Sink/float separation
Froth flotation
Wet grinding
Hydrocyclone
Static, hydrodynamic
separation tanks
x
Operating
plans
90%
of polymers
>6 mm
90% of
metals
>6mm
103
Thermo-mechanical
sorting
Manual sorting
Status of development
VWSicon
Operating
plans
90%
Operating
plans
Not
given
Operating
plans
86%
Operating
plans
80%
Operating
plans
92%
1 trial
plant +
2 under
construction
95%
Even in combination, liberation and separation methods do not create pure material streams. This is illustrated by two studies on the recovery of precious metals from
PCs with different pre-processing separation
techniques. One study compared a fully manual sorting process with a combined dismantling and shredding process using automatic sorting (Meskers et al., 2009). The other
study investigated the precious metal flows
in a state-of-the-art European facility processing a mixture of ICT and consumer electronics. Both studies investigated precious
metal recoveries from material streams after
pre-processing.a Table 15 summarizes the
results, showing that high recovery can be
achieved, although the cost of manual dismantling must also be considered (see Table4).
Table 15:
Comparison of
precious metals
recovery rates
from suitable
material streams
after preprocessing.
Reference
Process description
Meskers
et al. 2009
49%
80%
66%
Meskers
et al. 2009
92%
97%
99%
Meskers
et al. 2009
75%
70%
41%
Chancerel
et al. 2008
Manual depollution and shredding and automatic sorting 27 tonnes ICT and consumer electronics
11%
26%
26%
104
Silver
Gold
Palladium
Figure 35:
Maximum
grade-recovery
curve (left)
for liberation
characteristics of
scrap (right).
Recovery %
100
5
15
80
25
35
60
45
55
40
65
75
20
0
30
85
95
40
50
60
70
80
90
100
10
15
20
25
30
35
Grade %
The second example (Figure 36) shows simple characteristics of the material with relatively good liberation, except for a material
joint that is difficult to break, seen as a peak
at 65% liberation of the mineral. It is clear
from this figure that 90% purity of the recyclate can be achieved with an 80% recovery,
i.e. a relatively high-grade recyclate can be
created with higher economic value than for
the previous example.
Figure 36:
Maximum
grade-recovery
curve (left)
for liberation
characteristics
of scrap (right)
(Heiskanen,
1993).
Recovery %
100
5
15
90
25
80
35
45
70
55
65
60
75
50
40
70
85
95
75
80
85
90
95
100
Grade %
10
15
20
25
30
30
35
40
45
Figure 37:
Typical WEEE
material
composition
(European
Topic Centre
on Sustainable
Consumption
and Production,
2009).
10
20
30
40
50
Weight in %
106
Understanding these physics and the economics for separating these elements lies
at the core of maximizing resource efficiency
and therefore of metals and materials recycling in general. The dark blue ring near the
centre of the Metal Wheel in Figure 15 and
Figure 38 shows metals currently used in
significant quantities by society. These are so
called 'Carrier Metals' because they are the
backbone of recycling processes and thus
'carriers' (usually called commodity or base
metals in industry jargon). Historically, they
were the target of primary production processes using concentrates derived from ores,
such as:
Box 9:
Steel recycling
Steel recycling can cope only to a certain extent with copper, tin and antimony in the input streams. These elements, because of their chemical and thermodynamic properties,
pose a formidable challenge for their removal during the production of high-quality steel.
Commonly, the only way to cope is to dilute them into concentrations that are tolerated by
alloy requirements. Sorting helps, but the steel scrap has to be de-tinned and de-galvanized before being fed into the smelter. Plastics containing antimony flame retardant must
also be removed to alleviate this problem. However, complex post-consumer scrap such
as WEEE can contain 50+ elements at the same time, many of which cannot be dealt with
during steel making and thus cannot be recycled. However, non-ferrous metallurgy can
cope with these elements, but, as the name non-ferrous metallurgy suggests, the iron will
then be lost as FeO in the slag.
Consult Appendix A: Details on Recovery of Metals from Recyclates, Appendix E: Models and Simulation in Recycling
and Appendix F: Physics of Extractive Metallurgy for more
details.
107
Figure 38:
Design for
resource
efficiency
showing the
destination of
elements from
an end-of-life
material. If a
WEEE product
falls in the copper
and Zn/Pb slices,
many metals can
be recovered,
but if it falls in
the incorrect
slice, e.g. the
steel cycle, the
metals may be
lost, diminishing
the resource
efficiency. Policy
should thus
pay particular
attention to
the complete
infrastructure
and systems.
Losses
Consumer, Collection
Losses
Losses
Market & Stocks
Functional Element
Combinations
Production
Collection &
Dismantling
Product Design
Societys Essential Carrier Metals: Primary Product
Extractive Metallurgys Backbone (primary and recycling
metallurgy). The metallurgy infrastructure makes a closed
loop society and recycling possible.
El
El
Al2O3
TiO2
ThO2
In2O3
BaO
SiO2
Pt
Al
CaO
Fe
FeOx
MgO
Cl
Mn
Fe
Cr
Pt
Ga
Cd
TiO2
Ta2O5
Nb2O3
In
In2O3
REs
Br
Sn
MgO
WO3
Cd
Ge
MnO
BaO
Smelt/Refine
Pt
Rh
Mo
Zn
Bi
SrO Ga2O3
ZrO2
Stocks
Se
Ag
V2O5
Ag
Cu
Pt
Th
Te
Co
Sn
SiO2
Mo
B
Zr
Pyro
Metallurgy
Remelt
REs
Th
Zr Al
Mg
Al2O3
Cl
Zn
Si
Al
FeOx
MgO
Si
F/Cl
Br
AIXy
RE(O)s
RE
Special Battery
P
Cl
Pd
NiO
ThO2
Zn
In
In2O3
TiO2
Ta2O5
WO3
CaO
Al2O3
SiXy
Al2O3
MgO
SrO
Losses
SiO2
CaO
Li2O
Bi
Pb
CaXy
FeOx
K
Cu
As
Ga/As
REOs
Ag
Sb
Na
SiO2 FeOx
CaO Cu2O
Co
Cu
Sb2O3
In
Ni
Smelt/Refine
P2O5
MnO
RE
Hydro-Metallurgy
Sn
CaO
K/Na
Li
Hydro&Pyro
metallurgy
As
Sb
Al2O3
REOs
TiO2
Nb
Ti
Remelt
Refine
ZrO2
Cr
Pd
Recycling
Cu/Ni
Au
Al2O3
Na
Ni
Au
Refine
Sn
Sb
MgO
Zn
Ti Sb Cr
Fe Mn
Si Mg
Sn
An
EoL
Product
Pb
Smelt
Bi
Pb
Hg
FeOx
Cd Hg
Pb
KCl
BaO
Hydro Metallurgy
Remelt
Ni/Cr
Au
CaO
SiO2
Fe
Stainless Steel
Co
Ge
SrO
Al
Steel (BOF&EAF)
Zn
Cu
Ti
Cr
Pd
Rh
RLE/Fume
In
Tr
V
W
V2O5
CaO REOs
TRIP Steel
Austenitic
Ni
Zn
Al2O3
Bi
Ta
Nb
Ni
Co
Mo Si
Pb
Au Sn
Sb
REs
Cu
Ag
As
Cd
Br
Al2O3
Na
Cl
Hg
Pb
Zn
CaF2
ZrO2
Ga2O3
REOs
Ta2O5
Nb2O3
Metals back to
consumer Production
MgO SiO2
CaO
CaF2 FeOx
SrO
Theft
Air Fill
Landfill
Physical
Separation
WO3
Unaccounted
Losses
El
ZrO2
REOs
MnO FeOx
MgO
Nb2O5
V2O5
SiO2
Multi-material
Recyclate Grades
Infrastructure
Metal & Energy
Recovery
Losses
Thermodynamics, Technologies, Economics,
Metal Price, Feed Morphology | Complexity
108
Linkages, Economics
Hydrometallurgy, or leaching, puts metals into a low-temperature aqueous solution, reaching +90C under atmospheric
conditions, and +200C when under pressure for separating different elements and
compounds. Again, various processes exist, based on either acid (low pH) or basic
(high pH) aqueous solutions. Hydrometallurgy generally first increases the entropy of metals, before recovering the ions in
solution with a significant input of energy
for lowering the entropy again (Tuncuk et
al., 2012).
Figure 39:
Electric Arc
Furnace (EAF)
for smelting steel
scrap (Krger et
al., 2005; SMSSiemag: www.
sms-siemag.
com).
(a) Electrodes
(b) Water-cooled walls
and roof
(c) Tiltable furnace
(d) Refractory lining
(e) Tilting mechanism
(f) Spout
(g) Eccentric tapping
(h) Ladle
109
Box 10:
110
a Electrowinning separates metals from solutions by electrolysis applying electricity to the solution.
Figure 40:
Technologies
used in
aluminium
recycling for
various scrap
types, including
salt-slag smelting
for producing
cast aluminium
from scrap (Boin
and Bertram,
2005; Bertram et
al., 2009).
Clean scrap of
distinct alloy
composition
Alloy
Production
Massive clean
scrap (little
oxidized, high
volatile content)
Wet turnings
Wet turnings processing
Dry Turnings
Alloy
Salt
Remelter
Salt Slag
Processor
Remelter
Dross
Flux-free
Melting
Furnace
Tiltable
Rotary
Furnace
Flux-free
Melting
Furnace
Fixed Axle
Melting
Furnace
Salt
Alloying Furnance
Filter Dust;
Spent Refactory Lining
Salt Slag
Filter Dust;
Spent Refactory Lining
Standard
Wrought Alloy
Rolling &
Extrusion
111
System
Boundary
ESSUM
Dry Turnings
Dross
Waste
Management
Mixed scrap
(medium oxidized)
Non metallic
Residue
Foundry Casting
Steel Industry
Waste
Management
Cement Industry
Mine Filling
Figure 41:
The effect of
scrap surface
area (left) on
recovery (right)
of two scrap
types recovery
is held back by
inactive alumina
coating scrap,
so scrap with a
higher surface
area/volume
ratio (upper
picture) has
lower recovery
rates than larger
pieces (bottom
set) (Xiao and
Reuter, 2002).
112
Figure 42:
The flow of
elements
associated
with copper
production
(hydro- and
pyro-metallurgy)
showing the link
between primary
production and
recycling. Gangue
minerals are
not included.
(Nakajima et al.,
2008; 2009; 2011;
Nakamura and
Nakajima, 2005;
Nakamura et
al., 2007). This
flowsheet fits
into the copper
segment of the
Metal Wheel
(Figure 15).
Silicate
Fe
Copper concentrate
Ag, As, Au, Bi, Co, Fe, Mo,
Ni, Pb, PGM, Sb, Se, Te
(Metal Wheel)
Waste
Smelting
furnace
Slag
Co, Fe, Mo, Zn
Matte
Dust
Cd, Pb, Zn
Converter
(refining)
Blister copper
Other
refinery
Electrolyte
As, Ni
Anode Furnace
Electrorefining
Copper scrap
E-waste
Mn, Mo, Ni,
Sn, Zn, Pt, Pd,
Au
Other
industries
Human
economic
activities
Electrolytic
copper
Copper alloys
Al, Ag, Ni, Pb, Sn, Zn
Metals
As, Cd, Ni, Pb, Zn
Anode slime
Ag, Au, Bi, Pb,
PGMs, Sb, Se, Te
113
Waste
Cd, Pb, Zn
a Reviews on metallurgical processes for recovering and refining (precious) metals from printed circuit boards were
issued by Cui and Zhang (2008), Goosey and Kellner (2003)
and Huang et al. (2009). The European Commission (2008)
provided an overview of Best Available Techniques to recover precious and other non-ferrous metals.
Hydro/pyroprocess
(extraction)
Metals
Ag, Au, Bi, Pb,
PGMs, Sb, Se, Te
tling, mechanical treatment; and iii) End-processing, incl. refining and disposal (UNEP,
2011a). Such input products cannot be considered as bundles of separate metals, alloys,
plastics, oxides, sulphides, etc., as these are
invariably connected to each other and enter
the recycling system together. Their recovery
and recyclability depend upon the combination of purity with which they enter the metallurgical stream and on the expertise applied
to these metallurgical processes.
Box 11:
Figure 43:
Weight and
material
composition
of the
SuperLightCar
light-weight
BIW concept
(SuperLightCar,
20052009;
Goede et al.,
2008; Krinke et
al., 2009).
114
SuperLightCar
Figure 43 shows a multi-material super-light body-in-white for a car, combining various
materials. The joints between the different materials must be strong enough to withstand
collisions. Hence, they will also hold materials together during recycling, leading to material contamination. If these joined materials are not thermodynamically compatible, they
will be lost into one of the recyclate streams. For example, if aluminium joined to steel
goes to a steel-scrap smelter, the aluminium will be lost as alumina (Al2O3) to the slag
after the deoxidation process during steel-making. If fibre-reinforced plastics go to any
metal smelting operation, they will be lost after supplying energy and carbon and hydrogen to the process. All the materials in Figure 43 therefore affect each others recovery/recyclability, and all somehow determine how much of the metals are lost during recycling.
Only if the materials can be well sorted and separated into pure recyclates, as shown by
the pie-chart, can the Carrier Metals in Figure 43 easily be processed back into metal with
minimal losses. Note that a printed circuit board significantly increases complexity.
Steel
Fibre reinforced Plastic
Magnesium
Aluminium Sheet
Aluminium cast
Aluminium extrusion
extract small quantities of metals from complex products and alloys requires a deep understanding of the metallurgy of more than
one Carrier Metal, and an investment in
larger, more complex systems and sophisticated non-ferrous metallurgy. This, in turn,
requires a mix of metallurgical and thermodynamics knowledge to bring together the infrastructure into a system that treats the residues/intermediate products from one Carrier Metal process in anothers. For example,
mixed lead- and copper-based metallurgy in
an integrated copper smelter (Figure 44 and
Figure 45) is an excellent basis for recovering
a wide range of elements from the feed materials. This also illustrates how the primary
smelting of in this case copper and lead is
used for the recycling of other metals found
in electronic waste and scrap (Hagelken,
2006; Cui and Zhang, 2008). Copper, lead and
matte (molten metal sulphide) are a solvent
for recovering precious metals. The primary metallurgical processing of copper and
lead is generally followed by electro-winning
(electrolysis) and refining, which effectively
removes and recovers elements from crude
metals, such as the Kayser Recycling System
(Figure 46).
Figure 44:
Metal-production
flowsheet
integrating
copper and
lead hydro- and
pyro-metallurgy
for maximizing
metal recovery
from Bolidens
operating facility
(Outotec, 2012;
NewBoliden,
2012), fitting
into the Pb and
Cu segment of
the Metal Wheel
(Figure 15).
Fuming Plant
Secondary
Raw
Materials
Dryer
Zinc Clinker
Iron Sand
Electric Smelting
Furnace
Copper
Conc.
Precious Metals
Plant
Converter Aisle
Fluidized
Bed Roaster
Flash Furnace
Electrolytic Refinery
Gold
Silver
Selenium
Pt/Pdsludge
Copper
Copper
Sulphate
Crude
Nickel
Sulphate
E-Kaldo Plant
Electronic Scrap
Gas Flow
Copper Flow
Lead
Conc.
115
Sulphuric
Acid
Sulphur
Dioxide
Dryer
Lead
Kaldo Plant
Lead Refinery
Lead Flow
Figure 45:
The Umicore
flowsheet based
on copper and
lead hydro- and
pyro-metallurgy,
using a TSL
furnace for
copper and a
blast furnace
for lead, which
permits the
processing of
slag, matte,
speiss, slimes,
sludges, dross,
etc. (Hagelken et
al., 2009) This
flowsheet fits in
the two Pb&Cu
segments of the
Metal Wheel
(Figure 15).
116
Figure 46:
The Kayser
Recycling System
for recycling
copper metal
and other copper
containing
residues. This
flowsheet fits into
the Cu segment of
the Metal Wheel
(Figure 15).
117
Copper/e-waste
(GRM, S Korea)
Copper/e-waste
(Umicore, Belgium)
Lead Battery
(Recylex, Germany)
Copper/e-waste
(Dowa, Japan)
Copper/e-waste
(Boliden, Sweden)
KRS
(Aurubis, Germany)
Figure 48:
The link between
the Iron and the
zinc cycles for
galvanized steel,
a Material (&
Metal)-Centric
view (Reuter et
al., 2005).
118
This situation with primary producers is unlikely to change by itself in the foreseeable
future, as increased global demand for Carrier Metals and incomplete information on
metal recycling (UNEP, 2010) provide few incentives for primary smelters to change their
flowsheets. In addition, the organization of
the industry tends to create inertia due to
high capital investment, long plant life, etc.,
encouraging the continuation of single Carrier Metal operations. The metal-production
industry has formed representative organizations based around the primary Carrier Metal operators; these organizations obviously
promote the common denominator between
their members in a more material-centric
environment, so will unlikely promote innovation or explore additional sources of revenue in a more product-centric environment
of metal recycling. Collaboration of different
metal associations would help much to increase resource efficiency.
However, parts of this industry already operate in ways that show how the mainstream
industry can change. Toll refineries (operators that charge for refining other peoples
ores) increasingly integrate different Carrier Metal technologies. Worldwide, various
operations, many of which are mentioned in
this document, already operate commercially
successful integrated production sites.
Metallurgical technology providers are well
placed for turning this industry limitation into
an opportunity. Improved treatment and recovery of valuable metals in input streams
generates additional revenue and hence profit or value-addition potential for metal producers. In addition, BAT usually is more resource efficient, significantly lowering energy
demand as well as emissions and environmental impact. This can be an opening and
opportunity for a fundamental resource-efficient-based change in the mainstream industry.
119
Figure 49:
Process steps
of EoL product
treatment with
indicators of
economic gain/
cost (Tanskanen
and Takala, 2006).
Table 16:
A brief overview
of earnings
and costs for a
1000tpa NiMH
battery recycling
facility (Mller
and Friedrich,
2006).
2004
2006
2007
2008
2009
Sales (1)
432562
1185280
184405
4134865
6730204
297925
775410
1263072
2750048
4514120
Earnings (1)
134637
409870
581833
1384817
2216085
36300
156090
181500
209378
238564
348190
Non-wage labour
costs (1)
13800
33000
34800
34800
34800
38400
11400
22800
22800
22800
22800
22800
Consultancy (1)
18000
36000
36000
36000
36000
36000
Marketing (1)
6000
12000
12000
12000
12000
12000
6498
16110
17148
8400
8400
8760
91998
276000
304248
323378
352564
466150
-91998
-141363
105622
258454
1032253
1749935
1750
4750
48635
163735
166235
166235
-93748
-146113
56987
94719
866018
1583700
4000
150000
-93748
-146113
16987
-55281
866018
1583700
389708
712665
-93748
-146113
16987
-55281
476310
871035
Costs (1)
EBITDA (1)
Depreciation,
amortisation (1)
EBIT (1)
interests (1)
EBT (1)
Taxes (1)
Earnings (1)
120
2005
Iron ore
US$/t
US$/t
400
120
350
100
300
80
250
200
60
150
40
100
20
50
0
1950
121
1960
1970
1980
1990
2000
0
2010
122
Because of CAPEX, smelters require a sufficiently large economy of scale for operating.
Profitable recycling smelters run well over
100,000 tonnes/year of diverse feed. The feed
can be limited by factors such as the energy
balance of the process (certain scrap types
may contain large percentages of plastics),
Labour costs relative to energy costs affect technological choices and the balance
of profitability between the use of new and
recycled inputs.
Box 12:
Figure 51:
Past and
projected growth
in available EoL
appliances with
LCD screens in
EU25 (Salhofer et
al., 2011).
LCD TV
LCD Monitors
Laptop PC
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
0
100
200
300
400
500
600
1000 t
123
Box 12: b
Today, indium extraction from EoL screens is economically unattractive, as treatment and
refining costs are higher than the metal value. The indium concentration in screens is very
small, as the ITO layer is very thin (125 nm), or about 234 mg indium/m2 (though a wide
range in values is given in the literature). Organic LEDs have about half of this concentration, so they are even less of an economic actuator for extracting indium.
However, extraction from EoL goods could become economically feasible in the future, if
indium scarcity drives prices high enough or if new technology becomes available. New
methods for recycling flat screens are currently under investigation; while the EU is stockpiling screens awaiting this appropriate technology. Here, the stockpiling cost is weighed
against the alternative of incineration, to determine the real cost of intermediate storage.
Note that indium is connected to tin and possibly numerous other elements and compounds. For this reason and as discussed in this document, the recovery metallurgy of indium must be considered in connection with these other elements. These issues are discussed and illustrated in more detail in Appendix F: Physics of Extractive Metallurgy. Also
refer to Li et al. (2009) for further information on LCD recycling.
124
4. Consequence of
Limiting Factors
4.1 Collection
125
System
Collection
Formal
(Europe,
UNU 2008,
Chancerel
et al. 2009)
Informal
(India, Keller
2006)
Pre-processing
Final processing
Net yield
60 %
formal
take-back
system
25 %
mainly
mechanical
processes
95 %
integrated
smelter
15 %
80 %
individual
collectors
50 %
manual
sorting and
dismantling
50 %
backyard
leaching
20 %
4.2 Pre-processing
Pre-processing methods affect the outcome.
A comparative study by Wang et al. (in preparation) of pre-processing scenarios shows
that recovery efficiency improves with better manual dismantling. Purely mechanical
pre-processing leads to major losses of, especially, precious metals in dust and ferrous
fractions (Meskers et al., 2008; Chancerel et
al., 2009). As labour cost is the main denominator for deciding between manual and mechanical treatment, the latter is mostly used
in developed industries, accepting lower recovery efficiency, while the cost of manual
dismantling is balanced by gains, and strongly influenced by metal prices. In developing countries, where labour costs are usually
low, manual treatment is the preferred option, with the double advantage of low investment cost and job creation (UNEP, 2011a).
Figure 53:
Metal recycling
rates predicted
by the recycling
model for
different metals
for disassembled
Printed Wire
Boards (PWBs)
either directly
fed into a copper
smelter or
shredded with
varying intensity.
Note the low
recovery of gold
and copper for
shredding and
the high recycling
values if the
PWBs are directly
recycled to
furnace without
shredding (van
Schaik and
Reuter, 2010a).
126
Aluminium Recyclate
Copper Recyclate
Ferrous Recyclates
Stainless Steel
Precious Metals
Solder
Polypropelene
PVC
To Steel
Epoxy
To Energy
IC's
To Cu
To Al
Figure 53:_b
Little shredding
Strong shredding
Direct to smelting
Al
Au
Cu
Fe
Sn
0
20
40
60
80
100
5% is lost in the
copper smelter,
and 1% during palladium refining.
127
Reference
Recovery rate
for gold
Recovery rate
for palladium
>99%
>99%
98%
99%
>95%
94%a
128
In contrast, Keller (2006) carried out a substance-flow analysis for investigating the processes of recovering gold from printed wire
boards (PWBs) during informal preciousmetal recovery in Bangalore, India. He compared two different processes, both starting
with manual dismantling of PWBs to remove
the parts containing apparent gold, which
later was recovered by cyanide leaching and
gold stripping. Between 40% and 84% of the
contained gold was lost during pre-processing (dismantling), mainly because of poor visual recognition of apparent gold. The recovery
of gold through chemical processes caused
further losses, so that, in all, only 8% to 18%
of the gold was recovered. In both processes,
palladium was not recovered.
It is obvious that there can be no single recycling rate, but only a distribution of recycling
rates. Different car models, different recycling scenarios, different recycling infrastructure and routes, etc., all create different recycling rates. It would be best, therefore, to
focus on the economics of these processes
to create a playing field in which recovery of
materials and energy can be maximized.
Table 18:
Various recovery
rates for endof-life vehicles
(ELVs) depending
on the objective
function of
the system
optimization
model (Ignatenko
et al., 2008).
Scenario
Total recovery
0.95
0.91
0.91
0.97
0.88
Metal recovery
0.74
0.74
0.72
0.63
0.73
Physical separation
0.73
0.74
0.72
0.63
0.72
Thermal processing
0.003
0.001
0.01
Material recovery
0.11
0.11
0.14
0.24
0.12
Plastics
0.02
0.03
0.05
0.02
0.04
0.004
0.05
0.05
0.03
0.05
0.05
0.03
0.05
0.19
0.03
0.1
0.07
0.05
0.1
0.04
0.003
0.002
0.002
0.005
0.002
Waste
0.06
0.09
0.09
0.03
0.12
Physical processing
0.01
0.03
0.05
0.002
0.06
Metallurgy plant
0.05
0.05
0.05
0.03
0.05
0.001
0.001
0.01
Silica
From thermal processing
Energy recovery
Zn-rich dust (from thermal
treatment)
Thermal processing
129
130
5. Infrastructure for
Optimizing Recycling
5.1 Stakeholder infrastructure
A wide range of decision-makers influences
the outcome of a recycling system and its infrastructure. Those most strongly affecting
the physical nature of global metal chains are
shown in the top half of Figure 54:
Figure 54:
The various
stakeholders of
recycling in a
two dimensional
simplified
representation
of a multidimensional
complex product
centric approach
(Harro von
Blottnitz, 2011).
131
kind of supported or offered take-back infrastructure will affect the collection and
recycling results.
Regulators and economic planners (at national and international level) encourage,
discourage or forbid forms of recycling,
through industrial support, regulation of
other forms of waste disposal, waste collection requirements, as well prohibiting
pollution of the natural environment.
Sustainability analysts increasingly provide vital knowledge of the complex system described thus far. As an example,
economic and environmental regulatory
concerns in the past were often in conflict,
because of apparent trade-offs based on
partial views of the economic system. In
the transition to a green economy, such
conflicts should disappear through sophisticated analysis that combines environmental, social and economic sustainability considerations with science-technical
constraints.
Not every stakeholder holds all the information he needs, but he must know where to
find this information. Good decision-making comes from knowing which questions to
ask from whom, as shown in Figure 54. Nobody in the materials and recycling or any
other field can work in ivory tower isolation anymore. For example, industry, knowledge institutes and government consortia are
starting to guide the regulation coming out of
governmental waste agencies to provide the
groundwork for enhanced metal recycling.
This schematic picture does not explicitly
cover the small private enterprises that are
crucial to the formal and informal economies
of recycling. Recent Brazilian experience with
the organizing of waste pickers into cooperatives with government support suggests that
the reach of micro-scale private enterprise in
resource recovery can be significantly extended through support from public infrastructure planners (Ferro and Amaral, 2006), and
that this may become a major component of
green-economy programmes. Such stakeholders respond primarily to the financial
value of many metals in EoL products and, as
such, can be seen as extensions of the industrial investors" grouping.
Better recycling will result from having an
infrastructure that supports cooperation between the different stakeholders in the recycling chain. Each of them has his own interests and incentives; to improve the system,
we need not only an effective route for information exchange, but also a set of incentives
making it worthwhile for the stakeholders to
cooperate.
Financial gain is the main way that stakeholders influence each other. This may be
enough to induce informal collection, but
when improvements rely on doing something differently, such as an unusual collecting method, financial incitement may not be
enough, and information is needed about potential benefits. The best improvements in recycling will come when more than one stakeholder changes his behaviour at the same
133
mass products and flows, and on the elimination of hazardous substances, has been the
long-time driver. This approach no longer fits
the new focus on recovery of critical metals
from complex products, and the overall approach needs re-inventing, best starting from
a visionary brainstorming exercise among key
stakeholders. Questions to answer could be:
What should a recycling system ideally look like under the new conditions and
objectives, regardless of where we stand
today?
Box 13:
Product composition, coming from consumer demand (e.g. functionality), policy change
(e.g. banning CFC in refrigerators or lead-free soldering), product trends (e.g. SUV
cars), changing technology (e.g. hybrid cars).
Life time (usage) product distribution (determining the distribution of EoL products over
time) driven by consumer behaviour (e.g. shifting trends from mobile phones to PDA/
smart phones).
Disposal behaviour, including consumer hoarding of old unused products (e.g. mobile
phones).
134
tem of design, collection, sorting, and processing that determines the performance of a
products recycling. A Product-Centric view of
recycling integrates all policy issues and legislation around products and their recycling.
Very importantly, it optimizes recycling, considering processes (and economics) for more
than one Carrier Metal, thus optimizing the
recovery of several metals (alloys and compounds) from complex products. To illustrate
the nature of this view, Figure 48 shows the
link between metals for a relatively simple
product: galvanized steel (about 50% of all
zinc is used for galvanizing, where it protects
steel from corrosion).
Taking a Product-Centric view of recycling
in the way described above is a form of systems thinking considering all factors that
affect a systems outcome, in an attempt to
improve this outcome. Recycling is a system,
or rather for complex recycled sources a
mesh of related systems. Optimization of this
system is best started from a Product-Centric view as this links the product designs
complex mineralogy to the recycling outcome. The Material (& Metal)-Centric thermodynamic and economic knowledge of the
processes involved is also taken into account
by this system.
Conceptualizing recycling in this way is helpful for all decision-makers involved in recycling, in industry as well as in the public sector. It helps them understand what actions
will affect recycling, and that changes to one
part of the recycling system (e.g. collection
volumes or the mixing of different product
categories) without consideration of the other
parts of the cycle may not have the desired
effect. Considering the full industrial system
of which recycling is a part, also helps private
and public decision-makers in understanding the important role of recycling for shaping
a global sustainable future. A better appreciation of how recycling can provide some of
the scarce materials needed for sustainability-enabling infrastructure and products, and
of how it can significantly reduce fossil-fuel
use, will provide the recycling and metallur135
Identification and separation of metal-containing components, though complex products with complex material linkages may
make this superfluous and impossible.
Table 19:
Not relevant
State-of-the-art at high recovery rates
A table of
challenges in
separation still
required in WEEE
recycling.
Fe
Al
Mg Cu
Ni
Ag Au Pd Ru Sb Ga Ge
In
Co REE Ta
Increasing overall
collection rate
Alloy-specific sorting
technologies
New liberation
technologies
Identifying metal
containing components
Separating metal
containing components
New concentration
technologies
Final-recovery
processesa
a) Even after mixed waste disposal metals can be covered in other waste treatment facilities.
136
Be
Te
Nb
Sn
The main separation tool for extracting aluminium from Municipal Solid Waste, the
Eddy Current machine, is increasingly (re-)
designed for extracting non-ferrous metals from specific-size grains in incinerator
bottom ash. This should result in higher
aluminium extraction levels within the fine
fraction (<5 mm). Further development of
sensor-ejector sorting systems will also
improve yield.
137
5.3.1 Collection
Increasing collection and pre-sorting of postconsumer and industrial waste is a key way
of improving recycling. Collection that produces technically and economically viable
processing streams is a prerequisite for high
returns from the rest of the process. Mixing
Box 14:
Table 20:
The benefits
of recycling
(International
Aluminium
Institute and
Brazilian
Association of
Aluminium www.
abal.org.br).
Environmental
Reduces the consumption of raw materials such as bauxite and alloying elements.
The world average of recycling aluminium is 27%; with the highest figure for the United
Kingdom (57.3%) (Figure 55). However, when considering only aluminium beverage cans,
Brazil has been the leader for ten consecutive years (Figure 56).
138
Box 14:_b
UK
Italy
Spain
Figure 55:
Ratio of scrap
recovered
and domestic
consumption
(%) 2009 (The
Aluminium
Association www.
abal.org.br).
USA
Brazil
South Korea
Germany
Japan
Canada
France
World Average
China
0
10
20
30
40
50
[%]
Figure 56:
Recycling rates
for beverage
cans (Sources:
Brazilian
Aluminium
Association,
ABAL, who
collected data
from: Brazilian
Association of
Highly Recyclable
Cans, The Japan
Aluminium
Can Recycling
Association,
Camara
Argentina de
la Industria
del Aluminio y
Metales Afines,
The Aluminium
Association,
and European
Aluminium
Association).
139
Argentina
Brazil
EU
USA
Unit: %
Japan
100
80
60
40
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
Aluminium cans are important in recycling because they have a high volume and a much
shorter life cycle than other aluminium products. In 2010, with a recycling rate of 97.6%,
Brazil again beat the world record with 239,100 tonnes of scrap cans (17.7 billion units,
48,500,000 cans/day, two million/hour). Currently, it takes about 30 days to buy, use, collect, recycle, remanufacture, refill and return an aluminium beverage can to the shelves.
The efforts of the recycling chain manufacturers, bottlers, cooperatives and recyclers
and the Government, and public awareness, have made the can recycling programme into
a successful experience with great social, economic and environmental impact.
140
The most important factors for enhancing recycling behaviour are convenience and
awareness of where and how to recycle. Inhibiting factors are an emotional attachment
to the old products. Making the consumer
aware of the opportunities of recycling, and
changing his mindset and disposal habits are
the true keys to any successful programme.
Again, consumer education is of vital importance.
Different cultures offer different opportunities. Recycling is a global theme that needs
local execution, appropriate to existing cultural norms. Different ways of communicating, providing incentives and motivating consumers, are effective in different countries.
Figure 57:
Features
affecting
consumer
recycling
behaviour
(Mkel, 2011).
Box 15:
141
142
Figure 59:
Product-Centric
recycling of
EoL goods with
a networked
structure of
technologies for
dealing with the
various streams.
This Figure shows
the complex
network of
technologies that
can be applied to
manage resource
efficiency.
(van Schaik and
Reuter, 2004a;
2004b; 2007;
2010a; 2010b;
van Schaik and
Reuter, 2012;
van Schaik, 2011;
Reuter et al.,
2005; Reuter,
2009; Ignatenko
et al., 2008).
Input
Density
Separation
Heavy
Magnetic
Separation
NF Mix
Ferrous Metals
Silica
EoL
Goods
Grinding/
Screening
Rubber
Plastics
Eddy Current/
Heavy Medium
Separation (HMS)
NF Metals
Air
Separation
Silica
Plastics
Density
Separation
Mechanical
Sorting
e.g. Car,
WEEE
Thermal
Processing
Cement Kiln
Mixer
(Blending)
Plastics
Concentrate
Mixer
(Blending)
Silica
Concentrate
Mixer
(Blending)
Waste to
Incineration
Plant
Mixer
(Blending)
Waste to
Landfill
Mixer
(Blending)
Copper
Production/
Recycling
Copper Alloy
Mixer
(Blending)
Metallic Zinc
Recycling
Zinc Alloy
Mixer
(Blending)
Magnesium
Recycling
Magnesium
Alloy
Mixer
(Blending)
Aluminium
Recycling
Cast
Aluminium
Alloy
Mixer
(Blending)
Steel
Converting
Steel
Alloy
Flue Dust
Slag
Building
Material
Non-Chloride Plastics
Chloride Plastics
Fluff
Dust
Glass
NF Metals
Cars
(In-)organics processing
Landfill
Fluff
Ferrous Metals
Plastics
NF Mix
Secondary metallurgy
Thermal treatment
Mixer
(Blending)
Light
Dismantling
Dismantled Cars
Non-Metals
Shredding/
Air Suction
Eddy
Current
Light
NF
Eddy
Current
Heavy
Cu-Rich
Heavy NF Metals
Color Sorting
Zn-Rich
Light NF Metals
Non-Metals
Magnetic
Separation
NF Mix
Eddy
Current
China
India
Others
NF Metals
Waste
Cu-Rich
Zn-Rich
Mg-Rich
Al-Rich
Ferrous Metals
Waste
Heavy NF Metals
HMS
HMS
Light NF Metals
Mg-Rich
Al-Rich
Primary
Metallurgy
Electrolytic
Copper
Electrolytic
Zinc
Magnesium
Electrolysis
Aluminium
Electrolysis
143
Blending
Physical separation
Silicon
Production
(Submerged arc)
Pig Iron
(Blast
Furnace)
By extrapolating past trends, we can predict that future products will have a different composition from current products, and
that new uses will be found for metals. This
will lead to a surge in the use of certain valuable elements that, with time, will arrive in
the waste stream. However, it is hard to predict which of these elements will arrive, and
thus which types of metallurgical expertise
will be most needed in future. Lessons might
be learnt from the recent situation with REE,
where much expertise was lost worldwide,
holding back recycling. Once such metallurgical know-how is lost within a sector or region, it is usually very hard to recover it, so
maintaining a broad infrastructure of expertise within industry may be prudent.
144
Figure 60:
A key message
concerning
Product-Centric
recycling:
Product design
must be linked
to liberation,
separation
efficiency, and
quality of both
recyclate and
of final output
streams,
based on the
thermodynamic
limits of recycling
(Reuter et al.,
2005; Reuter
and van Schaik,
2008, 2012a&b;
van Schaik and
Reuter, 2012).
145
Dismantling
Shredding
Physical separation/sorting
Imperfect
separation
Recyclate 1
Design determines connections
Imperfect
liberation
Recyclate 2
Furnace smelting
technology
Alkali metals
Alkaline metals
Transition metals
Recyclate 3
ly
ain
fga
f
to o
Main
ly to
s
Mainly to slag
Can report to
metal, slag and
flue dust as a
function of
operation
lag
Main
ly to
copp
e
146
cycled metal on offer. These are not technical but marketing issues, which nevertheless
influence the success of recycling. Designers
can help to create markets by being willing to
take up suitable recycled material.
Figure 61:
LCA of a personal
computer (Choi et
al., 2006).
147
An further benefit comes from including information on recycling BAT in the LCA. This
can help producers to understand the positive impact of recycling and what opportunities this presents for their brand. For instance, Figure 61 shows the LCA of a personal computer, which traditionally was based
on a standard impact of one metal. Though
this is helpful, it cannot show how different
recycling processes for a product will affect
the products sustainability. Discussion with
recyclers will enhance a standard LCA, showing how a different arrangement of components within a product for aiding recyclability
can improve a products environmental performance. Equally, for the LCA to show how
using recycled metal in a product improves
its sustainability, it needs data on the environmental impact of recycled, rather than
primary, metal, again sourced from recyclers.
ADP
Eut
Acid
POCP
GWP
HT
ODP
ET
Pre-manufacture
Manufacture
Distribution
Use
Disposal
0%
20 %
40 %
60 %
80 %
100 %
Figure 62:
All functions in
a company play
an important
role in Life Cycle
Management
(adapted from
UNEP, 2007a).
Life-cycle-based
environmental policy
and product strategy
Green
distribution
Management
Product
developement
Distribution
Life-cycle
management
Procurement
Green
procurement
Sales and
marketing
Production
Cleaner production
be successful for companies, different departments need to work closely together for
considering the sustainability aspects (UNEP,
2007a). For example, product designers benefit from cooperating with engineers, to ensure that the design is compatible with the
metallurgy they seek to apply.
148
Green
marketing
Figure 63:
Life-cycle
management
within ALCAN,
engaging and
collaborating with
stakeholders in
the value chain
(Balkau and
Sonnemann,
2010).
ASSET*
Life Cycle
Thinking
Support
Businesses
Supply Chain
Cooperation
Product
Stewardship
* ASSET (Alcan Sustainability Stewardship Evaluation Tool) is a trademark of Alcan Inc. and/or its affiliates, patent pending.
149
Box 16:
Steps by the aluminium industry for recycling non-ferrous materials from Municipal
Solid Waste (MSW)
The aluminium industry, acting together, could increase recycling from MSW through:
Encouraging use of de-metallized recycled bottom ash as a raw material for road construction, cement making, etc. Today, standards and/or specifications differ strongly between countries and even cities. One way to open up new markets is to achieve greater
harmonization in these standards for creating larger international markets.
Developing and promoting sampling and testing methods for untreated bottom ash
from Waste-to-Energy plants and bottom-ash processors. This will clarify the benefits
of non-ferrous metals extraction and/or of optimizing the whole plant.
150
6. Tools to Aid
Decision Making
Chapter 6 provides an outline of some of the
best tools for helping decision-making in
the recycling field. These include the Metal-Wheel, Grade Curves, Liberation Performance modelling, Systems Engineering modelling, Economic Outcomes modelling, Design for Resource Efficiency modelling, Life
Cycle Assessment modelling, and Design for
Sustainability modelling. These models condense and describe technical and scientific
information, providing user-friendly predictions of results. This helps recycling stakeholders in visualizing the complex aspects of
recycling on a technical and economic basis,
and to translate the results into simple facts,
as well as helping industry and policy-makers to improve the recycling system.
Finding ways for optimizing recycling as a
system is much easier with the development of several specific tools, as discussed
in Chapter 5, some of which help in understanding the thermodynamic drivers of recycling. Detailed models provide specific estimates of how changes in design, collection or
processing, will alter economic and environmental recycling results.
152
to Metal phase
Elements that have
distributed among the
metal phase as a solid or
liquid metal
to Slag phase
Elements that have
distributed among the slag
phase as oxide
to Gas phase
Elements that have
evaporated and distributed
among the gas phase
Recoverable element
(as pure metal)
Alloying element
Bi
Sb
Sn
Pu
Ge
Ag
Tl
Na
Zn
Ni
Mg
Sr
Mn
Cu
Fe
Al
Si
Hg
Ca
La
Ce
Cd
Gd
Zr
Y
Zn
Li
Yb
Hg
Pt
Au
Pd
Ni
W
Ag
Sn
Cu
Fe
Bi
In
Cr
Pb
Ga
Mn
Al
Zn
Mg
Bi
Pb
In
Li
(Remel5ng)
Sb
Sr
Yb
Ag
Ca
(Blast
furnace)
Ga
W
Al
Mn
Sn
As
Pt
Be
Cu
Ge
Dy
Si
Cr
Au
Fe
Pd
Ni
Cr
Ho
(Remel5ng)
Sn
Ti
Fe
Au
Gd
Co
Pd
Cu
Al
V
B
Ni
Ag
In
Ga
Mn
(ISP)
Ce
U
Mg
Bi
Y
Pb
Zr
La
Mo
Nb
W
Ir
Zn
Ca
Mg
Ta
(Converter)
(BOF,EAF)
Pt
Sr
Zn
W
La
Hg
B
Al
Ce
Al
Pb
Mn
Cr
Sr
U
Re
Mg
Cr
Zr
Fe
Ga
Ag
Ti
Ge
Mn
Ni
Ta
Fe
Si
V
In
B
Sn
Nb
Cu
Rh
Sb
Pt
Pd
Cu
Pb
Zn
Sn
Bi
Co
Ag
Cd
Mo
W
Ni
Au
Hg
Se
Te
Hg
Mg
Mg
Pb
Al
Zn&Pb
Cu
Fe
to
MDeoxidation
etal
phase
agents
Elements
that
have
distributed
among
the
metal
phase
as
a
solid
or
liquid
metal
to
Slag
phase
Elements
that
have
distributed
among
the
slag
phase
as
oxide
to
Gas
phase
Elements
that
have
evaporated
and
distributed
among
the
gas
phase
.
Recoverable
element
(as
pure
metal)
Alloying
element
DeoxidaPon
agents
Figure B3
Box 17:
153
Economic Outcomes.
These engineering- and industry-friendly simulation models define and provide the
essential metrics for measuring, controlling and improving recycling. They also help
determining recycling concepts as well as
facilitating product design for high recycling and energy-recovery rates while advising policy makers. The distinguishing factor
of these multi-level models is their basis on
the physics behind recycling systems. Reuter
(2011a) discussed several of these commercially available tools.
Such multi-level dynamic-simulation models reproduce recycling rates quite accurately as they consider all metallurgical interactions, as suggested by a Product-Centric view
of recycling. Appendix E: Models and Simulation in Recycling provides a more in depth description of the application of some of these
models.
In addition, advanced tools such as computational fluid dynamics (Figure 138, Section 13.11, Appendix F: Physics of Extractive
Mettallurgy) and similar tools help optimizing processes within reactors to improve resource efficiency.
6.2.1 Liberation performance
Even in the field of classic mineral processing, it is difficult to model the liberation of
multi-component materials (WEEE products). The breakage and liberation behaviour
of consumer products fundamentally differs from that of natural ores (Richard et al.,
2005), indicating that a different approach is
required for predicting the liberation behaviour and hence recyclate quality of consumer products (van Schaik and Reuter,
2004a; 2007; van Schaik and Reuter, 2012).
In addition, the dispersion of critical, scarce
and/or toxic elements over the various output streams, caused by imperfect liberation,
separation and design choices, drives the
need for improvements in recycling-system
performance and for closing material loops.
The complex and unusual mix of material
properties in many modern products requires
some heuristic rules in support of the modelling of liberation behaviour, and for predicting
the particle and recyclate composition after
shredding. Based on such derived heuristics,
trained fuzzy sets can capture these aspects
(van Schaik and Reuter, 2010a; 2007), linking
product-design characteristics and liberation
behaviour in terms of:
154
Design tables (input definitions for recycling) that define the mass and material connections derived from the design in
real-time.
This can predict the distributed and timechanging recycling and recovery rates for the
materials in the product, and the particulate
properties, particle-size distributions and recyclate qualities.
In summary, complex particulate recycling
systems, as governed by product design, are
described on a physics basis that enables
practical calibration of the parameters. This
highlights the influence of design on recyclate quality, and on recovery and/or loss of
materials. This highly detailed approach is
critical for pinpointing design deficiencies
and possibilities related to recycling performance (both sorting and metallurgical recovery), to improve resource recovery from products such as e-waste.
6.2.2 Modelling on based on the physics of
processing systems system engineering
Liberation models can be linked to modelling
the thermodynamics of processing systems.
For more precision, rigorous metallurgicalprocess flowsheeting can be linked to environmental software for producing a specific
BAT for metal production, rather than relying
on the usual averages from LCA software.
This enables calculating and predicting the
dynamically changing recycling and recovery
rates of complex waste streams or individual
products. These can cover all individual materials in such products for different recycling
scenarios and objectives, such as maximum
total recycling/recovery, maximum recycling
of metals, minimum waste production, legislative constraints, etc., as a function of input.
In turn, this allows:
155
The amount of fossil fuels used also determines the environmental impact of any recy-
cling system. The same applies to any metalproduction facility, as each has its own technology. Where impact studies of metal use in
many cases are based on average environmental data, a BAT life-cycle inventory (LCI)
database of different technologies should be
available. New technology increasingly replaces old one, as the metallurgical and recycling industry constantly reduces its footprint.
Box 18:
Physics-based simulators
Environmental performance can be visualized with state-of-the-art process simulators,
linking them in real-time to environmental impact software for flowsheeting, simulation
and thermodynamic modelling, such as Linking HSC Sim (HSC Chemistry 7, 19742011),
or Outotec with the GaBi LCA tool for benchmarking process designs (GaBi 4, 19892009;
PE-International). Not only does this approach show the difference between BAT and nonBAT operators, but it also links GaBi to HSC Sim for 25,000 compounds in the database.
This gives a more accurate view of which compounds occur in the system, and better evaluates the quality and toxicology of most metal compounds in the system streams.
156
Figure 65:
Water cycle
connected to
metal and sludge
processing,
showing that
recycling is
not linear but
complexly
interlinked (van
Schaik and
Reuter, 2010b;
Fagan et al.,
2010).
157
Zinc
Stainless steels
Pt-family alloys
Magnesium
Lead
Copper
Input streams
Aluminium (wrought)
Aluminium (cast)
wiring
windows
tires
seats
rubbers
others
lights
wheels
grille
gear box
fuel tank
exhaust
engine
electronics
bumper
body
Compatibility
matrix for
materials in a
car, showing
compatible and
incompatible
metals in terms
of recovery
(Castro et al.,
2004, 2005;
Reuter et al.,
2005).
battery
Table 21:
Aluminium (cast)
Aluminium (wrought)
Copper alloys
Lead alloys
Magnesium alloys
Pt-family alloys
Stainless steels
Steel + Cast Iron
Zinc alloys
Glass
Elastomers
Natural Fibers
Natural Rubber
Porcelain
Thermosets
Thermoplastics
158
Figure 66:
Linking design
with sophisticated
recycling tools
drives innovation
and improves
resource
efficiency through
DfR for the
SuperLightCar
project (Goede
et al., 2008;
SuperLightCar,
20052009).
Life Cycle
Assessment
Cost Analysis
Feedback to Designer
Recycling Rate
Recyclability optimized as a function of technology, economics, material recycling and energy recovery.
159
Evaluation of the environmental impact associated with these inputs and outputs.
,
Box 19:
Figure 67:
LCA visualization
of the
SuperLightCar
concept (Goede et
al., 2008; Krinke
et al., 2009).
high
20 %
/kg
0
low
Advanced
Steel
high
Steel Body
(today)
Production Costs []
Aluminium
-20 %
-40 %
MultiMaterial
Design
Advanced
Light
/kg
Advanced
FRP
FRP
-60 %
-80 %
160
Box 19: _b
Reference
SLC-BIW
Production
Use-Phase
End-of-Life
Complete Life Cycle
-2000
-1000
1000
2000
3000
4000
5000
6000
a Midpoints in the causeeffect chain (environmental mechanism) of a particular impact category lie somewhere between stressor and endpoint.
161
use phase
Steel BIW
CFRP BIW
km
200,000
150,000
100,000
50,000
50
100
150
200
250
300
Ecopoints
steel
production
end-of-life
cfrp
production
end-of-life
28
71
21
151
162
In conclusion, while Design for Recycling enables high recycling rates, Design for Sustainability focuses on more than just one issue and is better suited for improving the
overall sustainability performance of a product. Such tradesoffs with regard to various is-
163
Standard deviation values of the composition of each metal, alloy, compound, and of
total flow rates.
164
165
Figure 69:
Rough costbreakdown for a
typical shredder,
where manual
dismantling
contributes up to
80% of the ELV
recyclate (Ferro
and Amaral,
2006).
166
less toxic lead will escape into the environment at the end of product life. One of the elements planned to be used as a substitute
for lead was bismuth. The policy was effective
at removing lead, but caused an inadvertent
reduction (rather than increase) in bismuth
production as bismuth and lead are mined
and produced together, and lead production
had decreased due to the lower demand.
Establishing weight-based product-recycling
rates for all individual trace- and critical elements is impossible, hence policy should
focus instead on well developed BAT Carrier Metal-recovery systems. The critical elements will then be recovered if there is an
economic reason for doing so.
A prime factor for investment is the security
of its future economic rate of return, helped
by knowledge of secure material streams of
known composition. Stability in government
policy affects the economics of recycling, and
timely announcements of any future policy
changes will help investment. Creating supply security for investors also implies stimulating collection and preventing illegal outflows such as theft.
167
168
Public authorities, and related public bodies like health providers, are both significant
generators of waste and product buyers. In
the former capacity, authorities with good
waste-separation policies can have a significant influence on recycling potential, and,
through public procurement processes, they
may boost the market for products containing
recycled materials, thus supporting recycling.
Green public procurement should also provide guidance for end-of-life, ensuring that
public devices find their way into a certified
recycling chain.
Table 22:
Possible
approaches
to EPR and
examples (OECD,
2001).
169
Examples
Mandatory take-back
Voluntary or negotiated take-back programmes
Regulatory approaches
Economic instruments
Depositrefund schemes
Advance recycling fees
Fees on disposal
Material taxes and subsidies
Box 20:
member countries, an issue now being tackled by a legislative revision (European Commission 2008 Questions and answers on
the revised directive on waste electrical and
electronic equipment (WEEE) Press release MEMO/08/764 http://europa.eu/rapid/press-release_MEMO-08-764_en.htm).
Only the best performing European countries,
which had started to implement WEEE management policies before the EU WEEE Directive came into force, now achieve collection
rates higher than 80% of waste generated.
170
Figure 70:
Schematic
explanation of
the stakeholder's
obligations
according to
Swiss WEEE
legislation ORDEE
(Widmer et al.,
2008).
Consumer
Obligation to return
Obligation to dispose of
Recycler
Exporter
In the USA, Canada and Australia, implementation of the EPR mechanism by industry is voluntary, but emphasis is put on the
fact that the responsibility is shared between
the producer, the packaging manufacturer, consumer and the retailer. Current takeback initiatives either have come in late or
are not comprehensive enough (Ongondo et
al., 2011). Probably the biggest issue is that
current take-back systems often only cover a
few products and ignore the comprehensive
Product-Centric aspects of recycling.
Emerging economies and developing countries generally face very different challenges
to OECD countries. Their challenges highlight
the main issues related to the implementation of take-back systems, such as defining
responsibilities, securing financing, setting
up the logistics, ensuring compliance, and
restricting monopolies (Sinha-Khetriwa et al.
2009). However, the general goals of e-waste
management need not differ from the EPR
approaches taken in OECD countries. Experience from the latter and cooperation initiatives in developing and emerging economies
countries have shown that a few overarching
principles should be followed for the implementation of successful take-back systems
(Widmer et al., 2008). These include:
171
participate in collecting WEEE (and if necessary fees) from consumers. The relevant
government bodies ensure a workable legal framework. Recyclers recycle or otherwise dispose of discarded equipment in
an environmentally sound way, using the
best available technique and users return
end-of-life equipment to dedicated collection centres.
Operational Simplicity: The system is convenient for all stakeholders. Most importantly, consumers can return any used
EEE free of charge to retail stores, collection points, and/or manufacturers. The
system allows for an easy and low-cost
administration.
Enforced Accountability: Independent external auditors and regular checks ensure that the system is transparent and
competitive. Well-defined roles, rules and
standards prevent any misunderstandings.
The EUs ELV legislation successfully stimulated several partnerships. In order to meet
recycling targets, car maker VW formed a
partnership with metal-processing specialists Si-Con, and French manufacturer Renault set up a joint venture with waste specialist SITA and the car recycling specialist
INDRA Investissement.
Figure 71:
A Material
(&Metal)Centric view of
recycling: Linear
and sequential
representation of
recycling for noncomplex metal
applications
such as in
construction,
packaging etc.
(UNEP, 2011b).
This recyclingrate definition is
one-dimensional
and lacks the
required nonlinear predictive
qualities for
successfully
driving a
recycling system.
172
Metal A
WM&R
Prod
Prod
(a)
(b)
Fab
(c)
Mfg
Use
Coll
(d)
Stock
(e)
(h)
(n)
(m)
(j)
Scrap
market
(g)
Rec
(o)
(f)
g:
h:
j:
m:
n:
o:
Rec
Metal B
WM&R
Prod
Fab
Mfg
Use
Coll
Stock
Scrap
market
Rec
173
However, for the strategic elements in complex product mixtures, the thermodynamics
and physics of separation often are so complex due to complex linkages and interactions that it is almost impossible to define
realistic recycling rates. Also, the dynamically changing use of individual elements in
specific applications (such as Ga, REE and W
needed to provide lighting) may complicate
things even further.
In summary, economic targets for the BAT
chain as a whole should focus on maximizing resource efficiency, and should be based
on understanding the physical properties and
destination of all materials.
7.5.3 Information tools and eco-labelling
Consumers can affect recycling rates through
their choice of products and disposal behaviour. This works well when they have effective information tools that provide them with
facts they can act on, such as labelling, which
is one of the simplest tools though making
it truly effective requires expertise. By labelling a product as recyclable, or as containing
recycled materials, consumers can choose
products that promote recycling. The producers must be careful not to create a recycling
expectance, as the absence of a recycling infrastructure for capturing EoL goods might
be perceived by consumers as green washing. However, when product manufacturers can source their materials from BAT recycling with its environmental benefits, they
may well be rewarded by higher profits from
consumers. Eco-Labelling is also useful for
separating goods for recycling, for example,
advising consumers not to discard WEEE in
domestic waste.
Eco-Labelling is most effective when used in
connection with other information tools, raising awareness about recycling benefits and
opportunities. The example of recycling mobile phones illustrates that, the more convenient such opportunities are, the more likely
people are to recycle them.
Many labelling schemes were set up by nongovernmental organizations. Policy is not
necessarily required for a successful label,
but it can be helpful for creating trust in a
label. Government can play a useful role in
bringing stakeholders together to agree on
design and meaning of the label. Government
Recovery of critical metals such as indium from small home appliances (mobile
phones, digital cameras, portable gaming
machines, MP3s, pads, etc.).
174
Japan has started to explore a systems approach for Rare-Metals recycling. Though
difficult to collect, small home appliances
(SHA) are known to contain high concentrations of critical metals. The relevant Japanese ministries jointly carried out a pilot project for SHA collection and technology R&D
for metal recovery from SHAs. The project
showed that the whole system of collection,
dismantling/separation, and material recovery, is financially feasible as a whole, but that
the collection stage was not financially viable by itself. Considering this, the Japanese
government started discussions for implementing a recycling scheme for these SHAs
in a working group under the central environmental council.
7.6.2 China
In China, a set of policies supporting the
whole system is being established for recyclable resources. This includes a tax preference for the recycling of waste materials to
reduce the operating costs of recycling. China
has promulgated The Circular Economy Promotion Law to promote the resource recycling; see also section 3.1.1.1 of this report.
Policy steps have included the creation of
suitable government units and, in recent
years, the central government also promoted
City Mineral Pilot Units. China has promulgated Regulations for the Administration
of recycling and Treatment of Waste Electrical and Electronic Equipment that govern
the whole cycle of product design, materials
use, collection, dismantling and treatment.
The Regulations also set up a recycling fund
for subsidizing the processing cost of WEEE,
funded by manufacturers and importers, and
thus, indirectly, by consumers.
This fund is used for steering WEEE flow to
regular enterprises rather than illegal recyclers, thus improving human safety and environmental protection. From June 2009 to
June 2010, China built more than one hundred regulated enterprises pre-processing
WEEE. Since then, over 600 million computers, refrigerators, TVs, air conditioners,
washing machines and other waste were collected and treated mechanically. However,
the informal sector still manually dismantles
WEEE in parts of China, such as Guiyu Town,
Shantou City and Taizhou City. Often, such
waste is illegally imported into China, where
these informal processes cause serious
health problems and environmental pollution.
Local governments find it hard to close this
illegal dismantling, particularly as part of this
activity is moving to more remote areas.
7.6.3 European Union (EC1 to EC9 and
European Commission)
The European Union has several policies that
relate to raw materials and recycling. The
Waste Framework Directive includes, among
others, the Battery Directive, End of Life Vehicle Directive and the WEEE Directive. It is implemented and relates to specific legislation
concerning waste handling and treatment.
Recently, the European Union developed the
Raw Materials Initiative, a long-term strategy based on three pillars: 1) Ensuring a level
playing field in access to resources in third
countries, 2) Fostering a sustainable supply of raw materials from European sources,
and 3) Boosting resource efficiency and promoting recycling. Fourteen critical (groups
of) materials are identified: antimony, beryllium, cobalt, fluorspar, gallium, germanium,
graphite, indium, magnesium, niobium, platinum group metals, rare earths, tantalum and
tungsten. The Directive also includes actions
in the areas of diplomacy, trade and development, and R&D, among others, via the European Innovation Partnership on Raw Materials, Resource Efficiency and Recycling. The
EU Strategic Energy Technologies plan is also
relevant, as it includes materials for energy technologies. In addition, many European
countries also have their own policies on resources and recycling.
175
176
The infrastructure and expertise for processing waste into recycled metal is often
the same as that for primary metal production. Therefore, the health of primary
production in a mining region is of vital importance for recycling goals, fostering the
required metallurgical systems knowledge.
This balance will also help mitigating any
cyclical disturbances affecting the primary-metals industry.
Computer-based-modelling of the recycling performance of products helps guiding product design that facilitates more
recycling. It should be based on the realities of how products and their constituents
break up and separate in BAT recycling
processes.
177
A certified BAT recycling processing infrastructure, supported by metallurgical expertise, will operate by itself for maximizing the recovery of all valuable elements
it receives, optimizing tradeoffs between
quality and volume of metals in the output.
Though the economic incentives usually
already exist to do this, BAT is frequently not in place, thus harming resource
efficiency.
Policy can improve results if it focuses on
promoting the adoption of BAT along the
material and metal chain. It can provide
the framework and innovative business
models that lead to adopting BAT in recycling systems, which can include help for
offsetting losses from parts of the treatment process for EoL products.
178
Product design strongly affects the physical properties of the waste stream, as do
collection methods. Optimal recycling can
therefore only succeed through increased
physics-based Design for Recycling (DfR)
or Design for Sustainability (DfS), which is
better covered by the term Design for Resource Efficiency that is more economics
based with links to Product-Centric recycling. Here, product design is based on, or
at least cognisant of, the limitations of the
recycling BAT (as concisely reflected by
the Metal Wheel). To achieve optimal designs for recycling and recycling systems
demands good understanding of the limits
imposed by physics, chemistry, thermodynamics and kinetics, as well as the technological, economic and social barriers
and inefficiencies encountered. However,
functionality demands mean that this may
not be possible, dictating that certain metals and materials must be combined, rendering Design for Recycling inefficient and
pushing Design for Resource Efficiency
into the place of systemic driving force.
Design for Recycling comes out of a design perspective that looks at the impact of products over their life cycle,
(LCM), and policy has a key role in assisting in the adoption of LCM by product
manufacturers.
179
The use of material-based recycling-performance output metrics (mass, or a percentage of a single metal within a waste
stream) can be counterproductive, as it
may ignore the complexity of recycling
and its inherent tradeoffs between the
different recycled-metal outputs from
mixed waste streams. If used, they may
cause the wastage of valuable metals; for
example, a system focused on increasing recycled iron output is likely to lose the
valuable and scarce metals shown in red
in the Metal Wheel. This is particularly the
case for more complex waste streams that
have a large diversity of rapidly changing compositions, as either product mix or
product composition changes.
tors for rendering them more ProductCentric (with an economic basis). Better
results are achieved where this practice is
complemented by indicators that better illustrate quality and range of metals resulting from recycling.
The economic value produced by BAT processes should be considered as a performance indicator. This would be the opposite of a mandated performance target to be achieved by industry. It would on
the contrary be an indication whether the
policy and industry have successfully created the conditions and incentive structures that facilitate high performance. This
would require policy actions across the
system to overcome the bottlenecks that
currently hold back optimized recycling.
180
This may be a change for some policy regimes. It certainly has implications for
how policy is set. Policy makers will have
to take into account the economics of the
system, the motivations of designers, innovators and collectors, forging a set of
policies that deliver the above mentioned
conditions.
8. Appendix A: Details
on Recovery of Metals
from Recyclates
This appendix provides an overview of the
technologies used in metallurgical recovery
of metals from recyclates and residues, ranging from steel to PWBs as well as TVs and
other WEEE.
181
processing each frame by the computer. After processing and identification, for instance
based on colour, the computer can activate
air valves that shoot identified particles into
collection bins.
Alternatively, a detector can consist of a
transmitting coil, a U-shaped copper rod
with pairs of receiving coils in the middle of a
transmitter, or an XRT/XRF-device (Owada et
al., 2011; Titech, 2012). This type of machine
can detect over 99% of all metal particles
larger than 4 mm in an input stream and, depending on the settings, 95% to 98% of the
metal will be removed. An electrical signal
produced by receiver coils can also be processed in different ways to determine metals
from non-metallic materials. The difference
between stainless steel and non-ferrous metals can also be determined.
8.1.3 Eddy Current separators
Another form of sorting uses a magnetic field
for separating materials that move off a conveyor into a magnetic field. In these Eddy
Current' separators (Figure 73), particles P1
and P2 have different trajectories because of
different rates of acceleration in the magnetic field. This variation is caused by the difference in conductivity of the metals, hence
creating stronger magnetic fields, or, more
precisely, conductivity divided by density
separates conductive lighter alloys (Al) from
heavier alloys (Cu).
For example, at low frequencies of a changing magnetic field, the acceleration of an aluminium particle will be twice as much as that
of a copper particle with the same dimensions. Poorly conducting materials, such as
lead and stainless steel, will respond with
a low acceleration to a changing magnetic
field, whereas non-conductors, such as glass
and plastics, will be accelerated at all by the
magnetic field. Both permanent magnets or
an electromagnet can generate the magnetic field.
Figure 73:
Eddy Current
physics: light grey
highly conductive
and light, white
non-conductive,
and black slightly
magnetic.
Magnetic field
strength, rotation
speed, and
positioning of
the two splitters,
among others,
determine
recyclate purity
(from HSC Sim
19742013).
Figure 74:
Rising-current
separator using
a rising water
flow in a column
to recover a light
floating fraction
from a feed
also containing
heavy material
that drops to the
bottom of the
water column.
182
183
8.1.6 Jigging
Jigging is one of the oldest methods of sinkfloat separation. In a piece of equipment
called a jig, input material is formed into a
thick layer (or bed). This is fluidized by pulsating a water current through it. On pulsation the bed of input material is lifted as
a mass; then, as the velocity of the waterstream decreases, the particles fall with different speeds to the bottom, depending on
their density. When this process is repeated,
the different materials will stratify in relation
to their density, and can be recovered accordingly.
This method is very similar to the rising-current separation process, but here the water
jet is projected through the screen in pulses. Jigging is used for separating shredded
metals and particularly plastics from metals.
The magnitude and direction of the water-jet
force can be varied to change the separation
result. A jig is generally used for concentrating relatively coarse materials down to 3 mm.
When the feed is fairly similar in size, it is not
difficult to achieve a good separation at low
cost.
Figure 76:
The heavymedium
separator
separates feed
into a heavy
fraction that sinks
to the bottom of
a rotating drum
that lifts it to
the top where
it discharges
onto a conveyor
belt. The light
fraction floats on
the separating
medium (water,
FeSi slurry, etc.)
and is collected
and discharged
via the floats
conveyor belt.
Cleaning of the
float medium
creates a sludge
that has to be
processed.
184
185
Figure 78 makes clear that recycling and primary production go hand-in-hand. In some
cases, such as Tornio, the BAT ferro-chrome
smelter is next to the stainless steel smelter
and mill, producing high-grade products. The
same situation is found next to the stainless
steel smelter in Middelburg (RSA), where a
40 MW plasma ferro-chrome furnace produces liquid-charge chrome for use in the stainless-steel plant, while the AOD converter also
accepts stainless steel scrap. See also Nickel
(2012) and ICDA (2012).
Figure 78:
The technology
of stainlesssteel production
(Johnson et al.,
2008).
186
Figure 79:
Primary refined
production with
primary and
secondary/scrap
feed shown (left)
and and World
refinery and
smelting capacity
(right) (Outotec
compiled/
estimated from
e.g. Brook Hunt,
International
Copper Study
Group etc.).
Primary Production
Smelting
Secondary Production
Refining
1993
2001
1994
1995
2002
1996
2003
1997
1998
2004
1999
2000
2005
2001
2002
2006
2003
2007
2004
2005
2008
2006
2007
2009
2008
2010
2009
2010
2011
2011
0
2,500
5,000
7,500
10,000
12,500
15,000
17,500
18,000
Figure 80:
Dedicated
copper-smelting
production
(Outotec).
Reverberatory Furnace
TSL
TBRC
Non-Outotec Technologies
210 ktpa
31 %
Blast Furnace
102 ktpa
19 %
57 ktpa
8%
242 ktpa
36 %
466 ktpa
69 %
187
275 ktpa
41 %
Material
Jarosite
Goethite
ISF slag
Zn%
16.9
10
3.6
Pb%
9.9
5.2
0.5
4.9
Fe%
28.9
25
40
35.4
11.2
S%
12.5
13
0.3
2.2
SiO2%
6.1
2.5
17.8
18.3
Cu%
1.1
0.2
1.5
0.1
0.8
Cd ppm
8100
200
500
As ppm
1800
600
2000
1000
6000
Ag ppm
1800
80
80
100
Sb ppm
1700
100
10
10
500
32.2
C%
188
Neutral leach
residue
Table 24:
Average
composition of
zinc concentrates
obtained in
flotation also
showing the
mineralogical and
thermodynamic
basis for the
Metal-Wheel (see
Zn-pie) (Grant,
1993).
Figure 81:
Element
Grade [%]
Zn
53.0
32.2
Fe
7.3
Pb
1.6
Ti
1.2
Si
0.8
Cu
0.6
Ca
0.4
Mn
0.4
Cd
0.2
Mg
0.2
As
0.1
Sb
0.04
Ag
0.02
Co
0.02
In
0.02
Hg
0.01
Ge
ISF
Ausmelt TSL
7 ktpa
1%
263 ktpa
29 %
274 ktpa
31 %
1 ktpa
1%
192 ktpa
21 %
Shaft Furnance
22 ktpa
17 %
55 ktpa
42 %
32 ktpa
25 %
160 ktpa
18 %
189
Waelz Kiln
Pb Smelter + Slag Fuming
0.005
The share
of various
technologies
for processing
zinc-containing
residues
(Outotec).
Note: The data assume treatment of all
residues generated at
operations with leach
residue.
21 ktpa
16 %
Filter
cake
Cupola
furnace
Typical Zn and
Pb containing
recycled raw
materials
(Schneider et al.,
2000).
Figure 82:
Waelz kiln for the
processing of EAF
dust (Ullmanns,
2005).
(a/b) Zn containing feed
(c) Waelz rotary kiln
(picture)
(d) Burner
(e to i) Slag processing
(k to n) Oxide processing
(o) Electrofilter
(p) Waelz-oxide
transport
(r to s) Blower/Stack
190
Dust
from
copper
and
brass
industry
Dust
Cupola
furnace
EAF dust
Lead
dust
Zinc-lead
oxide
Neutral
leach
residue
Zn
31
43
31
23
44
18
Pb
20
0.1
1.3
68
15
Cu
0.2
0.1
0.4
1.6
11
0.6
0.6
0.2
FeO
10
0.6
23
35
33
SiO2
15
1.3
Cl
0.4
0.5
0.6
0.2
H2O
45
0.3
0.4
10.6
10.4
1.8
30
ZnO + CO2
Zn + CO
Zn
O+
Table 26:
Typical analyses
of the raw
materials and
products of
a Waelz kiln
(Meurer, 2010).
+C
EAF dust
Slag
Waelz oxide
FeO + C > Fe + CO
CO2 + C > 2CO
FeO + CO > Fe + CO2
Leached Waelz
oxide
Zn
1835
0.22.0
5558
6068
Pb
27
0.52
710
911
Cd
0.030.1
<0.01
0.10.2
0.10.3
0.20.5
0.10.2
0.40.7
0.080.15
15
38
0.51
11.5
2038
3050
35
47
FeO
Fe(metallic)/Fe
Basicity
191
Fe
O
8090
basic 1.54.0
acid 0.20.5
Table 27 gives some additional zinc residues and materials that can be processed to
produce metals. High-grade materials can
be remelted directly to produce brass and
bronze products.
Table 27:
Composition
of major zinc
drosses and
ashes (James,
2000).
%Zn
%Pb
%Fe
%Cl
%Al
Galvanizing dross
9294
1.01.6
13
HD galvanizing ash
6075
0.52.0
0.20.8
25
6575
0.10.5
0.20.8
0.52
0.10.5
Die-casting dross
9094
0.10.2
low
17
Sal skimmings
4570
0.52.0
0.20.8
1520
Brass fume
4065
0.57.0
12
27
Die-casting ash
5560
0.10.2
low
low
310
5565
0.11.0
0.20.8
25
Zinc dust/Overspray
9295
12
0.10.5
192
Figure 84:
Red mud
production
and inventory
(Klauber et al.,
2011a, b).
cumulative inventory
140
2500
120
100
1500
60
500
20
Various patents
for the processing
of red mud
(Klauber et al.,
2011a; 2011b).
193
-FeOOH
SiO2
Fe3O4
TiO2
1000
40
Figure 85:
-Fe2O3
2000
80
Al2O3
1990
1992
1994
1996
1998
2000
CaO
Na2O
LOl
194
195
Figure 87:
Simplified view
of a recycling
plant (including
extensive PST
processing)
where 1153 cars
were recycled,
showing a
generalized
composition
of a fluff after
extensive
treatment (Reuter
et al., 2005;
Reuter and van
Schaik, 2012a&b).
Table 28:
Composition
of ASR light
and heavy fluff
for different
operators
(Numbers in
brackets refer
to references in
Vermeulen et al.
2011).
Light
fluffa
[26]
[27]
Metals
11.7
Wire
2.93
Rubber
3.84
[30]
21
3.1
[47]
[158]
[159]
[165]
8.8
2.5
3.7
0.3
4.7
2.2
2.6
8.8
10.3
4.1
26.2
8.3
7.9
0.5
Textile
27.529.5
36.1
32.5
PUR foam
6.6.20.6
35.3
Plastic
16.124.1
11.7
46.1
11.0
Wood
0.030.4
2.7
0.6
Paper
0.81.0
0.8
6.421.6
4.3
Soil/sand
Glass
31.8
2.3
3.8
8.7
43
(minerals)
Others
2.76.2
0.8
196
5.2
69.5
75
(<10 mm)
(fines)
Table 28_b:
Heavy
fluffa
[26]
(stainless
steel + heavy)
Metals
0.21.4
Wire
[47]
1.6
7.012.7
Rubber
14.117.3
Textile
7.711.6
PUR foam
[27]
[159]
0.7
3
9.3
0.7
55
43.7
44.8
10.5
10.5
0.92.8
Plastic
23.830.9
Wood
0.060.7
Paper
12.5
Soil/sand
7.612.3
Glass
8.311.0
Others
4.614.0
3.3
8
19
32.6
29
4.7
5.6
7.8
6.1 (fines)
8 (minerals)
9.4
197
[165]
Shredder
Working time (h/year)
Total shredded scrap (t/year)
2317
69,500
ELV (%)
44%
56%
113,446
Equipment costs shredder mill, non ferrous separator, cranes, other (1/year)
374,299
110,880
39,600
39,600
7,7
44,5
46
120
250
4,1
4,1
25
ASR to landfill
4,1
198
Ferrous
0,96
0,25
199
Based on these assumptions, waste treatment in WtoE plants of the EU-27 should at
least increase by 62% (from 60 to 97 million
tonnes) between 2006 and 2020, and even by
100% in a more ambitious scenario, assuming that the remaining landfill of residual
MSW will be fully replaced by recycling and
WtoE in a ratio of 60 to 40.
8.11.3 Technological innovation will
generate higher extraction yields
The main separation tool, the Eddy Current
(EC) machine is increasingly (re-)designed
so as to extract metals from specific bottomash grain sizes. This should result in higher
aluminium extraction levels within the fine
grainsize fraction (below 5 mm). New concepts of EC machines and of alternative sorting systems (sensor-ejectors) further stimulate the race for improved yields.
In addition, major adjustments in the
flowsheets of processing plants are being applied on an industrial scale. This includes the
removal by strong magnets of all ferrous material (in addition to iron and steel) ahead of
the EC machine, segregation in two or three
grain sizes, washing of bottom ash during
classification and, last but not least, dry cooling of bottom ash instead of using a water
box. This will lead to higher extraction levels
and a higher quality of the non-ferrous metals extracted.
Box 21:
200
AEB Amsterdam
Waste-to-Energy plants (Stehlik, 2009; Mnster and Lund, 2010) do not incinerate everything. Citing from AEB Amsterdam (AEB Amsterdam, 2012) 1000 kg of waste yields approximately:
25 kg iron
Trade/Fishery
Food & Feed
173.52
103.21
17.48
42.51
Livestock
Human
43.33
53.81
Miscellancous
drainage
145.20 91.57
39.58
Fertilizer
151.32
Fertilizer
Farm/Ranch
River/
Coast area
400.52
151.32
Sludge
14.87
218.84
155.92
Chemical
substance
155.92
110.56
Phosphate
ore
110.56
16.12
Landfill
Chemical
industry
375.71
23.89
Soil
accumulation
24.36
Domestic
products
Other
industry
88.16
Products/
byproducts
22.85
156.50
201
Other mineral
resources
112.54
4.70
Steel
93.07
Slag
turning the iron-rich residues to the sintering, hot-metal desiliconization, and hot-metal dephosphorization processes, the input of
raw materials such as CaO and the genera-
80m
Fe
Solid solution of
3CaOP2O5 - 2CaOSiO2
Other phases
(mainly FeO-CaO-SiO2 )
(mass%)
(mass%)
48
Si
Ca
(mass%)
(mass%)
96
16
76
38
Figure
P3.
EPMA
mapping
image
of
a
dephosphoriza8on
slag
(FetO
=
19%,
CaO/SiO2
=
4.4,
P2O5
=
2.8%)
supplied
by
a
Japanese
steelmaking
company.
202
Box 22:
Figure 90:
Recrystallized
slags with
minerals:
(1) Primary
dicalcium silicate
(C2S),
(2) Mixture of C2S
and CaO,
(3) Iron(II) oxide
wstite,
(4) Calcium
ferrite,
(5) Free lime and
droplets of metal
iron
(Imbricated
calcium, silica
and iron carriers
in BOF steel
slag).
The search for dedicated processes with a favourable material and energy eco-balance,
considering chemistry and mineralogy, the crystallinity of the constituent phases along
with their reactivity, their cooling behaviour, and the speciation of key elements (Fe, P),
has been the challenge of the project. Moreover, very demanding international economic
and environmental issues include: increased recovery of Fe metal, reduced CO2 emissions,
improved management of stockpiled slags, less pressure on natural resources. It was
shown (Bodnan et al., 2011) that:
203
Box 22: _c
204
Successfully grinding the steel slag to <50 m is not sufficient for complete liberation
of the iron- and calcium-bearing minerals due to the small size of crystallites. The only
method, at this particle size, of providing a product sufficiently enriched in iron for recycling into steel works is wet magnetic separation, but the quantities are too small to be
of industrial interest (<5% of slags).
Eco-balance calculations confirm that combined recycling of the slag reduces CO2
emissions by several hundred thousand tonnes a year; assuming that this reduction
would in particular be justified for the cement industry.
Hardmetal scrap
Chill
Classify
Vacuum distillation
Mill and blend
205
Analyze
Table 30:
Tungsten scrap in
pyrometallurgy
(Lassner and
Schubert, 1999).
Product
Superalloys
Stellites
1, 3, 6, 9
1, 6
Menstruum WC
4, 6, 9, 11, 12
Tool steel
1, 2, 4, 7, 11, 12
Ferrotungsten
1, 2, 4, 6, 7, 11, 12
Melting base
1, 2, 3, 4, 6, 7, 8, 9, 10, 11, 12
No.
206
Scrap type
%W
High-purity W
9698
6097
9294
Tungsten copper
6090
W grinding sludge
3060
W cutting sludge
7080
6095
10
1560
11
9297
12
9297
13
5090
14
4060
99
9899
Group
Hard scrap
(solid pieces)
Soft Scarp
(fine particles, powder, dust,
timings, sludges)
Natural ore
Tin slags
Flowsheets for
the reclamation
of niobium and
tantalum from
different sources
(Habashi, 1997).
Chemical decomposition
MIBK
H2SO4
Filtration
Residues to
waste
Solvent extraction
Raffinate to
waste
Ta/Nb separation
MIBK
Ta strip solution
NH4OH
H 2O
Purified
water
NH4OH
Ta-acid
H 2O
Purified
water
Filtration
Nb-acid
Filtration
Calcination
Calcination
Ta2O5
Nb2O5
Milling, classification
Blending
207
Nb strip solution
Crystallization
K2TaF7
Milling, classification
Blending
Ta-containing
process residues
Ta2O5-containing
ores
Ta2O5 > 25 %
High-grade
tin slags
Ta2O5 > 8 %
Low-grade
tin slags
Ta2O5 > 14 %
Synthetic ores
Ta2O5 > 20 %
Recycling
Liquid
liquid extraction
Chlorination
TaCl5
K2TaF7
Ta2O5
Ta powder
Electron beam
melting
Carborizing
Sintering
TaC
Mill products
Special alloys
Chemical
industry
Electronics
208
Optics
Hard metals
209
Figure 94:
Production of
yttrium oxide
from xenotime
(McGill, 2010).
Xenotime
Digestion with sulfuric acid
Dissolution in water
Removal of iron
Filtration
RE sulfate solution
20 g REO/L
30 % DEHPA in Shellsol
4-stage
extraction
4-stage selective
wash-out
8-stage selective
wash-out
HNO3
1.5 mol/L
LaCePr(Nd) Fe2+
+ other non-RE
impurities
HNO3
6 mol/L
NdSm(GdTb)
4-stage
re-extraction
YbLu(Th)
NaOH
H2SO4
0.5 mol/L
NH3
Yttrium concentrate with
ca. 75 % Y2O3/REO
NH4NO3 6 mol/L
26-stage
extraction
6-stage
wash-out
NH4SCN
3-stage
re-extraction
RE fraction
Gd-Er
NH4NO3
1.75 mol/L
HNO3
10-3 mol/L
26-stage
extraction
Y2O3 99.999 %
Yb 2.5 ppm
Er 3 ppm
Other SE < 1ppm
210
6-stage
wash-out
8-stage
re-extraction
NH4NO3
0.5 mol/L
NH4SCN
0.1 mol/L
TmYbLu
HNO3
10-3 mol/L
Solvent
treatment
NH4SCN
211
9. Appendix B: Details
on Metals found in
WEEE
Symbol
World mine
production (t/a)
Silver
Ag
Gold
Au
Bismuth
Bi
Cobalt
Co
Copper
Cu
Palladium
Pd
Antimony
Sb
Tin
Sn
20000
2500
5600
58000
15000000
230
130000
275000
6000
300
900
11000
4500000
33
65000
90000
Demand as %
of production
30
12
16
19
30
14
50
33
World reserves
(kt)
400
47
320
6600
540000
2100
5600
Demand for
EEE (t/a)
0.008
0.0019
1736
0.001
0.045
25.5
1B
958
1C
0.0023
0.00068
0.23
956
0.0014
0.029
0.00033
0.0001
0.18
484
0.0002
0.0041
3A
0.48
0.079
0.048
0.27
159
0.03
0.19
4A
0.12
0.016
0.06
0.14
423
0.0029
0.24
0.001
0.00028
1.29
1075
0.00058
0.012
0.072
0.008
0.29
25.58
0.00059
3B
0.21
0.013
0.95
0.18
723
0.0048
3.02
0.81
4B
2.65
0.17
0.66
0.21
971
0.067
5.75
13
3C
0.52
0.2
310
0.041
0.16
0.53
4C
0.45
0.11
824
0.034
0.71
18.3
5B
0.00027
0.000025
2.76
0.000015
0.00074
0.11
2, 5A, 8
212
1A: large domestic appliances excluding cooling and freezing equipment and smaller LDA items (e.g., cookers, washing
machines); 1B: cooling and freezing appliances (e.g., refrigerators, air conditioning units); 1C: Smaller items within the large
domestic appliances (e.g., microwaves); 2: Small domestic appliances (e.g., toasters, vacuum cleaners); 3A: IT and Telecom
excluding CRTs (e.g., computers, telephones); 3B: CRT Monitors; 3C: LCD Monitors; 4A: Consumer electronics excluding CRTs
(e.g., DVD players, audio amplifiers); 4B: CRT TVs; 4C: flat panel TVs; 5A: lighting equipment luminaries; 5B: lighting equipment lamps; 6: electrical and electronic tools (e.g., drills, lawn mowers); 7: toys, leisure and sports equipment (e.g., game
consoles); 8: small domestic medical devices; 9: monitoring and control instruments (e.g., smoke detectors, thermostats)
there was no data for this category; 10: automatic dispensers.
Product
Ag
Au
Pd
Mass of
equipment [kg]
Pt
Computer keyboard
22.1
700
70
30
LCD monitor
47.8
1300
490
99
Computer
mouse
88.2
700
70
30
1016.2
700
100
21
2.953.4
810.6
674
31
10
4.155.05
1517.1
1000
250
110
674
31
10
2222.1
35735540
368980
285287
8.913
6001000
81600
90 110
40
6.68
350
47
Radio set
2020.5
520
68
Telephone
21.922
2244
50
241
1014
674
31
10
674
31
DVD player
Hi-fi unit
Laptop
Speaker
Mobile phone
PC
Printer/fax
Video recorder
Audi & video
213
Content of
motherboard in
product
[%]
5.136.2
4.06.4
Table 32: _b
Product
Ag
Au
Pd
150
Small IT and
communication equipment
5700
1300
470
TV set CRT
Monitor
2801600
17110
1041
TV set LCD
Monitor
250
60
19
Coffee
machine
0.3
Drill machine
0.2
Shaver
2.2
Hair dryer
0.1
Hand held
videogame
console
21.5
Mixer/
blender
0.7
2.1
14.1
Bread machine
2.8
Vacuum
cleaner
0.7
Game
computer
19.6
Mass of
equipment [kg]
Pt
Computer CRT
Monitor
Calculator
214
Content of
motherboard in
product
[%]
Table 33:
The average composition of PWBs in fractions (total=1) of the various
WEEE categories (United Nations University, 2007).
Component 1A
1CL
3A1 IT
3A2 IT
3A3 IT
3B IT
3C IT
4A1 CE 4A2 CE 4B CE
Materials
HHA-
SHHA
ex CRT
ex CRT
ex CRT
CRT
FDP*
ex
ex CRT
PCs
print-
Small
CRT
ing
IT
Large
Audio
LHHA
small
devic-
7,1
7,2
Toys
Toys
VCRs
Game
Game
DVD
cons.
cons.
etc
Power
Power
b.
b.
CRT
4C CE
5B
FDP
Lamps
6 Tools
es
Fe
9,9E-02 2,1E-01 1,2E-01 1,3E-01 3,9E-01 8,0E-02 1,0E-01 5,2E-03 9,3E-02 5,3E-02 1,1E-02 1,2E-01 1,2E-01 4,1E-02
2,7E-02
8,3E-02
Cu
1,3E-01 1,3E-01 1,1E-01 1,8E-01 1,4E-01 1,0E-01 1,8E-01 4,0E-01 1,9E-01 1,6E-01 1,2E-01 2,2E-01 1,1E-01 1,6E-01
2,0E-01
2,0E-01
Ag
1,6E-04 4,8E-05 2,2E-04 1,0E-03 3,5E-04 5,7E-03 1,5E-04 1,3E-03 5,2E-04 7,0E-04 1,6E-03 2,5E-04 2,2E-04 1,1E-03
4,3E-04
3,0E-04
Au
3,8E-05 1,4E-05 2,0E-05 2,3E-04 4,7E-05 1,3E-03 9,2E-06 4,9E-04 6,8E-05 1,0E-04 1,1E-04 6,0E-05 2,0E-05 1,8E-05
1,6E-04
1,8E-05
Pd
2,0E-05 2,9E-05 1,2E-05 9,0E-05 9,0E-06 4,7E-04 3,4E-06 9,9E-05 8,0E-06 2,1E-05 4,1E-05 1,9E-05 1,2E-05 4,8E-05
1,8E-05
Al
(general)
7,7E-02 7,6E-02 8,6E-02 4,0E-02 4,4E-02 2,0E-02 4,6E-02 1,9E-02 1,3E-01 5,9E-02 6,3E-02 1,5E-01 8,6E-02 5,8E-02
6,1E-02
1,8E-01
As
2,7E-05
Be
8,8E-05
Bi
2,0E-04 6,9E-04
Cd
1,4E-06
6,0E-04 4,0E-04
Cr
1,0E-04 2,9E-04 2,1E-04 5,5E-04 7,5E-04 2,5E-02 6,9E-04 2,0E-04 0.0E-00 4,0E-04 2,1E-04 3,5E-04 2,1E-04 2,1E-04
Ni
5,0E-04 9,0E-04 1,1E-03 9,0E-03 1,2E-03 3,5E-02 2,5E-03 9,0E-03 2,8E-03 2,8E-03 3,0E-03 1,8E-03 1,1E-03 1,1E-03
3,5E-03
1,0E-03
Pb
1,5E-02 1,0E-02 3,0E-02 3,3E-03 5,4E-03 1,4E-02 1,1E-02 5,7E-03 5,6E-03 1,6E-02 1,5E-02 6,8E-03 3,0E-02 3,0E-02
4,5E-03
5,8E-03
Sb
9,0E-04 6,0E-04 6,0E-04 4,5E-04 4,0E-04 3,1E-03 2,2E-03 4,0E-04 1,2E-03 1,3E-03 3,5E-03 4,0E-04 6,0E-04 6,0E-04
Sn
2,4E-02 5,8E-03 2,7E-02 4,8E-03 6,9E-03 2,1E-02 5,7E-04 1,3E-03 4,5E-03 6,6E-03 7,9E-03 1,0E-02 2,7E-02 2,7E-02
3,0E-03
3,2E-03
Zn
3,2E-02 6,8E-03 1,4E-02 1,6E-02 1,6E-02 1,4E-02 1,9E-02 2,5E-03 1,3E-02 1,7E-02 3,9E-03 1,3E-02 1,4E-02 1,4E-02
Plastics
(general)
4,4E-01 3,9E-01 4,6E-01 2,5E-01 2,3E-01 5,3E-01 3,9E-01 1,1E-01 1,6E-01 3,7E-01 2,7E-01 2,0E-01 4,6E-01 4,8E-01
2,8E-01
2,0E-01
4,2E-01
3,3E-01
Epoxy
Ceramics
1,7E-01 1,6E-01
1,4E-01
4,6E-02
1,9E-01 6,9E-02
Glass LCD
Other
(average)
2,0E-01
3,9E-01
1,6E-01 1,5E-01
Liquid
Crystals
1,5E-01
2,3E-01
1,1E-01
3,0E-02
8,0E-03
Br
3,2E-03 1,0E-04
3,8E-02 2,9E-03
Cl
3,9E-03 4,3E-03
5,0E-04
215
1,0E-04 1,2E-02
1,0E-02 2,3E-03
4,3E-03 2,7E-03
Table 34:
Various elements
in e-waste, and
their application,
typical
concentration
and emission
(Williams et al.,
2008).
a
Assuming a global
e-waste production
of 20 million tonnes
per year.
216
Contaminant
Relationship with
E-waste
Flame retardants
Condensors, transformers
Chlorofuorocarbon (CFC)
Product of combustion
Polychloronated dibenzo-p-dioxins
(PCDDs) polychlorinated dibezofurans
(PCDFs)
Americium (Am)
Smoke detectors
Antimony (Sb)
Flame retardants
Arsenic (As)
Barium (Ba)
Beryllium (Be)
Silicon-controlled rectifiers
Cadmium (Cd)
Chromium (Cr)
Copper (Cu)
Wiring, conductors
Gallium (Ga)
Semiconductors
Indium (In)
Lead (Pb)
Solder, batteries
Lithium (Li)
Batteries
Mercury (Hg)
Nickel (Ni)
Batteries
Selenium (Se)
Rectifiers
Silver (Ag)
Wiring, switches
Tin (Sn)
Typical E-waste
concentration
(mg/kg)a
Annual global
emission in
E-waste (tons)b
14
280
1700
34000
180
3600
9900
198000
41000
820000
2900
58000
0,68
13,6
10300
206000
2400
48000
Zinc (Zn)
Die castings
5100
102000
Table 35:
Average
composition of
a PC (European
Commission DG
Environment,
2006).
Name
Plastics
Recycling
Efficiency
(current recyclability)
Weight of
Material
(Ibs.)
Use/Location
22,9907
20%
13,8
6,2988
5%
3,8
Aluminium
14,1723
80%
8,5
Structural, conductivity
housing, CRT, PWB, connectors
Germanium
0,0016
0%
<0.1
Semiconductor/PWB
Gallium
0,0013
0%
<0.1
Semiconductor/PWB
Iron
20,4712
80%
12,3
Structural, magnetivity/
(steel) housing, CRT, PWB
Tin
1,0078
70%
0,6
Copper
6,9287
90%
4,2
Conductivity/CRT, PWB,
connectors
Barium
0,0315
0%
<0.1
Vacuum tube/CRT
Nickel
0,8503
80%
0,51
Structural, magnetivity/
(steel) housing, CRT, PWB
Zinc
2,2046
60%
1,32
Tantalum
0,0157
0%
<0.1
Capacitors/PWB, power
supply
Indium
0,0016
60%
<0.1
Transistor, rectifiers/PWB
Vanadium
0,0002
0%
<0.1
<0
0%
<0
Beryllium
0,0157
0%
<0.1
Thermal conductivity/PWB,
connectors
Gold
0,0016
99%
<0.1
Connectivity, conductivity/
PWB, connectors
Europium
0,0002
0%
<0.1
Phosphor activator/PWB
Titanium
0,0157
0%
<0.1
Lead
Terbium
217
Content
(% of total
weight)
Table 35_b:
Average
composition of
a PC (European
Commission DG
Environment,
2006).
Name
Recycling
Efficiency
(current recyclability)
Weight of
Material
(Ibs.)
Use/Location
Ruthenium
0,0016
80%
<0.1
Resistive circuit/PWB
Cobalt
0,0157
85%
<0.1
Structural, magnetivity/
(steel) housing, CRT, PWB
Palladium
0,0003
95%
<0.1
Connectivity, conductivity/
PWB, connectors
Manganese
0,0315
0%
<0.1
Structural, magnetivity
(steel) hoursing, CRT, PWB
Silver
0,0189
98%
<0.1
Conductivity/PWB, connectors
Antinomy
0,0094
0%
<0.1
Bismuth
0,0063
0%
<0.1
Chromium
0,0063
0%
<0.1
Decorative, hardener/(steel)
housing
Cadmium
0,0094
0%
<0.1
Selenium
0,0016
70%
0,00096
Niobium
0,0002
0%
<0.1
Welding alloy/housing
Yttrium
0,0002
0%
<0.1
Rhodium
<0
50%
<0
Platinum
<0
95%
<0.1
Mercury
0,0022
0%
<0.1
Arsenic
0,0013
0%
<0.1
24,8803
0%
15
Silica
218
Content
(% of total
weight)
Rectifiers/PWB
Material [%]
(Matusewicz
(Dodbiba et
(DEFRA,
(United Na-
(Wecycle,
(Witik et al.,
and Reuter,
al., 2006)
2007)
tions Uni-
2011)
2011)
2008)
versity,
2007)
Iron/steel
17.8
12.0
15.1
4.5
Copper
1.8
8.0
1.2
Aluminium
7.0
2.0
0.2
Other metal
Glass
0.1
58.0
51.0
65.3
Plastics
8.2
10.5
16.7
Printed Wire
Board (PWB)
5.0
3.0
9.7
17.0
6.2
Fluorescent
powder
0.0131
0.0136
Wood
3.8
Rubber
Other
Total
219
2.0
0.1
2.1
13.5
58.5
3.4
100.0
100.0
100.0
100.0
[kg]
Mass
6.1
[kg]
[kg]
[kg]
26.7
24.4
25.6
24.1
Rare earths are used in CRT TVs, primarily for the red-phosphor powder: YVO4: Eu3+
(4.5%), Y2O3: Eu3+ (3.5%) and/or Y2O2S: Eu3+
(3.65%) (Franz et al., 2010 and McGill, 2010).
In the calculation, it is assumed that the
green, blue and red phosphors are used in
equal ratio.
Table 37:
Calculated
critical
materials in CRT
TVs (Van Schaik,
2011).
Max
24.1
26.7
[kg]
3.0
9.7
[%]
0.20
4.14
[gram]
0.01
0.28
[gram]
0.01
0.11
[gram]
0.19
0.21
[gram]
5.20
5.75
[gram]
0.0131
0.0136
0.37
0.50
[gram]
0.03
0.05
[gram]
% PWB in CRT TV
220
[%]
Figure 96:
Materials in a
mobile phone
(UNEP, 2009).
221
1
H
2
He
3
Li
4
Be
5
B
6
C
7
N
8
O
9
F
10
Ne
11
Na
12
Mg
13
Al
14
Si
15
P
16
S
17
Cl
18
Ar
19
K
20
Ca
21
Sc
22
Ti
23
V
24
Cr
37
Rb
38
Sr
39
Y
40
Zr
41
Nb
42 43
Mo Tc
55
Cs
56
Ba
72
Hf
73
Ta
74
W
87
Fr
88
Ra
**
104 105 106 107 108 109 110 111 112 113 114 115 116 117 118
Rf Db Sg Sg Hs Mt Ds Rg Uub Uut Uug Uup Uuh Uus Uuo
25 26
Mn Fe
75
Re
27
Co
28
Ni
29
Cu
30
Zn
31
Ga
32
Ge
33
As
34
Se
35
Br
36
Kr
44
Ru
45
Rh
46
Pd
47
Ag
48
Cd
49
In
50
Sn
51
Sb
52
Te
53
I
54
Xe
76
Os
77
Ir
78
Pt
79
Au
80
Hg
81
Tl
82
Pb
83
Bi
84
Po
85
At
86
Rn
Table 38:
Composition of
mobile phones
from various
sources.
Reference
Materials
(UNEP,
2009)
(UNEP,
2009; Umicore, 2011)
[%]
[%]
Al
2.300
2.914
Cu
26.800
14.235
Fe
2.400
8.039
Glass
5.500
10.594
44.000
59.600
Ag
0.080
0.244
Au
0.080
Pd
(UNEP,
2009)
[%]
0.250
0.079
0.122
0.038
0.024
0.008
0.022
0.061
0.015
0.009
0.006
0.006
Pt/La
0.000
0.004
0.000
0.000
Sb
0.000
0.084
Be
0.000
0.003
18.779
4.230
Other
[gram]
(UNEP,
2009)
[%]
Plastics
222
(UNEP,
2009)
Battery
20.000
(3.8 gram Co)
Battery
20
(3.8 gram Co)
Table 39:
Average
composition of
various white
goods (Wecycle,
2011; Van Schaik,
2011).
Diverse plastics and organic materials, including their additives, fillers, stabilizers,
as well as rubber, wood, textile, fibres, etc.
Material [%]
Iron/Steel
Dryer
Dish washer
Oven
52.1
68.8
45.2
81.3
Copper
1.2
2.3
1.5
0.2
Aluminium
3.1
2.1
0.8
1.9
Stainless Steel
1.9
1.2
23.2
0.7
Brass
0.1
0.1
0.2
0.5
Plastics
6.8
15.9
12.6
0.7
Rubber
2.8
0.9
1.6
0.4
Wood
2.6
4.5
2.1
0.0
Other organic
0.1
5.3
0.0
23.8
1.9
0.0
1.9
1.3
0.9
12.6
PWB
0.4
0.4
0.1
0.1
Cables (internal/external)
1.1
1.8
1.5
1.3
Other materials
2.2
0.8
3.2
0.3
100
100
100
100
Concrete
Total
223
Washing
machine
Table 40:
Variation in the
composition
of washing
machines and
large white
goods from
various literature
sources.
Material [%]
Washing machine
Reference
(Wecycle,
(Matusewicz
(Truttmann
(Wecycle,
(DEFRA,
(United Na-
2011)
and Reuter,
and Rech-
2011)
2007)
tions Uni-
2008)
berger,
versity,
2006)
2007)
Iron/Steel
52.1
50.6
50.7
54.9
54.3
54.2
Copper
1.2
1.4
2.4
1.4
5.6
2.2
Aluminium
3.1
0.8
2.6
2.5
1.7
Stainless Steel
1.9
5.4
1.7
Brass
0.1
0.0
0.1
Plastics
6.8
40.5
8.9
9.3
12.4
12.4
Rubber
2.8
0.3
2.1
2.2
2.9
2.8
Wood
2.6
3.3
2.8
1.8
1.8
Other organic
material
0.1
1.0
0.3
0.0
23.8
28.8
14.8
7.5
20.2
Other inert
material
1.9
1.3
1.9
0.7
0.7
PWB
0.4
0.4
0.3
0.1
0.001
Cables (internal/external)
1.1
2.0
1.3
1.8
1.8
Other
materials
2.1
4.0
2.0
12.7
0.5
100.0
100.0
100.0
100.0
100.0
100.0
Concrete
Total
224
The composition of these white goods strongly varies from product to product, and as they
become 'greener' their resource efficiency increases. The complexity and time-varying composition of the products entering a
physical recycler makes recycling-efficiency
estimates rather difficult, and there may be
large variations in composition as shown by
van Schaik and Reuter (2002), as well as by
van Schaik and Reuter (2004a&b) for cars.
The critical materials are mainly found on
PWBs (United Nations University, 2007). According to these data, large white goods contain on average 20 ppm palladium (Pd), 160
ppm silver (Ag) and 38 ppm gold (Au). Usually, large white good recycling focuses on
the recovery of bulk commodity materials
according to WEEE recycling guidelines. For
PWBs the following holds true:
PWBs form a very small part of this recycling stream and are mostly lost.
Table 41:
Summary of data
and calculated
amount of REOs
per lamp (Van
Schaik, 2011).
Table 42:
Calculated mass
of REOs in EU27
(Van Schaik, 2011
based on data by
Chemconserve,
2011; United
Nations
University, 2007).
The average composition of REOs in phosphor powders of lamps is estimated from diverse literature sources (Rabah, 2004; United
Nations University, 2007; Rabah 2008; European Lamp Companies Federation, 2009;
Wecycle, 2011; Eurometaux, 2010; Welz et al.,
2011; Schler et al., 2011; Hoek van den et al.
2010) and summarized in Table 41.
0.070.2 kg
Percentage of fluorescent
powders in lamps
0.32.9%
0.22.3 gram
671,250
[tonne]
[kg]
a Calculated on the basis of average mass REO/collected kg lighting Cat. 5; further assumed that the End-of-Life
population in the EU is similar to that in the Netherlands (real values can therefore differ due to errors in these
assumptions).
225
Table 43:
Production,
demand and use
of REOs in 2010
(Van Schaik, 2011
based on data by
United Nations
University, 2007;
European Lamp
Companies
Federation, 2009;
Hoek van den et
al. 2010).
World
6,512,000,000 (Hoek
van den et al. 2010)
934,1701,189,381
7,839,324
[kg]
114,330,000 (Lynas
Corporation, 2011)
[kg]
127,500,000
[kg]
6%
[%]
7,650,000
[kg]
226
EU27
10. Appendix C:
Details on Battery
Recycling
Batteries convert chemical energy to electrical energy for powering a wide variety of
cordless electrical products. The high variety of applications, from flashlights to vehicles, demands different battery chemistries and materials to be able to meet a wide
range of power, energy, size, weight, safety
and cost requirements. The 2010 global battery market size was reported at $60 billion
with a breakdown of 70% secondary batteries (rechargeable) and 30% primary batteries
(non-rechargeable), as seen in Figure97. The
dominant primary battery types are alkaline
and zinc, while lead/acid dominate secondary
batteries. Other secondary batteries include
portable batteries dominated by Li-ion and
NiMH, while HEV batteries (mostly NiMH)
compose a small but growing share of the
market at 3%.
Figure 97:
Worldwide
battery market
in 2010 HEV
is mostly Ni/
MH, while large
rechargeable
includes Ni/
Cd and Ni/MH,
created with data
from May (2011).
227
Figure 98:
Primary
Lead/acid
Other Secondary
Inside a metal or plastic case, a battery consists of a positively charged cathode and a
negatively charged anode, which are kept
from touching by an inert separator membrane that allows ions to pass (Figure 98).
The electrolyte is a liquid, gel or powder that
conducts ions from anode to cathode producing an electric current. The metal fraction
of batteries is dominant, but varies greatly
both in amount and in elements, with metals potentially contained in the anode, cathode, electrolyte and case/can, and being both
valuable (Co, REE, etc.) and hazardous (Pb,
Cd, etc.). Material compositions by weight of
some batteries are shown in Table 44. The
reaction equations occurring in each battery
type is given by Table 45.
Li-ion
Ni/MH
Ni/Cd
HEV
Large rechargeable
General
composition of a
battery (Umicore).
Table 44:
Material
compositions
of some battery
types by weighta.
a Various data can
also be found in:
Bernardes et al.,
2004; Briffaerts et
al., 2009; Sayilgan et al., 2009;
Rombach et al.,
2008; Umicore,
2010; 2011; Xu et
al., 2008; Dewulf et
al. 2010; Xua et al.,
2008.
Fe
Primary
Secondary
Zinc/
Alkaline
Ni/Cd
530%
Ni
Zn
1530%
Mn
1025%
Cd
Co
Ni/MH
Button
Li-ion
Cylindrical
Prismatic
Toyota
Prius II
4045%
3147%
2225%
69%
36%
1822%
2939%
3642%
3840%
23%
23%
34%
23%
4%
68%
810%
78%
2%
27.5%
35%
(LiCoO2)
(LiCoO2)
14.5%
16%
7%
Cu
Al
K
15%
12%
12%
34%
Metals, unspecified
228
2%
Graphite/
Carbon
23%
<1%
<1%
Plastics/
Polymer
12%
34%
1619%
810%
1517%
1618%
H,O
1%
1618%
Li
REE
24.5%
Lipolymer
18%
16%
15%
14%
3%
Table 45:
Batterychemistry for
different battery
types.
Zinc-Carbon:
Alkaline:
Button:
ZnO + 2Ag
Ni-MH:
H2O + M* + e- OH- + MH.
Ni(OH)2 + OH- NiO(OH) + H2O + eLi-ion:
LiCoO2 Li1-CoO2 + Li+ + e Li+ + e- + 6C LixC6
NiCd:
* M=AB5
2NiO(OH) + Cd + 2H2O
2Ni(OH)2 + Cd(OH)2
229
Combined
Pyro+Hydro
Combined
Mechanical+Hydro
Dismantling
Figure 99:
Plastics
Al, Steel
Schematic
overview of Li-ion
battery recycling
processes.
Cu, BMS
Modules
Cells
Modules
Optional:
Inertization
Optional:
Incinerator
Shredder
Smelter
Alloy
Refining
(Hydro)
Cu Fe Co Ni
Metal/
Compounds
230
Slag
Construction
or
Li/REE valorization
or
Landfill
Flue Dust
Fluff
Landfill
(Optional:
Recovery
Halogens
or Li)
Landfill
Metals
Sorting
Cu Fe Al
Remelting
Black Mass
Hydro
Process
Metal Salts
Graphite
Landfill
Figure 100:
Process
flowsheet for
Umicore Battery
Recycling (2010).
231
10.3 Drivers
Battery recycling is driven by metal value
and legislation. The metal value of used rechargeable batteries is significant, driven
mainly by Co and Ni, which in 2010 had average prices of $45 and $21 per kg (Metal Bulletin, 2010), respectively. The nickel in one
tonne of NiMH batteries represents a value
of about $6,000. Even greater value can be
extracted from recycled batteries if the battery materials are recovered as compounds
instead of breaking them down to elemental state. The continuous evolution of battery
compounds, use of manufacturer-specific
formulations, and extremely high quality requirements make this approach very difficult,
though, unless one-to-one relationships between manufacturers and recyclers are developed. Though critical today for geopolitical
reasons, Li and REE will require increased
battery collection volumes to leverage scale
effects and make their recovery economic.
It is important to note from a recycling perspective that REEs are not the same in different applications. Combining REE waste
streams to leverage scale effects would not
232
materials to construction slag may be preferable. In general, though, LCA has shown the
positive impact of recycling batteries with appropriate technology, including CO2 reduction
benefits from using recycled Co and Ni rather
than primary resources. Resource use, quantified as cumulative exergy extracted from the
natural environment (CEENE), was shown to
be 51% lower for recycled cathode Co and
Ni for a Li-ion battery, than primary material. The exergy savings arise mainly in fossil resources, nuclear energy and water resources (Figure 101). In response to an LCA
study, which concluded that an HEV with a
NiMH battery has greater acidification potential than a conventional vehicle, it was shown
that HEV acidification potential can be largely neutralized if the batteries are efficiently
collected and recycled. This is a result of the
large benefit from replacing virgin nickel with
recycled Ni.
tery recycling. The BD targets a 25% collection rate by 2012 and a 45% collection rate
by 2016. The 2012 target has not yet been
reached in all member states. Other relevant EU legislation includes the WEEE and
ELV directives, which encourage battery recycling by targeting the main applications of
rechargeable batteries, EEE products and vehicles, by setting collection and recycling targets as well. As the batteries remain in these
products at the end-of-life, they are easily removed from the product as long as the product is collected.
In the US and Canada, battery recycling is
based on domestic recycling competency. As
no environmentally-friendly recycling of Liion batteries is available, only low or voluntary targets have been set on the State and
Provincial levels. Regulation may become
more severe if appropriate technology be-
Figure 101:
Dependency on
natural resource
categories for
recycled (A)
and primary
material (B) to
fill the Co and Ni
requirement of
a Li-ion cathode
(Dewulf and van
Langenhove,
2005).
Scenario A
Scenario B
Renewable res.
Fossil res.
Nuclear en.
Metal ores
Minerals
Water res.
Land
0
100
200
300
400
500
MJ CEENE
233
In response to these concerns, the EU has instituted the most advanced battery recycling
legislation in the world through the European
Batteries Directive (BD). This has clear collection and recycling targets, though as these
are for all batteries combined, the already
high recycling rates of primary batteries allow some countries to meet the target without significantly increasing secondary bat-
234
The IME-ACCUREC (RWTH Aachen) recycling concept is illustrated in Figure 103: LiIon batteries are disassembled into casings,
waste of electronic and electrical equipment
(WEEE), plastics and battery cells. Casings,
plastics and WEEE are processed in existing recycling infrastructure. The battery cells
are deactivated at 500C to evaporate organics, to ensure save handling and to remove
halogenides such as fluorides and chlorides safely. Afterwards, the battery cells are
shredded and separated into a Cu/Al-foil and
a fine fraction. The foil fraction is integrated
into the existing recycling infrastructure. The
fine fraction contains the valuable electrode
materials Co, Ni, Mn, and Li of a Li-Ion cell
(electrode material, EM). The EM is pyrometallurgically processed to gain the valuable
metals in an alloy and to concentrate the lithium in the generated flue dust. Afterwards,
the flue dust is treated hydrometallurgically for generating a high quality Li-compound
such as Li2CO3.
Figure 103:
Flowsheet of the
IME-ACCUREC
recycling
concept.
235
236
Used predominately for conventional car batteries, such batteries have lead electrodes
and a sulphuric acid electrolyte solution.
Collection rates are typically high (>90% in
many developed countries, though significantly lower globally) due to leads characterization as a hazardous substance and the
existence of well-established recycling systems. Processing begins by breaking the batteries open, crushing and mechanically separating them into case materials, metal grids
and poles, lead pastes (oxides and sulphate),
and the acid, which is collected and reused or
disposed. Pastes are then treated to remove
sulphur before entering the furnace with the
grid metal. Lead metal low in antimony is
produced along with antimony metal containing lead from the grid metal. Smelting can
occur in rotary furnaces as well as TSL technology (Figure 47), for example, which can
produce around 130,000 tpa of recycled lead
from a variety of feeds. Finally, the lead is refined to produce soft lead or, most commonly, new battery alloys. If other lead scrap is
added during smelting, extra refining may be
needed to produce a suitable metal quality.
The possible increase in the use of electric vehicles poses the question if there are
enough resources for these new products.
Lithium is an important element in this regard due to the required battery technology. A recent study by Fraunhofer ISI (EU,
2010) shows that if newly registered cars
would globally consist of 50% electric vehicles, only about 20 per cent of the currently
known global lithium resources would have
been used by 2050 (Figure 104). This scenario
considers the use of recycled materials and
lithium demand for other applications. Even if
market penetration would reach 85%, the resource would not be depleted by 2050, but the
current resources that can be recovered by
present technology will have been exhausted. Thus, developing recycling is important in
addition to the development of technologies
allowing the highest possible recovery of lithium form its natural deposits. Various projects recently started in the EU to address the
recycling of lithium-containing batteries for
the automotive sector.
Figure 104:
car batteries
portable batteries
The demand
for Lithium for
50% market
penetration of
electric vehicles
(EU, 2010;
Schler et al.,
2011).
button cells
primary battery
glass & ceramics
dissipative use
others
air conditioning
rubber & thermoplastics
continuous casting
aluminium smelting
secondary lithium
reserves + secondary lithium
resources + secondary lithium
Tonnes Lithium
16,000,000
14,000,000
resources
(USGS)
12,000,000
10,000,000
8,000,000
6,000,000
reserves
(USGS)
4,000,000
2,000,000
0
2008
2014
2020
2026
2032
2038
2044
2050
Year
237
Nickel
2010 Nickel uses in Batteries: > 5 %
Figure 105:
The use of Ni,
REs, Co and Li in
batteries in the
EU and the use
of the metals
relative to total
production (HEV:
Hybrid Electric
Vehicle; EV: Full
Electric Vehicle)
(Eurometaux,
2010) (also EU
Critical Metals).
2010
2010
2020
2020
Nickel
Portable
Nickel
HEV
Rare-Earth
Portable
Nickel
EV 6.0 %
Rare-Earth
HEV
0
2000
4000
6000
8000
10000
Tonnes/Year
12000
500
1000
1500
2000
2500
3000
3500
Tonnes/Year
Cobalt
Lithium
Pour redimensionner la plage de donnes du graphique, faites glisser le coin infrieur droit de la plage.
2010 Cobalt uses in Batteries: 20 %
2010 Lithium uses in Batteries: > 25 %
2010
2010
2020
2020
Cobalt
Portable
Lithium
Portable
Cobalt
HEV
Lithium
HEV
Cobalt
EV (6.0 %)
Lithium
EV (1.5 %)
0
2000
4000
6000
8000
10000
12000
Tonnes/Year
500
1000
1500
2000
2500
3000
Tonnes/Year
Pour redimensionner la plage de donnes du graphique, faites glisser le coin infrieur droit de la plage.
238
11. Appendix D:
Mobile Phone
Collection
The efforts of mobile phone company Nokia
(Nokia, 2012) to recycle mobile phones provide an example of what can be achieved with
collection schemes (Elker 2012).
Figure 106:
Reasons for
not recycling a
mobile phone
(Damanhuri,
2012).
10
15
20
25
30
35
[%]
239
Commonly used methods for collecting mobile phones, batteries and accessories are
special collection bins for phones, mail-back
envelopes and general e-waste collection locations. However, such bins need to be emptied often and finding an effective logistics
solution that is economically viable is difficult
in rural environments. People also tend to
put all kinds of rubbish in the recycling bins,
but their advantage is that they are effective
in communicating the recycling message.
For a consumer, one of the easiest ways to
recycle is to use the mail, which is especially suitable for small items such as mobile phones. Using pre-paid postage envelopes one can drop off the phone in the
nearest mailbox and it will be sent to recycling. An example of a recycling envelope
is shown in Figure 107. Results from envelope programmes have shown an average
of 1.2handsets per package. This cannot be
classified as low environmental impact in
terms of logistics, compared to programmes
where hundreds or even thousands of handsets can be collected in a single drop-off location. However, mail back programmes offer consumers the easiest method possible.
Communal waste collection points can also
be used as take-back locations for a wider spectrum of waste, with special containers for mixed e-waste. This is a cost efficient
way of collecting waste materials, and easy
for people who can drop off different kinds of
waste in one location.
Figure 107:
Recycling
envelope for
mobile phone.
240
242
12. Appendix E:
Models and
Simulation in
Recycling
12.1 Multi-level models
Recycling modules in computer models often
are relatively simple, as is still the general
case for LCA analysis. Usually, they are based
on rather simplistic models of systems and
their design, often neglecting detailed physics (Brunner and Rechberger, 2004).
Figure 108:
Product-Centric
multi-level
dynamic process
simulation
models that
predict recyclate
quality, grade,
and recovery
levels linked to
product design
(Reuter and van
Schaik, 2012a&b;
van Schaik and
Reuter, 2012a&b).
243
Recycling tools, models and derived guidelines have been developed and applied
by Reuter (1999), van Schaik and Reuter
(2004a&b, 2010a, 2011) to try and correct this
problem, embracing a more Product-Centric
view to recycling (Figure 108).
Recent research based on extensive industrial and experimental data (van Schaik and
Reuter, 2004a, 2007, 2010a; van Schaik et
al., 2004; Reuter et al., 2005; Reuter and van
Schaik, 2012a&b) has developed physicsbased models that simulate the effect of design on the liberation behaviour and quality of recyclates from complex consumer
products. Through this physics-based link
between product design and resource efficiency through DfR, they developed dynamic
recycling simulation models for cars and ewaste/WEEE. Comminution-breakage laws
as a function of material connections and related to particulate characteristics of recyclate flows, are addressed and linked to sorting physics, chemistry and thermodynamics
of high-temperature processing and resource
recovery from recyclate streams. Since such
recycling models are far too complex to be
linked to CAD and LCA software, van Schaik
and Reuter have developed and applied fuzzy
recycling models (van Schaik and Reuter,
2007; Krinke et al., 2009) that capture the detail of the recycling optimization models in
a semi-empirical way. These were linked to
CAD and LCA software for the automotive
industry in the SuperLight Car project (SuperLightCar, 2005-2009; Goede et al., 2008;
Krinke et al., 2009; Reuter, 2011a; van Schaik
and Reuter, 2007) and were used for calculating the recycling rates of this lightweight
multi-material design.
Such models (Reuter et al., 2005; Reuter,
2011a) can predict the recycling performance
of different EoL-systems and mixtures of
products, recovery of (precious/scarce) materials, and loss of elements for different
plant configurations (including dismantling),
shredder settings, and future design and recycling trends. They capture the dynamics
of product- and plant-input composition and
mixture, and predict recycling performance
as a function of time. Figure 109 shows the
predicted recycling rate for an e-waste product over time, and Figure 110 illustrates the
distributed properties of the recycling rate of
individual materials in e-waste.
244
Figure 109:
Dynamic
recyclingperformance
calculations
of an e-waste
product as a
function of time,
showing different
recycling rates
due to distributed
properties, such
as material
liberation,
complex
interlinked
materials in
products due
to functionality,
quality
distribution
of recyclates,
distribution of
analyses, range
of products and
changing designs
(van Schaik and
Reuter, 2012).
85.5
1998
1996
1994
85.0
1992
1990
84.5
84.0
83.5
83.0
82.5
82.0
81.5
81.0
80.5
80.0
79.5
79.0
78.5
78.0
77.5
77.0
0
0.02
0.04
0.06
0.08
0.10
0.12
0.14
0.16
0.18
0.20
245
Figure 110:
Dynamic
recycling rates
per material
(total recycling
rates given in
Figure 109) as a
function varying
product weights,
composition and
plant input over
time (van Schaik
and Reuter, 2012).
10
1992
9
8
7
6
1991
5
4
3
1990
2
1
1989
1988
1987
1986
1985
1984
1983
1982
1981
1980
1979
1978
1977
0
0.02
0.04
0.06
0.08
0.10
0.12
0.14
0.16
0.18
0.20
0.22
246
rate calculations. Figure 112 shows, as an example, the calculated mass flow (relative to
input/output of plant) of selected recyclate
streams from e-waste recycling. These predictions include a bandwidth of the results as
a function of changing processing conditions,
input composition (based on changing mixture of plant input), changing product weight,
composition, etc. Figure 113 shows the calculated distributed nature of quality, based
on the example of a ferrous recyclate. This illustrates that the quality and grade of recyclates are not only calculated from its ferrous
content, but also include other materials and
The predicted recyclate and recycling-product mass flows by these models, including
the presence of contaminants and dispersion
of critical and/or toxic materials during recycling, is the basis for the illustrated recycling
Figure 111:
Post-shredder
technology plant
for ELVs as
operated by ARN
(2013).
Figure 112:
Bandwidth of
various produced
recyclate streams
(van Schaik and
Reuter, 2012).
Inert recyclate
Fines (non
combustible) recyclate
Organic/combustible
recyclate
Ferrous recyclate
Aluminium recyclate
Stainless Steel
recyclate
Copper recyclate
0
10
20
30
40
50
60
247
Figure 113:
Quality of ferrous
recyclate stream
including the
quantification
and specification
of the
composition and
contamination
of the recyclate
streams it is
obvious that the
3.1% copper in
the top figure
is not good for
steel quality
(van Schaik and
Reuter, 2012).
Max
Min
% Other Materials
% Fe/Steel
0
20
40
60
80
100
[%]
Min
Max
Aluminium
Stainless Steel
Copper
Copper wire
Plastics
Wood
Glass
Ceramics
PWB
Rubber
Brass
Magnets
Concrete
Bitumen
Main cord
Others
0.0
0.2
0.4
0.6
0.8
248
Figure 114:
Quality of (a) ferrous and (b) aluminium recyclate
streams, including quantification
and specification
of the composition/contamination of recyclate
streams (c) and
(d) respectively
for ferrous and
aluminium fraction (presented
as bandwidths
as a function of
changes in input,
recycling routes,
etc.) (Reuter et
al., 2005; SuperLightCar,
20052009).
249
Calculation and prediction of the dynamically changing recycling and recovery rates
of ELVs and light-weight car-design concepts and of all individual materials in
these products for different recycling scenarios and objectives (maximum total recycling/recovery, maximum recycling of
metals, minimum production of waste,
legislative constraints, etc.) as a function
of the distributed ELV population over time
(see Figure 10); this approach has also
been applied to different types of e-waste
products;
Max
Min
% Others
% Fe/Steel
0.0
0.2
0.4
0.6
0.8
1.0
[%]
Figure 114_b:
% Others
% Al cast
% Al wrough
Max
Min
0.0
0.1
0.2
0.3
0.4
0.5
0.6
Figure 114_c:
Max
Min
Aluminium cast
Aluminium wrought
Copper
Glass
Magnesium
Organic non-plastics
Plastics
PVC
Others
Rubber
Zinc
0.00
0.005
0.01
0.015
0.02
0.025
250
Figure 114_d:
Max
Min
Aluminium cast
Aluminium wrought
Copper
Glass
Magnesium
Organic non-plastics
Plastics
PVC
Others
Rubber
Steel
Zinc
0
10
20
30
40
50
60
251
Box 23:
k
i ,y
Fi l ,k
l
i ,y
R =
k
i ,x
Fi l ,k
l
i ,x
R =
where
F
k
l ,k
l ,k
where
Ril, y , Ril,x
recovery
factor(separationefficiency)for
omposition(includingliberation)classl
recovery
factor (separation efficiency) forparticle
particleccomposition
(including liberation) class I for unit
operation i to intermediate
and recycle output streams
y,x, etc. y,
x,
etc.
utputstreams
forunitoperation
i
tointermediateandrecyclateo
k
i , y
k
i ,x
R ,R
l ,k
Fi
recovery
factor
of
of
purematerial/element
or
uunit
nit
operation
operation
i ito
to
stream
,
etc.
recovery
factor
pure material/elementkk
ffor
stream
y, yx,,
xetc.
input
stream
composed
of
ofmmaterials
aterials
k
kin
article
ccomposition
omposition
class
class
Il
to
to
unit
unit
operation
operation
input
stream
composed
inpparticle
i i
in which (maintaining closed mass balances for all connected and liberated materials)
Rik,y + Rik, x + Rik,z = 1
and
Ril,y + Ril, x + Ril,z = 1
252
Box 23_b:
This description and modelling of the efficiency of the physical recycling processes ensures that the actual composition (and thus quality) of each recyclate stream in every
stage of the recycling system is captured as a function of design and shredding intensity.
This is in turn determined by particle composition and separation physics, and the input to
metallurgical treatment processes is predicted based on industrial reality. The imperfection in separation and liberation (as a function of design and dismantling/shredding intensity) directly determines the grade of recyclate streams and the recovery during physical
sorting. This also implies that the relation between grade and recovery for complexly connected multi-material products such as WEEE/e-waste and cars as depicted by the grade/
recovery curve for physical sorting does not comply with the standard shape as shown in
Figure 116. This relationship changes as a function of particulate nature (degree of liberation and amounts of different materials present) of the particles.
The above equations can also be cast into distributions that reflect the distributed nature
of data, i.e. complete bulk flow of products as well as the distribution of elements within products. The theory has its roots in classic minerals processing, and the mathematics for product recycling and the derivation of recycling rates was developed by van Schaik
and Reuter (2004a&b). Recycling rates as defined on this basis include the standard deviation of analyses and flows, and therefore give an indication of the accuracy of all presented
data.
Figure 115:
Dynamic
recycling models
that include also
the convolution
integral, and
hence permitting
the simulation
as a function
of standard
deviation of
all analyses
and flows of
the system
for products
and mixture of
products (van
Schaik and
Reuter 2004a).
In addition to this, analysis exergy (Szargut, 2005) has also been included for evaluating
recycling systems, as shown by Amini et al., (2009), Ignatenko et al., 2007, and Meskers et
al., (2008).
253
Figure 116:
Design for
Resource
Efficiency
Designer
Mineral to Metal
(The effect of
Aluminium in
WEEE on Slag and
Metal Properties
in Smelter).
Metal recovery
as a function
of process
technology,
thermodynamics
and transport
processes, here
showing the
effect of liberated
and un-liberated
steel on the
recycling quality
of aluminium
and slag (Reuter
et al., 2005;
Reuter, 2011a).
Products with
high aluminium
content, which
oxidizes during
processing, have
a disruptive effect
on processing
and hence
on resource
efficiency as the
systems have to
be diluted with
virgin material
to operate them
well.
254
Material
connections
Jointed
Materials
Design
Physical Recycling
Particle Physics
Grade/Recovery
Shredding/Separation
Metallurgy
Thermodynamics
Transfer Processes
Technology
Figure 117:
Overview of
the fuzzy rule
liberation
recycling model,
predicting
liberation
behaviour and
hence recycling/
recovery rate as a
function of design
specifications
(list of materials,
joints and
material
combinations)
(van Schaik and
Reuter, 2007).
Figure 118:
Example of
recycling-rate
calculations for
the SLC concept in the fuzzy
recycling model
(illustrated for
Al) as a function
of variations in
design for steel
and polymer content. There is no
single recycling
value as it is a
complex function
(van Schaik and
Reuter, 2007).
The figure shows
why the simplistic
one-dimensional
recycling rate
definitions used
in the IRP's
report 2a (UNEP
2011b) only apply
to limited cases
as they do not
consider complexity.
255
256
The total metal-flow rates (usually as required by MFAs) including their average
and standard deviation.
The morphology of the recyclate as, for instance, aluminium turnings or swarf react
differently than an ingot in a furnace when
remelting/refining.
Maximum
the higher
quartile (80 %)
the lower
quartile (20 %)
Minimum
Medium
1800
1600
1400
1200
1000
800
600
400
200
0
Cable
Ferrous
Metal
Glass/
Ceramics
NonFerrous
Metal
Other
Plastic
Printed
circuit
board
Total
mass
Median [g]
118.0
11.0
73.0
0.0
87.0
0.0
729.0
0.0
1022.0
Arithmetic
mean [g]
114.1
10.9
74.2
48.4
100.3
2.3
634.5
3.0
987.7
46.0
6.1
47.6
125.7
64.0
6.3
427.1
18.2
501.9
12
23
31
510
31
562
34
2731
20
Standard
deviation [g]
Required
sample size*
n (=90%,
e=20%)
257
Emotor
Box 24:
Figure 120:
Aluminium
recyclates from
EoL vehicles,
showing the
effect of product/
component
composition
and material
connections on
the particulate
nature and
degree of
(im)purity of
recyclates
(Reuter et al.,
2005; Reuter and
van Schaik, 2008).
It is important to consider a multi-level approach (Figure 108), the available options and
the detail they reveal when using different methodologies and hence the results of each:
Material-flow approach (MFA): purely mass oriented, provides some availability information, but does not show the relationship between all the metals in a consumer product, such as an aluminium laptop and the effect of all its other 50+ elements on the ultimate quality of the produced recyclate and alloys.
Metallurgical limitations of scrap usage: quality constraint on material uses in subsequent processes, as shown by the technologies shown in Figure 40.
Therefore, to improve the models for aluminium, the following aspects will have to be developed based on available data and theories, moving from a more Material (&Metal)-Centric viewpoint to a Product-Centric view:
258
With changing demand and supply patterns of different materials and alloys, material
purity will become much more important. The above-cited example of automotive castings will then lead to the question of which other car component or product area can
absorb ELV scrap?
Box 24_b:
Already today, customers require a high recycled content and it could well be that EU
legislation will favour the recycled content for green labelling.
Consequently, we must know how much scrap can be used in closed or open loop systems before the metallurgical limits are reached in terms of castability/formability/
physical properties/surface appearance, as well as losses, residues created, etc.
Dynamic models are required, due to the changing chemical composition of todays
scrap and the ongoing development of material specifications (and properties) (Figure28, Figure 29 and Figure 30).
To move from static MFA models to dynamic models the following limitations and challenges must be considered.
Material flow approach: The present situation is:
At European level, different recycling efficiency indicators exist for product and material
considerations (recycled content vs. end-of-life recycling).
Presently, MFA considers material flow as mass flow only and not in a dynamic manner
as shown by Figure 60 (van Schaik and Reuter, 2004a).
For recycling quotas and recycled content calculations, only theoretical scrap amounts
are used, based on product shipments and static lifetimes.
259
In MFA models, the accessibility of recycled EoL raw materials in terms of collection
probability is still missing.
MFA models already give a good description of the order of magnitude of recycling raw
material for stakeholders, but now must aim at the understanding of stocks as dynamic
consumer- and application-determined systems.
Regional and temporal data (lifetime distribution, trade and per capita consumption of
materials) are needed.
With such a demand and supply model in place, an extension including CO2 emissions
is possible. Furthermore, scenarios for different targets and the contribution of recycling can be calculated (e.g. long-term scenarios evaluating the contribution of recycling in IEA 2050 targets).
Box 24_c:
Because aluminium applications are relatively simple, the MFA approach works. However,
considering a complex tablet type application packaged in aluminium and containing 50+
elements, some of the above statements could be problematic as these elements, plastics, etc. may affect produced alloys and losses as shown in section 3.4.1.3.
Material quality consideration: The detailed recycling models discussed in this document,
describing scrap and particle types, liberated or not and connected to various metals,
brings us to quality, the key point that recycling models (van Schaik and Reuter, 2004a;
2004b; 2007; 2010a; 2010b; van Schaik and Reuter, 2012; van Schaik, 2011) must describe.
If scrap flows are known in terms of collection, defined recycling loops and their amount,
the next criterion is material quality. Consider:
260
Secondly, the metallurgical accessibility at element or alloy level must define the need
for thermal or mechanical upgrading or sorting processes and, if possible, for metal refining (see section 3.4.2).
The achievable purity before the melting step determines the recyclability or scrap value for the target application, if no later refining is possible (see section 3.4.1.3).
The aim is to discover element accumulation trends in life cycles (alloying and trace elements; see section 5.4.5).
With the quality extension of the pure demand and supply model application, specific
scenarios can be calculated: e.g. will casting alloys in car applications remain available
as a sink for high alloyed scrap if alternative drive concepts require fewer and smaller
engines?
Figure 121:
The LCA
framework
according to the
ISO 14040/14044
series (ISO,
2006a).
Inventory Analysis
Interpretation
Impact Assessment
261
Goal and scope definition: The scope, including system boundaries and level of detail, of an LCA depends on the subject and
the intended use of the study. The depth
and breadth of LCA can differ considerably,
depending upon the goal of a particular
LCA (ISO 2006b).
262
Table 46:
Table with
metal-recyclingloop examples
(Dubreuil et
al.,2010).
263
Type 1
Closed metal loop
Type 2
Alloy loop
Type 3
Transfer to another
metal pool
Type 4
Metallurgical
re-separation
Chromium coating
on steel is recycled
into the steel loop,
where it is retained
in dilute fractions in
the steel pool.
Due to inefficiencies
in physical separation, copper particles are entrained
with the steel recycling flow. Once
melted, copper cannot be removed
economically from
the steel.
So far, however, there are no generally accepted, accurate allocation factors available
for an application of these four above described types and, as mentioned in Dubreuil
et al. (2010), important work needs to be
done to achieve this. Despite this shortcoming, several LCA and/or LCI studies on metals
exist and are published, using their own, specific allocation factors.
264
266
13. Appendix F:
Physics of Extractive
Metallurgy
Figure 122:
A comparison
of pure copper
scrap melting
756.9 MJ/t Cu
(top) and impure
copper recyclate
smelting
1493.8MJ/tCu,
showing
the effect of
impurities in
scrap feed (down)
at 1250C as
calculated by
HSC for adiabatic
conditions with
methane as fuel
(HSC Chemistry 7,
19742013).
267
268
Figure 124:
Various
thermochemical
data for the given
reaction (HSC
Chemistry 7,
19742013).
269
Si + O2 = SiO2
G = G 0 + RT ln Q
where the reaction quotient Q (e.g. SiO2 formation) refers to the actual activities of reactants and products:
Q=
aSiO2
aSi .aO2
The activities of pure solids and liquids are the activities in the corresponding standard states
and are equal to 1. The activity of gas at moderate pressures is equal to the actual pressure of
the gas, therefore:
Q=
1
p O2
A reacting system comes to equilibrium when its Gibbs free energy reaches its minimal value,
when the driving force for the reaction is:
G
= G = 0
where is the so-called progress variable. From the above equation we conclude that at equilibrium:
G = G 0 + RT ln Qeq = 0
and hence:
1
= RT ln pO
G 0 = RT ln Qeq = RT ln
2 ,eq
pO
2 eq
In the case of SiO2 formation, the standard reaction free energy predicts what will be the equilibrium pressure of oxygen as a function of temperature (which is log(pO2) = -11.453 at 2000C
as can be seen from Figure 124). The more negative GT0 becomes, or the more stable the
oxide, the lower will be this equilibrium pressure of oxygen: the oxide hardly decomposes. A
negative GT0 for the formation of a compound indicates directly how much energy is at least
required for decomposing the compound into its elements, hence to produce pure metal out of
its mineral.
The Gibbs free energy is composed of two contributions: enthalpy (H) and entropy (S):
G = H TS
thus, for the formation of the above-mentioned compounds (see Figure 124),
GT0 = H T0 TST0
270
Figure 125:
Various G
(Ellingham)
functions of
temperature for
given oxides,
showing that the
REO La2 O 3 is
most stable and
CuO the least.
Therefore it is
easiest to create
metal from CuO
and most difficult
from La2 O 3 (HSC
Chemistry 7,
19742013).
Ellingham was the first to plot GT0 as a function of temperature for oxidation and sulphidation reactions for a series of metals, relevant to the extraction of metals from their
ores. Figure 125 shows an Ellingham diagram for oxides. In between temperatures at
which phase transitions of reactants or products occur, the relation between GT0 and T is
approximately linear, the slope being equal to
the average value of -ST0 . From Figure 125 it
is clear that the slopes are almost the same
for all oxides. This is because the entropy
changes in all these cases are similar, being almost entirely due to the condensation of
1mole of oxygen:
2 x 0
0
0
0
(O2 ) 2 S 298
S 298
= S 298
[M ] + S 298
M xOy
y
y
271
Figure 126:
Standard free
energy of
formation of
selected oxides,
corresponding
to the general
reaction (2x/y)
M+O 2 = (2/y)
MxOykcal/mol
(HSC Chemistry 7,
1974 2013).
kcal/mol
Delta G (Ellingham)
2.00 NiO
-50
2.00 PbO
2.00 Cu2O
2.00 CO(g)
0.67 Fe2O3
2.00 ZnO
-100
0.40 Ta2O5
SiO2
2.00 MgO
2.00 MnO
-150
0.67 Al2O3
2.00 CaO
0.67 La2O3
-200
0.67 Tb2O3
-250
-300
500
1000
1500
2000
Temperature
C
File:
2C + O2 = 2CO
C + O2 = CO2
2CO + O2 = 2CO2
We see that in reaction 3 there is a net loss of
one mole of gas (slope of GT0 versus T curve
similar as for most metal oxides). In reaction 2, the number of moles of gas remains
the same (entropy change close to zero and
hence a horizontal line in the Ellingham diagram) and in reaction 1 there is a net production of 1 mole of gas (slope of GT0 versus T
curve similar in magnitude as for most metal
oxides, but opposite in sign). This means that
at sufficiently high temperatures CO becomes
272
Figure 127:
The use of C (red
line producing
CO(g)), CO(g)
(magenta line
producing
CO 2(g)) and H2(g)
(dark blue line
producing H2 O(g))
as reductants
kJ/mol (HSC
Chemistry 7,
19742011).
273
i = i0 + RT ln a i
As the activity of i, ai, is proportional to the
mole fraction of i, xi, the chemical potential decreases strongly at very low concentrations of i.
The chemical potential being a measure for the
amount of energy needed to remove remaining
i from the given solution, it is clear that metal
refining can be very expensive in terms of energy and that it is mandatory to avoid unwanted
mixing of elements during recycling.
Table 47:
Common
compounds
in a slag and
their melting
points (HSC
Chemistry7).
Note that due
to various
crystalline forms
of SiO 2 a lower
value of 1600C is
given. For CaO a
value of 2572C is
reported showing
some variations
in data.
Table 48:
Common
compound
mixtures in a slag
(see Figure 128
and Figure 129)
and their melting
points and Fe/
SiO 2 ratios (HSC
Chemistry 7).
274
Slag compound
Name
FeO
Iron oxide
(Fe: iron & O: oxygen)
1377
SiO2
Silica
(Si: silicon & O: oxygen)
1723
CaO
Lime
(Ca: calcium & O: oxygen)
2899
MgO
Magnesia
(Mg: magnesium & O: oxygen)
2832
Al2O3
Alumina
(Al: aluminium & O: oxygen)
2054
ZnO
Zinc Oxide
(Zn: zinc & O: oxygen)
1975
PbO
Lead Oxide
(Pb: lead & O: oxygen)
887
Slag compound
FeO + SiO2
(2FeOSiO2 fayalite)
1217
FeO + SiO2
1187
CaO + FeO
1059
CaO + SiO2
(CaSiO3)
1540
A simplified
SiO 2-FeO-CaO
phase diagram
showing the area
that is molten at
1300C with an
industrially safe
range of Fe/SiO 2
as shown (FACT
Sage).
275
Straight dotted lines on the diagram represent targets relating to slag composition.
Maintaining the slag composition on this
operating line provides the greatest operational flexibility (i.e. small changes in slag
composition can be absorbed by the system without the occurrence of operational
difficulties).
To reduce refractory damage and fuel usage, maintaining the slag composition
within this region to ensure the slag is fluid for effective furnace operation and easy
tapping.
It is necessary to control the slag composition within these maximum and minimum
target values to ensure the slag remains
fluid.
Figure 128:
276
Figure 130:
A simplified SiO 2FeO-CaO phase
diagram showing
the area that is
molten at 1300C
with the operating
point well within
the molten slag
area (FACT Sage).
277
278
This is essentially the meaning of the second law of thermodynamics (Kondepudi and
Prigogine, 1998), which is why it is a perfect
starting point to discuss the aggregated resource consumption of recycling processes.
In the context of this law, the concept of entropy is used for measuring the downgrading
of resources. Interpretation of the second law
279
In recycling practice, usually only some metals will be of economic interest and are then
concentrated, while others might get dissipated. In evaluating the whole recycling
smelting process, it is instructive to look at
all metals that enter the process. The aggregated relative effectiveness then gives a
measure for the balance between concentration vs. dissipation:
280
out
out
in
in
e
e
e
e
4 s, j
4 s, j
q ,l
q ,l
out
in
s
m
s
m
i S =
j 3 T in k k k k k k dt
out
l Tq ,l
l Tq ,l
j 3 Ts , j
s, j
Heat balance
Radiation balance
Material balance
with heat flow eq at temperature Tq, radiation flow es at temperature Ts, specific entropiessk, and material flows mk.
Box 25:
Figure 131:
General
flowsheet of the
Mintek Enviroplas
process (Input
flows are in
green, output
flows in red)
(Denton et al.,
2005).
281
Exergy of a smelter
For illustrating the above assessment methods, we consider a real-life example (Gling-Reisemann, 2011). The basis for the assessment is detailed material flow data, including chemical analysis of the components. Thus, the data requirements of the methods are quite high, and application depends on their availability. A well-described process
in the literature is the Enviroplas process by Mintek, RSA (Denton et al., 2005), mainly used
for recycling Electric Arc Furnace (EAF) dust. The target metals are zinc and iron, but nickel, chromium and molybdenum are also of commercial interest, the latter two even considered critical by some sources. The flowsheet is shown in Figure 131. Please see also
Cebulla and Bernard (2010) for more details on metal-specific mixing entropy flows.
Box 25:_b
Fe, Ca and Zn are well concentrated, consistent with the main economic incentive. Other metals are only concentrated slightly like Al, Cr, and Mg, and Mn, Mo, Ni, and Ti are
even slightly dissipated. Compared to the concentrating effect on zinc, the overall performance in terms of metal concentration is only medium (-33%), but in terms of economics
it is probably sufficient since zinc and iron are the main motivation for operating the whole
process.
The entropy production of the Enviroplas process has not yet been analysed in detail, but
by using the data in Denton et al. (2005) and with the help of GEMIS and Ecoinvent, two
life-cycle assessment databases, one can roughly estimate the entropy production to be in
the range of 90 MJ/K per tonne of metal produced. The entropy-based efficiency can then
be calculated to be in about 0.001 (or 0.1%). Without a benchmark, however, this number
does not say very much about the maturity of the process. All one can say, is that probably
much room exists for improvement, either in decreasing the resource consumption or by
improving the overall metal concentration.
Viewed from a sustainability perspective, the Enviroplas process can be improved. Just by
how much is not clear from the above analysis, which shows that choosing certain technologies for concentrating target metals affect the possible dissipation of non-target metals. To approach a closed-loop metals economy, we must consider these side effects and
design recycling flowsheets that capture the widest range of metals, without too much
dissipative loss.
Box 26:
282
Box 26_b:
Figure 132:
Phase
relationship in
molten metal
alloy and multioxide slag
(ternary diagram)
(FACT Sage;
Castro et al.,
2004; Castro et
al., 2005; Reuter,
2011a; Reuter,
2009).
To maximize separation in metallurgical smelting, the slag must be suitably molten for
optimal recovery of the reduced metal, which implies that the molten slag must have a
sufficiently low viscosity, i.e. the temperature must be sufficiently high. However, molten
slag mixtures of CaO-FeO-SiO2-Al2O3-MgO-metal oxides are complex high temperature
liquids that, depending on the composition, will have a complex liquidus profile. Figure 133
clearly shows the marked influence of alumina (Al2O3) on the melting point of slag as also
shown in Figure 132 for different conditions. Usually, alumina is created from aluminium
in e-waste in a non-ferrous copper smelter. Removal of aluminium from e-waste is thus
beneficial for smelting as well as being desirable because of aluminiums reduced energy
footprint during remelting and refining.
Figure 134 shows the relative stability of some indium and tin oxides in the ratio used for
flat-panel TV screens. The thermodynamics-based figure shows that this stability has a
direct effect on their recovery and recycling rate due to various different compounds In
and Sn can appear in when processed. This is attributable to their oxidation states, vapour
pressure, etc. Obviously, a proper understanding of the thermodynamics within this technological/economic context will determine how well indium and tin are recovered in suitable phases for further processing. Usually, BAT operators do this very well in a most resource efficient manner, as they have a good understanding of the physics involved. The
example in Figure 134 shows the various compounds of indium and tin and their behaviour
under different temperatures and different carbon-starting values (i.e. with little carbon
it is more oxidizing and with more it is more reducing). It is clear that under more reducing conditions more indium metal is produced, while tin oxide is readily reduced to metal.
Various volatile species of indium oxide and tin oxide exist and, depending on the gas flow
through the system, more or less of these are removed to the gas phase and then oxidized
to flue dust.
Figure 135 shows that if the lime (CaO) content in the slag changes for given experimental
conditions, the distributions are affected and will complicate matters further.
283
Box 26_c:
Figure 133:
The effect of
different alumina
levels (from
aluminium in
e-waste) on the
slag liquidus
temperature, on
solids in solution
as a function of
temperature, and
on oxygen partial
pressure of a
typical slag (FACT
Sage; Reuter et
al., 2011b).
Figure 134:
The stability
of some of tin
(Sn) and indium
(In) oxides
under different
operating
conditions:
(a, left) shows
more reducing
conditions while
(b, right) shows
more oxidizing
conditions (HSC
Chemistry 7,
19742013;
Outotec).
284
Box 26_d:
Figure 135:
The distribution
of indium and
copper between
metal and slag
as a function of
lime addition
at 1300 oC, Fe/
SiO 2=1.1-1.2
and log(pO 2)=-7
(Anindya et al.,
2011).
Figure 136:
Ellingham
Diagram for
the Stability
of various
compounds
in e-waste
the bottom
compounds being
the most stable
(HSC Chemistry7,
19742013;
Outotec).
285
Figure 136 shows Gibbs Free Energy (Ellingham) graphs for various oxides as a function of
temperature. This so-called Ellingham diagram shows the relative stability of oxides and
how easily these can be reduced to metal. SnO2/In2O3 are easiest to reduce, while various
REO are extremely difficult to reduce with, e.g., carbon and hydrogen, requiring the use of
hydrometallurgy for refining.
Box 27:
Figure 137:
Eh-pH diagram
for an aqueous
electrolyte
showing the
behaviour
of different
dissolved
elements, which
are subsequently
recovered by
various refining
processes (HSC
19742013).
Box 28:
286
Figure 138:
Using
computational
fluid dynamics
for optimizing
conditions within
furnaces (which
can be 1040m
high) this
drives process
understanding
to its limits
and maximizes
resource
efficiency (Huda
et al., 2012).
287
provide a good understanding of reactor furnaces such as the TSL type (Figure 47). Huda
et al. (2012) showed the flow and transfer
phenomena in this type of furnace and described to which phase elements will report,
i.e. metal, matte, slag, speiss, flue dust, etc.
(Figure 138).
The element radar chart (Figure 64) graphically shows how easy or difficult it is to separate metals within various mainstream-metal (Carrier Metal) reactor types (Nakajima et
al., 2009; 2011; Hiraki et al. 2011) for primary production. The chart shows how metals
(and their compounds) split between metal, slag and flue dust, and therefore whether
they are recoverable in the indicated reactor
types (note that this tells us nothing about
the downstream processes). The theoretical
aspects discussed above determine the distribution of all these elements in a specific
reactor. For example, alloying elements for
steel such as nickel, tungsten, molybdenum,
and cobalt are stable in molten iron. This
thermodynamic feature usually leads them
to stay in metallic iron, where they are lost
for other uses and become impurities in the
steel, which cannot be removed by conventional recycling systems of steel, aluminium
or magnesium. The radar chart shows this,
indicating that removing impurities and/or
Figure 139:
Manipulating
conditions within
a TSL to achieve
desired metal
production and
energy recovery,
recycling and
waste processing
(www.outotec.
com).
Oxidizing
Precious
metal
cuppelation
Cu/Ni
Precious
metal
smelting
SPL
(Converting/
continuous-C3,
e-waste)
Cu/Ni
(Smelting)
Pb
(High grade
concentrates)
pO2
Pb
(Battery
recycling)
Pb
Low grade
concentrates,
Slags
Cu
Black & e-waste
MWI (Slag)
Zn
Sn (Smelting)
Reducing
(EAF,
Residues and
Oxidic Ores)
Sn (Slag)
Ni Laterite
Fe (AusIron-Pilot)
800 C
1000 C
1200 C
1400 C
Ferroalloys
1600 C
Ilmenite
Processing
1800 C
Operating Temperature
288
Box 29:
Box 30:
Figure 140:
Recycling
lithium-ion
batteries
(Recupyl SAS).
289
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312
ADP
Abiotic Depletion
AHSS
AOD
ASR
BAT
BIR
BIW
BOF
CAD
Computer-Aided Design
CAPEX
Capital Expenditure
C2C/CtC
Cradle-to-Cradle
Carrier Metals
CO2eq
Equivalent CO2 (each Greenhouse gas is scaled relative to CO2 and added
to obtain the CO2eq)
DfD
DfE
DfR
DfS
DfRE
EoL
End of Life
EEE
EEP
ELFM
ELV
EPA
EPR
ET
Ecotoxicity
EU27
EWM
Exergy
HT
Humantoxicity
IRP
KPI
LCA
LCD
LCI
LCM
LED
Light-Emitting Diode
LFM
Landfill Management
LIBS
Laser-Induced-Breakdown-Spectroscopy
LME
Material Centric Recycling that considers only single elements, i.e. one at a time without
the non-linear interactions between all connected materials to that element. This is the basis for the data in the 1st UNEP report on recycling.
313
MFA
Multiphysics
ODP
OEM
OLED
OPEX
Operating Expenses
PGM
PM
Precious Metal
POCP
ppm
314
Product Centric
Recycling that considers the entire product, including all non-linear interactions of materials on the recycling of all metals, elements and materials
from complex products and their designer minerals similarly as is the
basis for processing of geological minerals. To calculate this, requires detailed flowsheeting as well as considering the physics involved. This is the
topic of the present report, in addition to defining multi-dimensional and
non-linear definitions for recycling. This approach quite naturally leads to
techniques for reuse, etc., for improving resource efficiency to be included
in optimizing the recycling system.
PST
PWB
Printed Wire Board (also called Printed Circuit Board PCB, but this may
be confused with PCBs, the chemical)
Recyclate
Raw material sent to, and processed in, a waste recycling plant or materials recovery facility.
REE
REO
SHA
SLC
tpa
UNEP
USGS
WBCSD
WEEE
WIO
Waste Input-Output
WtoE
Waste to Energy
XRF
X-Ray Fluorescence
XRT
X-Ray Transmission
Alphabetic list of all elements and their names, symbols and atomic numbers
Actinium Ac 89 Aluminium Al 13 Americium Am 95 AntimonySb51 ArgonAr18
Arsenic As 33 Astatine At 85 Barium Ba 56 BerkeliumBk97 BerylliumBe4
Bismuth Bi 83 Bohrium Bh 107 BoronB5 BromineBr35 Cadmium Cd48
CalciumCa 20 Californium Cf 98 CarbonC6 CeriumCe58 Cesium Cs55
ChlorineCl 17 ChromiumCr24 CobaltCo27 CopperCu29 Curium Cm96
Darmstadtium Ds 110 DubniumDb105 DysprosiumDy66 EinsteiniumEs99
Erbium Er 68 Europium Eu63 FermiumFm100 Fluorine F 9 Francium Fr87
Gadolinium Gd 64 Gallium Ga31 Germanium Ge 32 Gold Au 79 Hafnium Hf72
Hassium Hs 108 Helium He2 Holmium Ho 67 Hydrogen H 1 Indium In 49
IodineI53 Iridium Ir 77 Iron Fe26 Krypton Kr 36 Lanthanum La 57
Lawrencium Lr 103 Lead Pb 82 Lithium Li 3 Lutetium Lu 71 Magnesium Mg 12
Manganese Mn 25 Meitnerium Mt 109 Mendelevium Md 101 Mercury Hg 80
Molybdenum Mo42 Neodymium Nd 60 Neon Ne 10 Neptunium Np 93
Nickel Ni 28 Niobium Nb 41 Nitrogen N 7 Nobelium No 102 Osmium Os 76
Oxygen O 8 Palladium Pd46 Phosphorus P 15 Platinum Pt 78 Plutonium Pu 94
Polonium Po 84 PotassiumK19 Praseodymium Pr59 Promethium Pm 61
Protactinium Pa 91 Radium Ra88 Radon Rn 86 Rhenium Re 75 Rhodium Rh 45
Rubidium Rb 37 Ruthenium Ru44 Rutherfordium Rf 104 Samarium Sm 62
Scandium Sc 21 Seaborgium Sg106 Selenium Se 34 SiliconSi14 Silver Ag 47
Sodium Na 11 Strontium Sr38 SulfurS16 Tantalum Ta73 Technetium Tc 43
Tellurium Te 52 TerbiumTb65 Thallium Tl 81 ThoriumTh90 Thulium Tm 69
Tin Sn 50 Titanium Ti22 TungstenW74 Ununbium Uub 112 Ununhexium Uuh 116
Ununoctium Uuo 118 Ununpentium Uup 115 Ununquadium Uuq 114
Ununseptium Uus 117 Ununtrium Uut 113 Ununium Uuu 111 UraniumU 92
Vanadium V 23 Xenon Xe 54 Ytterbium Yb 70 Yttrium Y 39 Zinc Zn 30
Zirconium Zr 40
315
International
Resource Panel
316
see www.unep.fr
ISBN: 978-92-807-3267-2
DTI/1535/PA