WWW.NICHTEISENMETALLURGIE.AT Chair of Nonferrous Metallurgy By-products from industrial processes – A potential substitution for primary resources? Characteristics, case studies and certification strategies Juergen Antrekowitsch 06.09.2019 Chair of Nonferrous Metallurgy – University of Leoben, Austria Juergen.Antrekowitsch@unileoben.ac.at
WWW.NICHTEISENMETALLURGIE.AT Chair of Nonferrous Metallurgy Introduction 06.09.2019 Chair of Nonferrous Metallurgy – University of Leoben, Austria Juergen.Antrekowitsch@unileoben.ac.at
Introduction – Montanuniversitaet Small specialized University in the fields of Mining, Metallurgy and Material Science Founded 1840 4000 students, 1100 employees Close relations to industry Various international activies 11 Bachelor courses, 14 Master courses • Department of Metallurgy • Chair of Nonferrous Metallurgy • Currently biggest chair at the University Recycling of Industrial By-Products
Chair of Nonferrous Metallurgy Recycling of Industrial By-Products
Strategy – from fundamental to applied research Recycling of Industrial By-Products
WWW.NICHTEISENMETALLURGIE.AT Chair of Nonferrous Metallurgy Raw Materials in Europe 06.09.2019 Chair of Nonferrous Metallurgy – University of Leoben, Austria Juergen.Antrekowitsch@unileoben.ac.at
Recycling - Circular Economy Recycling of metallic scrap is well developed for main metals However, there are further materials containing metals, offering a quite high potential as future metal resource. United Nations Environment Program / Challenges of Metal Recycling, M. Reuter The EU Circular Economy and Its Relevance to Metal Recycling, Ch. Hagelüken Recycling of Industrial By-Products
Policies and Legislation Is it nowadays really possible to install a new metallurgical process in Europe? Very often the metal winning process itself is not the relevant cost factor! Instead it is: Off-gas treatment and cleaning Waste water treatment How to combine these Avoidance of CO 2 – emissions generally positive Permissions aspects for the environment with an Safety economic resource etc. utilization? Recycling of Industrial By-Products
Raw Materials leaving Europe Electronic scrap Gold concentrate Car scrap Car catalysts Zinc-, Lead-Residues Zinc-concentrate 9 Research Group: Recycling of Heavy Metals from Complex Residues Research Group: Recycling of Heavy Metals from Complex Residues 9
WWW.NICHTEISENMETALLURGIE.AT Chair of Nonferrous Metallurgy By-products Introduction 06.09.2019 Chair of Nonferrous Metallurgy – University of Leoben, Austria Juergen.Antrekowitsch@unileoben.ac.at
By-products – Residues – Secondary Resources Hydrometallurgy Pyrometallurgy 11 Recycling of Industrial By-Products
By-Products – Secondary Resources Multi-metal containing primary ores . Lead to complex but valuable by-products 1 Electric Arc Furnace steel mill Dust, 2 Dusts from copper recycling, 3 Slags from lead industry, 4 Jarosite from zinc industry, 5 Dusts from cupola furnaces, 6 Stainless steel production dust More value due to importance of minor metals United Nations Environment Program / Challenges of Metal Recycling, M. Reuter Recycling of Industrial By-Products
WWW.NICHTEISENMETALLURGIE.AT Chair of Nonferrous Metallurgy By-products Examples 06.09.2019 Chair of Nonferrous Metallurgy – University of Leoben, Austria Juergen.Antrekowitsch@unileoben.ac.at
Zinc Primary Metallurgy 500–900 kg/t zinc World wide: Zn % 1.5 – 8.4 Pb % 0.5 – 7.1 Ag % 0 – 0.05 6.5-8.0 Mio. t leaching residues Au ppm 0 – 3 In % 0 – 0.03 Ga % 0 – 0.03 Ge % 0 – 0.04 Recycling of Industrial By-Products
Copper Primary and Secondary Metallurgy Aurubis and Grillos metal loop, Business Europe 40–80 kg/t copper amount Zn % 35.0 – 45.0 Pb % 10.0 – 15.0 World wide: Ag % 0.02 – 0.3 Cu % 1.0 – 5.0 Sn % 2.0 – 4.0 6.5-8.0 Mio. t leaching residues 15 Cl % 3.0 – 6.0 Br % 2.0 – 5.0 F % 0.5 – 1.5 Recycling of Industrial By-Products
Lead Primary Metallurgy 500–800 kg/t zinc amount Zn % 2.5 – 18.3 World wide: Pb % 0.1 – 3.6 Ag % 0 – 0.01 Fe % 20,0 – 31.5 6.5-8.0 Mio. t leaching residues Cu % 0.1 – 1.6 Sn % 0.1 – 0.8 Recycling of Industrial By-Products
Steel Industry 18-22 kg/t of steel amount Zn % 20,0 – 38,0 Pb % 2.0 – 8.0 World wide: Fe % 15.0 – 30.0 Cl % 1.0 – 5.0 - 10 Mio. t high zinc containing F % 0.2 – 0.8 CaO % 5.0 – 12.0 - 20 Mio. t low zinc containing SiO2 % 4.0 – 9.0 Recycling of Industrial By-Products
State of the Art – By-products Why are By-products interesting nowadays - Interesting metal contents - Increased Base Metal prices - The Minor Metals in the by-products have become more important and with this increase the overall value - Landfilling fees increased and environmental considerations became more important - The strategy of different companies to realize Zero-Waste solutions - Conservation of primary resources Recycling of Industrial By-Products
State of the Art – By-products Reasons for low recycling rates of industrial by-products - Missing characterization (know-how) of the material - Missing interdisciplinary activities between involved scientific fields (Mineral processing, Metallurgy, Mineralogy, Analytics) - No efficient base for the evaluation regarding investment decisions causing high efforts in project planning, execution and final decisions. - Utilization of less innovative concepts Recovery of only one metal High amounts of newly generated residues Low product quality Recycling of Industrial By-Products
WWW.NICHTEISENMETALLURGIE.AT Chair of Nonferrous Metallurgy Case-study Slags from lead industry 06.09.2019 Chair of Nonferrous Metallurgy – University of Leoben, Austria Juergen.Antrekowitsch@unileoben.ac.at
Key Facts Dump with 1.5 Mio. tons of lead slag (south of Europe) Environmental problems (ground water contamination etc.) Composition: Element Concentration Method Element Concentration Method [wt.-%] [wt.-%] Pb 2.36 DIN EN ISO 11885 MnO 1.29 DIN EN ISO 11885 9.05 Zn 8.05 DIN EN ISO 11885 Na 0.38 DIN EN ISO 11885 Ag 0.003 DIN EN ISO 11885 Fe 27.90 DIN EN ISO 11885 Cu 0.57 DIN EN ISO 11885 C 0.13 DIN EN ISO 15350 SiO 2 21.80 DIN EN ISO 11885 S 2.31 DIN EN ISO 15350 CaO 14.00 DIN EN ISO 11885 Al 2 O 3 6.99 DIN EN ISO 11885 MgO 1.70 DIN EN ISO 11885 amount Huge number of similar dumps worldwide Zn % 2.5 – 18.3 Pb % 0.1 – 3.6 Ag % 0 – 0.01 Fe % 20,0 – 31.5 Cu % 0.1 – 1.6 Sn % 0.1 – 0.8 Recycling of Industrial By-Products
Detailed dump evaluation Characterization Drilling program: - grid with 80 holes - 700 samples Results: - SEM - XRD - Confirmed analytics of first samples - Melting - Homogeneous dump structure behaviour - Etc. - No harmful contaminations - Confirmed amount of roughly 1.5 Mio. t Concept for treatment Recycling of Industrial By-Products
Feasibility Process development Reduction on lead bath Revenues Small scale experiments as well as Out of Zn-concentrate: 136 USD/t technical scale trials (100 kg per batch) Out of Pb-bullion: 32 USD/t TBRC and Electric furnace Treatment fees: 20 USD/t Sum: 188 USD/t OPEX (100 000 t/a) 123 USD/t CAPEX (100 000 t/a) 23 Mio. USD Results Up-scaling to 1000 kg Zn- and Pb-yield above 90 % Some silver and copper recovered Recycling of Industrial By-Products
WWW.NICHTEISENMETALLURGIE.AT Chair of Nonferrous Metallurgy Case-study Steel Dust recycling 06.09.2019 Chair of Nonferrous Metallurgy – University of Leoben, Austria Juergen.Antrekowitsch@unileoben.ac.at
Key Facts 12,000 tons of dust per year out of steel production (Austrian steel producer mix) Currently treated via Waelz kiln technology or dumped Composition: % Zn Pb SiO 2 CaO Na K F Cl Fe mix 30.4 5.3 4.2 7.6 1.6 1.2 0.4 5.2 28.5 % Zn Pb SiO 2 CaO Na K F Cl Fe European EAF and EAF 18-40 3-8 3-5 6-9 1.0-2.0 0.8-1.5 0.2-0.5 2.0-5.5 18-35 BOF dust: BOF 1-15 0.1-2.3 2-6 5-15 0-1.0 0.5-1.1 0-0.5 0-2.0 24-45 Recycling of Industrial By-Products
Characterization Process definition Complexity of dust Process developed by the University of morphology Leoben and the company ARP GmbH -> special characterization required 2sDR – 2-step-Dust-Recycling - Seperates chlorides and most of fluorides - Allows the recovery of iron - Generates only low amounts of final residues Recycling of Industrial By-Products
Process development Feasibility Calcination and reduction on iron bath Revenues Small scale experiments as well as Out of Zn-concentrate: 462 USD/t technical scale trials (100 kg per batch) Out of Fe-alloy: 45 USD/t agglommeration calcination reduction Treatment fees + savings in transport: 100 USD/t Sum: 607 USD/t OPEX (12 000 t/a) 182 USD/t CAPEX (12 000 t/a) 18 Mio. USD Results Zn-yield above 95 % (high quality oxide) Up-scaling to 1000 kg 90 % iron-recovery (low quality) Recycling of Industrial By-Products
WWW.NICHTEISENMETALLURGIE.AT Chair of Nonferrous Metallurgy Further case-studies Summary 06.09.2019 Chair of Nonferrous Metallurgy – University of Leoben, Austria Juergen.Antrekowitsch@unileoben.ac.at
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