LCM 2007 , Zurich, August 27-29 2007 Dynamic material flow analysis of copper and its alloys in Japan Ichiro Daigo, Susumu Hashimoto, Yasunari Matsuno, Yoshihiro Adachi Graduate School of Engineering, University of Tokyo Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo University of Tokyo Dept. of Materials Engineering, Graduate School of Engineering,
Tools for a sound material cycle Ore Electrolytic Material Flow Analysis Cathode copper Substance Flow Analysis Feedstock (MFA/SFA) Upgraded (?) Closed-loop recycling recycling High-purity copper Downgraded Conventional MFA/SFA studies recycling paid little attention to Closed-loop the grade of the materials. recycling Copper alloys Recycling system in copper Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo University of Tokyo Dept. of Materials Engineering, Graduate School of Engineering,
Copper and copper alloys (Production) Cu contents >99.90% Oxygen-free copper High- >99.90% purity Tough pitch copper copper >99.90% Phosphorous-deoxidized copper Brass (copper-zinc alloys) 59.0-71.5% Copper alloys 57.0-63.0% Free-cutting brass >96.0% High copper alloys Negli- Tin bearing brass 87.0-90.0% gible small Aluminum bronze 77.0-92.5% Source: Japan industrial standard Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo University of Tokyo Dept. of Materials Engineering, Graduate School of Engineering,
Copper and copper alloys (Scrap) Cu contents >97% Copper scrap >50% Copper-alloy scrap The instruction of census forms ‘when scrap can not be recognized as high copper or copper alloys, it should be categorized as copper alloy scraps.’ Certain amounts of high-copper scraps have been collected as copper alloy scraps, such as high-purity copper being discarded without separation from copper alloys, or metal plating or other metal components being collected as copper alloy scraps. Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo University of Tokyo Dept. of Materials Engineering, Graduate School of Engineering,
Objectives � A dynamic MFA was conducted separately for copper and copper alloys in Japan in order to estimate the stock and the potential for recycling of each of these materials. Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo University of Tokyo Dept. of Materials Engineering, Graduate School of Engineering,
Material stock and flow taken into account in this study Trades of Trades of finished materials products Output (C) consumption Obsolete In-use production Domestic (B) Input (H) material scrap (A) stocks (E) (F) (G) (D) Industrial Export as mixed metals scrap Dissipation Loss into Remaining steel cycle Landfill Environment “Uncollected materials” “ uncollected materials ” denotes disused materials that are not recovered domestically as copper- based scraps and that are lost from the domestic copper cycle. Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo University of Tokyo Dept. of Materials Engineering, Graduate School of Engineering,
Structure of Japanese copper industries Category of industry Electric wire Copper fabricated products (they have each and cable association) Category of metal Copper High-purity copper grade alloys Copper Copper Category in this Electric wire fabricated fabricated study and cable products products (Cu) (Cu alloys) Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo University of Tokyo Dept. of Materials Engineering, Graduate School of Engineering,
Population Balance Model; PBM Investigation Steel Production year Lifetime distribution Use in products of Steel-office buildings Discarded scrap The amount of steel products 2003 2002 2001 Lifetime distribution 1 of Automotives 2000 0.8 Remaining rate 0.6 0.4 1999 0.2 0 4 0 0 0 2 0 5 Lifetime 4 9 5 10 9 e 1 r u t c 15 a f Age u 10 n 4 a m 20 8 9 1 f o 15 r a 25 e Y 4 20 30 7 Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo University of Tokyo Dept. of Materials Engineering, Graduate School of Engineering, 9 1
Dynamic MFA Generation* collection rate= Obsolete scrap Data preparation Population -Recovery rates of EOL products -Separation efficiency of metals balance model Copper fabricated Electric wire and cable products Communication line and power cables 100% - Data preparation Electric and electronic machinery 55% 55% -historic consumption Automobiles 61% 58% -lifetime distribution of products Other machinery 50% 50% 1.0 自動車 AUT Construction 80% 56% 建設 CONST 電気機械 EEE Others 23% 23% 0.8 ケーブル W&C Remaining rate その他機械 MACH Others その他 Collection rates for each end use 0.6 0.4 0.2 0.0 0 20 40 60 80 100 Age/ year Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo University of Tokyo Dept. of Materials Engineering, Graduate School of Engineering,
Scrap generation (including uncollected materials) 1,200 From Electric appliances From Automobiles 1,000 From Construction Discarded scraps / 1,000t From Other machinery From Electronic wire and cable 800 From Others 600 400 200 0 1970 1975 1980 1985 1990 1995 2000 2005 Year Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo University of Tokyo Dept. of Materials Engineering, Graduate School of Engineering,
Comparison of collected scraps 1400 High- purity copper (EW C) Collected scraps [1,000t/ y] 1200 High- purity copper (CFP) Copper alloys 1000 Statistics 800 600 400 200 0 1970 1975 1980 1985 1990 1995 2000 2005 Year Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo University of Tokyo Dept. of Materials Engineering, Graduate School of Engineering,
Downgraded recycling Obs. from Electric appliances 1,000 Obs. from Automobiles Collected pure- Cu scraps [1,000t/ y] Obs. from Construction Obs. from Other machinery Obs. from Electronic wire and cable 800 Obs. from Others Industrial scraps Statistics 600 400 200 Obs. from Electric appliances 1,000 Obs. from Automobiles Collected Cu- alloy scraps [1,000t/ y] Obs. from Construction Obs. from Other machinery 0 Obs. from Electronic wire and cable 800 Obs. from Others 1970 1975 1980 1985 1990 1995 2000 2005 Industrial scraps Statistics Year 600 Collected high-purity copper scraps 400 200 0 1970 1975 1980 1985 1990 1995 2000 2005 Year Collected copper alloy scraps Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo University of Tokyo Dept. of Materials Engineering, Graduate School of Engineering,
Estimated amounts of in-use stocks, and cumulative uncollected materials 35,000 Cumulative uncollected materials 30,000 Communication line and power cables Electric and electronic machinery In- use Automobiles 25,000 Stocks [1,000 t] Other machinery stocks Construction Others 20,000 15,000 10,000 5,000 0 1950 1955 1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 Year Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo University of Tokyo Dept. of Materials Engineering, Graduate School of Engineering,
Annual uncollected materials 450 Annual uncollected materials [1,000t/ y] Communication line and power cables 400 Electric and electronic machinery Automobiles 350 Other machinery Construction 300 Others 250 200 150 100 50 0 1950 1955 1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 Year Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo University of Tokyo Dept. of Materials Engineering, Graduate School of Engineering,
The possible final destinations for uncollected materials in 2000 Final destinations Total for Exported Uncollected Loss into Other materials Landfill as mixed steel cycle losses metals Net weight of 334 114* 40 150 30 copper [1000 t] Proportion 100% 34% 12% 45% 9% * This was originally 160,000 tons in 1997, and was converted to the amount for 2000. Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo University of Tokyo Dept. of Materials Engineering, Graduate School of Engineering,
The cycle of high-purity copper in Japan for 2005 Import/Export Finished Used products Ore Copper Old scrap Exports as 424 products products mixed metals 238 (Net exp.) 152 64 Use Production 743 Fabrication & Waste 1190 639 96 Mill, Smelter, manufacturing management Refinery Stocks material cycles 14 17 276 209 496 Other 47 271 Loss 486 48 Landfill Environment Landfill 42 10 To other materials To copper alloys Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo University of Tokyo Dept. of Materials Engineering, Graduate School of Engineering,
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