By-products from industrial processes A potential substitution for - - PowerPoint PPT Presentation

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By-products from industrial processes A potential substitution for - - PowerPoint PPT Presentation

Aug 20, 2022 44 likes •385 views

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

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WWW.NICHTEISENMETALLURGIE.AT

Chair of Nonferrous Metallurgy

Juergen.Antrekowitsch@unileoben.ac.at Chair of Nonferrous Metallurgy – University of Leoben, Austria 06.09.2019

Juergen Antrekowitsch

By-products from industrial processes – A potential substitution for primary resources? Characteristics, case studies and certification strategies

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WWW.NICHTEISENMETALLURGIE.AT

Chair of Nonferrous Metallurgy

Juergen.Antrekowitsch@unileoben.ac.at Chair of Nonferrous Metallurgy – University of Leoben, Austria 06.09.2019

Introduction

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Recycling of Industrial By-Products

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
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Recycling of Industrial By-Products

Chair of Nonferrous Metallurgy

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Recycling of Industrial By-Products

Strategy – from fundamental to applied research

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WWW.NICHTEISENMETALLURGIE.AT

Chair of Nonferrous Metallurgy

Juergen.Antrekowitsch@unileoben.ac.at Chair of Nonferrous Metallurgy – University of Leoben, Austria 06.09.2019

Raw Materials in Europe

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Recycling of Industrial By-Products

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.

The EU Circular Economy and Its Relevance to Metal Recycling, Ch. Hagelüken United Nations Environment Program / Challenges of Metal Recycling, M. Reuter

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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
  • Avoidance of CO2 – emissions
  • Permissions
  • Safety
  • etc.

How to combine these generally positive aspects for the environment with an economic resource utilization?

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9 Research Group: Recycling of Heavy Metals from Complex Residues Research Group: Recycling of Heavy Metals from Complex Residues

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Raw Materials leaving Europe

Electronic scrap Car scrap Car catalysts Gold concentrate Zinc-concentrate Zinc-, Lead-Residues

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WWW.NICHTEISENMETALLURGIE.AT

Chair of Nonferrous Metallurgy

Juergen.Antrekowitsch@unileoben.ac.at Chair of Nonferrous Metallurgy – University of Leoben, Austria 06.09.2019

By-products Introduction

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Recycling of Industrial By-Products

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By-products – Residues – Secondary Resources

Pyrometallurgy Hydrometallurgy

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Recycling of Industrial By-Products

By-Products – Secondary Resources

.

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

Multi-metal containing primary ores Lead to complex but valuable by-products

United Nations Environment Program / Challenges of Metal Recycling, M. Reuter

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WWW.NICHTEISENMETALLURGIE.AT

Chair of Nonferrous Metallurgy

Juergen.Antrekowitsch@unileoben.ac.at Chair of Nonferrous Metallurgy – University of Leoben, Austria 06.09.2019

By-products Examples

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Recycling of Industrial By-Products

Zinc Primary Metallurgy

Zn % 1.5 – 8.4 Pb % 0.5 – 7.1 Ag % 0 – 0.05 Au ppm 0 – 3 In % 0 – 0.03 Ga % 0 – 0.03 Ge % 0 – 0.04

500–900 kg/t zinc World wide: 6.5-8.0 Mio. t leaching residues

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Recycling of Industrial By-Products

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Copper Primary and Secondary Metallurgy

amount Zn % 35.0 – 45.0 Pb % 10.0 – 15.0 Ag % 0.02 – 0.3 Cu % 1.0 – 5.0 Sn % 2.0 – 4.0 Cl % 3.0 – 6.0 Br % 2.0 – 5.0 F % 0.5 – 1.5

40–80 kg/t copper World wide: 6.5-8.0 Mio. t leaching residues

Aurubis and Grillos metal loop, Business Europe

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Recycling of Industrial By-Products

Lead Primary Metallurgy

amount 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

500–800 kg/t zinc World wide: 6.5-8.0 Mio. t leaching residues

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Recycling of Industrial By-Products

Steel Industry

18-22 kg/t of steel World wide:

  • 10 Mio. t high zinc containing
  • 20 Mio. t low zinc containing

amount Zn % 20,0 – 38,0 Pb % 2.0 – 8.0 Fe % 15.0 – 30.0 Cl % 1.0 – 5.0 F % 0.2 – 0.8 CaO % 5.0 – 12.0 SiO2 % 4.0 – 9.0

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Recycling of Industrial 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

State of the Art – By-products

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Recycling of Industrial 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

State of the Art – By-products

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WWW.NICHTEISENMETALLURGIE.AT

Chair of Nonferrous Metallurgy

Juergen.Antrekowitsch@unileoben.ac.at Chair of Nonferrous Metallurgy – University of Leoben, Austria 06.09.2019

Case-study Slags from lead industry

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Recycling of Industrial By-Products

Key Facts

Dump with 1.5 Mio. tons of lead slag (south of Europe) Environmental problems (ground water contamination etc.) Composition: Huge number of similar dumps worldwide

Element Concentration [wt.-%] Method Element Concentration [wt.-%] Method Pb 2.36 DIN EN ISO 11885 MnO 1.29 DIN EN ISO 11885 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 SiO2 21.80 DIN EN ISO 11885 S 2.31 DIN EN ISO 15350 CaO 14.00 DIN EN ISO 11885 Al2O3 6.99 DIN EN ISO 11885 MgO 1.70 DIN EN ISO 11885 amount 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 9.05

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Recycling of Industrial By-Products

Characterization Detailed dump evaluation

  • SEM
  • XRD
  • Melting

behaviour

  • Etc.

Drilling program:

  • grid with 80 holes
  • 700 samples

Results:

  • Confirmed analytics of first samples
  • Homogeneous dump structure
  • No harmful contaminations
  • Confirmed amount of roughly 1.5 Mio. t

Concept for treatment

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Recycling of Industrial By-Products

Process development Feasibility

Reduction on lead bath Small scale experiments as well as technical scale trials (100 kg per batch) TBRC and Electric furnace Results Zn- and Pb-yield above 90 % Some silver and copper recovered Revenues Out of Zn-concentrate: 136 USD/t Out of Pb-bullion: 32 USD/t 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

Up-scaling to 1000 kg

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WWW.NICHTEISENMETALLURGIE.AT

Chair of Nonferrous Metallurgy

Juergen.Antrekowitsch@unileoben.ac.at Chair of Nonferrous Metallurgy – University of Leoben, Austria 06.09.2019

Case-study Steel Dust recycling

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Recycling of Industrial By-Products

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: European EAF and BOF dust:

% Zn Pb SiO2 CaO Na K F Cl Fe 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 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 % Zn Pb SiO2 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

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Recycling of Industrial By-Products

Characterization Process definition

Complexity of dust morphology

  • > special

characterization required Process developed by the University of Leoben and the company ARP GmbH 2sDR – 2-step-Dust-Recycling

  • Seperates chlorides and most of fluorides
  • Allows the recovery of iron
  • Generates only low amounts of final residues
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Recycling of Industrial By-Products

Process development Feasibility

Calcination and reduction on iron bath Small scale experiments as well as technical scale trials (100 kg per batch) Results Zn-yield above 95 % (high quality oxide) 90 % iron-recovery (low quality) Revenues Out of Zn-concentrate: 462 USD/t Out of Fe-alloy: 45 USD/t 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

Up-scaling to 1000 kg

agglommeration calcination reduction

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WWW.NICHTEISENMETALLURGIE.AT

Chair of Nonferrous Metallurgy

Juergen.Antrekowitsch@unileoben.ac.at Chair of Nonferrous Metallurgy – University of Leoben, Austria 06.09.2019

Further case-studies Summary

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Recycling of Industrial By-Products

Zinc precipitation residue Treatment of Nickel-jarosite

2 Mio. t dump (northern Europe) Combined Concept: Mineral processing – Metallurgy Value Creation: 100 kg scale successfully finalized

LME-based: 420 USD/t Realistic: 300 USD/t

Continuously produced in PGM(Ni)-smelter (Africa) Concept: Sulphur/Arsenic-removal – Reduction Final product: Ferro-Nickel-alloy 100 kg scale successfully finalized

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WWW.NICHTEISENMETALLURGIE.AT

Chair of Nonferrous Metallurgy

Juergen.Antrekowitsch@unileoben.ac.at Chair of Nonferrous Metallurgy – University of Leoben, Austria 06.09.2019

Assessment

  • f By-products
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Recycling of Industrial By-Products

Assessment of Secondary Resources

  • geochemical and mineralogical characterization of

raw materials

  • mineral processing of heavy metal containing by-

products

  • metallurgical processing principles and methods for

various metals

  • recover material from dumps
  • definition of products and their values
  • economic considerations

Example for a system for primary resources: Planned assessment for by-products:

PERC Reporting standard

Geology and mining of main importance

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Recycling of Industrial By-Products

Interdisciplinary Network

Involvement of different R&D companies

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Recycling of Industrial By-Products

  • By-products will play a more important role in future
  • A lot of these materials are continuously produced and much more is available on

dumps

  • Recycling of by-products could contribute to the metal supply especially in the fields
  • f zinc, lead copper and precious metals
  • More knowhow, more sophisticated processes and a concept for a reliable

evaluation are required to bring these resources more efficiently to the market

Summary

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Recycling of Industrial By-Products

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Thank you for your attention!

University of Leoben Chair of Nonferrous Metallurgy Franz-Josef-Str. 18 A-8700 Leoben Austria/Europe juergen.antrekowitsch@unileoben.ac.at http://www.nichteisenmetallurgie.at