Materials Production Materials Production Materials Production Materials Production T. G. Gutowski with significant contributions by A. Thiriez 2.83/2.813 2008
Reading Reading Reading Reading Masini and Ayres, “An Application a) of Exergy Accounting to Five Basic Metal Industries” , 2001 (click here for PDF).
Materials Production Materials Production Materials Production Materials Production Mining Primary Mfg Distribution Use Disposition Mining Primary Mfg Distribution Use Disposition & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & m m m m m & & & & & m m m m m & & & & & m m m m m & & & & & m m m m m & & & & & m m m m m & & & & & m m m m m & & & & & m m m m m m m m m m m m m m m m m m m m m m m m m m m m m m 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 & & & & & & & & & & & & & & & & & & & & & & & & & & & & & & m & m & m & m & m & m m m m m p p p p p o o o o o m & m & m & m & m & m m m m m p p p p p o o o o o m & m & m & m & m & m m m m m p p p p p o o o o o m & m & m & m & m & m m m m m p p p p p o o o o o m & m & m & m & m & m m m m m p p p p p o o o o o m & m & m & m & m & m m m m m p p p p p o o o o o p p p p p i i i i i p p p p p i i i i i p p p p p i i i i i p p p p p i i i i i p p p p p i i i i i p p p p p i i i i i k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k Recycle, Remanufacture, Reuse Recycle, Remanufacture, Reuse Recycle, Remanufacture, Reuse
Mat Mat Mat ’ Mat ’ ’ ’ l l l l Production and Mfg Production and Mfg Production and Mfg Production and Mfg Carbon Dioxide and Toxic Materials per Value of Shipments 5 4.5 4 Weight/Dollars 3.5 CO2 (metric 3 ton/$10,000) 2.5 2 Toxic Mat'ls (lb/$1000) 1.5 1 0.5 0 Transportation Machinery Primary Metal Petroleum Plastics and Electronic Chemicals Fabricated and Coal Metal Rubber Manufacturing industries
Outline Outline Outline Outline 1. Extraction, Mining 2. Refining, Smelting 3. Mass and Exergy for US industry • Copper, Iron, Aluminum, Zinc, Polymers
Crustal Abundance
Reserves Vs Crustal Abundance Chapman
“ “ “ McKelvey “ McKelvey McKelvey McKelvey Box ” Box ” Box ” Box ” UNKNOWN UNKNOWN UNKNOWN UNKNOWN KNOWN KNOWN KNOWN KNOWN Increased Economic Feasibility Reserves Undiscovered marginally economical Resource Base Decreasing Geologic Assurance of Existence Adapted from C. F. Murphy, and McKelvey, 1972
Known Resources of Uranium Known Resources of Uranium Known Resources of Uranium Known Resources of Uranium Chapman
Definitions Definitions Definitions Definitions Reserves - the amount of a commodity that has been • Reserves Reserves Reserves located and which can be economically extracted with current technology and prices Resources - reserves plus an estimate of the amount the • Resources Resources Resources commodity that is as yet undiscovered but would be profitable to extract plus an estimate of located deposits that are expected to be profitable in the near future due to emerging technologies (cost reductions) or moderate price increases Resource Base - all of a commodity contained in the • Resource Base Resource Base Resource Base earth’s crust C. F. Murphy
Probability of Discovery Probability of Discovery Probability of Discovery Probability of Discovery • Function of size of target area and number of attempts to locate a field – Early in discovery process, low number of hits – Late in discovery process, low probability of undetected field C. F. Murphy
Chapman
Open-Pit Copper Mine, Utah Source: http://encarta.msn.com/media_461533479_761561391_-1_1/Open-Pit_Copper_Mine_Utah.html
Copper Ore Grades in the US Copper Ore Grades in the US Copper Ore Grades in the US Copper Ore Grades in the US
Chuquicamata Chuquicamata Chuquicamata Chuquicamata, Chile , Chile , Chile , Chile
drilling rig in underground mine in the G ł ogow area of Poland Copper concentrations in this area are about 2%
energy requirements for mining and milling, possible future trends underground ~ 1000/g (MJ/t metal) open pit ~ 400/g (MJ/t metal) Chapman and Roberts p 113 & 116
“ “ “ “ Sherwood ” Plot Sherwood ” Plot Sherwood ” Plot Sherwood ” Plot Chapman & Roberts 1983 Grubler 1998
Main Ore Types for Copper Main Ore Types for Copper Main Ore Types for Copper Main Ore Types for Copper globally 90% sulfides, 1 0% oxides globally 90% sulfides, 1 0% oxides globally 90% sulfides, 1 0% oxides globally 90% sulfides, 1 0% oxides Cu 2 S: Chalcocite Cu 2 0: Cuprite CuFeS 2 : Chalcopyrite (50% Cu 2 CO 3 (OH) 2 : Malachite of Copper Production) Sources: http://en.wikipedia.org/
Acid mine drainage Acid mine drainage Acid mine drainage Acid mine drainage 4FeS 2 + 15O 2 +14H 2 O → 4Fe(OH) 3 + 8H 2 SO 4
Outline Outline Outline Outline 1. Extraction, Mining 2. Refining, Smelting 3. Mass and Exergy for US industry • Copper, Iron, Aluminum, Zinc, Polymers
G ł ogow* Copper Smelter *pronounced Gwogov
Copper Smelting Process Source: http://encarta.msn.com/media_461533478_761561391_-1_1/Production_of_Copper.html
Copper Smelting Process 1) Copper Ore (~ 1%) → Concentrate (~20 to 35%) • milling, flotation, separation 2) Roasting and Smelting Cu (blister) Cu 2 S (matte) ~98% Cu CuFeS 2 2FeOSiO 2 (slag) 0.34 - 1 % Cu
Copper Smelting Process 3) Roasting and Smelting 2FeS+3O 2 ! 2FeO+2SO 2 xFeO + ySiO 2 ! (FeO) x ·(Si0 2 ) y - slag 2Cu 2 S + 3O 2 ! 2Cu 2 O + 2SO 2 Cu 2 S + 2Cu 2 O ! 6Cu + SO 2 (blister copper ~98%) 4) Electrolytic Refining (99.99%) sulfuric acid electrolyte anode mud (1:100) contains (Cu, Ag, As, Se, Bi, ..Au, Te…)
Source: http://encarta.msn.com/media_461547490_761561391_-1_1/Smelting_Copper.html
electro-refining of copper Cu Ag Au Se Te As Sb Bi Fe Ni 20 5 0.5 5 1 5 1 3 0.25 0.05 Anode slime analysis (%) see Greadel et al (2002)
“The Metal Wheel”
Outline Outline Outline Outline 1. Extraction, Mining 2. Refining, Smelting 3. Mass and Exergy for US industry • Copper, Iron, Aluminum, Zinc, Polymers
Copper Mass Flows (US)
Copper Exergy (US)
Copper Summary (US)
Tailings pond at G ł ogow, Poland
. 02X.9 to smelt, .02X.1 to tailings these tailings will be mined in the future
Summary from Summary from Summary from Summary from Masini Masini Masini Masini & Ayres & Ayres & Ayres & Ayres Exergy Exergy Exergy Exergy Analysis for U.S. Industries Analysis for U.S. Industries Analysis for U.S. Industries Analysis for U.S. Industries B o / B in Metal B o (MJ/kg) B in (MJ/kg) Ore grade (percent) Steel 6.7(Fe) 34.2 20% Ore 53% + scrap 93% Aluminum 32.9 346.5 10% 26% Alu (bauxite) Copper 2.1 203.7 1% 0.6% Zinc 5.2 252 2% 9%
& → B Q * , T R R * & + & + fuel air fuel air H H 1 0 * Energy Conversion for & Manufacturing (B) + & + fuel air fuel air S S 1 0 * & → B W & ← S C Q * , T & ← A W R R * S & materials & H 1 & product materials H 3 H 2 Materials Manufacturing & & Processing (C) materials Process (A) & materials S 1 S 2 product S 3 & ← C W S & → D W Q ← & A * , T S R R * & & + + fuel air fuel air H H 1 0 * Energy Conversion for & Materials Processing (D) + & + fuel air fuel air S S 1 0 * & → D Q * , T R R *
the fuel requirements of smelting
possible future trends in energy use trends reflect lower ore grades
bio-toxicity of copper • Copper in drinking water (USEPA, WHO) • Copper in fresh water ( 5 pbb) • bioavailability and the biotic ligand model “BLM” • gastrointestinal effects (NOAEL 2mg/L) • Wilson’s disease and 5% of population • aggressive water
Check out these websites for copper mining and smelting http://www.na-ag.com/NA_en http://www.mining-technology.com/projects/kghm/
Iron: Important oxide ores Hematite: Fe 2 O 3 Magnetite: Fe 3 O 4 Taconite Sources: http://en.wikipedia.org/ & http://resourcescommittee.house.gov/subcommittees/emr/usgsweb/materials/images/imgTaconite.jpg
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