[PPT] - Materials Production Materials Production Materials Production PowerPoint Presentation

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Materials Production Materials Production Materials Production Materials Production

T. G. Gutowski

with significant contributions by A. Thiriez

2.83/2.813 2008

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Reading Reading Reading Reading

a) Masini and Ayres, “An Application

f Exergy Accounting to Five Basic

Metal Industries”, 2001 (click here for PDF).

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Materials Production Materials Production Materials Production Materials Production

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Recycle, Remanufacture, Reuse Mining Primary Mfg Distribution Use Disposition

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Mining Primary Mfg Distribution Use Disposition

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Recycle, Remanufacture, Reuse

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Recycle, Remanufacture, Reuse

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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

0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 Chemicals Petroleum and Coal Plastics and Rubber Primary Metal Fabricated Metal Machinery Electronic Transportation

Manufacturing industries

Weight/Dollars

CO2 (metric ton/$10,000) Toxic Mat'ls (lb/$1000)

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Outline Outline Outline Outline

1. Extraction, Mining
2. Refining, Smelting
3. Mass and Exergy for US industry
Copper, Iron, Aluminum, Zinc, Polymers

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Crustal Abundance

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Reserves Vs Crustal Abundance

Chapman

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“ “ “ “McKelvey McKelvey McKelvey McKelvey Box” Box” Box” Box”

Reserves

Decreasing Geologic Assurance of Existence Increased Economic Feasibility

marginally economical

Adapted from C. F. Murphy, and McKelvey, 1972

Resource Base Undiscovered

KNOWN KNOWN KNOWN KNOWN UNKNOWN UNKNOWN UNKNOWN UNKNOWN

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Known Resources of Uranium Known Resources of Uranium Known Resources of Uranium Known Resources of Uranium

Chapman

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Definitions Definitions Definitions Definitions

Reserves

Reserves Reserves Reserves- the amount of a commodity that has been located and which can be economically extracted with current technology and prices

Resources

Resources Resources Resources- reserves plus an estimate of the amount the 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

Resource Base Resource Base Resource Base- all of a commodity contained in the earth’s crust

C. F. Murphy

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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

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Chapman

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Source: http://encarta.msn.com/media_461533479_761561391_-1_1/Open-Pit_Copper_Mine_Utah.html

Open-Pit Copper Mine, Utah

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Copper Ore Grades in the US Copper Ore Grades in the US Copper Ore Grades in the US Copper Ore Grades in the US

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Chuquicamata Chuquicamata Chuquicamata Chuquicamata, Chile , Chile , Chile , Chile

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drilling rig in underground mine in the Głogow area of Poland

Copper concentrations in this area are about 2%

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energy requirements for mining and milling, possible future trends

Chapman and Roberts p 113 & 116 underground ~ 1000/g (MJ/t metal)

pen pit ~ 400/g (MJ/t metal)

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“ “ “ “Sherwood” Plot Sherwood” Plot Sherwood” Plot Sherwood” Plot

Chapman & Roberts 1983 Grubler 1998

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Main Ore Types for Copper Main Ore Types for Copper Main Ore Types for Copper Main Ore Types for Copper globally 90% sulfides, 10% oxides globally 90% sulfides, 10% oxides globally 90% sulfides, 10% oxides globally 90% sulfides, 10% oxides

Sources: http://en.wikipedia.org/

Cu2S: Chalcocite Cu20: Cuprite Cu2CO3 (OH)2: Malachite CuFeS2: Chalcopyrite (50%

f Copper Production)

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Acid mine drainage Acid mine drainage Acid mine drainage Acid mine drainage

4FeS2 + 15O2 +14H2O→ 4Fe(OH)3 + 8H2SO4

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Outline Outline Outline Outline

1. Extraction, Mining
2. Refining, Smelting
3. Mass and Exergy for US industry
Copper, Iron, Aluminum, Zinc, Polymers

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Głogow* Copper Smelter

*pronounced Gwogov

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Copper Smelting Process

Source: http://encarta.msn.com/media_461533478_761561391_-1_1/Production_of_Copper.html

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1) Copper Ore (~ 1%) → Concentrate (~20 to 35%)

milling, flotation, separation

2) Roasting and Smelting

Copper Smelting Process

CuFeS2 Cu2S (matte) 2FeOSiO2 (slag) 0.34

1

% Cu Cu (blister) ~98% Cu

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3) Roasting and Smelting 2FeS+3O2! 2FeO+2SO2 xFeO + ySiO2 !(FeO)x·(Si02)y - slag 2Cu2S + 3O2 ! 2Cu2O + 2SO2 Cu2S + 2Cu2O ! 6Cu + SO2 (blister copper ~98%) 4) Electrolytic Refining (99.99%) sulfuric acid electrolyte anode mud (1:100) contains (Cu, Ag, As, Se, Bi, ..Au, Te…)

Copper Smelting Process

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Source: http://encarta.msn.com/media_461547490_761561391_-1_1/Smelting_Copper.html

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electro-refining of copper

0.05 0.25 3 1 5 1 5 0.5 5 20 Ni Fe Bi Sb As Te Se Au Ag Cu

Anode slime analysis (%) see Greadel et al (2002)

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“The Metal Wheel”

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Outline Outline Outline Outline

1. Extraction, Mining
2. Refining, Smelting
3. Mass and Exergy for US industry
Copper, Iron, Aluminum, Zinc, Polymers

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Copper Mass Flows (US)

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Copper Exergy (US)

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Copper Summary (US)

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Tailings pond at Głogow, Poland

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.02X.9 to smelt, .02X.1 to tailings

these tailings will be mined in the future

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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

9% 2% 252 5.2 Zinc 0.6% 1% 203.7 2.1 Copper 26% Alu (bauxite) 10% 346.5 32.9 Aluminum Ore 53% + scrap 93% 20% 34.2 6.7(Fe) Steel Ore grade (percent) Bo / Bin Bin(MJ/kg) Bo(MJ/kg) Metal

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Manufacturing Process (A) Materials Processing (C) Energy Conversion for Materials Processing (D) Energy Conversion for Manufacturing (B)

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the fuel requirements of smelting

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possible future trends in energy use trends reflect lower ore grades

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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

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Check out these websites for copper mining and smelting

http://www.na-ag.com/NA_en http://www.mining-technology.com/projects/kghm/

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Iron: Important oxide ores

Hematite: Fe2O3 Magnetite: Fe3O4

Sources: http://en.wikipedia.org/ & http://resourcescommittee.house.gov/subcommittees/emr/usgsweb/materials/images/imgTaconite.jpg

Taconite

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Taco – night (not to be confused with Taconite)

This slide brought to you by Tacoo Bell

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Iron Blast Furnace

Materials required: 1. Iron Ore

2. Carbon (coke is used both as fuel and reducing agent). 3. Hot air (hot enough to ensure combustion of the fuel). 4. Flux (removes earthy matter – turns into slag) 5. Slag (combination of calcium carbonate, silica, alumina and other impurities).

Source: http://www.yourdictionary.com/images/ahd/jpg/A4blfurn.jpg

SLIDE 44

Reactions taking place in the furnace:

2 C + O2 ! 2 CO (1300 °C)
CaO + SiO2 ! CaSiO3

(1200 °C)

FeO + CO ! Fe + CO2

(800 °C - 1000 °C)

CaCO3 ! CaO + CO2

(800 °C - 1000 °C)

CO2 + C ! 2 CO (800 °C)
Fe3O4 + CO ! 3 FeO + CO2 (600 °C)
3 Fe2O3 + CO ! 2 Fe3O4 + CO2 (450 °C)

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Blast Furnace

Source: http://www.ssabox.com/news/Imagebank/blast%20furnace4.jpg

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Steel Exergy (US)

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Steel Summary (US)

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Aluminum

It is the most abundant metal (7% of the earth’s crust) but one of the most difficult metals to refine

Aluminum occurance:

Bauxite : Al2O3·2H20 Cryolite: Na3AlF6 + many silicates such as clay: H2Al2(SiO4)2·H20

Sources: http://en.wikipedia.org/ & http://www.musee.ensmp.fr/mineral//1021x.jpg

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Aluminum Production: 1. Bayer Process: obtain Alumina (Al2O3) from Bauxite.

A. Extraction: dissolve oxides with hot

solution of NaOH. Al(OH)3 + Na+ + OH

! Al(OH)4
+ Na+
B. Precipitation: reverse of above, but

controlling crystal formation. Al(OH)4

+ Na+ ! Al(OH)3 + Na+ + OH-
C. Calcination: water is driven off Al(OH)3

to form alumina (aluminum oxide). Al(OH)3 ---> Al2O3 + 3 H2O

Source: http://www.world-aluminium.org

SLIDE 50

2. Hall-Heroult Process

(Electrolytic Reaction).

Source: http://www.world-aluminium.org

Prebake Cell

A. Al2O3 is dissolved in molten

cryolite (Na3AlF6)

B. As the current passes

through this mixture, (4-5 volts, 50,000-280,000 amperes) aluminum ions reduce to molten aluminum at the cathode, and oxygen is produce at the anode reacting with carbon to produce CO2. 2 Al2O3 + 3 C ! 4 Al + 3 CO2

Prebake Anode

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Aluminum Exergy (US)

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Aluminum Summary (US)

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Zinc

Main Ore Types:

Smithsonite: ZnCO3 Sphalerite: (Zn, Fe)S Hemimorphite: Zn4Si2O7(OH)2·H2O

Sources: http://en.wikipedia.org/ & http://webmineral.com/specimens/FrankliniteSmall.jpg

Franklinite: (Fe,Mn,Zn)(Fe,Mn)2O4

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1. Concentrating Zinc

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flotation to 52
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0% 2. Roasting

Zinc Production

Sulfide to oxide (ZnO) reduce/distillation leaching and electrowinning

SLIDE 55

Roasting reactions
2 ZnS + 3 O2 ! 2 ZnO + 2 SO2
ZnS + 2 O2 ! 2 ZnSO4
One can either obtain a mixture of ZnO and

ZnSO4 (for the leaching process) or ZnO (for the distillation process).

The product of the above reactions is imbedded

in mixtures with other impurities.

Leaching & Distillation.

Zinc Production

SLIDE 56

Leaching: I. ZnO and ZnSO4 are leached with dilute H2SO4 to produce a zinc sulfide solution . ZnO+ + H2SO4 ! ZnSO4 + H2O II. The solution is purified to precipitate any metal impurities. III. An electrolytic cell is used to deposit the Zinc and sulfuric acid is produced as a by

p

roduct (can be used in step I.)

“The Electrolytic Plant, which is the size of four football fields, consumes the same amount of power as a city of 250,000 people”. Source: http://www.metsoc.org/virtu altour/processes/zinc- lead/electrolytic.asp

SLIDE 57

Source: http://www.swanseaheritage.net/img/article/100000_00767.jpg

Zinc Distillation Furnaces Old School

Batch Retort Process (Distillation): I. ZnO in the calcine mixture is mixed with anthracite coal and place in a fire

c

lay retort.

II. It is heated to 1250 °C.
III. Zinc vapor distills into an attached condenser.

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Polymer Production

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energy requirements for materials production (per cm3)

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Materials Production, Homework Materials Production, Homework Materials Production, Homework Materials Production, Homework

1. Estimate the efficiency for the Roasting and Smelting of copper sulfide ore in US Industry. 2. Estimate the efficiency for the final refining step for copper in US Industry. 3. Estimate the energy required to process recycled copper if you can skip the roasting and smelting process. 4. Using the CMU I/O model compare primary and secondary production of 1) aluminum and 2) copper in terms of energy use per dollar of output. Can you also do energy use per kg of output? How do these results compare with Masini and Ayres? 5. Please do an exergy analysis for 2Cu2S + 3O2 ! 2Cu2O + 2SO2 (An important reaction in copper smelting) Determine Bin, Bout and Blost How much energy is needed to drive this reaction?