Metrics of Material and Metal Ecology (eBook)

Cover 1
Contents 8
Preface 6
Contents 8
Introduction 16
Harmonizing the resource, technology and environmental cycles 18
Sustainability of metals? 21
Metals 23
Economics of metal processing and recycling 25
Societal and scientific relevance 25
Development of waste infrastructures 26
Support of decision-making 27
Systems approach 30
Motivation for processing of residual material 31
System approach to car recycling 32
System approach to the recycling of aluminium 38
The system for recycling of products and metals 44
Overview of Book 45
Metal and Material Ecology 47
Product Recycling as applied to the Car 49
Aluminium Metallurgical and Recycling 52
Various appendices of data and case studies 53
Metal and Material Ecology 54
Sustainability and industrial ecology 56
Sustainability or sustainable development? 56
Achieving Sustainability 59
Going where? 59
Getting there 60
Industrial Ecology 61
The concept 62
The industrial notion 62
The ecological notion 63
The toolbox 67
Prescriptive approaches 67
Descriptive approaches 71
The promise of Industrial Ecology 74
The concept of industrial ecology 74
Tools 75
Summary 76
A description of the metal cycles 78
Metal resource cycles 78
An introduction to metal production 81
Interdependence 81
Resilience 87
Tacit Knowledge 91
Industrial ecology models for metal production and recycling 94
Methodology 94
Goal, scope and resolution 95
Interdependence between metal production circuits 96
Interdependence in metal production processes 96
Goal and scope revisited 99
Data availability 100
Mass balance models 100
Data requirements and availability 101
Data reconciliation 104
Potential for industrial ecology: Convergence of methods 105
Summary 109
A prescription for the metal cycles 110
Metal ecology 110
Goals for "sustainable" metal metabolism 111
Dynamics in the resource cycles 112
The dilution of metals 113
Interaction with the society cycles 114
Interaction with the technological cycle: Metal recycling 115
Discussion 118
The role of metallurgy in closing the resource cycles 119
Waste managers: Adaptive waste management strategy 119
Product designers: Design for metallurgy strategy 123
Metallurgists: new approaches to process control and design 124
Discussion 129
Controlling the resource cycles 130
Integrated control of the metal resource cycles 132
Metal resource cycles as self-organizing feedback systems 132
Feedforward control of resource cycles 137
Hybrid Feedback and Feedforward control 138
Discussion 139
Summary 140
Electronics Recycling: Lead free solder 142
Why lead production? 142
Sources 143
Lead toxicity 144
Legislation 144
Modelling the metal cycles 145
Bottom-up approach 145
Flowcharts of the metal cycles 147
Detailed Model description 148
General model framework 148
The inventory and modelling approach 151
Bottom-up approach 156
Interpretation and impacts assessment 173
Simulations 178
Detoxification strategy - lead-free solders 180
Lead-free solders options 180
Metallurgist 181
Product designer and manufacturer 184
Waste manager 188
Policy-maker and Legislator 189
Containment strategy - Cleaner recycling 191
Policy-maker and legislator 193
Waste manager 195
Metallurgist 196
Product designer and manufacturer 196
Discussion 199
Linking decision-making 199
Capturing interdependence 199
Closing the resource cycles, a dynamic problem 200
A further phase-out of lead 200
Eco efficient optimization of an Isasmelter 201
Background and relevance of the copper smelting 201
Umicore smelting 203
LCA model approach 206
FEED Model parameterisation and validation 207
LCA statistics 209
Chain optimization 209
Summary 210
Examples and case study 210
Decrease of copper production due to replacement of copper pipes with PVC pipes 210
Use of different DVD players 211
The sensitivity of the model 211
Web of Metals model discussed 214
Sustainability of industrial ecology 214
Technological knowledge, a bottleneck for sustainability? 215
The role of models to co-ordinate decision-making 216
Can industrial ecology models provide the necessary knowledge? 217
Conclusions 218
Sustainability, an emerging system property 218
Connecting the industrial and ecological thinking in industrial ecology 218
The dynamic interdependence of the metal metabolism 219
Feedforward control in the metal ecology 219
A predictive dynamic model to control the metal metabolism 220
Metal Ecology 221
Product Recycling as applied to the Car 222
The dynamic and distributed nature of the recycling rate of the car - a fundamental description of recycling systems 224
Introduction 225
Recycling Rates 225
Directive 2000/53/EC on ELV's 230
EU definition of the recycling rate of the car 231
Literature definitions of the recycling rate 232
Dynamic modelling of the resource cycle of end-of-life vehicles 233
Statistical nature of the resource cycle of products 234
Formulation of model and definition of recycling rate 241
Dynamic model 242
Definition of the Recycling Rate (RR) 242
Alternative definitions for the recycling rate 244
Accuracy of the model 244
Standard deviation/error margin 245
Dynamic simulation of the recycling and recovery rate of cars 245
Definition of the distribution functions for simulation 245
The weight and composition of the average car at recycling 248
The recycling rate at end-of-life 251
Recycling rate over the in-/output of the system 253
Recovery rate over the system 254
Examples and case study 256
Building waste 256
Recycling of Al from buildings 256
Is 95% recovery rate for ELV's a "Perpetuum mobile"? 256
Evaluate the EU recycling definition 258
Calculate recycling rate (I) 258
Calculate recycling rate (II) 259
Summary 260
Dynamic modelling and optimization of the resource cycle of passenger vehicles - a technological framework 264
Recycling rate 265
Modelling/simulating the recycling of cars - A theoretical dynamic framework 266
Formulation of dynamic model 267
Parameterisation of the dynamic model 269
Optimization & Simulation model for recycling end-of-life vehicles
Technology of recycling - The multi-level flowsheet 270
Interconnected processes and material streams 272
Definition of the optimization model for recycling end-of-life vehicles 274
Optimal dynamic modelling of aluminium recycling - a case study 280
Dynamic simulation of the aluminium recycling 280
Optimization of the recycling of the car - various simulation results 281
Discussion 285
Examples and case study 291
Monitoring and chain management for ELV recycling 291
The role of particle size reduction, liberation and product design in recycling passenger vehicles 296
Introduction 297
Recycling optimization model linking the liberation to the recycling rate of end-of-life vehicles 299
Phase description of the material streams 300
Formulation of the recycling optimization model 301
Flowsheet of the model 304
Parameterisation of the recycling optimization model 304
Simulations on the optimization of product design, liberation and metallurgy 307
Simulation results 309
Modelling of particle size reduction and liberation in recycling of ELV's 312
Design for recycling and design for environment 312
Particle liberation modelling of ELV's in relation to minerals processing 314
Flowsheet of the model for recycling end-of-life vehicles 316
Phase description of the model 316
Alloy types 318
Separation models 319
Formulation of the recycling optimization model 320
Parameterisation of the model 325
Linking design to recycling 335
Simulations on the optimization of product design, liberation and metallurgy 339
Discussion 344
Recycling experiments - from theory to practice 350
Introduction 351
An industrial recycling experiments 352
Calculation of required batch size of ELV's and sampling for analyses 354
Mass balancing 354
Weighing, sampling and analyses of material flows 356
Characterisation of input (1153 ELV's) 356
Weighing of the material streams 357
Sampling 357
Procedures on the plant during sampling 357
Analyses of material flows 359
Calculation of mass balance on such an experiment 361
Data reconciliation 361
Recovery (split) factors 363
Grade of recycling (intermediate) products 363
Samples on material flows 367
Standard deviation 369
Recycle streams 370
Practical calculation of the recycling rate from the recycling experiment 370
De-pollution 370
System boundaries 370
Procedure for the calculation of recycling/recovery rate and corresponding statistics 371
Recycling and recovery rate 372
Data for model calibration 372
Discussion 372
Examples and case study 374
Calculate sample size for an ELV steel sample 374
Definition of the ISO norm and monitoring protocol for the calculation and prediction of the recycling rate of end-of-life vehicles 374
Design of a monitoring optimization model 375
Aluminium Metallurgy and Recycling 378
Raw materials for aluminium production 380
Aluminium primary raw materials 380
Ore reserves and bauxite 381
Mining 382
Aluminium secondary/recycled materials 382
Unalloyed scrap and residues 383
New scrap 384
Old scrap 385
Pre-treatment of aluminium containing material 388
Mineral processing of aluminium ores 388
Separation processes for aluminium metal containing material 388
Separation methods for aluminium recycling 390
Shredding and cutting 396
Processing by dry separation 398
Processing by wet separation 402
Compacting of aluminium scrap 403
Thermal treatment 404
Aluminium metal production 406
Primary production of aluminium 407
Alumina production 407
Smelting flux electrolysis 408
Other processes 409
Recycling of aluminium metal containing material 409
Re- or Downcycling? 411
Preparation of charges 411
Melting furnaces for scrap 415
The properties of the salt flux for aluminium melting 423
Sedimentation of aluminium in the salt flux 434
Processing of salt flux 444
Melting of some modern aluminium materials 447
Treatment of liquid metal 459
Emissions 463
Products 464
Simulating a rotary furnace for aluminium recycling 468
Mass and energy balance model 468
Mass balance model for the rotary furnace 471
Energy balance for the rotary furnace 473
Results of combined mass and energy balance calculations 475
Sensitivity analysis with the model 475
Data reconciliation 476
Smelter balance 477
Conclusion 479
CFD simulation of a furnace for Al recycling 479
CFD framework of the process model 480
User developed sub-models 481
Results 487
Discussion of CFD model 493
Fundamentals of physical separation and metallurgical recycling 494
Participate recycling systems 494
Sampling 494
Population Balance Modelling (PBM) 497
Physical Separation basics 503
Thermodynamics of recycling metallurgy 510
Properties of materials,'metals and alloys (by example) 511
Metallurgical thermodynamics 517
Exergy: Measure of the quality loss of recycled materials 535
Computational fluid-dynamics modelling 540
Introduction 540
Basic principles of CFD 543
Examples of the modelling of furnaces 559
Description of metal production flowcharts 572
Bismuth production and recycling profile 575
End uses 575
Production 575
Reconciled mass balances 577
Copper production and recycling profile 581
End uses 581
Production 581
Reconciled mass balances 585
Gold production and recycling profile 592
End uses 592
Production 592
Reconciled mass balances 593
Lead production and recycling profile 598
End uses 598
Production 598
Reconciled mass balances 602
Nickel production and recycling profile 609
End uses 609
Production 609
Reconciled mass balances 613
Platinum Group Metals 620
End uses 620
Production 620
Silver 623
End uses 623
Production 623
Reconciled mass balances 624
Tin production and recycling profile 630
End uses 630
Production 630
Reconciled mass balances 624
Zinc production and recycling profile 639
End uses 639
Production 640
Reconciled mass balances 642
Calculation waste composition 647
Method 647
Consumption 647
Solid waste management 658
Car recycling - a numerical study 664
Matlab Source code for Dynamic Model 664
AMPL code for optimization model 673
Excel optimization model 677
Simulink model for Metal Web 680
Bibliography 682
Index 712