rmi 2010-09 hagelüken - mmta · 2020. 2. 23. · title: rmi 2010-09 hagelüken author: u995857...

Recycling opportunities & limits

Dr. Christian HagelükenUmicore Precious Metals Refining

Workshop Critical raw materials

at EU levelBrussels

10. Sept. 2010

� Opportunities – why recycling is crucial

� Basics of recycling technology

� Challenges & limits of recycling

� Conclusion & recommendations

3Christian Hagelüken, Brussels RMI workshop, 10.9.2010

a) Mobile phones:

1300 Million units

x 250 mg Ag ≈ 325 t Ag

x 24 mg Au ≈ 31 t Au

x 9 mg Pd ≈ 12 t Pd

x 9 g Cu ≈ 12,000 t Cu

1300 M batteries*

x 3.8 g Co ≈ 4900 t Co

* Li-Ion type

World mine / a+bproduction / share

Ag: 21,000 t/a ► 3%

Au: 2,400 t/a ► 4%

Pd: 220 t/a ► 16%

Cu: 16 Mt/a ► <1%

Co: 60,000 t/a ► 23%

Global sales, 2008 (2009):

b) PC & laptops:

300 Million units

x 1000 mg Ag ≈ 300 t Ag

x 220 mg Au ≈ 66 t Au

x 80 mg Pd ≈ 24 t Pd

x ≈ 500 g Cu ≈ 150,000 t Cu

≈140 M laptop batteries*

x 65 g Co ≈ 9100 t Co

** Li-Ion type

Example metal use in electronics – volume counts

� Tiny metal content per piece � significant total demand

� Add hereto all the other electronic devices, cars etc.


Our “urban mine” is growing continuously

0

200

400

600

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1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009

Annual sales mobile phones [Million devices]

Based on Gartner market studies

Cumulated sales of mobile phones:

8.6 billion devices with 2100 t Ag, 200 t Au, 80 t Pd Precious metal value at June 2010 prices ≈ 8,5 billion € (gross value)

How much of this will finally be recycled ?


Example automotive – impact on metal demand

Metal demand automotive

in 1000 t/a

Share of

primary

production**

Stahl 100 000 10%

Al 7 300 30%

Pb* 7 000 170%

Cu 1 900 12%

Ni 140 10%

…

Pt 0,12 65%

Pd 0,14 >60%

Rh 0,03 110%

2008 data (rounded)

* Pb use in batteries (mainly automotive)

Pt, Pd, Rh mainly in autocatalysts

** > 100% = additional supply from recycling

Global sales 2008 (2009)52.2 (50.9) MillionCar fleet ~ 1.3 Billion

Modern vehicles: rising demand of „technology metals“ (car electronics, EV/HEV etc.)


Kalgold Gold Mine, South AfricaQuelle: www.mining-technology.com

Recycling: 200-250 g/t Au in PC circuit boards 300-350 g/t Au in cell phones,2000 g/t PGM in autocat-ceramic

Primary production @ ≈5 g/t Au in oreSimilar for PGMs

The “urban mine” - a huge & rich “above ground deposit” for precious metals – a comparison


Although we learned that geological scarcity is a „none-issue“, recycling is crucial to …

� Mitigate environmental impacts of mine supply

• less energy/CO2 (higher metal concentrations; easier access)

• less land & water use

• less impact on biosphere (rain forest, (Ant)artica, ocean mining …)

� Prevent impact from non-recycling (hazardous emissions, land use etc.)

� Reduce geopolitical dependence on few mining countries/companies

� Support ethical sourcing of raw materials (supply chain transparency …)

� Partly eliminate the supply risks from by-product/coupled metals production

in primary supply (see next slides)

� Dampen metal price volatility

• Improves demand – supply balance

• Extents / preserves resource stocks

• limits speculation (broader supply base is less vulnerable to disruptions)

� Mining & recycling (“mining the technosphere”) are complimentary


Structural scarcity: production of many critical metals* is coupled…

…hence supply of primary by-product metals is price inelastic & finite

� recycled critical metals are independent from geological restrictions (but new/other metal couplings exist in products)

PGM

• Increased demand can only be met by primary production if demand for carrier metals rises accordingly

• This places an absolute cap on total availability (accessible reserves & primary supply)

*By product metals:Ga, Ge, In, (Be)Coupled metals: PGM, REE, Ta/Nb


� technical solutions to improve resource efficiency & mitigate climate impact rather need more than less precious/special metals (PV, EV, catalysis etc.)

but: � primary supply of by-product technology metals will drop in case of:

�Successful decoupling for base metals (Cu, Ni, Al, Pb)

�Improved recycling of base metals

�Supply restrictions for lead, nickel etc.

�� Double need to efficiently recycle technology metals

Quelle: Next steps for EU waste and resourcepolicies, R. v.d.Vlies, DG Env., Brussels 17.6.2009

� EU-strategy useful & realistic for base metals, especially if used in infrastructure

Decoupling of resource use from GDP growth is unlikely for technology metals


Aim & opportunity: Closed loop approach around metals/products life cycle

End-of-LifeProduct

manufacture

from industrial materials

Use

from concentrates,

ores

Natural resources

Metal & compounds

New scrap

Residues

Raw materials production

Residues

Residues

Residues

� Minimise critical metal losses into residues at each step� Maximise the recycling of critical metals along the lifecycle


Challenge: insignificant EoL-Recycling for many technology metals, high dependence on primary supply

End-of-LifeProduct

manufacture

from industrial materials

Use

from concentrates,

ores

Natural resources

Metal & compounds

New scrap

Residues

Raw materials production

Residues

Residues

Residues

task: avoid dissipation, collect

EoL-products, (tech.) optimise recycling chains


Good recycling is more complex than in the movies …

PbBi

Se

In

Cu

Sn Au

Pd

+ “Eternal” recycling of metals without loss of quality

+ High yields in high tech recycling

+ Significantly less CO2 emissions compared to mining

- Limits for dissipated metals

- System approach needed for complex products

- Laws of Nature cannot be broken → technologychallenges for some metals (Ta, Li, Rare Earths, …)

- Challenges to effectively close the loop forconsumer products

From: Disney/Pixar www.wall-e.com

High Tech & Economies of Scale � Key for precious & special metals refining from complex materials

• Focus PM-containing secondary material, input > 300 000 t/a, global customer basis

• Recovery of 7 PM & 11 other metals: Au, Ag, Pt, Pd, Rh, Ru, Ir, Cu, Pb, Ni, Sn, Bi, Se, Recycled metal value 2007: 3 Bn US-$ Te, Sb, As, In, Ga.

• Investments since 1997: 400 M €; Invest. for comparable green field plant: >> 1 Bn €!

• Complex processes, high recovery rates > 95 % for PM, minimal waste

Umicore‘s integrated smelter/refinery at Hoboken/Antwerp

ISO 14001 & 9001, OHSAS 18001


RecycledmetalsCollection

Pre-processing

Dis-mantling

Materialsrecovery

WEEEELV

Separated components & fractions Handling of final waste

reuse

Complex products require a well organised & dedicated recycling chain

• Consider the entire chain � system approach is crucial.

• Success factors � interface optimisation, specialisation, economies of scale.

• Precious metals dominate economic & environmental value � minimise PM losses

• Eco-efficient recovery of PM (trace elements) �“high-tech”, large scale processes.

Example: 50% x 90% x 80% x 95% = 34%

The total recycling efficiency is determined by the weakest step in the chain

!

!


Appropriate pre-processing is key for efficient metals recovery

Pre-processing

Precious +special metals

� Steer materials into most suitable refining processes � challenge for complex products.

� Precious- & special metals are lost unless directed into PM- & Cu-refining. Pre-processing can cause substantial losses.

� To maximise recovery of precious & special metals certain losses of plastics & base metals are inevitable (& should be tolerated).

Example:

WEEE-collection

Fe-recovery

Al-recovery

Cu-recovery

PM-recovery

plastics-recycling

Disposal of hazardous materials

Slags & other

residues

WEEE not collected

Waste electrical & electronic equipment (WEEE)



� Challenges & limits of recycling� Non-collection & dubious

exports

� Inappropriate technology & chain interfaces

� Economic & technological challenges

� Conclusion& recommendations


Improve collection and stop dubious exports & inefficient backyard recycling

Fotos BAN

− Backyard “recycling“ in Asia & Africa

− High metal losses (Au-yield ≈ 25%)

− Dramatic environmental & health impact

− Failing law enforcementphotoEMPA

WEEE from Europe:

�60% WEEE not properlyrecycled, metals are lost(exports, trash bin, …)*

� 70% for IT & telecom,small household appliances*

� Loss of metals > 5 billion US-$

*source: Huisman, Kühr et. al: WEEE review report, 2007


Recycling potential 2009: 800 million units per anno x 100 g = 80,000 t/a

Recyclingreality²:

< 2000 t (< 20 M)in 2007

%?

collected Not collected

reuseRecy-cling¹

Stored “in drawer”(potential for recycling at later stage)

Disposed with household waste(unrecoverable loss)

%?%?

¹ 25-35% of professionally collected phones are not fit for reuse and sent directly to recycling.

² global quantities treated for material recovery efficiently and env. sound

Exported to deve-loping countries

Final end of life

Use in “2nd life”

Not collectedCollec-

ted

Re-export to ESM-recycling

Local ‘backyardrecycling’

%?

Use in 2nd life

EOL not

collectedGlobal Sales of new phones*:2001: 400 M2002: 420 M2003: 520 M2004: 670 M2005: 800 M2006: 990 M2007:1140 M2008:1380 M2009:1360 M

* incl. smart phones, source Gartner

Not to scale*Based upon 4 years lifecycle

Example mobile phones – very low recycling in spite of efficient technology


Optimise process chain interfaces

Study Reference Process description Input

St 1 Chancerel & Rotter 2008 Manual pre-processing 176 kg of IT & consumer eq.

St 4 Meskers et al. 2009 Low intensity mechanical pre-processing 1.4 tons of PC

St 5 Chancerel et al. 2009 High intensity mechanical pre-processing 27 tons of IT & consumer eq.

St 6 Van Schaik & Reuter 2009 High intensity mechanical pre-processing Not indicated

Rotter et al. Elektronik Ecodesign Congress München (Oct.2009)

Choice of preprocessing technology strongly impacts Au recovery rates

� Remove high grade circuit boards prior to intense shredding; for technical background see next 2 slides.

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St 1 St 4 St 5 St 6

Gold

recove

ry in c

ircuit b

oard

fra

ctio

n

aft

er

pre

-pro

cessin

g [%

]


Challenges in mechanical processing of complex materials

Fully liberated

• Pre-requisite for mechanical sorting/separation

• Limits of shredder technology in case of complex material interconnections (e.g. circuit boards, cell phones) → complete liberation is impossible

Before shredder

See also Reuter, M.A. et al: The Metrics of Materialand Metal Ecology. Elsevier (2005).

After shredder

Fully liberatedMixed

a) Liberation

• Sorting based on physical properties (density, conductivity, magnetic properties,…)

• Low selectivity for mix-material (e.g. circuit board part with Fe screw)

• Incomplete liberation causes (unintended) co-separation

• Fine ground powder cannot be sorted well (+ safety issues)

b) Separation of target substances

gradere

cove

ry

2

1

Where is optimum?

1 low grade, high recovery (a lot ofmixed material)

2 high grade, low recovery (littlevery pure material but high losses)


Minimising of precious metal losses during pre-processing

• A less complete separation of Fe, Al, plastics can reduce PM losses significantly

• A low PM content in ferrous or plastic fractions does not mean that PM losses are low ! -> only mass balance can tell

Recovery % at…

Pre

cio

us m

eta

l lo

sses

Where isoptimum ?

100% 100%100%Fe Al plastics

PM losses in case of complete separation of Fe, Al, plastics from complex materials

Reduced PM losses if only fully liberated Fe-/Al-/ plastic particles are separated → Mix material to be recovered metallurgically


Overcome economic & technical challenges

� Economic recycling challenges (missing intrinsic value)• Negative net value due to low critical metal concentrations in products without “paying metals”

and their low current prices. However, mass applications lead to significant total metal use.

• E.g. lithium in batteries, indium in LCDs & PV-modules

• Create economic recycling incentives (subsidies) & improve technology (costs & efficiency)

� Dissipative use inhibits economic recycling (regardless of price level)

� E.g. silver in textiles or RFID chips

� Avoid dissipative use or look for non-critical substitutes

� Technical accessibility of relevant components

� E.g. electronics in modern cars, REE-magnets in electric motors

� Develop “design for disassembly”, sorting & “pre-shredder” separation technologies

� Thermodynamic challenges & difficult metal combinations

� E.g. rare earth elements, tantalum, gallium, beryllium in electronics, lithium in batteries

� Consider recyclability in development of new material combinations

� Further develop refining technologies, especially treatment of slags, effluents & other residues


Innovation in recycling technology – example new Umicore process for rechargeable batteries

R & D started to recover Li

Source:Eurometaux’s proposals for the Raw Materials Initiative, annex, a case story on rechargeable batteries, prepared by Umicore & Recharge, June 2010


Criticality – a new driver for recycling ?

Recycling-drivers:

� value: taken care of by the market, pays for itself (set EHS frame conditions!)

� EHS & volume: society driven, negative net value

value

volumeenvironment

Economic incentive e.g. : autocat,Al-wheel rim,

Cu-scrap, precious metals, …

„too much to dump it“e.g.: household waste, debris,

packaging, …

Risk for

environment, health,

safety (EHS)e.g..: asbestos, Hg,

airbags, waste oil, …

Recycling

Sustainable access to critical metals

� “critical metals”: macro economic significance, enhanced recycling worthwhile also without volume- or EHS risks

toda

yfu

ture

Politics & legislation

e.g. circuit boards; Pb-acid

batteriese.g. ELV


Recycling needs to deal with complexity …

Interlinkage metal production systems

product composition

life cycle

metal recovery

formal/informal sector

human behaviour

geographic regions

design substitution

Flows aroundthe world

and interdependencies

Interdisciplinary system approaches are crucial for success


Conclusion: Time for fundamental changes

� Attitude: Waste management � resource management

� Targets: Focus on mass � focus on quality & critical substances

� Practice: Traditional scrap business � High-tech recycling

� adapt structures accordingly and provide global solutions

� Vision (OEMs): burden � recycling as opportunity

� creative business models to really close the loop (leasing, deposits, …)

� For future technologies (PV, EV/HEV, FC, …) smart recyclingstrategies need to be developed at an early stage!


General recommendations developed by the RMI critical metals group

Undertake policy actions to make recycling of critical raw materials more efficient, in particular by:

� Mobilising relevant EoL products for proper collection instead of stocking, landfill or incineration

� Improving overall organisation, logistics & efficiency of recycling chains by focussing on interfaces and system approach

� Preventing illegal exports of relevant EoL products & increasingtransparency in flows

� Promoting research on system optimisation & recycling of technically challenging products & substances


Additional/ specific recycling recommendations developed by the Eurometaux RMI task force*

10 concrete proposals under 4 pillars:

(1): Trade aspects

• Customs identification of second hand goods

• Improved enforcement of Waste Shipment Regulation

• End-of-Waste

(2) Level playing field

• Certification scheme for exports and imports of secondary RM

• Facilitate & encourage the re-shipping of complex materials to BAT-recycling plants in Europe

(3) Improved EoL management

• Promote the Efficient Collection and Recycling of Rechargeable Batteries

• The eco-leasing concept

• Better recycling data

• Research on recyclability

(4) Economic viability of recycling*Eurometaux’s proposals for the Raw Materials Initiative, Darmstadt / Brussels,11th June 2010, Jointly prepared by:

www.resourcefever.org/news/items/eurometauxs-proposals-for-the-raw-materials-initiative-jointly-prepared-with-oeko-institut-ev-now-online.html

Thank you

contact: [email protected] www.preciousmetals.umicore.com

rmi 2010-09 hagelüken - mmta · 2020. 2. 23. · title: rmi 2010-09 hagelüken author: u995857...

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