Metal Recovery From Bottom Ash

Embed Size (px)

DESCRIPTION

Metal Recovery From Bottom Ash

Citation preview

  • 5/28/2018 Metal Recovery From Bottom Ash

    1/18

    1

    Global economics of bottom ash processing

    CEWEP EAA Seminar

    From Ashes to Metals

    5th 6thSept. 2011Copenhagen

    Dr.- Ing. Ulrich KohauptConsultant to EAA

  • 5/28/2018 Metal Recovery From Bottom Ash

    2/18

    22

    Outline:

    - General Conditions- Technologies- Flow sheet example- Mass and value flow, earnings- Costs, Investments- Break-even- Additional flow-sheets- Conclusions

    Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

  • 5/28/2018 Metal Recovery From Bottom Ash

    3/18

    3Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

    Municipal Solid Waste in Europe basic assumptions

    People: 500 mio (EU 27)

    Waste amount: 250 mio t/a = 0,5 t/a* Inhabitant

    45% of all waste landfilled: 112,0 mio t/a

    37% of all waste mechanically

    treated:

    92,5 mio t/a

    18% of all waste incinerated: 45,0 mio t/a

    Mass reduction:

    Incineration:

    75%

    Bottom Ash (BA) mass EU: 11,25 mio t/a

    Example used in this presentation: 50 t/h, which is the equivalent of:

    120.000 t/a480.000 t BA/a or

    960.000 t inhabitants

  • 5/28/2018 Metal Recovery From Bottom Ash

    4/18

    44

    Metal Contents and Metal Values in Bottom Ash

    Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

    MetalRange

    percentage in

    BA [%]

    Average

    percentage

    in BA [%]

    metal

    distribution

    [%]

    Value [!/t]Theoretical

    potential total

    values [!/t BA]

    min max min max

    Iron, ferrous 5 15% 10,00% 83,33% 80 300 8 30

    Stainless Steel 0 0,8 % 0,50% 4,17% 500 1500 2,5 7,5

    Non Ferrous

    NF0,5 3 % 1,50% 12,50% 500 1500 7,5 22,5

    SUM 12,00% 100,00% 18 60

  • 5/28/2018 Metal Recovery From Bottom Ash

    5/18

    5Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

    The generated economic added value depends on:

    a)The availability of the required technologyb) The willingness to make strategic investments

  • 5/28/2018 Metal Recovery From Bottom Ash

    6/18

    6

    Available technologies Process scenarios

    - suspension magnet

    - magnetic drum

    - eddy current separator

    ECS

    - Inductive Sensoring

    - liberation

    1) START: magnet, 1 screen, 1 ECS

    2) DEVELOPED: magnets, 2 Screens, 2 ECS

    3) ADVANCED: magnets, 2 screens, 3 ECS

    4) INNOVATIVE: magnets, 2 screens, 3 ECS, 2 Inductive sorting,

    crushing circuit

    Bottom Ash Treatment: 4 different scenarios

    Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

  • 5/28/2018 Metal Recovery From Bottom Ash

    7/18

    77

    1) START: on coarse ferrous and non-ferrous recovery

    Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

  • 5/28/2018 Metal Recovery From Bottom Ash

    8/18

    8

    2) DEVELOPED: multiple screening, ferrous & non-ferrous recovery

    Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

  • 5/28/2018 Metal Recovery From Bottom Ash

    9/18

    99Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

    3) ADVANCED: multiple screening, ferrous & non-ferrous recovery

  • 5/28/2018 Metal Recovery From Bottom Ash

    10/18

    1010

  • 5/28/2018 Metal Recovery From Bottom Ash

    11/18

    11

    Example Developed ProcessTotal Investment needed for 50 t/h flow-sheet (2 screens, 2 magnets, 2 ECS)

    Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

    Flow rate per hour [t/

    h]:

    tonnage per

    year [t/a]:

    hours per

    day:

    days per

    month:

    Operating

    hours perYear: description Financing

    50 120.000 10 20 2.400 years %

    Separation

    technology Machine !*Conveyor

    !*number of

    units

    Sum Invest

    [!] 5 5%

    Suspension magnet,

    rectifier25.000 50.000 1 75.000 15.000 1.875

    Magnetic drum,

    feeder20.000 50.000 2 140.000 28.000 3.500

    Eddy Current

    Separator, feeder

    (Middle , + Low

    Frequency)

    85.000 50.000 2 270.000 54.000 6.750

    2 Screen 200.000 50.000 1 250.000 50.000 6.250

    total Sep Tech: 485.000

    Plus Diverse costs 50%

    on Invest:242.500 48.500 6.063

    *= assumed costsTOTAL

    Invest [!]:727.500 195.500 24.438

  • 5/28/2018 Metal Recovery From Bottom Ash

    12/18

    1212

    Example Developed ProcessAssumed energy consumption and total energy costs per year

    Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

    Power installed

    each machineTotal power power

    consumption

    Energy costs !/

    kWh

    0,08

    Separation Technology kW kW kWh/ a !

    Suspension magnet, rectifier 6 6 14.400 1.152

    Magnetic drum, feeder 3 6 14.400 1.152

    Eddy Current Separator,

    feeder (Middle , + Low

    Frequency)

    10 20 48.000 3.840

    screen 20 20 48.000 3.840

    Total Powerconsumption

    per year [kWh/

    a]

    Total Energy costs

    per year [!]

    52 124.800 9.984

  • 5/28/2018 Metal Recovery From Bottom Ash

    13/18

    1313

    Developed Process: Earnings and Costs (basis: 50 t/h)

    Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

    0

    5

    10

    15

    20

    25

    30

    0% 50% 100% 150% 200% 250%

    Costs [!/t] DEVELOPED

    100% mean a market with: 80!/t iron; 500 !/t Non--Ferrous relative Metal value

    Earnings,costs

    perton

    [!/t]

  • 5/28/2018 Metal Recovery From Bottom Ash

    14/18

    1414

    Start Process: Earnings and Costs (basis: 50 t/h, Ferrous andcoarse NF-metals)

    Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

    0

    5

    10

    15

    20

    25

    30

    0% 50% 100% 150% 200% 250%

    Costs [!/t] START

    relative Metal value

    Earning,costs

    perton

    [!/t]

    100% means average scrap prices of 80!/t for Ferrous and 500 !/t for NonFerrous Metals

  • 5/28/2018 Metal Recovery From Bottom Ash

    15/18

    1515

    Green to be filled

    Flow rate [t BA/h]: 50

    Hours per day [h/d]: 10days per month [d/M]: 20

    hours per year [h/a]: 2.400 Flow rate per year [t/a]: 120.000

    Metal

    content

    market price

    [!/t]

    maximum,

    theoretical

    metal value

    [!/t BA]

    values per

    year [!/a]

    Value

    portion

    technical

    recovery

    raterecoverable

    values [!/a]

    Ferrous (iron) [%]: 10,0% 80 8,0 960.000 1/2 90% 864.000

    Non Ferrous Metal [%]: 1,0% 500 5,0 600.000 1/3 60% 360.000

    Stainless Steel [%]: 0,5% 500 2,5 300.000 1/6 60% 180.000

    Sum 15,5 1.860.000 1 1.404.000

    Size metal

    distribution

    < 10

    mm 10 50 mm (>30 mm)** > 50 mmsuspension

    magnet

    Ferrous (iron): 10% 50% 60% 32% 8% 100,00%Non-Ferrous Metal: 25% 50% 60% 25% -% 100,00%

    Stainless Steel: 5% 70% 80% 25% -% 100,00%

    **: only for START

    Economics for different process layouts

  • 5/28/2018 Metal Recovery From Bottom Ash

    16/18

    16Incl. landfill fees saved per ton[!/t] 29,36 34,71 35,43 33,24

    Flow sheet:

    START:

    Magnet,

    screen 30mm,

    1 ECS

    DEVELOPED:

    Magnets, 2screen, 2 ECS

    ADVANCED:

    Magnets, 2

    Screens, 3 ECS

    INNOVATIVE:

    Magnets, crusher, 2

    screens, 3 ECS, 2

    Inductions

    additional metal recovery due to

    liberation [%]:10%

    ! ! ! !

    Investment - machinery: 540.000 727.500 997.500 2.497.500

    Financing: 13.500 24.438 31.188 62.438

    Description: 108.005 195.500 249.500 499.500

    Energy: 6.912 9.984 12.288 34.560

    Maintenance (10% Inv): 54.000 72.750 99.750 249.750

    Staff (3 / 5 pers): 180.000 180.000 180.000 300.000

    payment for supply*:TOTAL COSTS: 362.417 482.672 572.726 1.146.248

    total costs per t BA [!/t BA] 3,02 4,02 4,77 9,55

    earnings per tonne [!/t BA]: 2,38 8,73 10,20 12,79

    Iron 0,58 6,48 7,20 7,92

    Non-Ferrous Metal 1,80 2,25 3,00 3,30

    Stainless 1,57

    Earnings per year [!] 285.120 1.047.600 1.224.000 1.534.500BA treatment fee [!/t]*:

    direct advantage [!/t BA]: -0,64 4,71 5,43 3,24

    advantage per year -77.297 564.929 651.275 388.253

    Factor yearly adv./Invest -0,14 0,78 0,65 0,15

  • 5/28/2018 Metal Recovery From Bottom Ash

    17/18

    17

    Conclusions

    The metal potential in bottom ash is high and worth to be recovered.

    The price levels for metals are good today and will be increasing in thefuture due to a growing demand world-wide for raw materials.

    The level of technology used depends on local circumstances. But it canbe safely stated that Ferrous and Non Ferrous recovery in the coarsesize fraction is a must for every plant.Additional screening and sorting increases the output and the value of

    the NF-metals in specific.

    The need of inductive sensoring needs to be clarified from case to caseand within the overall process. The potential for additional metalrecovery is high and in many cases worth to be mechanically recovered.

    Even more important is the back office, which has to sell the products.

    Larger quantities allow higher values. Not only because the transportcosts per ton are less but also due to better prices with larger quantities.

    Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

  • 5/28/2018 Metal Recovery From Bottom Ash

    18/18

    18

    Many thanks for your attention!

    Dr.- Ing. Ulrich Kohauptraw Material processing

    Korn-Recycling GmbHAlbstadtwww.korn-recycling.de

    Erftstr. 5953879 Euskirchen

    Germany

    [email protected]