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Metal Recovery From Bottom Ash
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5/28/2018 Metal Recovery From Bottom Ash
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Global economics of bottom ash processing
CEWEP EAA Seminar
From Ashes to Metals
5th 6thSept. 2011Copenhagen
Dr.- Ing. Ulrich KohauptConsultant to EAA
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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
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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
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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
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The generated economic added value depends on:
a)The availability of the required technologyb) The willingness to make strategic investments
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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
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1) START: on coarse ferrous and non-ferrous recovery
Bottom Ash Treatment Economics - Dr. Kohaupt / EAA
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2) DEVELOPED: multiple screening, ferrous & non-ferrous recovery
Bottom Ash Treatment Economics - Dr. Kohaupt / EAA
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99Bottom Ash Treatment Economics - Dr. Kohaupt / EAA
3) ADVANCED: multiple screening, ferrous & non-ferrous recovery
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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
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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
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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]
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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
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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
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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
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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
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Many thanks for your attention!
Dr.- Ing. Ulrich Kohauptraw Material processing
Korn-Recycling GmbHAlbstadtwww.korn-recycling.de
Erftstr. 5953879 Euskirchen
Germany