SUSTAINABLE PROCESSING OF RAW MATERIALS · SUSTAINABLE PROCESSING OF RAW MATERIALS ... Optimising the alumina and aluminium manufacturing process to increase the intrinsic value and

SUSTAINABLE PROCESSING OF RAW MATERIALS

Associate Professor D. Panias

National Technical University of Athens School of Mining and Metallurgical Engineering Laboratory of Metallurgy

Raw Materials University Day 19/06/2014 Athens, Greece

Global Iron and Steel

Production

Global Copper Production

Global Aluminum Production

Mil

lio

n t

on

s

Global Iron and Steel Production

Global REOs Production Global Aluminum

Production




Social

Economic Environment

Sustainable

Via

ble


Redesign of Industrial Production through Innovative Raw Materials Processing

The 3 Pillars

Environment Economy

Society


The series of unit operations that

transforms industrial materials from

a raw material state into

finished parts or products is called

processing


Conc.

Refined Metal

Product

Scrap

&

EOL

Ore

Beneficiation Processes

Metallurgical Processes

Extractive

Metallurgy

Physical Metallurgy

Materials Technology

Products Manufacturing

Use of Product

Recycling Processes

RC = the fraction of metal scrap in the total metal input

of fabricated

metal

UNEP Status Report of 2011 on the Recycling Rates of Metals



European Aluminium Association (EAA)

& Organization of

European Aluminium Refiners and Remelters


Handbook of Recycling

E. Worrell

& M.A. Reuter

Elsevier 2014



Urban Mining is an emerging field for innovations

New Business Models


Landfills host

almost everything

Energy Production

Materials Recycling

Sustainable Nature

Smaller & Modern Landfills

Policy & Legislation

Issues

Culture aspects

Market Issues

Business & Organization

Models

Engineered Systems

&

Processing Routes


Raw Materials Processing

Primary/Secondary Raw Materials

Marketable Products

Aqueous wastes

Gaseous wastes

Solid wastes or

Residues

Disposal Site

Valorization

Solid wastes or

Residues

Modern and Smaller Disposal

Site

New Business Models


Chemical

Species

%wt

(dry basis)

Fe2O3 47.74%

Al2O3 16.22%

CaO 10.73%

SiO2 6.09%

TiO2 5.93%

Na2O 2.51%

V2O5 0.21%

-SO3 0.60%

-CO2 1.63%

H2O(cry) 8.35%

Resource for Pig-Iron Production

Common Resources for Mineral Wool

production

Red Mud


Red Mud

Pig Iron

Mineral Wool

CO2 off-gases


Environment Economy

Society

BRAVO: Holistic Approach on Primary Aluminum Production

Al-Ore

Optimising the alumina and aluminium manufacturing process to increase the intrinsic value and recyclability of by-products including red mud

Al-Source

Recovers critical metals from RM (Ga, Ti, Se, Ge, Dy, Ce)

Al-Build

Produces construction

Materials from RM

Al-Aware

public awareness, acceptance and trust regarding aluminium sector activities and generation and

management of red mud Al-

Chain

Undertakes all the Innovation & Commercialization activities (IP, New Strategies & Business models, Market Analysis, Policy Issues etc)

Al-Chain

More Sustainable

Primary Aluminum

Production


FineNi: Processing of low grade fine feeds

Processing

in

DC or AC EAFs

Fines

Converting FeNi

Slag

FeNi Alloy to Market

Valorization Techs

Fe Recovery

Residue Valorization in Construction sector


Documents

SUSTAINABLE PROCESSING OF RAW MATERIALS · SUSTAINABLE PROCESSING OF RAW MATERIALS ... Optimising the alumina and aluminium manufacturing process to increase the intrinsic value and