1

Industrial Ecology and Industrial Ecology and

Metal ProductionMetal Production

Nickolas J. ThemelisNickolas J. Themelis

Minprex 2000

Melbourne, September 11-13

2

IntroductionIntroduction

Sustainable development (UN) :

How to meet the needs of the present generation…

…without compromising the ability of future

generations to meet theirs

3

IntroductionIntroduction

Industrial Ecology for metal production:

The design or re-design of processes and products

with full knowledge of their environmental impacts

4

An Example of Applying An Example of Applying Industrial Ecology in Metal Industrial Ecology in Metal ExtractionExtraction

The Outokumpu and Noranda processesfor copper smelting helped reduce unit capital and operating costs….

...as well as sulfur and carbon emissions

5

Noranda Bath smelting process Noranda Bath smelting process for producing copper for producing copper

Off-gases

Skimming HoleSlag

Tapholes

Matte

Riding Rings

Feeding Port

Tuyeres

Burner

• Can smelt any kind of metal scrap

6

IndustrialIndustrial Ecology Ecology concernsconcerns in in metalmetal extraction extraction

Environmental impact of emissions: Prior, during, and after process

Conservation of Earth resources

7

Environmental Environmental Load Units Load Units (ELU/kg)(ELU/kg)Swedish Env. Res. Inst. Swedish Env. Res. Inst.

(1991)(1991) Impact of emissions in air:CO2: 0.04; CH4: 1; Sox: 6; Nox: 250;

PAH: 600

Impact of emissions in water:Fe: 1*10-7; Cu: 5*10-7; Pb=0.1; Cr : 0.5;

Cd: 10; Hg: 10; TOC: 1*105

8

Annual consumption of copper Annual consumption of copper during the 20th century during the 20th century

--> it is a good measure of the material standard of living

• 10 kg/capita for the highly developed nations

• 0.6 kg/capita in China

• 0.2 kg/capita in India

Copper is principally used in electrical and water conduitsCopper is principally used in electrical and water conduits

9

Ore RESERVES are not infinite: The Ore RESERVES are not infinite: The “tyrannies” of ore type and grade “tyrannies” of ore type and grade (Kellogg)(Kellogg)

10

Energy requirements for production of Energy requirements for production of metals from primary and secondary metals from primary and secondary materialsmaterials

11

Estimated global anthropogenic Estimated global anthropogenic emissionsemissionsin tons/yearin tons/year

As Cd Cr Cu Hg Ni Pb Zn

To atmosphere:18800 7600 30500 35400 3600 55700 332400 131900

% Contribution of global metal industry:75% 80% 50% 75% 1% 35% 10% 80%

To aquatic systems:4100 9400 142000 112000 4600 113000 138000 226000

% Contribution of global metal industry:10% 10% 20% 10% 2% 20% 5% 10%

12

LD or Basic Oxygen Furnace LD or Basic Oxygen Furnace for steel making for steel making

• introduced in Europe in 1954

• 60 % of the U.S. steel production

• accept 10 to 30% scrap in the metal charge

13

Electric Arc FurnacesElectric Arc Furnaces

slag

slag

metal

metal

coke

coke

Electric Arc Furnace

Submerged Arc Furnace

Slag Resistance Furnace

• introduced in 1965

• 40 % of the U.S. steel production

• can accomodate 100% scrap in the feed

14

Application of 20Application of 20thth century century technologies to 21technologies to 21thth century problems century problems

TTeecchhnnoollooggyy

FFoorr hhuummaanniittyy

FFoorr EEaarrtthh

Applied geophysics

Exploration for minerals and fuels

Environmental assessment and remediation

Mining

Extraction of minerals

Brownfield/greenfield Mine rehabilitation Landfill engineering Constructed wetlands

Hydrometallurgy

Metal production and refining

Water/soil decontamination

Metal recovery from wastes

Pyrometallurgy

Metal production and refining

Materials/energy from wastes Vitrification

15

Earth and Environmental Earth and Environmental Engineering :Engineering :materials and the environment materials and the environment

16

ConclusionsConclusions

As the world’s population and global standard of living continue to increase, the role of metals in the economy will not diminish in the 21st century, despite substitution and dematerialization trends.

17

ConclusionsConclusions

Production and use of metals and all other materials must take into account the needs of both Humanity and the Earth.

18

ConclusionsConclusions

Metal extraction is one of the most Earth-intrusive industrial activities. Mineral engineers need to be fully cognizant of upstream (raw materials) and downstream (products) effects of their activities.

19

ConclusionsConclusions

Dispersive uses of metals should be phased out and post-use material/energy recovery must increase: Advantage for processes that can use as feedstock both “virgin” and recycled materials, such as scrap and waste streams.

20

ConclusionsConclusions

Important emerging roles for mining and mineral processing technologies:

- land and water rehabilitation

- environmental assessment

- materials/energy recovery from used materials

- contaminant neutralization (vitrification, etc.)

21

Energy and metal resource recovery Energy and metal resource recovery at Waste-to-Energy plant at at Waste-to-Energy plant at Rochester, MA Rochester, MA (Energy Answers Corp.) (Energy Answers Corp.)

22

ConclusionsConclusions

Industrial Ecology is a virgin field pregnant of possibilities!