Non Ferrous Recycling a Closed Loop - m2r2.expomin.clm2r2.expomin.cl/material_presentaciones/Workshop... · in the non-ferrous metal industry Greenhouse gases are being recorded

1

Non Ferrous

Recycling

a

Closed Loop

Content

1. Introduction

2. Company Presentation Küttner GmbH & Co.KG, Essen

3. Activities of Küttner Non Ferrous GmbH, Essen

4. Selected Examples for Metal Recycling and Energy Recovery

4.1 Production and Economics

4.2 The Process of Recycling

4.2 Examples for Integrated Environment Management Systems

4.3 Linked Processes for Energy Recovery utilizing biogas, industrial waste and sewage

sludge

5. Summary and outlook

1. Introduction

2

Iron & Steel Foundry NF-MetalEnergy &

EnvironmentProcess

Automation

3

1. Introduction


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Automation

4

Principle problem:

to stay within our ecosystem

while promoting economic growth

without destroying the social system

1. Introduction

http://en.wikipedia.org/wiki/Waste_management



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Automation

5

Waste minimisation involves efforts to minimise resource and energy

use during manufacture.

1. Introduction

Waste Hierarchy


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Automation

6

The waste hierarchy refers to the 3Rs:

reduce, reuse and recycle,

which classify waste management strategies.

1. Introduction


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Automation

7

Technical Challenge:

use of resources improve efficiencies

waste generation / emissions

major reductions

1. Introduction



Engineering & Contracting Company

The KÜTTNER Group

is mainly operating in industrial plant engineering and construction.

Küttner presently consists of a group of mid-sized partner companies with international operation.

In the Küttner group 600 specialists are employed

82. Company presentation Küttner GmbH & Co.KG, Essen


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Automation

9

INDUSTRIES

Steel Mills

Foundries

Non-Ferrous

Environmental Industry

Energy generation

TECHNOLOGIES

Material Handling

Industrial Furnaces

Heat Recovery Systems

Flue Gas Cleaning Systems

Automation

SERVICES

Planning

Design

Delivery

Construction

Commissioning



EnvironmentProcess

Automation

10

Küttner GmbH & Co. KGHead office & Key technology teams

• Küttner Energy GmbHEnergy & Environmental

•Küttner Non-FerrousNon-Ferrous Metallurgy

• Küttner International GmbH International supervision services

• Küttner Automation GmbHIndustrial-Automation

Joint ventures

• HuDe GmbHCoking Technology

• MWE GmbHRolling Mill Technology

• WÜRZ GmbHThermal Recuperation Engineering

Location of the companies in Germany

Sophisticated know-how from specialised German Technology teams

~250 members in Germany



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Automation

11

Locations in Europe

Küttner BelgiumSales office

Küttner FranceBranch office

Küttner SpainBranch office

Representation Küttner UkraineSales office

Küttner UKSales office

Know-how transfer and close relationto the customers from domestic offices

~ 50 representatives



EnvironmentProcess

Automation

12

Küttner do BrasilBranch office

Küttner South Africa, (pty) Ltd.Sales office

Küttner Asia Co. Ltd.Sales office

Somani Küttner India (P) Ltd. DelhiSales office

Somani Küttner India (P) Ltd. KolkataBranch office

Küttner North AmericaBranch office

Company locations, worldwide

Branch offices acting as full local supplier with access to the Group´s German technology

overseas workforce of 250



EnvironmentProcess

Automation

ALUMINUM

ZINC

COPPER

LEAD

Engineering & Contracting

Material Handling

Pyrometallurgy

Heat Recovery

Off-gas Cleaning

Automation

COBALT

NICKEL

VANADIUM

OTHERS

3. Activities in the Non Ferrous Industry13

Küttner Non Ferrous GmbH, Essen


EnvironmentProcess

Automation

1) Layout und Engineering

Plant-Layout and Design

Design of Production Logistics

Design of Material Flow

2) Material Handling

Scrap- and Raw Material Handling

Charging Systems (Skip, Conveyor)

Pneum. Transport (Dust, Coal, etc.)

By-Product Treatment (Granulation)

3) Pyrometallurgy

Melting Furnaces

Refining Furnaces

Converter Furnaces

Slag Cleaning Furnaces

Heating and Casting Furnaces

Technology Packages

4) Off-gas Treatment

Afterburning

Filter

Dry- and wet gas cleaning

5) Energy Recovery

Media pre-heating (air, gas, etc.)

Waste Heat Boilers (Steam, Thermooil)

Supply into plant network

Generation of Electricity

6) Automation

Complete Plant Automation

Visualizing, etc.

3. Activities in the Non Ferrous Industry14

Küttner Non Ferrous GmbH, Essen



















EnvironmentProcess

Automation

Recycling of copper scrap (electronic motors, brass, cables, coins, etc.)

Recycling of computer scrap in order to extract precious metals

Use of RDF (Refuse derived fuels), e.g. plastic wastes, mechanical treated municipal

wastes, etc.

Recycling of lead bearing residues (car batteries, Cd/Pb batteries, Pb-bearing slag, etc.)

Recycling of Zn-bearing residues (geothide and jarosite residues from

hydrometallurgical plants)

RECYCLING METALS FROM INDUSTRIAL WASTE:

4. Selected Examples for Metal Recycling and Energy Recovery15


EnvironmentProcess

Automation

Recycling is not only appealing for environmental reasons, but for economics too.

2.6


Source: RHI Catalogue

1990 2000 2002 2003 2004 2005 2006 2007

World mine production [mill.tonnes]

8,957 13,238 13,578 13,757 14,594 14,922 14,983 15,439

Germanproduction [thou. tonnes]

Refined copper 476 709 696 598 653 638 662 666

From primary materials 204 310 327 287 284 294 312 302

From secondary materials 272 399 369 311 369 344 350 364

Cast copper alloys 55 63 63 46 44 46 49 46

Semi-finished products inc.alloys [mill. tonnes]

1.319 1.908 1.619 1.657 1.723 1.603 1.869 1.857

of which is conductive material[thou. tonnes]

528 757 645 685 679 655 800 829

quotation per 100 kg [EUR] 224,28 205,47 166,71 164,04 262,83 310,83 547,18 533,67

LME copper price per 1,000 kg 1.815$ 1.813 $ 1.498$ 1.780$ 2.868$ 3.679$ 6.727$ 7.119$

16


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17

Economic conditions

decide the final quality

Quality and composition of the starting materials

influence the process



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Automation

Bloc flowsheet / Overview

Copper

ResiduesElectrolysis

Auxiliaries

Anode

Furnace

Waste Heat

Recovery

Converting (possibly)

e.g. PS, CT

RedOx

Furnace

Gas

Cleaning

Melting and

possibly

Converting

e.g.

ISA Smelt

AUSMELT

Shaft-

Furnace

Casting

Slag Treatment

Off Gas

metal

recyclables



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Automation

Bloc flowsheet / Overview

Alloys

End usersElectrolysis

Auxiliaries

Casting

Waste Heat

Recovery

Holding

Alloy

Furnace

Gas

Cleaning

Melting

e.g.

Asarco,

Induction

Furnace

Semi and

Finished

Products

Off Gas



EnvironmentProcess

Automation



EnvironmentProcess

Automation

Bloc flow sheet / Pre –Treatment Battery Scrap

Plastic Fraction

Batteries

Metal Fraction

Breaker

Mill

Classification, Sorting, Separation by screening ,sink and

floating

ThickenerStorage

Waste Water

Treatment

Oxide Fraction



EnvironmentProcess

Automation

Waste Heat

Recovery

Gas

Cleaning

Off Gas

Slag / Matte

Bloc flow sheet Lead Recycling. Shaft Furnace Process / Overview.

Auxiliaries

Auxiliaries

Converting (possibly)

e.g. PS, CT

RedOx

Furnace

Melting and

possibly

Converting

e.g.

ISA Smelt

AUSMELT

Shaft-

Furnace

Lead

Residues

End User

Auxiliaries

Waste Heat

Recovery

Purification and

Alloying e.g. Colcord,

Parkes, Softening

Slag

Treatment

Gas

Cleaning

Melting

e.g.

Shaft-

Furnace,

Short

Rotary

Furnace

Ausmelt/isa

smelt

Off Gas

Slag / Matte



EnvironmentProcess

Automation

23 4. Selected Examples for Metal Recycling and Energy Recovery


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Automation

max

min

max

min

dust-coke-mix

rotating distributer

max

min

petrol coke

max

min

max

min

max

min

transmitter

scale

max

min

max

min

Other dusts

Cupola dustfrom the

bag house

to zinc recovery

wetning

petrol coke



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Automation


Integrated Environment Management

for energy recovery


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Automation


Different types of heat recovery systems are used.


EnvironmentProcess

Automation



EnvironmentProcess

Automation



Linked Processes for Energy Recovery

Mechanical-biological waste reclamation (production of methane) for the city of

Rostock, Germany.

Intermediate storage

Preparation

Decomposition tunnel


EnvironmentProcess

Automation

29

Fermentation Biogas Utilisation

Conditioning

Dosing Bunker Fermenter

Pump

El. Energy Heat

Dewatering

Press

Fresh Compost

Power Plant

Liquid Fertilizer

Ventilation

Biofilter

Dewatering

Exhaust AirTreatment

Ventilation

Heat-

Exchanger

Preparation

Dosing

unit

Fuel

Feed

Treated Air

flow sheet biogas produced in fermenters


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Automation

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Energy Generation with 1 t of Waste

130 - 150 Nm3 Biogas = approx. 800 kWh total Energy

> 1’000 km CO2-neutral journey with a car

6’000 hours light (40W bulb)


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Automation



Linked Processes for producing heat / electricity

Sewage sludge incineration with steam generation; Gendorf, Germany


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Automation

32

FLUIDIZED BED

COMBUSTION

TECHNOLOGY

HDM, Germanyfoundry sand regeneration


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Automation

5. Summary and outlook33

Different Goals:

•individual company measures

•national and international political goals

One example: European emissions trading

should contribute more than an equal share to achieve

European environmental protection goals

in the non-ferrous metal industry

Greenhouse gases are being recorded


EnvironmentProcess

Automation

5. Summary and outlook34

`[Copper] recycling is an efficient use of a raw

material:

Almost 100 per cent of copper, e.g. in

electronic waste, which also contains other

valuable non-ferrous metals, can be

reclaimed by recycling without compromising

quality, and reused in production processes.

Hans Gerhard Hoffmann, Division Manager of Aurubis AG, on the website of the German Trade Association for Metals (WVM)

35

There is still a lot of energy inside . . .


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Automation

36Dipl.-Ing. H. Kassebaum, Küttner Non Ferrous GmbH; www.kuettner.com

Thank you for your attention

http://www.kuettner.com/

Documents

Non Ferrous Recycling a Closed Loop - m2r2.expomin.clm2r2.expomin.cl/material_presentaciones/Workshop... · in the non-ferrous metal industry Greenhouse gases are being recorded