The Metrics of Material and Metal Ecology: Harmonizing the resource, technology and environmental cycles

Cover......Page 1
Contents......Page 8
Preface......Page 6
Introduction......Page 16
Harmonizing the resource, technology and environmental cycles......Page 18
Sustainability of metals?......Page 21
Metals......Page 23
Societal and scientific relevance......Page 25
Development of waste infrastructures......Page 26
Support of decision-making......Page 27
Systems approach......Page 30
Motivation for processing of residual material......Page 31
System approach to car recycling......Page 32
System approach to the recycling of aluminium......Page 38
The system for recycling of products and metals......Page 44
Overview of Book......Page 45
Metal and Material Ecology......Page 47
Product Recycling as applied to the Car......Page 49
Aluminium Metallurgical and Recycling......Page 52
Various appendices of data and case studies......Page 53
Metal and Material Ecology......Page 54
Sustainability or sustainable development?......Page 56
Going where?......Page 59
Getting there......Page 60
Industrial Ecology......Page 61
The industrial notion......Page 62
The ecological notion......Page 63
Prescriptive approaches......Page 67
Descriptive approaches......Page 71
The concept of industrial ecology......Page 74
Tools......Page 75
Summary......Page 76
Metal resource cycles......Page 78
Interdependence......Page 81
Resilience......Page 87
Tacit Knowledge......Page 91
Methodology......Page 94
Goal, scope and resolution......Page 95
Interdependence in metal production processes......Page 96
Goal and scope revisited......Page 99
Mass balance models......Page 100
Data requirements and availability......Page 101
Data reconciliation......Page 104
Potential for industrial ecology: Convergence of methods......Page 105
Summary......Page 109
Metal ecology......Page 110
Goals for "sustainable" metal metabolism......Page 111
Dynamics in the resource cycles......Page 112
The dilution of metals......Page 113
Interaction with the society cycles......Page 114
Interaction with the technological cycle: Metal recycling......Page 115
Discussion......Page 118
Waste managers: Adaptive waste management strategy......Page 119
Product designers: Design for metallurgy strategy......Page 123
Metallurgists: new approaches to process control and design......Page 124
Discussion......Page 129
Controlling the resource cycles......Page 130
Metal resource cycles as self-organizing feedback systems......Page 132
Feedforward control of resource cycles......Page 137
Hybrid Feedback and Feedforward control......Page 138
Discussion......Page 139
Summary......Page 140
Why lead production?......Page 142
Sources......Page 143
Legislation......Page 144
Bottom-up approach......Page 145
Flowcharts of the metal cycles......Page 147
General model framework......Page 148
The inventory and modelling approach......Page 151
Bottom-up approach......Page 156
Interpretation and impacts assessment......Page 173
Simulations......Page 178
Lead-free solders options......Page 180
Metallurgist......Page 181
Product designer and manufacturer......Page 184
Waste manager......Page 188
Policy-maker and Legislator......Page 189
Containment strategy - Cleaner recycling......Page 191
Policy-maker and legislator......Page 193
Waste manager......Page 195
Product designer and manufacturer......Page 196
Capturing interdependence......Page 199
A further phase-out of lead......Page 200
Background and relevance of the copper smelting......Page 201
Umicore smelting......Page 203
LCA model approach......Page 206
FEED Model parameterisation and validation......Page 207
Chain optimization......Page 209
Decrease of copper production due to replacement of copper pipes with PVC pipes......Page 210
The sensitivity of the model......Page 211
Sustainability of industrial ecology......Page 214
Technological knowledge, a bottleneck for sustainability?......Page 215
The role of models to co-ordinate decision-making......Page 216
Can industrial ecology models provide the necessary knowledge?......Page 217
Connecting the industrial and ecological thinking in industrial ecology......Page 218
Feedforward control in the metal ecology......Page 219
A predictive dynamic model to control the metal metabolism......Page 220
Metal Ecology......Page 221
Product Recycling as applied to the Car......Page 222
The dynamic and distributed nature of the recycling rate of the car - a fundamental description of recycling systems......Page 224
Recycling Rates......Page 225
Directive 2000/53/EC on ELV's......Page 230
EU definition of the recycling rate of the car......Page 231
Literature definitions of the recycling rate......Page 232
Dynamic modelling of the resource cycle of end-of-life vehicles......Page 233
Statistical nature of the resource cycle of products......Page 234
Formulation of model and definition of recycling rate......Page 241
Definition of the Recycling Rate (RR)......Page 242
Accuracy of the model......Page 244
Definition of the distribution functions for simulation......Page 245
The weight and composition of the average car at recycling......Page 248
The recycling rate at end-of-life......Page 251
Recycling rate over the in-/output of the system......Page 253
Recovery rate over the system......Page 254
Is 95% recovery rate for ELV's a "Perpetuum mobile"?......Page 256
Calculate recycling rate (I)......Page 258
Calculate recycling rate (II)......Page 259
Summary......Page 260
Dynamic modelling and optimization of the resource cycle of passenger vehicles - a technological framework......Page 264
Recycling rate......Page 265
Modelling/simulating the recycling of cars - A theoretical dynamic framework......Page 266
Formulation of dynamic model......Page 267
Parameterisation of the dynamic model......Page 269
Technology of recycling - The multi-level flowsheet......Page 270
Interconnected processes and material streams......Page 272
Definition of the optimization model for recycling end-of-life vehicles......Page 274
Dynamic simulation of the aluminium recycling......Page 280
Optimization of the recycling of the car - various simulation results......Page 281
Discussion......Page 285
Monitoring and chain management for ELV recycling......Page 291
The role of particle size reduction, liberation and product design in recycling passenger vehicles......Page 296
Introduction......Page 297
Recycling optimization model linking the liberation to the recycling rate of end-of-life vehicles......Page 299
Phase description of the material streams......Page 300
Formulation of the recycling optimization model......Page 301
Parameterisation of the recycling optimization model......Page 304
Simulations on the optimization of product design, liberation and metallurgy......Page 307
Simulation results......Page 309
Design for recycling and design for environment......Page 312
Particle liberation modelling of ELV's in relation to minerals processing......Page 314
Phase description of the model......Page 316
Alloy types......Page 318
Separation models......Page 319
Formulation of the recycling optimization model......Page 320
Parameterisation of the model......Page 325
Linking design to recycling......Page 335
Simulations on the optimization of product design, liberation and metallurgy......Page 339
Discussion......Page 344
Recycling experiments - from theory to practice......Page 350
Introduction......Page 351
An industrial recycling experiments......Page 352
Mass balancing......Page 354
Characterisation of input (1153 ELV's)......Page 356
Procedures on the plant during sampling......Page 357
Analyses of material flows......Page 359
Data reconciliation......Page 361
Grade of recycling (intermediate) products......Page 363
Samples on material flows......Page 367
Standard deviation......Page 369
System boundaries......Page 370
Procedure for the calculation of recycling/recovery rate and corresponding statistics......Page 371
Discussion......Page 372
Definition of the ISO norm and monitoring protocol for the calculation and prediction of the recycling rate of end-of-life vehicles......Page 374
Design of a monitoring optimization model......Page 375
Aluminium Metallurgy and Recycling......Page 378
Aluminium primary raw materials......Page 380
Ore reserves and bauxite......Page 381
Aluminium secondary/recycled materials......Page 382
Unalloyed scrap and residues......Page 383
New scrap......Page 384
Old scrap......Page 385
Separation processes for aluminium metal containing material......Page 388
Separation methods for aluminium recycling......Page 390
Shredding and cutting......Page 396
Processing by dry separation......Page 398
Processing by wet separation......Page 402
Compacting of aluminium scrap......Page 403
Thermal treatment......Page 404
Aluminium metal production......Page 406
Alumina production......Page 407
Smelting flux electrolysis......Page 408
Recycling of aluminium metal containing material......Page 409
Preparation of charges......Page 411
Melting furnaces for scrap......Page 415
The properties of the salt flux for aluminium melting......Page 423
Sedimentation of aluminium in the salt flux......Page 434
Processing of salt flux......Page 444
Melting of some modern aluminium materials......Page 447
Treatment of liquid metal......Page 459
Emissions......Page 463
Products......Page 464
Mass and energy balance model......Page 468
Mass balance model for the rotary furnace......Page 471
Energy balance for the rotary furnace......Page 473
Sensitivity analysis with the model......Page 475
Data reconciliation......Page 476
Smelter balance......Page 477
CFD simulation of a furnace for Al recycling......Page 479
CFD framework of the process model......Page 480
User developed sub-models......Page 481
Results......Page 487
Discussion of CFD model......Page 493
Sampling......Page 494
Population Balance Modelling (PBM)......Page 497
Physical Separation basics......Page 503
Thermodynamics of recycling metallurgy......Page 510
Properties of materials,'metals and alloys (by example)......Page 511
Metallurgical thermodynamics......Page 517
Exergy: Measure of the quality loss of recycled materials......Page 535
Introduction......Page 540
Basic principles of CFD......Page 543
Examples of the modelling of furnaces......Page 559
Description of metal production flowcharts......Page 572
Production......Page 575
Reconciled mass balances......Page 577
Production......Page 581
Reconciled mass balances......Page 585
Production......Page 592
Reconciled mass balances......Page 593
Production......Page 598
Reconciled mass balances......Page 602
Production......Page 609
Reconciled mass balances......Page 613
Production......Page 620
Production......Page 623
Reconciled mass balances......Page 624
Production......Page 630
End uses......Page 639
Production......Page 640
Reconciled mass balances......Page 642
Consumption......Page 647
Solid waste management......Page 658
Matlab Source code for Dynamic Model......Page 664
AMPL code for optimization model......Page 673
Excel optimization model......Page 677
Simulink model for Metal Web......Page 680
Bibliography......Page 682
Index......Page 712