1 Industrial Ecology and Metal Production Nickolas J. Themelis Minprex 2000 Melbourne, September 11-13

2 Introduction Sustainable development (UN) : How to meet the needs of the present generation… …without compromising the ability of future generations to meet theirs

3 Introduction 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 Industrial Ecology in Metal Extraction The Outokumpu and Noranda processes for copper smelting helped reduce unit capital and operating costs…....as well as sulfur and carbon emissions

5 Noranda Bath smelting process for producing copper Off-gases Skimming Hole Slag Tapholes Matte Riding Rings Feeding Port Tuyeres Burner Can smelt any kind of metal scrap

6 Industrial Ecology concerns in metal extraction  Environmental impact of emissions: Prior, during, and after process  Conservation of Earth resources

7 Environmental Load Units (ELU/kg) Swedish Env. Res. Inst. (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*10 5

8 Annual consumption of copper 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 conduits

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

10 Energy requirements for production of metals from primary and secondary materials

11 Estimated global anthropogenic emissions in tons/year

12 LD or Basic Oxygen Furnace for steel making introduced in Europe in % of the U.S. steel production accept 10 to 30% scrap in the metal charge

13 Electric Arc Furnaces Electric Arc Furnaces slag metal coke Electric Arc Furnace Submerged Arc Furnace Slag Resistance Furnace introduced in % of the U.S. steel production can accomodate 100% scrap in the feed

14 Application of 20 th century technologies to 21 th century problems

15 Earth and Environmental Engineering : materials and the environment

16 Conclusions  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 21 st century, despite substitution and dematerialization trends.

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

18 Conclusions  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 Conclusions  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 Conclusions  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 at Waste-to-Energy plant at Rochester, MA (Energy Answers Corp.)

22 Conclusions Industrial Ecology is a virgin field pregnant of possibilities!