Other language confidence: 0.9705512643125185
Production of cathode copper by electrolytic refining.
technologyComment of sulfate pulp production, from hardwood, bleached (RER): Average European technology in 2017 of kraft pulp production of ECF and TCF pulp technologyComment of sulfate pulp production, from softwood, bleached (RER): Average European technology in 2017 of kraft pulp production of ECF and TCF pulp
technologyComment of molybdenum production (RER, RoW): A mix of 80% hydrometallurgical and 20% pyrometallurgical production of zinc is chosen to represent the molybdenum production
Objective: The aim of the proposed Integrated Project is to solve the persisting generic problems with planar Solid Oxide Fuel Cells (SOFC) in a concerted action of the European fuel cell industry and research institutions. Main topics addressed include decreased ageing, cost effective materials, low cost components and manufacturing processes, highest electricity generation efficiency in pressurised operation and waste heat utilisation. In close co-operation between industry and research institutions the following steps are accomplished: *improved understanding of ageing in planar SOFC stacks considering all modes of operation, including pressurised, long-term testing over 10.000 hrs., thermal cycling up to 100 cycles, and the influences of fuel composition; these results will flow into *adaptation of materials and protective coatings in order to reduce ageing to well below 0,5Prozent/1000 hrs., introduction of requirements from pressurised operation to materials and cell development; the modified materials then are used in *manufacturing of improved components under commercial conditions and subsequent characterisation in long- term and cycling tests. Two proofs-of-concept including laboratory equipment tests will address * the pressurised operation of stacks coupled with gas turbines (including pressurised stack development in the 5 and 50 kW range) and *the utilisation of the high-value waste heat for industrial processes , namely sorption cooling. The project addresses the topics of Life Cycle Analysis as an essential tool for assessing the environmental impact and recycling of the materials used, industrial standardisation as a means of lowering costs, and training and dissemination as a tool of human resource management and gender equality. The structure of the project is similar to the U.S. American SECA programme targeted at decisive cost reductions in SOFC systems.
technologyComment of gold mine operation and refining (SE): OPEN PIT MINING: The ore is mined in four steps: drilling, blasting, loading and hauling. In the case of a surface mine, a pattern of holes is drilled in the pit and filled with explosives. The explosives are detonated in order to break up the ground so large shovels or front-end loaders can load it into haul trucks. ORE AND WASTE HAULAGE: The haul trucks transport the ore to various areas for processing. The grade and type of ore determine the processing method used. Higher-grade ores are taken to a mill. Lower grade ores are taken to leach pads. Some ores may be stockpiled for later processing. HEAP LEACHING: The ore is crushed or placed directly on lined leach pads where a dilute cyanide solution is applied to the surface of the heap. The solution percolates down through the ore, where it leaches the gold and flows to a central collection location. The solution is recovered in this closed system. The pregnant leach solution is fed to electrowinning cells and undergoes the same steps as described below from Electro-winning. ORE PROCESSING: Milling: The ore is fed into a series of grinding mills where steel balls grind the ore to a fine slurry or powder. Oxidization and leaching: Some types of ore require further processing before gold is recovered. In this case, the slurry is pressure-oxidized in an autoclave before going to the leaching tanks or a dry powder is fed through a roaster in which it is oxidized using heat before being sent to the leaching tanks as a slurry. The slurry is thickened and runs through a series of leaching tanks. The gold in the slurry adheres to carbon in the tanks. Stripping: The carbon is then moved into a stripping vessel where the gold is removed from the carbon by pumping a hot caustic solution through the carbon. The carbon is later recycled. Electro-winning: The gold-bearing solution is pumped through electro-winning cells or through a zinc precipitation circuit where the gold is recovered from the solution. Smelting: The gold is then melted in a furnace at about 1’064°C and poured into moulds, creating doré bars. Doré bars are unrefined gold bullion bars containing between 60% and 95% gold. References: Newmont (2004) How gold is mined. Newmont. Retrieved from http://www.newmont.com/en/gold/howmined/index.asp technologyComment of primary zinc production from concentrate (CA-QC): Hydrometallurgical process Sulphide concentrates are roasted first in fluidized bed roasters to produce zinc oxide (calcine) and sulphur dioxide. Roasting is an exothermic process and no additional fuel is used to sustain the reaction, the heat generated is recovered to produce steam. Calcine is then sent to the leaching step. Roaster gases are treated in hot electrostatics precipitators to remove dust. The remaining dust and volatile metals such as mercury and selenium are removed in the wet section of the acid plant through a cooling tour, a mist precipitator and a mercury tower (Boliden mercury removal processs). The sulphur dioxide is then converted to sulphuric acid in a conventional recovery system (converted and absorbing tower). Leaching of the calcine is carried out in a number of successive stages using a gradually increasing strength of hot sulphuric acid. The initial stages dissolve the major part of the zinc oxide and the other stages dissolve the zinc ferrite (ZnO.Fe2O3) and convert iron into Jarosite (sodium Jarosite). Zinc sulfate (ZnSO4) entering the electrolysis stage produce electrolyte (H2SO4) that is returned to leaching plant. Other metals are also dissolved during the process and are removed after leaching. Iron is the major impurity, which is precipitated in the form of Jarosite. Overall waste: The production of metals is related to the generation of several by-products, residues and wastes. Relatively large quantities of iron based solids, depending on the iron content, are generated by the leaching process (6.14E-1 kg Jarosite/kg zinc). Cement is added to the Jarosite to produce Jarofix (an inert waste). Solid residues also arise as the result of the liquid effluents treatment. The main waste stream is gypsum (CaSO4) and metal hydroxides that are produced at the wastewater neutralization plant. Mercury and selenium residues arise from the weak acid bleed treatment from the acid plant. Selenium can be recovered from these residues depending on the market demand for this metal. Overall emissions: The emissions to air can either be stack emissions or fugitive emissions. Stack emissions are normally monitored continuously (SO2) or periodically (other emissions) and reported. The main emissions to air from zinc production are sulphur dioxide (SO2) and particulate matters including metals. Main emissions to water are metals and their compounds. The monitored metals are zinc, cadmium, lead, mercury, selenium, copper and arsenic. technologyComment of primary zinc production from concentrate (RoW): The technological representativeness of this dataset is considered to be high as smelting methods for zinc are consistent in all regions. Refined zinc produced pyro-metallurgically represents less than 5% of global zinc production and less than 2% of this dataset. Electrometallurgical Smelting The main unit processes for electrometallurgical zinc smelting are roasting, leaching, purification, electrolysis, and melting. In both electrometallurgical and pyro-metallurgical zinc production routes, the first step is to remove the sulfur from the concentrate. Roasting or sintering achieves this. The concentrate is heated in a furnace with operating temperature above 900 °C (exothermic, autogenous process) to convert the zinc sulfide to calcine (zinc oxide). Simultaneously, sulfur reacts with oxygen to produce sulfur dioxide, which is subsequently converted to sulfuric acid in acid plants, usually located with zinc-smelting facilities. During the leaching process, the calcine is dissolved in dilute sulfuric acid solution (re-circulated back from the electrolysis cells) to produce aqueous zinc sulfate solution. The iron impurities dissolve as well and are precipitated out as jarosite or goethite in the presence of calcine and possibly ammonia. Jarosite and goethite are usually disposed of in tailing ponds. Adding zinc dust to the zinc sulfate solution facilitates purification. The purification of leachate leads to precipitation of cadmium, copper, and cobalt as metals. In electrolysis, the purified solution is electrolyzed between lead alloy anodes and aluminum cathodes. The high-purity zinc deposited on aluminum cathodes is stripped off, dried, melted, and cast into SHG zinc ingots (99.99 % zinc). Pyro-metallurgical Smelting The pyro-metallurgical smelting process is based on the reduction of zinc and lead oxides into metal with carbon in an imperial smelting furnace. The sinter, along with pre-heated coke, is charged from the top of the furnace and injected from below with pre-heated air. This ensures that temperature in the center of the furnace remains in the range of 1000-1500 °C. The coke is converted to carbon monoxide, and zinc and lead oxides are reduced to metallic zinc and lead. The liquid lead bullion is collected at the bottom of the furnace along with other metal impurities (copper, silver, and gold). Zinc in vapor form is collected from the top of the furnace along with other gases. Zinc vapor is then condensed into liquid zinc. The lead and cadmium impurities in zinc bullion are removed through a distillation process. The imperial smelting process is an energy-intensive process and produces zinc of lower purity than the electrometallurgical process.
technologyComment of platinum group metal mine operation, ore with high palladium content (RU): imageUrlTagReplace6250302f-4c86-4605-a56f-03197a7811f2 technologyComment of platinum group metal, extraction and refinery operations (ZA): The ores from the different ore bodies are processed in concentrators where a PGM concentrate is produced with a tailing by product. The PGM base metal concentrate product from the different concentrators processing the different ores are blended during the smelting phase to balance the sulphur content in the final matte product. Smelter operators also carry out toll smelting from third part concentrators. The smelter product is send to the Base metal refinery where the PGMs are separated from the Base Metals. Precious metal refinery is carried out on PGM concentrate from the Base metal refinery to split the PGMs into individual metal products. Water analyses measurements for Anglo Platinum obtained from literature (Slatter et.al, 2009). Mudd, G., 2010. Platinum group metals: a unique case study in the sustainability of mineral resources, in: The 4th International Platinum Conference, Platinum in Transition “Boom or Bust.” Water share between MC and EC from Mudd (2010). Mudd, G., 2010. Platinum group metals: a unique case study in the sustainability of mineral resources, in: The 4th International Platinum Conference, Platinum in Transition “Boom or Bust.” technologyComment of treatment of automobile catalyst (RoW): After collection and transportation to the intermediary dealer, the scrap is ground in a mill. The resulting material is fed to specialised refineries. The metallurgical step consists of an arc-furnace. Same refining process as in primary production assumed (selective precipitation) technologyComment of treatment of automobile catalyst (RER): The production process consists of three steps: Collection, Beneficiation and Refining. COLLECTION: Spoiled automotive catalysts are bought by specialised enterprises from different origins. Part of it originates from scrap dealer recycling end-of-life cars. Further more during the cars operating phase, defective catalysts are exchanged in garages. The third sources is the production waste, i. e. defective catalysts which do not reach market. In most cases, there are fix agreements between the different supplier and the intermediary trade. Although the trade with PGM containing scrap is risky. Motor car manufacturer built up their own internal recycling systems with their contractor garages and gained access to exchanged catalysts. Emissions: Emissions during collection are gases from transportation and dust from dismantling. Also in this step the combustion leads to emissions of SO2. No serious water emissions are reported. BENEFICIATION: The catalysts are dismantled and then sold to refining companies. Refineries too have long-term contracts with the intermediary trade. Emissions: Emissions during beneficiation are gases from transportation and dust from dismantling. Also in this step the combustion leads to emissions of SO2. No serious water emissions are reported. REFINING: The scrap first is shredded and then pyrometallurgicaly processed: The scrap is smelted in an electric arc furnace, and the ceramic wafer is slagged. The PGMs are concentrated in the collector metal, usually copper. Low-content PGM scrap is often smelted together with other non-ferrous metal matte. This is cheap, but effects a high loss in PGM. The collector matte from the furnace then is treated hydrometallurgically by re-precipitation. In this step usually production scrap from other industries (glass, chemical laboratories) is joined. The overall PGM-yield is 98 % for platinum and 85 % for rhodium. Emissions: Dust and metals are generally emitted from incinerators and furnaces. VOC can be emitted from solvent extraction processes, while organic compounds, namely dioxins, can be emitted from smelting stages resulting from the poor combustion of oil and plastic in the feed material. All these emissions are subject to abatement technologies and controlling. Effluents from refining contain considerable amounts of metals and organic substances. Waste: Solid residues from pyrometallurgical step are usually re-used in copper facilities, final residues generally comprise hydroxide filter cakes. References: Hagelücken C. (2001b) Die Märkte der Katalysatormetalle Platin, Palladium und Rhodium. In: Autoabgaskatalysatoren, Vol. 612. pp. 95-115. Expert Verlag, Renningen. Online-Version under: http://www.dmc-2.de/pmc_eng/Veroeffentlichungen_2/Die%20M%C3%A4rkte%20der%20Katalysatormetalle%20Pt%20Pd%20Rh.pdf. technologyComment of treatment of precious metal from electronics scrap, in anode slime, precious metal extraction (SE, RoW): Anode slime treatment by pressure leaching and top blown rotary converter. Production of Silver by Möbius Electrolysis, Gold by Wohlwill electrolysis, Palladium to further processing
technologyComment of platinum group metal mine operation, ore with high palladium content (RU): imageUrlTagReplace6250302f-4c86-4605-a56f-03197a7811f2 technologyComment of platinum group metal, extraction and refinery operations (ZA): The ores from the different ore bodies are processed in concentrators where a PGM concentrate is produced with a tailing by product. The PGM base metal concentrate product from the different concentrators processing the different ores are blended during the smelting phase to balance the sulphur content in the final matte product. Smelter operators also carry out toll smelting from third part concentrators. The smelter product is send to the Base metal refinery where the PGMs are separated from the Base Metals. Precious metal refinery is carried out on PGM concentrate from the Base metal refinery to split the PGMs into individual metal products. Water analyses measurements for Anglo Platinum obtained from literature (Slatter et.al, 2009). Mudd, G., 2010. Platinum group metals: a unique case study in the sustainability of mineral resources, in: The 4th International Platinum Conference, Platinum in Transition “Boom or Bust.” Water share between MC and EC from Mudd (2010). Mudd, G., 2010. Platinum group metals: a unique case study in the sustainability of mineral resources, in: The 4th International Platinum Conference, Platinum in Transition “Boom or Bust.” technologyComment of treatment of automobile catalyst (RoW): After collection and transportation to the intermediary dealer, the scrap is ground in a mill. The resulting material is fed to specialised refineries. The metallurgical step consists of an arc-furnace. Same refining process as in primary production assumed (selective precipitation) technologyComment of treatment of automobile catalyst (RER): The production process consists of three steps: Collection, Beneficiation and Refining. COLLECTION: Spoiled automotive catalysts are bought by specialised enterprises from different origins. Part of it originates from scrap dealer recycling end-of-life cars. Further more during the cars operating phase, defective catalysts are exchanged in garages. The third sources is the production waste, i. e. defective catalysts which do not reach market. In most cases, there are fix agreements between the different supplier and the intermediary trade. Although the trade with PGM containing scrap is risky. Motor car manufacturer built up their own internal recycling systems with their contractor garages and gained access to exchanged catalysts. Emissions: Emissions during collection are gases from transportation and dust from dismantling. Also in this step the combustion leads to emissions of SO2. No serious water emissions are reported. BENEFICIATION: The catalysts are dismantled and then sold to refining companies. Refineries too have long-term contracts with the intermediary trade. Emissions: Emissions during beneficiation are gases from transportation and dust from dismantling. Also in this step the combustion leads to emissions of SO2. No serious water emissions are reported. REFINING: The scrap first is shredded and then pyrometallurgicaly processed: The scrap is smelted in an electric arc furnace, and the ceramic wafer is slagged. The PGMs are concentrated in the collector metal, usually copper. Low-content PGM scrap is often smelted together with other non-ferrous metal matte. This is cheap, but effects a high loss in PGM. The collector matte from the furnace then is treated hydrometallurgically by re-precipitation. In this step usually production scrap from other industries (glass, chemical laboratories) is joined. The overall PGM-yield is 98 % for platinum and 85 % for rhodium. Emissions: Dust and metals are generally emitted from incinerators and furnaces. VOC can be emitted from solvent extraction processes, while organic compounds, namely dioxins, can be emitted from smelting stages resulting from the poor combustion of oil and plastic in the feed material. All these emissions are subject to abatement technologies and controlling. Effluents from refining contain considerable amounts of metals and organic substances. Waste: Solid residues from pyrometallurgical step are usually re-used in copper facilities, final residues generally comprise hydroxide filter cakes. References: Hagelücken C. (2001b) Die Märkte der Katalysatormetalle Platin, Palladium und Rhodium. In: Autoabgaskatalysatoren, Vol. 612. pp. 95-115. Expert Verlag, Renningen. Online-Version under: http://www.dmc-2.de/pmc_eng/Veroeffentlichungen_2/Die%20M%C3%A4rkte%20der%20Katalysatormetalle%20Pt%20Pd%20Rh.pdf.
technologyComment of processing of anode slime from electrorefining of copper, anode (GLO): Based on typical current technology. Anode slime treatment by pressure leaching and top blown rotary converter. Production of Silver by Möbius Electrolysis, Gold by Wohlwill electrolysis, copper telluride cement and crude selenium to further processing. technologyComment of selenium production (RER, RoW): Production from selenium is based on simplified roasting process with sodium carbonate. The inventory is based on stoechiometric calculations, according to the following equations: 2 X-Se + 2 Na2CO3 + 3 CO2 -> 2 Na2O4Se + 2 CO2 + 2 X (with X = compounds that were connected to Se - e.g. Cu2, CuAg, ....) 2 Na2O4Se + 4 HCl -> 2 H2O3Se + 4 NaCl + O2 2 H2O3Se + 2 SO2 -> 2 Se + 2 H2SO4 + O2 A surplus input of 25% is assumed. The air emissions occurring from the process are estimated to 0.2% of the raw material input. The remaining amount of unreacted raw materials is assumed to leave the production process to 95% as a solid waste and to 5% in the wastewater. Further it is assumed that this wastewater is treated in an internal wastewater plant. The carbonate is dissolved in the water and not shown anymore in the dataset. Sodium and chloride are assumed to be neutralized within the waste water treatment plant, leading to emissions of Cl- and Na+ in the water outflow. Sodium dioxide will be reacted into sulphuric acid and therefore leads to emissions of SO42- in the water outflow.
technologyComment of lubricating oil production (RER): A huge variety of different compositions are known under the name “lubricants” – actually, 5’000 to 10’000 different formulations are used to satisfy about 90% of the different lubricants applications. In terms of quantity, mineral oil components continue to be the most important ingredients. But more and more, derivatives of natural, harvestable raw materials from the oleo-chemical sector are finding their acceptance within the used substances. In 1999 around 37 Mt of lubricants have been consumed – thereof more than half in the automotive sector (56%), and another 29% as industrial lubricants. This amount is produced by around 1700 producers worldwide. Thereof, about 200 are vertically-integrated petroleum companies where lubricants are only a minor part of their profit. Nevertheless, less than 2% of all lubricant manufacturers are producing more than 60% of the total production volume. In case of the remaining 1500 companies, lubricants are their core business. In terms of the volume, base oils are the most important parts of lubricants. The rest is composed of additives. For this dataset, the additives are based on data published in Raimondi et al. (2012). imageUrlTagReplace8b52761e-ab96-49e0-a771-a229ae16ec10 The image above represents the typical yields of the different cuts from a conventional lubricating oil refining process To achieve base oils, a variety of different steps have to be done starting with the crude oil that is extracted until the right components are isolated. Different steps therefore are for example refining, distillation, de-asphalting, traditional refining process, solvent dewaxing or finishing. Additional steps that are often used are as well hydrogenation and hydrocracking operations. Based on the fact that a multitude of different processes are possible for the production of lubricants, the following choices are done for this dataset – with the aim to create a typical dataset for petrochemical lubricants – called “lubricants”: - Hydrocracking as basic technology for the extraction of the lubricant oils due to the fact that according to Bartels et al. (2003) more than 50% of the new manufacturing plants work with this principle. - Distillation and dewaxing as subsequent process steps to achieve high-quality base lubricant oils - Diesel as input due to the fact that these hydrocracker need low-sulphur oils. References: Bartels T., Bock W., Braun J., Busch C., Dresel W., Freiler C., Harperscheid M., Heckler R.-P., Hörner D., Kubicki F., Lingg G., Losch A., Luther R., Mang T., Noll S. and Omeis J. (2003) Lubricants and Lubrication. In: Ullmann's Encyclopedia of Industrial Chemistry, Sixth Edition, 2003 Electronic Release (ed. Häussinger P., Leitgeb P. and Schmücker B.), 6 th Electronic Release Edition. Wiley InterScience, New York, Online-Version under: http://www.mrw.interscience.wiley.com/ueic/ull_search_fs.html. Andrea Raimondi, Giorgia Girotti, Gian Andrea Blengini and Debora Fino (2012) LCA of petroleum-based lubricants: state of art and inclusion of additives. Int J Life Cycle Assess (2012) 17:987–996.
Secondary copper consists of various types of scrap. Prompt scrap is directly reused in foundries and is not further processed. Old scrap has to be treated in a secondary copper smelter, where a variety of metal values are recuperated. Depending on the chemical composition, the raw materials of a secondary copper smelter are processed in different types of furnaces, including: - blast furnaces (up to 30% of Cu in the average charge), - converters (about 75% Cu), and - anode furnaces (about 95% Cu). A scheme of the process considered is given in Fig 1. The blast furnace metal (“black copper”) is treated in a converter; then, the converter metal is refined in an anode furnace. In each step additional raw material with corresponding copper content is added. In the blast furnace, a mixture of raw materials, iron scrap, limestone and sand as well as coke is charged at the top. Air that can be enriched with oxygen is blown through the tuyeres. The coke is burnt and the charge materials are smelted under reducing conditions. Black copper and slag are discharged from tapholes. The converters used in primary copper smelting, working on mattes containing iron sulphide, generate surplus heat and additions of scrap copper are often used to control the temperature. The converter provides a convenient and cheap form of scrap treatment, but often with only moderately efficient gas cleaning. Alternatively, hydrometallurgical treatment of scrap, using ammonia leaching, yields to solutions which can be reduced by hydrogen to obtain copper powder. Alternatively, these solutions can be treated by solvent extraction to produce feed to a copper-winning cell. Converter copper is charged together with copper raw materials in anode furnace operation. For smelting the charge, oil or coal dust is used, mainly in reverberatory furnaces. After smelting, air is blown on the bath to oxidise the remaining impurities. Leaded brasses, containing as much as 3% of lead, are widely used in various applications and recycling of their scrap waste is an important activity. Such scrap contains usually much swarf and turnings coated with lubricant and cutting oils. Copper-containing cables and motors contain plastic or rubber insulants, varnishes, and lacquers. In such cases, scrap needs pre-treatment to remove these non-metallic materials. The smaller sizes of scrap can be pre-treated thermally in a rotary kiln provided with an after-burner to consume smoke and oil vapours (so-called Intal process). Emissions and waste: Elevated levels of halogenated organic compounds may arise, such as TCDD. Slags are usually used in construction. Waste water is led to a communal treatment plant. References: EEA, 1999. imageUrlTagReplacef2b602ec-dc47-48e3-88a7-ab8ec727bd33
| Organisation | Count |
|---|---|
| Bund | 1 |
| Europa | 1 |
| Weitere | 139 |
| Wissenschaft | 1 |
| Type | Count |
|---|---|
| Förderprogramm | 1 |
| Text | 139 |
| License | Count |
|---|---|
| Offen | 1 |
| Unbekannt | 139 |
| Language | Count |
|---|---|
| Deutsch | 139 |
| Englisch | 1 |
| Resource type | Count |
|---|---|
| Archiv | 139 |
| Datei | 139 |
| Dokument | 139 |
| Keine | 1 |
| Topic | Count |
|---|---|
| Boden | 25 |
| Lebewesen und Lebensräume | 47 |
| Luft | 13 |
| Mensch und Umwelt | 117 |
| Wasser | 16 |
| Weitere | 140 |