“Made to be Made Again” The ShoreMet Program Bruce Kasen
Vice President ShoreMet, LLC
[email protected]
RECYCLING METALS FROM INDUSTRIAL WASTE A Short Course and Workshop With Emphasis on Plant Practice Golden, Colorado June 21 - 23, 2016
Sponsored by the Colorado School of Mines Office of Continuing Education 1
Presentation Agenda 1. About ShoreMet 2. The Circular Economy 3. Strategic Approach 4. Upcycling Capabilities
About ShoreMet
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Indiana headquarters: customized chemical manufacturer A joint venture entity with Conecsus LLC: the largest tin/lead secondary smelter in the western hemisphere (Terrell TX) Valparaiso IN: chemical manufacturing of metallic compounds Nabb IN: Part B permitted processor for F006/F019 residues with RCRA exemption for byproduct remarketing Employs unique hydromet and pyromet recycling processes for lower cost of operations and market price effectiveness Key ShoreMet management:
◦ Danny Mislenkov - president & co-founder ◦ Bruce Kasen – vice president ◦ Dana Cassidy – vice president (Conecsus)
Nabb IN Facility Permit
EPA ID no.: INR000128975 RCRA permitted waste: F006, F019 WWT material RCRA permit issued: August 27, 2014 (5 yrs) RCRA exemption issued: August 27, 2015 (10 yrs) Acceptance criteria: >4.0% Cu, Ni, Sn + PM
Nabb IN Facility Description
50,000 sq. ft. building, rotary mixers/dryers 3 permitted storage areas • Bulk bunkers (3) – incoming bulk solids • Area 1 – incoming hazardous waste • Area 2 – storage for finished product Air emissions baghouse Waste approval – waste profile + rep. sample
Valparaiso IN Facility Description
Est. 1997 for chemical detinning of Cu/brass Currently, chemistry conversion of metals 42,000 sq. ft. building on 7 acres Rotary chemical reactors Chemical storage tanks Metal scrap storage All processing & storage conducted indoors
Shoremet Nabb
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The Circular Economy
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Since the post WWII industrial revolution, industrial manufacturing have been dominated by a one-way or linear model of production and consumption in which products are manufactured from raw materials, sold, used and then discarded or incinerated as waste. In the face of significant signs of resource depletion, the need for a new economic model is getting attention. A “circular economy” is a higher level recycling system (“upcycling”) that is restorative or regenerative by intention and design (“made to be made again”). The Ellen MacArthur Foundation works with business, government and academia to build a framework for an economy that is restorative and regenerative by design.
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Materials
Six Principles
Closing resource loops, mimicking natural ecosystems for organizing society and business.
recycle indefinitely
Value
Energy
generating value
renewable/ sustainable
Health
Ecosystem
Final Result is an Economy in which:
• Materials are efficiently managed & recycled: • Running on renewable energy, and; • Without negative effects on human life or ecosystems
rebuilding natural resources
supporting human health
Society healthy culture 8
– Jim Miller, Google VP, stated in October 2015 that “over the coming months, we’ll be working with the Foundation (Ellen MacArthur Foundation) to explore and shape a series of initiatives to embed circular economy principles into the fabric of Google’s infrastructure, operations and culture. (Miller) hopes that these efforts will take waste reduction and sustainability to the next level.” Mr. Miller states two example of Google efforts: • Google has reduced waste in areas of energy, materials, food and water, and has repurposed enough outdated servers since 2007 to avoid buying 300,000 new machines. • Google has kept 10,000 tons of material out of landfills by recycling demolition waste and onsite materials. – Trisa Thompson, Dell VP and chief responsibility officer, stated (September 2015) that the “technology industry has a unique responsibility to help shift the world to a circular economy model. We are always looking for collaboration that brings efficiencies to our business, and help our customers do the same.” For example, Dell has partnered with supplier Sabic to recycle excess carbon fiber and scrap raw materials into new Dell products beginning in 2015. Dell estimates it will prevent 820,000 pounds of carbon fiber from ending up in landfills. The recycled carbon fiber materials have an approximately 11% smaller carbon footprint than simply using virgin carbon fiber.”
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ShoreMet Strategic Approach
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Key questions 0
Strategy
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Overarching principles
▪ 1
1 Production
Customer 2
7 Reintroduce
Collec2 tion
Sorting and 3 bulking
Recycling 6
recycle, dispose Specific material/product for focus
▪ How could ShoreMet help identify ▪
Product design
Operations
▪ Rethink, redesign, reduce, reuse,
problem areas? How could ShoreMet support innovation (materials, processing)?
▪ How to secure waste volume? ▪ Which materials to collect/expect?
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▪ How to be distinctive on these
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▪
5
▪
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▪ Technical & economic feasibility
steps? How to extract the materials with the required quality? Understanding which grades are required by the market?
for transformation? Finesorting 5
Dismantling 4
▪ How to re-introduce recycled 7
▪ ▪
material in the supply chain? How to trade commodities? How to identify new markets?
“Made to be Made Again” 11
ShoreMet “Upcycling” Capabilities
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Example of copper “upcycling” Copper chop
Copper wire
Copper chloride
Acids
Shoremet Processing
Copper scrap sheet
Copper oxide
Copper carbonate
Gases Printed circuit boards Copper sulfate
“Made to be Made Again” 13
Operations: unique hydromet and pyromet recycling processes for low cost of operations and market price effectiveness
Raw Materials Spent sulfuric and hydrochloric acid Spent caustic solutions & solids Spent chelated metal solution Spent metallic catalysts Scrap metal with unusual impurities Scrap E-waste components Products Produced ◦ Copper oxide ◦ Copper cyanide ◦ Copper carbonate ◦ Ammonium carbonate ◦ Copper chloride ◦ Ammonium hydroxide ◦ Copper sulfate ◦ Tin hydrate ◦ Copper sulfide
Nabb IN Facility Operations Raw Materials F006 metal hydroxide Non-regulated metal hydroxide Products Produced Copper, nickel, tin, cobalt byproducts Future Innovation Metallic leaching for “upcycled” products
1 Production
Product design
Operations
Valparaiso IN Facility Operations
Customer
7 Reintroduc e
Collection 2
Sorting and 3 bulking
Recycling 6 Finesorting 5
Dismantling 4
• Materials and sludges that ShoreMet will process under the IDEM RCRA exemption contain 50‐80% water, which makes them initially unsuitable for use as raw materials in a smelting process. • Materials that contain water must therefore be dried (
