sustainability challenge of the aluminum industry: transforming wastes into products
DESCRIPTION
The work that follows is a contribution to the aluminum industry’s sustainability. It deals with the critical issue of solid wastes accruing to that sector. By-products from aluminum refining are solid wastes, liquid effluents and gaseous emissions. Each kilogram of metal produced is accompanied by three and a half kilograms of bauxite residue, commonly known as red mud. Current practice is to use decantation lagoons that are built with elaborate precautions for preventing environmental contamination. The aim of the present work is to investigate this pollutant within the perspective of current solid industrial waste technologies, and to study the practicalities for utilization and new processes. The very high ratio residue/end product provides a strong incentive insofar as the residue concerned does in fact offer numerous commercial opportunities. Thus the feasibility of converting the residue into a raw material is a real alternative to landfill disposal. Numerous industrial processes and technologies have been considered in relation to environmental legislation, industrial marketing, competitive processes and other factors. In conclusion the subject paper recommends a series of activities that would achieve transformation of red mud into valuable substances and substitute other existing raw materials without adversely affecting quality and the environment.TRANSCRIPT
The challenge of sustainable development of the aluminum industry:
"turning waste into products”
1
Marcelo Suster- EcouniversoAntonio Carlos da Cruz- RecAltech
Presented at 6th International Aluminum Meeting- Brazilian Aluminum Assotiation- April/2014
Research and development of processes and operation of demonstration plants
Aluminum recycling without salt: Tilting rotary furnace plasma; Stationary plasma furnace with circulating bath for electromagnetic pump.
Power generation: Thermal processing of biomasses and waste industrial and urban.
Projetos Ambientais para o combate às mudanças climáticas
Consulting
Carbon Managment• GHG inventory
• Projects to reduce emissions
• Verification of GHG inventory
• Product Carbon Footprint
Socioenvironmental Responsibility
• Study of benchmarks and metrics
• Evaluation of supply chain
• ISE, GRI, CDP, reports
• ICO2- Carbon Efficient Index
Trainning
• Workshops and courses
• Trainnings in company
Sustentability
Solid Waste• PNRS - GRS and Verification Plan
• Technological Innovation in the Treatment
• Recycling and Reverse Logistics
• Transformation in Products
Work Motivation / "Cryolite Coal "
4
Coal skimming
Electrolyte
Cryolite Coal
20.000 ton
USD 70/MtonCoprocessing
USD 18/tonSales
(USD 1,400,000) + USD 360,000Source: Elaborated by author
Aluminum: Sustainability Partner?
5
Solid Waste
Emissions Energy
Consumption
Source: Elaborated by author
Sustainabil ity Tripod
6
SocialSocial EnvironmentalEnvironmental
EconomicEconomic
Source: Elaborated by author
Steel X AluminumSolid waste generation
7
1 Mton of product
Steel
700 Kg
Aluminum
3.500 Kg
1 Mton of product
Source: Elaborated by author
8
SteelArcelor- Mital- 2012
Source: www.arcelor.com.br- visited on 22nd/oct/2014
Global Aluminum Flow in Mton
9
Total de ProdutosEstocados/em usoDesde 1888586 .0
ProdutosAcabados(
output)
40.4
Outras Aplicações
1.0
Produtos pré-fabricados
e finais (input) 67.4
Sucatanova
8.6
SucataFabricante
18.4Sucata
Nova 1.4
Lingotes 68.8
Perdas de Metal
1 .4 Não reciclado 3.5 Sob investigação 3.7
sucataVelha
7.8
Bauxite 180.
Resíduo de Bauxita
75
Água 38
Alumina 65.
Alumínio Primário
34.
Alumínio Refundido
35.
Construção 32% Transporte 28%.Automotivo 16%
Adição Líquida2006: 24.4
Emabalagens 1%
E Cabos 28%EngenhariaOutros 11%
Total de alumínio produzido até 2013: 1.137 Milhões de toneladasSource: CRU
Total volume of red mud generated over
History
Brazil Situation
10
3o Largest Bauxite Producer
3o Largest Bauxite Residue Producer
Brazilian Alumina Production: 11 Million MtonEstimated Bauxite Residue Generation: 22 Million Mton
3o Largest Alumina Producer
8o Largest Aluminum Producer
Source: Elaborated by author
Working Lines with Bauxite Residue- BR
Environmental safety of residue lakes/ landfil ls
Dry generation
Neutralization of BR
Recovery of elements/substances
Application of BR products
11
Goal: Collaborate with management of industrial solid waste, seeking the application of waste products
Results:
1.Roadmap of activities for this application and
2.A choice of strategic direction
12
Technological
Research
Market Research
Legal and Fiscal
Suitability Business Process
Residue Product
Source: Elaborated by author
Application of waste from the aluminum industry
13
Source: Elaborated by author
Patents- BR Applications
14
Nº patentes
0 100 200 300
C04: cement, concrete, artificial stone, ceramic, refractory
C10: industries of oil, gas or coke,technical gases containing carbon monoxide, fuel, lubricants, peatC21: iron metallurgy
C09: dyes, polidires, natural resin adhesives, various compositions,various applications of substances
F27: furnaces, ovens, kilns, retorts
B03: separation of solid materials using liquids or tables
C05: fertilizers, their manufacture
E01: construccion de rodovias, ferrovias ou de pontes
C03: glass, rock wool and slag wool
A01: agriculture, forestry, livestock, hunting, capture in traps, fishing
B28: manipulation of cement, clay or stone
E04: building
B22: foundry, metallurgy of metallic powders
D21: the manufacture of paper pulp production
C04
C10
C21
C09
F27
B03
C05
E01
C03
A01
B28
E04
B22
D21
Source: NIT- UFSCar
Resíduo de
Bauxita
glassSoil corrective
Concrete
Chemicals
Pigment /Plastic filler
Sinthetic steel slag
Gallium
Sequestration of heavy metals
Red ceramicAlo
Sulphate
Raw material cement flour
Ceramic tiles
Potential applications identified
15Source: Elaborated by author
Attractiveness Matrix
16
Source: Elaborated by author
Environmental Safety
Concrete
Soil Corrective Ceramic
Plastic f i l ler
SequestrantGlass
VidrosObjetivo: Incorporação na matriz de vidro âmbar como matéria-prima.
Cases Study
17
Soil correctiveRed ceramic
No residue With Residue
Amber glass
Standart concreteConcrete with BR
Construction Concrete
Source: Elaborated by author
18
SWAT analysis
STRENGTHSCost reduc on of residues disposalAddi onal cash with residues salesDecrease of environmental liability
Use of current resources tocommercialize the residues (sales force)
THREATSMarket reac on, dropping prices of theproducts that were affected by residue
compe onConsump on market rejec on beingdue to using residues in the products
OPPORTUNITIES
Image gain and company trademarkreinforcement
Fiscal gains: green seal, less taxes, etc.…
WEAKNESSExposure to new poten al liabili es
outside own landfillExposure of the environmental
management systemCompany
Market
Source: Elaborated by author
Market Forces Balance
19
NEWENTRANTSNew companies
hema te producers,cement, clay and
limestone suppliers
Suppliers
INDUSTRYRIVALRYHema te producersCement Producers
Clay SuppliersLimestone Suppliers
BUYERSGlass producers
Concrete producersCeramic, agricultureand, at second level:
final consumers
TRENDSThebuyerscanearnwiththeop onsoffersincreaseof rawmaterials. Costdecrease, andagreen
image.The final consumerscanearnalsowithapricereduc onof the final
products. But on theotherhand, the consumerscanreject productsthat contain
residues.
Subs tutesSource: Elaborated by author
Legislative environmentTransportation and disposal
extensively regulated
PNRS- National Solid Waste PolicResponsibility for the entire supply chain,
including post-consumer
20
Iden fying a poten alapplica on for the
residue
Checking the opera nglicense of the poten al
customer
Tax classifica on ofthe product
Send the productsafety data sheet
To know the residuePhysicochemicalcharacteris cs
Iden fying a poten alapplica on for the
residue
Applica on inlaboratory scale
Measure the impact of theaddi on of the tradi onal
product residue
Contact the environmentalagencies in their regions of
origin and applica on ofresidue
License to transportwaste
Permit for biosolidsapplica on
Iden fy a partner(client-poten al)
Search poten al applica onsfor the residue according to
their proper es
Industrial trial
marke ng
Monitoring theapplica on of the test
residue
Remove the residue ofthe waste inventory,
the company
Put the new product inthe descrip ve Memorial
venture - MCE
11
22
33
44
55
66
77
88
99
1010
1111
1212
1313
1414
1515
1616
1717
1818Source: Elaborated by author
Valuation of aluminum / Cost Socio-Environmental
22
Custo
Sócio-Ambiental
Faturamento do setor
Atmospheric
emissions
Generation of Solid Wasteeffluents
Raw Material
Energy
Other inputs
Workforce
Services
Replacing steel in transportation
Energy consumption
Durability of aluminum lengthens the life cycle of products
Recyclability of the metal
Sale of waste
Waste Generation
Source: Elaborated by author
Socio cost of aluminum
23
Source: Elaborated by author
SOCIO COST OF
ALUMINUM
NEGATIVE EXTERNALITIES
(energy intensive use + GHG emissions +
waste generation + bauxite use)
POSITIVE EXTERNALITIES(Revenue + fuel
saving + recycling +
aluminum long shelf l ife)
= -
ConclusionsThe process of transforming waste into products
based on their financial, environmental and social impacts, is a key factor in the change of positive and negative externalities in this way contribute to the aluminum industry sustainability;
The literature is rich in studies of technological application for the RB, but little or nothing has turned into sustainable commercial activities;
A roadmap of activities to transform waste into products is very important in directing the efforts of the aluminum industry;
24
Conclusions
The targeting of efforts to transform the raw material into a RB to be sold in the market can not generate results;
The aluminum industry should think about adding value to the RB within their own generating plants RB, transforming it into a product, before being transported;
This paper attempts to serve as a gateway to an approach of applying RB broader, involving from the beginning trade and market variables.
25
Thanks toIPT- Instituto de Pesquisas Tecnológicas do
Estado de São Paulo
Alcoa
NIT- UFSCar
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Thank [email protected]
"The world we will leave to our children depends on the children to leave the world"
2º Fórum Internacional Criança e Consumo