Dynamic material flow analysis of steel resources in Korea

Material flow analysis (MFA) is an evaluation technique that systematically identifies the flows and stocks of materials within predefined spatial and temporal boundaries. In this paper, the steel resources in Korea are investigated using dynamic MFA. Iron ore and steel scrap are added as raw material components during the production processes of steel, which is then used in a variety of product groups such as construction products, transportation equipment, machinery/metal products, electrical/electronic devices, and other products through fabrication and manufacturing processes. When such product groups are discarded, they are either recycled or landfilled. With consideration for the lifetimes of various product groups in conjunction with steel resource flows in Korea, dynamic MFA is conducted on the flows of steel stock change and annual scrap generation. By 2020, these two flows are expected to increase by as much as 40% and 30%, respectively, compared to 2008, with transportation equipment, in particular, envisaged to experience high growth. At the current recycling rate, however, it will be hard to meet future scrap demand. According to the scenario analysis, 100% of this future scrap demand can be supplied domestically if the recycling rate is increased to over 70% for all product groups, except construction products and transportation equipment, which already have high recycling rates. By 2020, the reduction in scrap importation costs is projected to offer a financial gain of 2.3 billion dollars.     

Welfare gains from aluminium recycling in the USA

In this paper we estimate a flexible form cost function of the aluminium industry in the USA and use our estimates to obtain derived demand curves for aluminium inputs such as electricity and bauxite. We then calculate the welfare gains arising from decreased energy use when the level of secondary recycling is increased. The process is repeated for several model specifications. All of our tests, however, yield similar results and indicate that substitution of scrap for only 5% of the bauxite presently used in US aluminium manufacturing would result in annual savings of close to a quarter of a billion dollars.     

Energy Consumption in the Turkish Industrial Sector

Turkey's primary energy resources seem limited as indigenous energy production meets nearly 31 % of the total primary energy demand. But the growth of Turkey's industry gives rise to a substantial increase in energy demand. Final energy consumption grew from 52.6 Mtoe (million tons of oil equivalent) in the year 1990 to 78.4 Mtoe in the year 2002. Industrial demand accounts for about 41.6 % of the final energy demand in Turkey. Basic metal industries, non-metallic material products and chemical and petroleum products have the highest energy consumption in industrial sector. In this work, industrial energy consumption and energy consumption of different indsutrial subsectors in Turkey are investigated.     

Long-term global availability of steel scrap

Primary steelmaking involves CO₂-intensive processes, but the expansion of secondary steel production is limited by the global availability of steel scrap. The present work examines global scrap consumption in the past (1870–2012) and future scrap availability (2013–2050) based on the historical trend. The results reveal that (i) historically, the consumption of old scrap has been insufficient compared with the amounts of discarded steel, and (ii) based on historical scrap consumption, the future availability of scrap will not be sufficient to satisfy the two assumed cases of steel demand. Primary steelmaking is expected to remain the dominant process, at least up until 2050. Under the reference-demand case of 2.19 billion tons in crude steel production by 2050, the total production of pig iron and direct reduced iron could reach 1.35 billion tons. Consumption of old scrap could reach 0.76 billion tons. Because the availability of scrap will be limited in the context of the global total, it is important to research and develop innovative low-carbon technologies for primary steelmaking and to explore their economic viability if we are to aim for achieving large reductions in CO₂ emissions from the iron and steel industry.     

The material resources for the iron and steel industries

The future supplies of iron ore, coking coal and ferrous scrap are discussed. There is no likelihood of the resources of iron ore being exhausted until well into the twenty-first century. Coking coal, on the other hand, is in shorter supply but it is being eked out by blending with non-coking coal and by making blast furnaces more efficient. Briquettes made completely from non-coking coal will play a part in iron making in the future. To ensure greater flexibility in steel making, hydrocarbons are being considered as possible substitutes for coal. Scrap has always played an important part in steel making and the amount recycled is increasing every year. But more effort is needed, for example, to ensure that the steel in car scrap is fully utilised and that refuse is efficiently recycled. Steel making increasingly demands the scrap to have few impurities and to be in uniform sized pieces. A cryogenic method of preparing such scrap is described. A futuristic way of extracting iron, non-ferrous metals and other saleeable by-products from refuse, by using redundant blast furnaces, is also discussed.     

Recycling opportunities in the UK for aluminium-bodied motor cars

The purpose of this paper is to review, and draw attention to, issues raised by the recycling of wrought aluminium from motor cars, even though the time horizon for significant arisings of such aluminium scrap is in the order of 20 years from now. Recycling of specific grades of wrought aluminium will be viable only when a means of positively identifying different types of scrap is available. A solution must be reliable, rapid, and low-cost; probably used in conjunction with a vehicle shredder. Such a system of identification will eliminate the need for costly hand-dismantling and segregation. Simple segregation of cast and wrought alloy will, however, be essential when wrought aluminium from car bodies dominates the scrap arisings. Such segregation will produce two high-value scrap products. The first of which will be similar to the A380 casting alloy specification, maintaining the current supply of this scrap, and the second will be a composite of wrought alloys. These issues are relevant to the aluminium scrap industry, which will have to accommodate future changes in the composition of the scrap it receives, and the motor industry, which may adopt in-house recycling of wrought alloy in order to offset the high purchase cost of aluminium.     

Metals recycling in the United States

Twenty-two metals for which secondary recovery is important, in terms of quantity and/or value, were compared and ranked for rate and efficiency of recycling, and availability of recycled metal. In general, their recycling rates trended upward over the period 1970–1993. Iron, aluminum, copper, gold, platinum, and lead accounted for most of the value of all secondary metal produced, while iron and steel dominated in terms of quantity produced and exported. The factors most influential on recycling rates are profitability, public support, organization of infrastructure, sortability, legislative support, and scrap purity. The share of supply accounted for by secondary metals is expected to surpass that of primary metals sometime in the next decade.     

Modeling methods for managing raw material compositional uncertainty in alloy production

Operational uncertainties create disincentives for use of recycled materials in metal alloy production. One that greatly influences remelter batch optimization is variation in the raw material composition, particularly for secondary materials. Currently, to accommodate compositional variation, firms commonly set production targets well inside the window of compositional specification required for performance reasons. Window narrowing, while effective, does not make use of statistical sampling data, leading to sub-optimal usage of recycled materials. This paper explores the use of a chance-constrained optimization method, which allows explicit consideration of statistical information on composition. The framework and a case study of cast and wrought production with available scrap materials are presented. Results show that it is possible to increase the use of recycled material without compromising the likelihood of batch errors, when using this method compared to conventional window narrowing. This benefit of the chance-constrained method grows with increase in compositional uncertainty and is driven by scrap portfolio diversification.     

Modelling price fluctuations of ferrous scrap

This paper presents a model that analyses the interrelationships between markets of light non-flat steel products (such as concrete reinforcing bars) and iron and steel scrap, both of which are characterized by wide price fluctuations. The model, which was developed as a linear complementarity programming problem, seems to be robust in analysing unstable and simulataneous price movements of those markets. The model may be applied to other metal and scrap markets without substantial changes.     

Short-Term Opportunities for Decreasing CO2 Emissions from the Steel Industry

There is a strong political will to decrease CO₂ emissions. Although the steel industry only accounts for some 5% of worldwide CO₂ emissions (which totalled 1,200 million tonnes per annum in the late 1990s), it will be strongly affected by this. The EU, for example, is putting up strong economic incentives for reductions. This is taking place at a time when demand for steel products is greater than ever. To radically change existing processes and production routes to decrease the CO₂ emissions would be extremely expensive, even if it were possible. Nevertheless, many of the solutions which have been discussed seem to go in this direction. The other alternative discussed seems to be the creation of process solutions and alterations that lead to a focusing of CO₂ streams, i.e., much higher CO₂ concentrations in flue gases than today, for entrapment of the CO₂ so that it is not discharged into the atmosphere. These solutions are feasible, but expensive.

However, there exists today a number of solutions and technologies which, if fully implemented, could substantially decrease CO₂ emissions without seriously altering current methods of operation; they are short-term viable solutions. The present paper reviews and discusses such technologies, throughout the steel production paths. If these solutions are fully implemented, the combined impact on CO₂ emissions from the steel industry worldwide is estimated to be a reduction of 100–150 million tonnes of CO₂ per annum, i.e., current emissions can be reduced by some 8–10% within a relatively short time span.     

Historical evolution of anthropogenic aluminum stocks and flows in Italy

Dynamic stocks and flows analysis was applied to the anthropogenic aluminum cycle in Italy in order to detect and quantify metal flows and in-use stocks over the years 1947–2009. The model utilized a top-down approach, including data for production, consumption, loss, and trade flows of aluminum. Seven end-use markets were considered, namely buildings and construction, transportation, consumer durables, machinery and equipment, electrical engineering, containers and packaging, and miscellaneous appliance types. The results of this dynamic stocks and flows analysis model quantified the contemporary anthropogenic reservoirs (or in-use stocks) of aluminum at about 320 kg per capita, mainly embedded within the transportation and building and construction sectors. Cumulative in-use stock represents approximately 11 years of supply at current usage rates (about 20 Mt versus 1.7 Mt/year), implying significant potential for recycling in the future as this stock comes out of use. Flow analysis revealed that Italy imports mainly unwrought aluminum and exports final products, while the main material losses occur during alumina refining and collection of old scrap: specifically, containers and packaging have the highest old scrap generation rate, but for the lowest recovery rate (50%). Increasing support to collection of scrap and initiatives oriented to aluminum recovery specifically would allow Italy to increase its reliance on domestic material, and may also allow a decline of the country import-dependence on primary sources. The dynamic stocks and flows model created here provides a quantitative historical record of the aluminum required by Italian society during important periods of development and provides guidance for future decision-making around the use of domestic secondary resources.     

Life cycle inventory of recycling portable nickel–cadmium batteries

In this study, the environmental impact of recycling portable nickel–cadmium (NiCd) batteries in Sweden is evaluated. A life cycle assessment approach was used to identify life cycle activities with significant impact, the influence of different recycling rates and different time boundaries for emissions of landfilled metals. Excluding the user phase of the battery, 65% of the primary energy is used in the manufacture of batteries while 32% is used in the production of raw materials. Metal emissions from batteries to water originate (96–98%) from landfilling and incineration. The transportation distance for the collection of batteries has no significant influence on energy use and emissions. Batteries manufactured with recycled nickel and cadmium instead of virgin metals have 16% lower primary energy use. Recycled cadmium and nickel metal require 46 and 75% less primary energy, respectively, compared with extraction and refining of virgin metal. Considering an infinite time perspective, the potential metal emissions are 300–400 times greater than during the initial 100 years. From an environmental perspective, the optimum recycling rate for NiCd batteries tends to be close to 100%. It may be difficult to introduce effective incitements to increase the battery collection rate. Cadmium should be used in products that are likely to be collected at the end of their life, otherwise collection and subsequent safe storage in concentrated form seems to offer the best solution to avoid dissipative losses.     

Challenges and political solutions for steel recycling in China

The circular economy is an essential component of China's sustainable development. To promote the recycling of end-of-life products, the government has adopted various policies. Steel scrap is an important resource for steelmaking. Yet, the Chinese iron and steel industry uses less scrap to produce new steel compared to other large steelmaking countries. This article examines the reasons, why steel recycling is still relatively weak in China and what measures the government takes to improve the situation. We found that limited availability of scrap, high scrap prices, inadequate steelmaking capacities, industry fragmentation and unclear responsibilities for manufacturers are the main obstacles for steel recycling in China. The government is trying to improve steel recycling through tax incentives, import facilitation, support for supply, industry reorganization, and recycling parks, but with modest results.     

Copper recycling and scrap availability

According to existing estimates, available old copper scrap has more than tripled over the past 40 years. Secondary production (that is, copper produced from recycling old scrap), however, has only doubled. Indeed, over the past 10 years, while copper consumption and primary production have continued to expand briskly, while available old scrap has increased by over 35%, secondary production has actually stagnated.For a world concerned with sustainable development and the quality of the earth's environment, this performance is disappointing and in need of explanation. Other things being equal, one would expect the amount of recycling to increase with the availability of scrap, as many econometric models of the world copper market developed over the past several decades explicitly assume.The key to understanding sluggish growth in secondary production, this paper argues, is distinguishing carefully between (1) the flow of old scrap that arrives each year from products reaching the end of their useful lives during the year and (2) the available stock of old scrap that was not recycled during earlier years presumably because it was too costly to do so. Using an econometric model, the paper shows that old scrap stocks, which have contributed most of the increase in available old copper scrap over the years, have a very modest impact on secondary production. Old scrap flows have a much greater effect, but they account for only about 4% of the available old scrap for any given year.     

UK metal reclamation : Prospects for improvement

Ferrous and non-ferrous metal-bearing scrap and waste arisings in the UK are discussed. Information is given on the quantities arising, their locations, the amounts recycled and the quantities of metal lost to the economy. Methods of increasing the recovery of metal values are discussed, with an indication of current R & D and possible future requirements.     

What caused the slack demand for metals after 1974?

This paper explores the general reasons for the sudden decline in the growth of world metal demand which began after 1974 and continues to impact the metal industries. For all of the eight metals studied, except aluminium, the dominant cause of this atrophy in demand is the stagnation in total world economic growth, which has caused reduced demand for all goods and services. In addition, consumer preferences have shifted away from metal-intensive goods, further reducing the need for metals. However, materials substitutions and manufacturing technologies have continued to evolve towards lower use of metal in each product at much the same rate after 1974 as before. Therefore, these aspects do not explain the sudden shortfall after 1974 except in the case of aluminium which experienced a dramatic change during the energy crisis years.     

Application of TiO2 nanoparticles for eco-friendly biodiesel production from waste olive oil

An environmentally benign, simple, and efficient process has been developed for biodiesel production from waste olive oil in the presence of a catalytic amount of TiO₂ nanoparticles at 120°C with a conversion of 91.2% within 4 h. The present method affords nontoxic and noncorrosive medium, high yield of biodiesel, clean reaction, and simple experimental and isolation procedures. The catalyst can be recycled by simple filtration and reused without any significant reduction in its activity.     

Environmental consequences of recycling aluminum old scrap in a global market

Nowadays, aluminum scrap is traded globally. This has increased the need to analyze the flows of aluminum scrap, as well as to determine the environmental consequences from aluminum recycling. The objective of this work is to determine the greenhouse gases (GHG) emissions of the old scrap collected and sorted for recycling, considering the market interactions. The study focused on Spain as a representative country for Europe. We integrate material flow analysis (MFA) with consequential life cycle assessment (CLCA) in order to determine the most likely destination for the old scrap and the most likely corresponding process affected. Based on this analysis, it is possible to project some scenarios and to quantify the GHG emissions (generated and avoided) associated with old scrap recycling within a global market. From the MFA results, we projected that the Spanish demand for aluminum products will be met mainly with an increase in primary aluminum imports, and the excess of old scrap not used in Spain will be exported in future years, mainly to Asia. Depending on the scenario and on the marginal source of primary aluminum considered, the GHG emission estimates varied between −18,140 kg of CO₂ eq. t⁻¹ and −8427 of CO₂ eq. t⁻¹ of old scrap collected. More GHG emissions are avoided with an increase in export flows, but the export of old scrap should be considered as the loss of a key resource, and in the long term, it will also affect the semifinished products industry. Mapping the flows of raw materials and waste, as well as quantifying the GHG impacts derived from recycling, has become an essential prerequisite to consistent development from a linear toward a circular economy (CE).     

Quantification of Chinese steel cycle flow: Historical status and future options

China is the largest steel producer and consumer around the world. Quantifying the Chinese steel flow from cradle to grave can assist this industry to fully understand its historical status and future options on production route transformation, capacity planning, scrap availability, resource and energy consumption. With the help of the systematic methods combined dynamic MFA (material flow analysis) with scenario analysis, the Chinese steel cycle during the first half of the 21st century was quantified and several thought-provoking conclusions were draw. In the past decade, lots of pig iron or molten iron was fed into EAF (electric arc furnace) and the scrap usage of EAF fluctuated slightly. Thus, the real scrap-EAF route share is much lower than the EAF production share. On the other hand, we reconfirmed that the scrap supply in China will rise significantly in the future. Meanwhile, the secondary production route share will grow sharply and exceed primary production share before or after 2050 depending on our options. The scrap recycling rate and construction's lifetime play a vital role in this trend. In the end, an intensive discussion on production capacities’ adjustment and energy and resource consumption was conducted and relative policy suggestions were given. It is worth noting that scrap usage is crucial to future energy saving and emissions reduction of Chinese steel sector and its energy consumption might peak as early as 2015.