Dynamic material flow analysis of copper and its alloys in Japan - - PowerPoint PPT Presentation

• Dept. of Materials Engineering, Graduate School of Engineering,
• Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo

University of Tokyo

Dynamic material flow analysis of copper and its alloys in Japan

Ichiro Daigo, Susumu Hashimoto, Yasunari Matsuno, Yoshihiro Adachi Graduate School of Engineering, University of Tokyo

LCM 2007 , Zurich, August 27-29 2007

• Dept. of Materials Engineering, Graduate School of Engineering,
• Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo

University of Tokyo

Conventional MFA/SFA studies paid little attention to the grade of the materials.

Tools for a sound material cycle

Material Flow Analysis Substance Flow Analysis (MFA/SFA)

High-purity copper Copper alloys

Ore

Electrolytic Cathode copper

Feedstock Downgraded recycling Closed-loop recycling Closed-loop recycling Upgraded (?) recycling

Recycling system in copper

• Dept. of Materials Engineering, Graduate School of Engineering,
• Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo

University of Tokyo

Copper and copper alloys (Production)

Cu contents Oxygen-free copper >99.90% Tough pitch copper >99.90% High- purity copper Copper alloys Negli- gible small Phosphorous-deoxidized copper >99.90% Brass (copper-zinc alloys) 59.0-71.5% Free-cutting brass 57.0-63.0% High copper alloys >96.0% Tin bearing brass 87.0-90.0% Aluminum bronze 77.0-92.5%

Source: Japan industrial standard

• Dept. of Materials Engineering, Graduate School of Engineering,
• Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo

University of Tokyo

Copper and copper alloys (Scrap)

Cu contents Copper scrap >97% Copper-alloy scrap >50%

The instruction of census forms ‘when scrap can not be recognized as high copper or copper alloys, it should be categorized as copper alloy scraps.’

Certain amounts of high-copper scraps have been collected as copper alloy scraps, such as high-purity copper being discarded without separation from copper alloys,

• r metal plating or other metal components being collected as copper alloy scraps.

• Dept. of Materials Engineering, Graduate School of Engineering,
• Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo

University of Tokyo

Objectives

A dynamic MFA was conducted separately

for copper and copper alloys in Japan in

• rder to estimate the stock and the

potential for recycling of each of these materials.

• Dept. of Materials Engineering, Graduate School of Engineering,
• Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo

University of Tokyo

Material stock and flow taken into account in this study

Obsolete scrap

In-use stocks Environment

Dissipation Remaining

Industrial scrap

Domestic consumption

Input (A)

Trades of finished products

Landfill

Loss into steel cycle

(C)

Trades of materials

material production

(D)

Output (H)

(G)

(B) “Uncollected materials”

(E) (F) Export as mixed metals “uncollected materials” denotes disused materials that are not recovered domestically as copper-

based scraps and that are lost from the domestic copper cycle.

• Dept. of Materials Engineering, Graduate School of Engineering,
• Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo

University of Tokyo

Structure of Japanese copper industries

Category of industry (they have each association) Electric wire and cable Copper fabricated products Category of metal grade Category in this study High-purity copper Copper alloys Copper fabricated products (Cu alloys) Electric wire and cable Copper fabricated products (Cu)

• Dept. of Materials Engineering, Graduate School of Engineering,
• Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo

University of Tokyo

Use in products Steel Production Discarded scrap

Lifetime The amount of steel products 1999 2000 2001 2002 2003

Investigation year

Population Balance Model; PBM

5 10 15 20 25 30 5 10 15 20 0.2 0.4 0.6 0.8 1

Remaining rate Age Y e a r

• f

m a n u f a c t u r e 1 9 7 4 1 9 8 4 1 9 9 4 2 4

Lifetime distribution

• f Automotives

Lifetime distribution

• f Steel-office buildings

• Dept. of Materials Engineering, Graduate School of Engineering,
• Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo

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0.0 0.2 0.4 0.6 0.8 1.0 20 40 60 80 100 Age/ year Remaining rate 自動車 建設 電気機械 ケーブル その他機械 その他

Dynamic MFA

Generation* collection rate= Obsolete scrap

Data preparation

• historic consumption
• lifetime distribution of products

Population balance model

Data preparation

• Recovery rates of EOL products
• Separation efficiency of metals

AUT CONST EEE W&C MACH Others

Electric wire and cable Copper fabricated products Communication line and power cables 100%

• Electric and electronic machinery

55% 55% Automobiles 61% 58% Other machinery 50% 50% Construction 80% 56% Others 23% 23%

Collection rates for each end use

• Dept. of Materials Engineering, Graduate School of Engineering,
• Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo

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Scrap generation (including uncollected materials)

200 400 600 800 1,000 1,200 1970 1975 1980 1985 1990 1995 2000 2005 Year Discarded scraps / 1,000t

From Electric appliances From Automobiles From Construction From Other machinery From Electronic wire and cable From Others

• Dept. of Materials Engineering, Graduate School of Engineering,
• Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo

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Comparison of collected scraps

200 400 600 800 1000 1200 1400 1970 1975 1980 1985 1990 1995 2000 2005 Year Collected scraps [1,000t/ y] High- purity copper (EW C) High- purity copper (CFP) Copper alloys Statistics

• Dept. of Materials Engineering, Graduate School of Engineering,
• Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo

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Downgraded recycling

200 400 600 800 1,000 1970 1975 1980 1985 1990 1995 2000 2005 Year Collected pure- Cu scraps [1,000t/ y]

• Obs. from Electric appliances
• Obs. from Automobiles
• Obs. from Construction
• Obs. from Other machinery
• Obs. from Electronic wire and cable
• Obs. from Others

Industrial scraps Statistics

200 400 600 800 1,000 1970 1975 1980 1985 1990 1995 2000 2005 Year

Collected Cu- alloy scraps [1,000t/ y]

• Obs. from Electric appliances
• Obs. from Automobiles
• Obs. from Construction
• Obs. from Other machinery
• Obs. from Electronic wire and cable
• Obs. from Others

Industrial scraps Statistics

Collected high-purity copper scraps Collected copper alloy scraps

• Dept. of Materials Engineering, Graduate School of Engineering,
• Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo

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Estimated amounts of in-use stocks, and cumulative uncollected materials

5,000 10,000 15,000 20,000 25,000 30,000 35,000 1950 1955 1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 Year

Stocks [1,000 t]

Cumulative uncollected materials Communication line and power cables Electric and electronic machinery Automobiles Other machinery Construction Others In- use stocks

• Dept. of Materials Engineering, Graduate School of Engineering,
• Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo

University of Tokyo

Annual uncollected materials

50 100 150 200 250 300 350 400 450 1950 1955 1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 Year

Annual uncollected materials [1,000t/ y]

Communication line and power cables Electric and electronic machinery Automobiles Other machinery Construction Others

• Dept. of Materials Engineering, Graduate School of Engineering,
• Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo

University of Tokyo

The possible final destinations for uncollected materials in 2000

Final destinations

Total for Uncollected materials

Landfill Loss into steel cycle Exported as mixed metals Other losses

Net weight of copper [1000 t] 334 114* 40 150 30 Proportion 100% 34% 12% 45% 9%

* This was originally 160,000 tons in 1997, and was converted to the amount for 2000.

• Dept. of Materials Engineering, Graduate School of Engineering,
• Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo

University of Tokyo Environment Import/Export

Production

Mill, Smelter, Refinery

Fabrication & manufacturing Use Waste management

639 496

Finished products 238 (Net exp.) Used products Old scrap

48 Landfill

Other material cycles

271 209 486 276 42 424 47 10 To copper alloys

Stocks

Exports as mixed metals

64 17 743

Ore

To other materials 96 Landfill 1190 14 Loss

Copper products 152

The cycle of high-purity copper in Japan for 2005

• Dept. of Materials Engineering, Graduate School of Engineering,
• Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo

University of Tokyo Environment Import/Export

Production

Mill, Smelter

Fabrication & manufacturing Use Waste management Stocks

183 75

Scrap

24 Landfill 147

Used products

Other material cycles

173 436 240 104 59 223 To other materials 361 From high-purity copper

Exports as mixed metals

36 9 Flash smelting 32

Cathode Finished products 93 (Net exp.)

Landfill 7 Loss 450

Copper alloy products 61

Refinery

251

The cycle of copper alloys in Japan for 2005

• Dept. of Materials Engineering, Graduate School of Engineering,
• Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo

University of Tokyo

Conclusions

Material stock and flow were dynamically analyzed on

copper and copper alloys separately in Japan.

The current in-use copper stock in Japan was estimated to be 18.7

million tons, and the amount of cumulative uncollected copper was estimated to be 9.9 million tons.

The result indicates that almost all obsolete stocks are not stocks

any more and have already gone into these three kinds of final sinks; landfill, mixing into steel cycle, and exports as the mix metals.

The annual differences of estimation and statistics of collected

copper alloy scraps; approximately 300 thousands tons, showed the amounts of high purity copper which are collected as copper alloy scraps.

From these results, copper cycles in Japan distinguished by

copper and copper alloys are drawn.

• Dept. of Materials Engineering, Graduate School of Engineering,
• Dept. of Materials Engineering, Graduate School of Engineering, University of Tokyo

University of Tokyo

Thank you !

Further information daigo@material.t.u-tokyo.ac.jp