Recycling of Secondary, Byproduct Materials and Energy: Reducing EMbodied-energy and Decreasing Emissions (REMADE)
Sponsored by: TMS Extraction and Processing Division, TMS: Recycling and Environmental Technologies Committee
Program Organizers: Mingming Zhang, Baowu Ouyeel Co. Ltd; John Howarter, Purdue University; Elsa Olivetti, Massachusetts Institute of Technology; Alan Luo, Ohio State University; Adam Powell, Worcester Polytechnic Institute; Ziqi Sun, Queensland University of Technology

Tuesday 2:00 PM
February 25, 2020
Room: 16A
Location: San Diego Convention Ctr

Session Chair: Alan Luo, The Ohio State University


2:00 PM  Invited
Thermodynamic Modeling and Experimental Validation of Iron-Containing Intermetallic Phase Formation in Recycled Cast Aluminum Alloys: Emre Cinkilic1; Colin Ridgeway2; Xinyan Yan3; Alan Luo2; 1Ohio State University; 2The Ohio State University; 3Alcoa Technical Center
    The formation of Fe-containing intermetallic phases during solidification of secondary cast aluminum alloys (e.g., Al-Si-Mg alloys containing 0.5 to 1%Fe) is critical to their mechanical properties. In this talk, the cooling rate dependent modification effect of Mn on the formation of intermetallic phases was investigated using CALculation of PHAse Diagrams (CALPHAD) modeling and solidification experiments. The critical Mn concentration required to prevent the formation of detrimental β-Al5FeSi depends on both the alloy composition (particularly the Fe/Mn ratio) and the cooling rate. A map of Fe/Mn ratio vs. cooling rate was created to summarize the metallurgical conditions of Fe-rich intermetallic phase formation, which can be used to control the microstructure of aluminum castings made of low-cost secondary alloys with high Fe contents.

2:30 PM  Cancelled
Recovery Nickel-ferous Compound from Nickel-bearing Secondary Resources: Qiuju Li1; 1Shanghai University
     The stainless steel pickling sludge contained quantities of valuable metals such as Fe, Cr and Ni, which met the strict environmental for disposal.The method of Carbon thermal reduction-magnetic separation process was proposed to recover Fe, Cr and Ni from the stainless steel sludge and the disposed waste environmental friendly. The laterite ore tailing was blended into the sludge to improve the recovery metals. The influence of reduction temperature, the atomic ratio of C/O (carbon/oxygen), the reaction time and charge ratio of pickling sludge were investigated. The experimental results showed that the best reduction condition were at temperature 1350℃,with 1.0 C/O atomic ratio and 25% pickling sludge percent. Under this condition, the recovery rate of Ni and Fe were reached up to 97.86% and 96.07% respectively. Meanwhile the content of Fe, Ni and Cr of the tailings were 4.04%, 0.13% and 0.08%.

3:00 PM  Invited
Sorting and Impurity Removal to Improve the Recycling of Steel Scrap from Auto Shredders: Patrick Taylor1; Sridhar Seetharaman1; Erik Spiller1; Zhijiang Gao1; 1Colorado School of Mines
     This REMADE project is looking at methods to overcome the barriers that currently limit the use of recycled steel (as recovered from scrap streams) in new steel products. Currently, the use of recycled steel is limited due to contaminants that downgrade the value of the steel by limiting the range of products in which the recycled steel may be used. These limitations are due to technical gaps that are addressed in this exploratory project. (1). The inability to identify and sort steel scrap from auto shredders, in an automated way: The composition of two bulk auto shredder steel scrap samples have been evaluated to determine the amount of copper (Cu) that end up in secondary steel that passes onward to steel production. Two new potential methods for sorting the scrap to reject impurities have been identified. Preliminary experimental results are presented. (2). The inability to efficiently separate Cu from steel scrap from auto shredders using post-shredder technologies: Two methods have been identified and will be evaluated on a lab scale. These experiments are intended to asses metallurgical ways of removing the impurities, downstream, either in the solid or the molten state.

3:30 PM  
Additive Manufacturing via the Direct Ink Writing Technique of Kaolinite-based Clay with Electric Arc Furnace Steel Dust (EAF dust): Edisson Ordoñez1; Henry Colorado1; 1Universidad de Antioquia
    Electric arc furnace steel dust was used as a complemented material for the fabrication of kaolinite-based clays via Direct Ink Writing. Steel dust waste is an unused hazardous materials mostly unused worldwide, generated by the steel making industry. Different samples were built with different water to clay ratios (W/C), and with waste between 0 and 20% contents. Cylinders for compression tests were printed, and sintered to be tested with compression tests. Additional characterization included scanning electron microscopy, density, Weibull statistics, rheology on the green body and creep analysis.

3:50 PM Break

4:05 PM  Invited
Carbon Black from Waste Tires: Purification Strategies and Recycle Potential: York Smith1; Marshall Boyton1; 1University of Utah
    Carbon black is a reinforcing filler used in car, truck, and mining equipment tires (~30 wt.%) and is made by the partial combustion or petroleum products. One management strategy for waste tires is pyrolysis, where the products are: high carbon steel, two grades of fuel, and carbon black. The steel requires no treatment post processing for recycling, while the fuel generated is used to heat and power the process. The remaining carbon black is contaminated by various additives in the original tire, as well as contaminates produced during pyrolysis. The presence of such contaminates on the surface and in the bulk of the carbon particles affects the fundamental characteristics of the virgin carbon black. As a result, the produced carbon black cannot be re-used directly and requires treatment to upgrade the purity. This work will discuss possible purification strategies of pyrolyzed carbon black and the associated embedded energy.

4:35 PM  
An Environmental Impact and Economic Evaluation of using Alternative Feedstock Powders in Metal Additive Manufacturing: Christopher Glaubensklee1; Haoyang He1; Parnian Kiani1; Kaka Ma2; Julie Schoenung1; 1University of California, Irvine; 2Colorado State University
    In metal based additive manufacturing processes such as Laser Engineered Net Shaping (LENS®), the primary feedstock is gas atomized powder because of its spherical morphology and controllable particle size. Unfortunately, this method of using gas atomization consumes a significant amount of energy and cost. Research has demonstrated that machine chips and other waste metal products can be processed into powder and then utilized as alternative feedstock materials for the additive manufacturing process. In this study, gas atomized powder and these alternative powder sources are evaluated and compared on the basis of energy demand, cost, and environmental impact. Life cycle and techno-economic assessment methodologies are utilized, assuming a system boundary that includes the extraction and processing of the raw materials, as well as the LENS® deposition of parts. Recycling of the powder waste in the LENS® process is also considered.

4:55 PM  
Recycling Technologies of Zn-C batteries: Review and Challenges for a Circular Economy in Colombia: Natalia Cardona Vivas1; Mauricio Correa1; Henry Colorado1; 1Universidad de Antioquia
    In this research, a comprehensive literature review was conducted over the valorization, utilization and circular economy of Zn-C batteries after their useful life. The status of this battery waste in Colombia and Latin America is also presented, as well as some case studies conducted in Medellin involving a small business enterprises and research at the university level. Therefore, some characterization including scanning electron microscopy, x-ray diffraction and other techniques. Results show the high potential of this waste for using in construction materials, electronic materials, and formulations tailored for agriculture fertilizers.

5:15 PM  Cancelled
Thermodynamic Process Simulation for The Recovery of Spent Pot Linings (SPL) from Aluminum Production: Burçak Ebin1; Martina Petranikova1; Dusan Klinar2; Mateja Kosir3; Panagiotis Angelopoulos4; Karsten Grossman5; Roeland Geurts6; Miroslav Halilovic7; 1Chalmers University of Technology; 2Scientific Research Center BISTRA; 3Slovenian National Building and Civil Engineering Institute; 4Natinoal Technical University of Athens; 5UVR-FIA GmbH; 6VITO; 7University of Ljubljana
    Primary Al production has been continuously increasing since the beginning of 20th century, and global production recently reached around 64 million tons in 2018. Each ton of Al produced in smelters generates approximately between 20 and 30 kg of spent pot lining (SPL), which is a mixture of the carbon lining and the refractory lining. It is as hazardous waste because of high amount of toxic cyanides and fluoride salts content. The current waste management practice of hazardous SPL is landfilling or incineration, which costs aluminum producers on average 200 EUR/ton and 256 million EUR annually on a global level. A new recycling route for detoxification and recovery of SPL was thermodynamically modelled to develop a sustainable process for aluminum industry. The process thermochemical modelling was studied by HSC Chemistry 9 software. The results show that fluoride and cyanides are decomposed by reactive extraction to detoxify the SPL.