Metals From Waste, Lessons From the Past to Shape the Future
April 23, 2010
This is a repost of a piece that I wrote for MetalMiner.
Until the 1900s it wasn’t uncommon to see women working in the tin and copper mines of Cornwall. These Bal Maidens all but ran the above ground operations taking the ore from the kibbles (ore buckets) and running it through hand sorting and processing, right up to the point of smelting. A combination of legislation, geology, automation and metals prices eventually smothered the Cornish mines, but we should remember that only 100 years ago virtually all hard-rock ores were hand processed everywhere in the world.
I was amazed by the resigned comments of US recyclers that it was simply uneconomic to recycle e-waste in the US and decided to take a look at the state of the art, because as the Bal Maidens demonstrate, time and technology do move on. It turns out that China is publishing scientific paper after scientific paper on industrial scale e-waste reprocessing. Some of the techniques, such as the dissassembly of printed circuit boards using ultrasound, are already operating at industrial scale. Others, like the use of super-critical methanol or water to boil the components off circuit boards, are still in R&D. But there is a definite and conscious technological effort going on to recover as much of the metal from e-waste as economically possible. Judging by the science the Chinese are having a great time mining these new deposits and are looking forward to the forecast increase in trade.
And it is potentially a very substantial trade. The figures quoted in the NYT do not do it justice. Using some of the more conservative grades reported in peer-reviewed journals, every year 50 million tonnes of e-waste could produce as much copper as 19 Bingham Canyons (4.7 Million tonnes) and as much gold as four AngloGold Ashantis (8 Million ounces). That’s around $50bn worth of refined metal, just in copper and gold. That is not to mention the millions of ounces of silver, thousands of tonnes of aluminium, steel, tin, nickel and lead and the possible extraction of some of the more specialist metals like gallium and cobalt. A back of the envelope calculation shows that if you had all the e-waste in one spot and efficient technology to exploit it you could build a company comparable in size to Rio Tinto or BHPBilliton.
When we hear about e-waste it is usually in terms of pollution due to mercury, lead and cadmium that is vented into the environment from small artisinal workshops. What we should also remember is that it is currently economic to have an estimated 700,000 Chinese employed in informal e-waste recycling. Right now there are around 7,000 people employed in the whole recycling sector in the US, similar to the number of Bal Maidens employed in the Cornish mines in the 1850s, and they are (were) all using similar manual techniques. China has started automating e-waste recycling and cleaning up the process as it does so. What is stopping the rest of us ?
Maybe we are waiting until we have to start mining our landfills. Its not as far fetched as it sounds. London hosted the first ever landfill mining conference in 2008. Any concentration of metals should attract attention as prices rise and landfill was no exception pre-crash. With advances in bacterial leaching, as well as an existing and substantial knowledge-base in both acid and alkali hydrometallurgy the only real technical issue holding back in-situ landfill mining is the grade, which in comparison to e-waste is low.
Which provokes the final question; why would you dilute high-grade e-waste with municipal solid waste and make metals recovery more difficult and less profitable in the future ? It seems to me that by exporting the raw material we have the e-waste business upside-down and it is waiting for the same kind of revolution that the mini-mills brought for steel.
Superconductors – Part Four A New Hope
January 11, 2010
Superconductors have been around in the labs for decades now. They have been a mainstay of high-end scientific research and niche medical applications for decades, but on the industrial scale they have always been a bit to expensive to run in mass market applications, like the energy sector. Theirs has been a story of potential energy efficiency boosts, power savings, zero transmission losses and all the first order energy system changes that no-one is against. Its time to take a look at them a little closer since I dismissed them so off-handedly in my previous post regarding the North Sea super grid.
Crash course
Superconductivity was discovered 99 years ago.
Different materials become superconductors at different temperatures.
HTS (High Temperature Super-Conductors) are defined as having a transition temperature above 30K (-243C), and the highest temp superconductors have a validated operating temperature around 135K. The boiling point of liquid nitrogen is 77K, so this has made HTS much more accessible and practical as nitrogen is commonly used as a liquified gas.
However, recently an HTS material that operates at 254K (-19C) has been claimed. This would clearly be a massive leap forward as standard compression-cycle refrigeration techniques could be used rather than immersion in liquified gas. Obviously these are lab findings and there is no guarantee that production of these materials could be scaled up to industrial quantities (they use some relatively commonplace elements, so there shouldn’t be any resource availability problems for once). The standard 10 years+ from first publication warning applies here i.e. no field application will arise from a lab discovery within 10 years of first publication.
So industrially we are looking at the 135K materials, which is still OK, but not the massive jump that we’d all like to see.
Energy Applications
Cabling – Zero transmission losses over long distances, or high capacity transmission without the current massive infrastructure (overhead pylons) are the main lures.
Power:Weight improvements – instead of copper conductors, using HTS in motors greatly increases their power:weight ratio. The applications in electric vehicles are obvious, so I won’t labour that point, but also consider all those static motors in air-conditioning units, factory assembly lines, and my personal favorite the conveyor belt. The infrastructure to hold these in place could be smaller and lighter, their maintenance quicker and safer as well as their operating costs lower.
For ‘motors’ also read ‘generators’ and you see the application for wind turbines and other renewable generating technologies. Smaller lighter nacelles means smaller lighter towers, means cheaper generating capacity and lower maintenance costs.
Renewable Energy Focus has done this two parter (Part One & Part Two) which covers all these much better than I ever could. You’ll need to subscribe for free to access the full articles, but its worth it.
The take home from these two articles is that super conductors should be on the shopping list of industry. I was too quick to dismiss them for the North Sea grid. With 150 times the carrying capacity per unit weight and 1/3 of the transmission losses superconducting cabling should be the first option for mega projects, not the last.
When/if those properly room temperature super-conductors reach the supermarket shelves a revolution will take hold.
Big Wind Movements
January 9, 2010
Round three of the UK offshore wind tender process totaled 32.2 GW of nameplate generating capacity. That’s a lorra lorra windmills and well above the expected 25GW power output. Lets be middle of the road and say for the sake of convenience that 3.22 MW turbines exist, that’d be 10,000 turbines located between 22km and 190km from the nearest landfall.
The London Array has started to hand out contracts. Nexans, the submarine cable specialist, has won the power export (windfarm to shore) cable contract. It is 100M Euro for 4x 53km long 150kV capacity copper cables to carry up to 1GW of power from 175 turbines.
If we do a quick bit of maths on that for 32 times the power, roughly twice the distance and 57 times the number of turbines, if the Round Three windfarms use the same technology as the London Array, the export cables alone should cost in the order of 6.5bn Euros (not including inflation or commodity risk). Using my previous estimation of the intensity of copper use in wind power, 10,000 offshore turbines and their associated cabling will use around 310,000 tonnes of conductor grade copper. Copper’s current price is around US$7,200 per tonne giving an embodied copper cost today of US$2.23bn. By the time these windmills get built, that figure looks cheap to me.
Perhaps that’s why the North Sea Supergrid got a bunk up the probability ladder by the nations next to the water. For an estimated one-off cost of 30bn Euro you get a ‘local’ connection, cutting the need for those expensive connections to shore and you get the ability to load balance using Norway’s hydro power excess.
If I had an extra billion or two I’d be looking at building a submarine cabling capacity right now. Not just the cable factory but the cable laying vessel and some upstream capacity in copper recycling. It’d be nice to think that we’d be at super conducting cables for this job, but at 6,000km total length and multi-GW capacity I’m not sure that the tech will be with us in time. Looks like HVDC instead, shame.
