Download Project work, description

CHEM-E6120 System Integrated and Sustainable Metals Production
Project work, fall semester 2015
The task is to design two recycling processes for certain components of end-of-life passenger
cars, that means cars up to 8+1 persons and less than 3.5 tons. The starting material is
dismantled and separated components. Your task is to design mechanical pre-processing of
the material that is followed by either pyrometallurgical or hydrometallurgical processing.
The aim is to maximize recovery of all possible valuables. The separated components or
component groups are:
1. Lead-acid batteries
2. Catalytic converters
3. Electrical motors
4. Cables
5. Radiators, brake pipes and bearings
To design the processes you have to determine and decide:
- throughput of the process, how many kilograms or tons of material per day, week or
year.
- valuables in your stream
- waste materials in your stream
- how to process, i.e. crush and separate your feed to recyclates, note that the processing
may be different for pyro and hydro stages.
- how to process the recyclates using pyrometallurgy
- how to process the recyclates using hydrometallurgy
Use the car component and its “mineralogy” to identify the major valuable materials. Create a
flowsheet for recycling process. Estimate the mass and elemental balances from your starting
material to products and wastes. It is not necessary to use HSC Sim for mass balance
calculations, tables are also suitable. Note that not all recyclates have to be processed by both
pyrometallurgical and hydrometallurgical process options. Decide what processes are most
suitable to different valuables. But your the process in your final report must include both
pyrometallurgical and hydrometallurgical steps.
The group need to submit 4 files:
1. Mech. Pro HSC Sim flow sheet, DL 18.11
2. Pyro HSC Sim flow sheet, DL 23.11
3. Hydro HSC Sim flow sheet, DL 30.11
4. Final report (including all the flow sheets), DL 4.12
If any of the parts is submit late (-2 p. / late submission) for the group total.
Total amount of points is 60 p. of the final report, the individual flow sheets are not graded.
CONTENT FOR PROJECT REPORT
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Introduction
a. Describe your task, i.e. the component you plan to recycle
b. Describe what are the valuables in your component.
c. Prepare a short literature survey of existing or planned processes for your
components. Use this survey to justify selections for your process and its unit
processes.
Process outline
a. Document how large is your planned throughput for the process. You can use as
guide for example the number of scrapped cars in Finland per year.
b. How much products you estimate that your process will produce.
c. Document what are your planned products, do you plan to produce metals, semis,
concentrates, cleaned scrap like de-tinned steel etc. Use the information of
compatible and non-compatible metals in course literature as help to decide
product types.
d. Document which of recyclates from the mechanical treatment go to pyro processes
and which to hydro processes.
The mechanical treatment
a. Describe how you will use mechanical treatment to liberate recyclates and control
properties of different recyclate flows to facilitate pyro or hydro process.
b. Draw a HSC Sim flowsheet for mechanical treatment, including input, outputs, unit
processes and mass flows.
c. Estimate the fractions of recyclates and waste from the raw material as you will
have to connect the mechanical processing output streams to pyro and hydro stages.
d. Describe what will be the waste and how you will treat it.
The pyrometallurgical treatment
a. Describe which recyclate flows from mechanical treatment will go to
pyrometallurgical processing. Outline mass flows, process targets and process
residues for each material flow.
b. Draw a HSC Sim flowsheet for pyrometallurgical treatment, including inputs,
outputs, unit processes and mass flows.
c. Estimate the amounts of products and wastes.
The hydrometallurgical treatment
a. As with the pyrometallurgical treatment, describe which recyclate flows from
mechanical treatment will go to hydrometallurgical processing. Outline mass flows,
process targets and process residues for each material flow.
b. Draw a HSC Sim flowsheet for hydrometallurgical treatment, including inputs,
outputs, unit processes and mass flows.
c. Estimate the amounts of products and wastes.
The whole process
a. Combine your three flowsheet groups to a single process or if you have only one
valuable material flow, prepare both pyro- and hydrometallurgical process
flowsheet with HSC Sim.
b. Prepare mass balances for valuables and wastes for your processes.
Discussion
a. Do you consider your process realistic, is it close to some existing one?
b. Do you consider your estimated recovery of valuables to be good enough?