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By Mark Van Dyke, Ted Klemetti, Joe Wickline

"The identification and mitigation of adverse geologic conditions are critical to the safety and productivity of underground coal mining operations. To anticipate and mitigate adverse geologic conditions, a formal method to evaluate geotechnical factors must be established. Each mine is unique and has its own separate approach for defining what an adverse geological condition consists of. The collection of geologic data is a first critical step to creating a geological database to map these hazards efficiently and effectively. Many considerations must be taken into account, such as lithology of immediate roof and floor strata, seam height, gas and oil wells, faults, depressions in the mine floor (water) and increases in floor elevation (gas), overburden, streams and horizontal stress directions, amongst many other factors.Once geologic data is collected, it can be refined and integrated into a database that can be used to develop maps showing the trend, orientation, and extent of the adverse geological conditions. This information, delivered in a timely manner, allows mining personnel to be proactive in mine planning and support implementations, ultimately reducing the impacts of these features. This paper covers geologic exploratory methods, data organization, and the value of collecting and interpreting geologic information in coal mines to enhance safety and production.The implementation of the methods described above have been proven effective in predicting and mitigating adverse geologic conditions in underground coal mining. Consistent re-evaluation of data collection methods, geologic interpretations, mapping procedures, and communication techniques ensures continuous improvement in the accuracy of predictions and mitigation of adverse geologic conditions. Providing a concise record of the work previously done to track geologic conditions at a mine will allow for the smoothest transition during employee turnover and transitions. With refinements and standardization of data collection methods, such as those described in this paper, along with improvement in technology, the evaluation of adverse geologic conditions will evolve and continue to improve the safety and productivity of underground coal mining."

Jan 1, 2019

By Z. Smieszek, J. Botor, Z. Miczkowski, S. Sobierajski

"From 1978, the direct process for the smelting of chalcocite concentrates in a flash furnace by the Outokumpu method has been applied at the Glogów II copper smelter. The chemical composition of these concentrates make it necessary to control the process very strictly. In this paper, the method for controlling and measuring the main technological parameters of the copper production by flash smelting is being presented. It includes the determination of the chemical composition of the concentrate, its grain structure, the temperature of liquid products of the process, oxygen content in process gases, as well as lead concentration in copper and copper concentration in slag.The main process parameters are determined from the mass and energy balances. The relations between parameters, such as an effect of grain structure of a concentrate on oxygen and oil consumption, and dependence of chemical composition of a concentrate on capacity and products quality are discussed. 1. IntroductionThe Polish copper concentrates, as most concentrates occurring worldwide, contain from 18% to 30% Cu, and less sulphur (7-11%) and iron (2-5%). The main copper-bearing mineral contained in the concentrates is chalcocite, while bornite and chalcopyrite are present in smaller quantities. Moreover, the organic carbon (5-7.5%), arsenic (0.05-0.3%) and lead (1.2-3.0%) are also contained in the concentrates. The gangue consists mainly of silica, aluminosilicates, calcium carbonate and magnesium carbonate. Their proportions make the addition of slag-forming agents unnecessary.The composition of Polish concentrates, especially their low iron content, allows their application in the direct flash smelting process for blister copper production. Low sulphur content is the factor which determines the necessity of oxygen application in this process."

Jan 1, 1989

By Michael Quadagno

Hudson River Pier 86, home of the historic USS Intrepid Aircraft Carrier and the Intrepid Sea-Air-Space Museum, is currently undergoing a $30M reconstruction. This project involves the demolition of the old timber pile supported pier and construction of a new 150 ft wide by 782 ft long concrete pier, built over the footprint of the old piles. The new pier consists of steel pipe piles, precast concrete pile caps, and a composite deck, made up of precast, prestressed concrete planks and cast-in-place concrete topping. This paper focuses on both the structural design and construction of the new pier, with emphasis on the pile foundation. Pier 86 is unique in that it is required to resist the extremely high lateral loads imposed on it by the permanently moored 898 ft long aircraft carrier during severe storms. A total of 360 steel pipe piles support the new pier. These piles, which are 24 in. in diameter and range in length from 58 ft to 175 ft, were driven down to bedrock. The piles, each having 200 ton allowable capacities, work together to resist the significantly large lateral loads exerted on the pier by the ship. The installation of the piles was unique in that all the piles, including the ?super-longs?, were fabricated to-length offsite, delivered to the site via truck and barge, and installed in one piece, eliminating the need for field splicing. The Pier 86 reconstruction will be completed within an extremely aggressive 18 month schedule, from January 2007 through June 2008. The refurbished aircraft carrier Intrepid will return home in September 2008, and the grand re-opening of the pier will be on Veteran?s Day 2008. This paper provides a case history for owners, government agencies, engineers, and construction professionals that will be faced with the challenges of designing and building new piers.

Jan 1, 2008

By S. T. L. Harrison, J. R. Amaral Filho, M. Smart, J. Broadhurst, J. Weiler

Technosol production from mine waste, following amendment with additional organic residues, to provide healthy and functional topsoil is an advantageous alternative to the long-term dump disposal of mine waste. Minimising the legacy of mine waste and supplying soil for mine site rehabilitation contributes towards more sustainable mining practices. Following the creation of the physicochemical structure of the soil from appropriate mixtures of coal waste with low sulfur content, physical ameliorants and nutrient sources, the inoculation of Technosols with active microbial suspensions may accelerate the decomposition of organic matter present and ensure nutrient availability for plant growth through active nutrient cycling, particularly of nitrogen, sulfur and phosphorous. In this paper, South African ultrafine coal waste was used as the main mineral matrix, and malt residue was used as source of organic matter and nutrients. In order to evaluate the effects of Technosol inoculation, five microbial treatments were used, including the addition of: commercial grade efficient microorganisms (EM Prosoil), anaerobic digested sludge supernatant from treating brewery waste, and ‘tea’ extracts prepared from compost, vermicompost and soil native to the mining area. Growth experiments were carried out using Eragrostis teff, commonly known as teff, a grass typically used for the rehabilitation of mined areas in South Africa. Preliminary results showed that Technosols inoculated with microorganisms performed better in terms of nutrient availability and plant growth. Varied performance was observed as a function of the microbial inoculation applied. This suggests that the inoculation of Technosols with appropriate microorganisms may be recommended to accelerate nutrient availability assisting plant growth during the initial establishing of the Technosols. Technosols continue to show promise as an alternative to both mine waste disposal and the burrowing of topsoils for mine rehabilitation. Keywords: Fabricated soil, mine waste, coal discards, malt residue, nutrient availability, soil microbiology, plant growth

Jan 1, 2020

By Constantine C. Popoff

Several limestone deposits in western Washington were examined by the Bureau of Mines in 1946. This report presents data obtained from the investigation of limestone deposits in the vicinity of Arlington, Snohomish County, Wash. The work consisted of surface surveys and sampling. Samples were taken where complete, or nearly complete, sections of limestone were exposed or where individual beds were exposed at a number of separate .localities. Areas were cleaned by blasting prior to sampling. Channel samples were cut where practical; otherwise chip samples taken. Twenty-one samples were taken. The locations of the samples and the analyses are shown on maps accompanying this report.

Jan 1, 1949

"The mountains of Utah contain one of the largest deposits of high grade bituminous coal in the world. According to the United States Geological Survey, there are 13,130 square miles of land known to contain workable coal, and these extensive fields contain 196,000,000,000 tons of coal. More remarkable than the extent of the coal fields is the thickness of the coal beds. Over three-fourths of the output of coal in Utah is recovered from beds ranging from 8 to 17 feet in thickness, as compared to one-eighth of the output of the entire country from such beds. In 1917, Utah mined one-third of its coal from seams at least 16 feet thick, compared to one-half of one per cent of the total bituminous output of the country from like seams.Coal at Wales, in Sanpete County, and in the vicinity of Coalville, Utah, was, it is reported, the first discovered by white men in the state. Wales claims the distinction of having produced the first coal mined in Utah. Two men, who had been coal miners in Wales, learned of the coal from an old Indian chief who called it ""rock that would burn."" In 1857, the town of Wales was founded and coal mined, and in 1858 some coke was manufactured and hauled by ox team to Salt Lake City. South of Wales is Castle Valley, in Wasatch Plateau field. From 50 to 60 miles of the Old Spanish Trail from Santa Fe, New Mexico, to Monterey, California, lies in Castle Valley. The coal in this field may or may not have been known at the time the trail was used extensively. The first published reference to this coal, however, was made by a party of the Corps of Topographic Engineers in their journal for October 11, 1853.After the completion of the Union Pacific railroad in 1869, mining on a commercial scale was attempted. In 1876 the Utah and Pleasant Valley railroad commenced operations between Scofield, in Carbon county, and Springville, Utah county, and following the year 1878, when the Rio Grande Western railway began construction through the Carbon county field, development increased until in 1900, when large smelters commenced operations in Salt Lake valley and gave coal mining in Utah an impetus that first carried it to an annual output of a million tons. During the past fifteen years many new mines have been opened, and with the construction of the Utah railway, an exclusive coal road, from the properties of the United States Fuel company in Carbon and Emery counties to connect with the Union Pacific system at Provo, the state reached a maximum production of 6,005, l 99 tons in 1920."

Jan 1, 1925

By J. P. Cooney

Placer Dome is learning from experience in Latin America, Asia and Africa, as well as in North America, that contributing effectively to sustainable human progress in the areas of its operations presents unending challenges to think creatively, communicate effectively and remain culturally sensitive. People must be better off in terms of their economic circumstances, their social conditions and the quality of their natural environment not only during the life of the mines, but after mines close. Stakeholders, all those who are directly or indirectly affected by a mining project, should be able to participate in decisions which affect them. The development of sustainability strategies, the monitoring of sustainability performance and the implementation of sustainability programs are best done in partnerships with governments, communities, nongovernmental organizations and multilateral development institutions. Ultimately, the success, if not the survival of mining, will depend on our ability to get the sustainability equation correct.

Jan 1, 2000

By Michael J. Marasa

"Geotechnical engineering and construction primarily relies on the subsurface characteristics of the particular site; however, obtaining both accurate and precise information on those features is challenging due to the numerous factors involved in testing procedures used to analyze varying site geology. This includes a detailed and thorough geotechnical investigation to understand the site conditions, allowing the implementation of the most practical and economical solution.This paper presents a case history of the installation of wick drains and construction of aggregate piers on the site of a large facility to be constructed in Memphis, Tennessee. Throughout intensive subsurface investigations, highly variable soils were encountered, requiring settlement control and increased bearing capacity. This paper will discuss the design and installation of the systems constructed, and procedures and execution of the work to ensure design specifications were achieved.BackgroundA 1.4 million square foot expansion directly adjacent to an existing 1.1 million square foot distribution facility in Memphis, Tennessee was planned to serve as a centralized facility for increased production. The first phase of construction included an 858,000 square foot warehouse and parking lot for approximately 400 trucks to the north of the existing structure. The anticipated column load for the warehouse was 125 kips; slab design bearing pressures ranged from 200 to 500 pounds per square foot (psf) and elevations ranged from EL. 264 to 282. Parking lot elevations ranged from EL. 264 to 290, requiring a design life of 10 years with an estimated 100 in- and out-bound trucks daily and maximum weight of 80 kips per truck. The second phase of construction took place east of the existing structure, and included a 794,000 square foot multi-level warehouse, a 100,000 square foot office, and additional employee parking. The anticipated column load for the second warehouse was 225 kips and slab design bearing pressures ranged from 200 to 500 psf. Elevations ranged from EL. 267 to 282. Anticipated column loads from the office were 25 125 kips, with slab design bearing pressures ranging from 100 to 200 psf. Due to the varying elevations within each planned footprint, up to 18 feet of new fill was required to match the existing structure’s finished floor elevation (FFE) at EL. 282."

Jan 1, 2017

By Animesh Jha

The carbothermic reduction of chalcopyrite has been studied in the temperature range 1073 to 1273K in presence of lime. The role of lime during the reduction process is explained and the phase equilibria leading to the metallisation of copper and iron are discussed. The effect of coal and carbon monoxide on the reduction process have been studied and the rate governing steps are identified. This investigation also cites examples of possible mechanisms of physical separation of metallic Cu from iron during the reduction process.

Jan 1, 1992

1.1 Bituminous-Coal and Lignite Dust. - Carboniferous material having a volatile ratio of 12 percent or more by weight and a fineness such that the material passes through a No. 20 sieve. 1.2 Active Underground Workings. - Underground places in which men are required to be or to pass through in the performance of normal mining operations for the production of coal. 1.3 Working Areas. - Underground areas where bituminous coal and lignite are mined, specifically: (a) Face. - The solid surface of the unbroken portion of the coalbed at the advancing end of the working place. (b) Face Area. - The working area inby the last open crosscut in an entry or a room, including the pillar being extracted or longwall being mined. (c) Room. - A place abutting an entry or airway where coal has been mined and extending from the entry or airway to a face. (d) Crosscut (Breakthrough). - Passageways or openings cut through a pillar to connect adjacent entries or rooms. 1.4 Entry. - Underground haulageways, travelways, and airways, except working areas as defined in section 1.3. (a) Active Entry. - An entry in which coal is being mined from a portion thereof or from connected sections. (b) Parallel Entry. - Usually an intake airway parallel to the haulageway. (c) Back Entry. - Usually a return airway parallel to the haulageway.

Jan 1, 1960

By D Giurco

This paper presents the results from research undertaken in the CSIRO-funded Mineral Futures Collaboration Cluster on developing a future vision for the mining and minerals industry – Vision 2040 – in which the industry proactively contributes to long-term benefit for communities and the nation. Our research finds that Australia is currently experiencing mining-led prosperity due to high commodity prices, yet underlying this are challenges for maintaining market share due to lower productivity from extracting lower grade, more remote and complex ores. Whilst much focus has been on developing new technologies for finding and processing such ores, this paper assesses these activities, together with policy and market innovations in the context of needing to strengthen social, environmental and financial capital for long-term benefit. Vision 2010 sees mining activities linked to systems that are net providers of clean water, energy and ecosystem services, rather than minimising negative impacts alone; sovereign wealth funds are used to harness current prosperity for future innovation. Using a case study in lithium and comparisons to iron/steel, coal and copper – we illustrate the opportunities for new technology, policy and market innovations to link the mining and minerals sector in Australia to more sustainable patterns of production, consumption and prosperity.

Nov 22, 2011

By Philip Arthur

The ISASMELT process is making a significant contribution to the global metals industry. ISASMELT furnaces are now operating successfully in eight different countries and treating approximately 3 million tonnes of concentrates and secondary materials per year. The process is currently used in both lead and copper smelting. The most recently commissioned plants were in Germany and China, one for treating scrap copper and the other treating low-grade copper concentrates. The Copper ISASMEL T furnace ("CIF") at Mount Isa Mines Limited (UMIM") has continued to set new operational records, with throughput of more than I million tonnes of concentrate per year and very low operating costs. This paper summarises the latest operational data from the Mount Isa Copper ISASMEL T plant and outlines the successful approach to industrial R&D taken by MIM in the development of the ISASMEL T process.

Jan 1, 2003

By Howard Scott

THE GREAT advances made in mechanical engineering during recent years through the use of alloy steels, as illustrated by the development of the airplane and automobile, may be ascribed primarily to the application of nickel as an alloying element. The ternary system iron-carbon-nickel has a wide industrial application and forms, further; the fundamental basis of the even greater class of the widely used quarternary steels such as nickel-chromium, nickel-silicon, and nickel-vanadium. As is not uncommon with such cases of virile growth in an industry, the application of the alloy steel in a largely empirical manner has outstripped its scientific development so that a fertile field for metallographic research still remains. In this field, the basic nickel steels require first consideration and are the subject of the present investigation, which is offered as a preliminary to the study of the more complex alloys of industrial importance. Of the principal tools of metallography-microscopic examination, determination of -mechanical properties, and thermal analysis-the last has developed much more slowly in its application to industrial needs so that the situation often exists that heat treatment operations are based on empirically determined temperatures; that is, temperatures determined without regard to the actual transformation characteristics of the alloy. This situation is undesirable as there is no uniform standard for comparison of results. It is due, outside the usual difficulties involved in temperature measurements, to the pioneer character- of much of the published work; to the lack of definiteness of the Ac2 transformation,1 particularly in low-carbon steels; to the failure to define operating conditions completely; and to the paucity of information correlating thermal characteristics with results of heat treatment.

Jan 2, 1920

By H. M. Howe, A. G. Levy

§ 1 Introduction.—This paper gives the results of our micro-graphic determinations of the position of Ae3 in a series of 14 hypo-eutectoid steels of varying carbon content, one of them very rich in phosphorus, and of SEe for one hyper-eutectoid steel. We have proceeded chiefly by noting the temperature at which the reabsorption of the pro-eutectoid element is found to be complete after a 30-min. holding, but in part also by noting the temperature at which its precipitation begins. Observations on these same steels by Messrs. Burgess, Crowe, and Rawdon, of the United States Bureau of Standards, are given in a paper1 issued simultaneously with this, while in a third paper2 one of us compares these data with those of earlier observers. These three papers are treated as one whole by numbering their sections, tables, and illustrations continuously, and by setting the folding plates of micrographs at the end of the last paper. The Composition of the Steels Experimented On is given in Table I. § 2. Notalion and Definitions.—Following Osmond's development of Tschernoff's notation, in which " Ac3 " is the upper limit of the hypo-eutectoid part of the transformation range as observed in heating up, and " Ar3 " is that same limit as observed in cooling down, and following the usual custom of calling the upper limit of the hyper-eutectoid part of that range " SE," we may go farther and call this latter limit " SEc" when observed in heating up and " SEr " when observed in cooling down. Further, we may call the equilibrium position of these lines, i. e., the position which they would have in pure iron-carbon alloys if all

Jan 1, 1914

By H. H. Stout

In the early fall of 1925, the writer was conducting, in the Ledoux and Co. laboratory, New York, experiments directed toward ascertaining the effect on its impurity content when cathode copper was subjected to a current of various gases at an elevated temperature below the melting point. The apparatus consisted of a vertical I-in. dia. silica tube about 12 in. long, heated on the outside. The cathodes were broken to pass 3/8-in. mesh, and a current of various different gases was passed up through a 4-in. long column of these loose cathode particles in the vertical tube furnace. Temperature was maintained to 1500º to 1600ºF. and the gas treatments lasted from 3 to 6 hr. The writer observed that whenever reducing gas (H2 or CO) was used, these cathode particles stuck together at points of contact with each other. The cohesion was so marked and tenacious that an examination was made of the fractured surfaces, when cathode particles were broken from the cluster. Crystal growth was always found to have taken place across the surfaces where separate particles were in contact, but only after all oxides, sulphates, etc., had been completely removed. The idea of a possible new process was then conceived and was disclosed to A. M. Smoot (V. P. Ledoux and Co.) with intent to obtain his views. The first conception as given Smoot was "to gas-clean broken cathodes, put them in an extrusion press, solidify and extrude them at around 1500ºF." Smoot's reaction, after a few moments considera- tion, was, "It looks perfectly all right to me.'' The writer and his assistants, W. H. Osborn and H. H. Stout, Jr., after conferring as to ways and means, decided to go ahead with preliminary laboratory experiments, which, it was thought, would move the new process from the possible to the probable. This program followed a course indicated by three basic considerations: 1. Since brittle cathodes were often unintentionally produced, it seemed probable that the laws controlling this type of deposition could be ascertained. 2. We had already proved the gas-cleaning feature. 3. There remained to prove: whether a sound, homogeneous metal billet could be produced with crystal growth established over the entire surface of each individual particle in the billet; and, if so, what would be the physical properties? Osborn arranged with Columbia University for conducting experiments in its research laboratory to prove or disprove the third item; Columbia assigned C. A. Phillipi, Jr. to assist in the project. A press with a cylinder 2 in. high and of I-in. dia. was used. It was surrouilded and heated by a resistance coil 01 Nichrome wire. Broken tough cathodes were used. Experimental Procedure The first run took place March 18, 1926. The resistance wire gave out when temperature of 1000ºF. was obtained. Pressure was immediately applied: perceptible ram movement stopped when 39,000 lb. per sq. in. on the copper was reached, with a maxi-

Jan 1, 1941

By J. Silva, M. Kotraba, F. Pontanilla

Blasting is the application of highly complex science that, in some cases, could be viewed as an art. Many variables are involved in a blast, including geology, pattern design, timing and firing sequence, and explosives selection. Assuming that better results can be achieved by only increasing the powder factor is inaccurate. The Drill-to-Mill (D2M) concept has been in the mining industry for over two decades. The D2M approach is commonly viewed in an oversimplified manner, assuming that by simply increasing drilling and the amount of explosives used (both of which add operational costs), the downstream value will be created. An optimized D2M initiative should combine the smart application of explosives at the beginning of the mining process, matching the dynamic properties of the rock to the explosive selected to improve the efficiency of the energy created by the explosive to the rock mass being blasted, and to bring benefits to the mining operation across the entire mining and processing value-chain. This paper reviews the principles behind matching the shock impedance of the rock and the explosive and compares the traditional use of explosives versus the smart application for two hypothetical blasts.

Jan 1, 2024

By M. Nagamori, A. J. Plumpton

"Commercial HCl-leaching of magnesite and serpentine yields highly concentrated aqueous solutions containing 25 mass % to 33 mass % MgCl2. The partial molar enthalpies and heat capacities, the ionic activities of Mg2+ and Cl–, and the Raoultian activity of H2O have been assessed for the concentrated MgCl2-H2O solutions at temperatures of 348 to 373 K. These thermodynamic data are used to calculate the pH of aqueous MgCl2 solutions saturated with a Mg-bearing mineral such as magnesite, serpentine, brucite, forsterite, enstatite or talc. On the basis of these thermodynamic data, technico-economic aspects are discussed as to neutralization with pulverized MgCO3, water evaporation from the MgCl2 solutions, and ore composition including such minor constituents as CaCO3, FeCO3 and Fe3O4. IntroductionA major magnesium electrolytic reduction plant operates in Quebec, where another will begin its production in the year 2000. One uses imported magnesite ore as raw material, while the other will utilize local asbestos tailings (serpentine). Both processes produce a concentrated salt solution of 25 mass % to 33 mass % MgCl2 by leaching the ore with concentrated hydrochloric acid. Thus, the two processes differ mainly in the HCl-leach and related operations. After the HCl-leach of the ore, the serpentine process yields about 25 times more wet cake to filter and wash than the magnesite counterpart. A comparative cost-engineering study with respect to slurry filtration and cake washing has been published elsewhere (Blackburn and Nagamori, 1994). By contrast, the present study considers the thermodynamics and technicoeconomics of the HCl-leach itself for both ores."

Jan 1, 1999

By M. J. Raffaldi, K. W. Harris, K. A. Perry

"Highwall miners have been widely used to extract additional coal reserves from existing surface operations, particularly on contour operations in the Appalachian coalfields. Using a continuous miner cutting head, coal may be extracted from significant depths (such as 150 m), leaving behind an array of web and barrier pillars with the purpose of maintaining highwall stability. This method inherently involves elevated risks to both equipment and personnel due to proximity to and increased exposure time near highwalls. As a result, modern operations should actively design web and barrier pillars to maximize extraction while providing adequate stability. The ARMPS-HWM software, an empirical-based program created for the design of web and barrier pillars at highwall mining operations, is one such approach. The calculated stability factor is compared with empirically established guidelines produced from examining case histories.The ARMPS-HWM program is a handy tool for initial design, but understanding the site’s structurally significant geologic features and geomechanical behavior is important and may potentially increase extraction. We created a two-dimensional numerical model using FLAC3D and calibrated it to ensure pillar strength, closely following the Mark- Bieniawski formula for a typical range of pillar geometries and overburden properties. The development of pillar stresses along a highwall panel was then numerically investigated as mining progressed, and the stress distribution between barrier pillars was found to be asymmetric, which can result in an over-design of the closeout web pillars if tributary area loading is assumed. Finally, the importance of adequate barrier pillar stability is highlighted."

Jan 1, 2014

By M Wortley, J McKay, D La Rosa, O Guyo

It has been a generally held concept that crushing operations were, by their nature, too simple to benefit from the implementation of advanced process control. The commissioning of an OCS¬ expert control system and image-based oversize detection system, VisioRock, at the Pilbara Iron Tom Price facility are dispelling these notions. A constraint-based OCS¬ expert control system has been designed and commissioned on the high-grade crushing and screening plant along with a vision-based oversize detection system functioning on six product conveyor belts. To date, the expert control has demonstrated the ability to increase production by maximising dynamic constraint utilisation. Dynamic constraint utilisation is a concept developed by Rio Tinto Technical Services for effectively evaluating constraint-based control logic performance. The VisioRock system has been installed and configured and has been operating for a period of several months. Currently, Tom Price and Metso personnel are working to define correct oversize detection thresholds. Details of the plant implementation are discussed.

Jan 1, 2006

By M. A. Reuter, N. J. Bartie

Metals make modern societies function, and increasingly, various high purity precious and special metals endow sustainability-driving technologies with specific functionalities. These metals become heavily intertwined within products, complicating end-of-life treatment. To counteract the resulting downcycling and potential depletion of scarce resources, maximising both the quantities and qualities of materials recovered during primary extraction and recycling, processes should be a priority in the pursuit of sustainable circular economy. Adopting a process simulation approach; a digital twin for the life cycle of cadmium-telluride solar photovoltaic (CdTe PV) modules was created. The system comprises an integrated metallurgical production system that produces, among others, cadmium, tellurium, selenium, zinc, copper, and lead, all of which are required to manufacture PV modules. System-wide resource efficiency and environmental impacts are assessed using exergy analysis and life cycle assessment, respectively. Simulation of this large and complex product life cycle at a high level of detail allows for the evaluation of potential system-wide effects of various production, recycling and residue exchange scenarios aimed at maximising the sustainability of the entire system. It diminishes the need to make arbitrary choices about allocation methods for the distribution of environmental impacts in multipleoutput production systems. Furthermore, it demonstrates the key importance of metallurgy in achieving circular economy. Keywords: Circular economy, sustainability, simulation, metallurgy, CdTe photovoltaics, life cycle assessment

Jan 1, 2020