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By M. Henneman, M. Kosma, M. Eyll-Vetter

"For a long time, the recultivation of depleted opencast mines and operating systems was aimed at restoring the original state. The focus, as desired by policy-makers and the local population alike, was on restoring high-quality agricultural land and on creating reforested areas of value that suit their location. Until the turn of the millennium, recultivation measures were only rarely the subject matter of public planning processes beyond these general objectives. They were never regarded as nucleus and origin of sustainable structural developments. The rehabilitation of inactive lignite opencast mines in central and eastern Germany brought about a change in mind-set that understood recultivation to be a unique opportunity to completely redesign a landscape and gear it towards the future in the Rhenish mining area as well. The ""Inden residual lake"" and ""terra nova"" projects, planned in the last 10 years in cooperation with policy-makers and authorities, are two undertakings that provide sustainable structural impetus for the future today."

Jan 1, 2011

By M. Eyll-Vetter

The operation of large opencast mines in a densely populated area in the centre of Europe involves an inevitable interference in the region. Thus, this is only possible with general acceptance by the regional stakeholders. In order to achieve this general acceptance, it is necessary to develop sound common concepts and to engage in a continuous dialogue with the stakeholders. The aim is to create seminal structures of relevance to the regional economy, taking into account the interests of the various stakeholders like e.g. authorities, local governments, the regional public, and churches. The recultivation of the mined-out areas represents the offset for the mining activities. RWE Power has reached high acceptance of its recultivation. This high acceptance is illustrated by various examples, from biotopes to high-yield agriculture and recreational areas. Thus, recultivation covers all the elements of sustainable development from social compatibility to ecological as well as economic aspects. This is only achievable through an intensive stakeholder dialogue in the region: The communities concerned are intensively involved in the planning and approval process for the new landscape. As far as social compatibility - one of the aspects of sustainable development - is concerned, the necessary resettlement of whole villages is one of the principal challenges. Over the last few decades, RWE Power has developed an approach that is broadly recognised by the stake-holders in the region. The best proof for this is the high proportion of resettlees taking part in the joint resettlement scheme offered. This can only be achieved by constant involvement of the stakeholders in the resettlement process. In conclusion, it can be stated that RWE Power has implemented a well-functioning stakeholder dialogue that guarantees the general acceptance necessary for mining operations.

Jan 1, 2007

By Georgios Kafantaris, Carsten Bonde, Nataša Katic

Within the investigation works for the Copenhagen Cityring metro, Geo/CMT have carried out 90 geotechnical boreholes. Together with the previously available investigation, this resulted in more than 15 km of vertical drillings and several thousands of laboratory tests. The design is made for 17 stations, four shafts and two parallel 16 km long tunnels. The geotechnical investigation and design have been carried out in several stages comprising appropriate refinement of structural design and design of excavation operations, including TBM break-in and launching operations at each station shaft. Acceptance of the solution and / or refinement of the investigation and design schedule in the next stage were based on the geological conditions, area availability at surface level, planning and cost-control criteria. The applied recursive design refinement is presented herein with an example of the Østersøgade shaft location.

Jan 1, 2016

By David Wilburn

Recycled materials are increasingly being used in road construction to supplement natural aggregate derived from crushed stone, sand, and gravel. An understanding of the amount of substitution that is taking place, its economics, and factors affecting the level of substitution is useful in estimating the potential for recycling and in assessing the total supply of aggregate. While U.S. consumption of recycled aggregates from crushed concrete is estimated to have increased 160 percent between 1994 and 1996; it comprised less than 5 percent of total aggregates consumed in 1995. Construction waste supply is regional, and is determined by infrastructure decay and replacement rates. Aggregate recycling rates are greater in urban areas where infrastructure is being replaced, natural aggregate resources are limited, disposal costs are high, or strict environmental regulations prevent disposal. Recycling is expected to increase as construction contractors attempt to save on transportation, disposal, and new material costs. Aggregate producers include recycled material as an option to consumers in order to prolong the life of their reserves and improve their range of products. Recycled aggregates can be a supplement for natural aggregates in selected applications, but their use should be evaluated locally based upon relative cost, quality, and market factors Because aggregate recycling is often affected by local and regional transportation systems, disposal and tipping fees, resource supply, the market for specific products, and municipal support, costs for three representative fixed site operations of different sizes were modeled. Under study conditions, all were found to be profitable, but highly dependent upon local tipping fees and market prices, which can differ significantly by location. Smaller operations were found to have different operational dynamics, often requiring creative marketing or incentives to maintain profitability.

Jan 1, 2001

By Charles R. Marek

There is an ever-increasing need for quality construction materials to provide the necessary housing and transportation facilities required for the protection and movement of people and goods. By the year 2000, requirements for housing in the United States will have doubled due to population growth. Requirements for transportation facilities in this same period will also have increased substantially. Further, all existing facilities for both housing and transportation will require substantial maintenance of one form or another. Aggregate is the basic material of the construction industry. There is some occurrence of aggregate source material in virtually every state of the United States, and in every country in the world. United States reserves of commercially useable aggregate have never been systematically estimated and are probably so vast as to be incalculable.1 However, in many areas its existence is largely negated by inaccessibility. Often it is lodged deeply or intricately in the earth or it is too distant from markets to offer a desirable "return on investment" under the present economic structure. Other factors that prevent its utility are the occurrence of small scattered deposits that individually are too small to justify the necessary capital investment for exploitation and collectively are too widely disseminated; also, the aggregate nay be deficient in certain desired chemical or physical qualitites.1

Jan 1, 1974

By D. A. Norrgran, J. A. Wernham

Introduction In view of the continuing depletion of natural resources, requirements for energy conservation, plant optimization and hazardous waste management, and environmental consciousness, recycling and secondary recovery of materials are being developed with increasing interest Many secondary recovery processes are being developed that apply mineral processing technology. Gravity separation, magnetic separation and flotation have all emerged as explicit methods for recovering residual values from various process streams and hazardous constituents from waste streams. Recently, a technique for concentrating metallics has been successfully reintroduced. The concept of the alternating magnetic field eddy-current separator was developed over a century ago using rudimentary electromagnets (Patent 400317 issued to Thomas Edison on March 26, 1889). Widespread acceptance was, however, hindered by high costs, marginal results and poor economic incentives for secondary recovery. With the recent increased interest in secondary recovery and the development of high-energy rare earth permanent magnets, the eddy-current separator has now gained prominent acceptance. The separation forces imparted by an eddy current separator are the function of the magnetic field intensity and the alternating frequency of the magnetic field. The evolution of permanent magnets has provided a cost effective alternative for the generation of high-intensity magnetic fields. High-energy rare earth permanent magnets have substantially reduced the capital and operating costs over the electromagnetic circuits employed in antecedent eddy-current separators. Specifically, in recent years, the strength of permanent magnets has increased several fold with neodymium-boron-iron rare earth magnets now providing an energy product of 35 million gauss-oersted. Figure 1 shows the evolution in the strength of permanent magnets. The development of these rare earth magnets has led to the design of circuits possessing a magnetic force an order of magnitude greater than that of conventional permanent magnetic circuits. The eddy-current separator has been successfully applied in several metal sorting and recovery operations. Most common is the sorting of metal from shredded automobile scrap and municipal waste. With the advent of high-frequency, high-intensity magnetic fields, the separator has advanced to the point where it has direct application in the beneficiation of fine sized metals. Relatively fine sized (-1/4 in.) metal bearing slags and spent foundry casting sands as well as precious metal hearing electronic scrap demonstrate excellent metallurgical response to the eddy-current separator, and applications have progressed to finer materials and more selective separations. Theory Electrical currents are induced in all conductors when exposed to an alternating magnetic field. The induced current generates a magnetic field in the conductor that opposes that of the alternating magnetic field. Figure 2, is a schematic illustration of generated eddy currents. In this particular example, the alternating magnetic field is produced by a series of permanent magnets mounted on the circumference of a rotor. The permanent magnets have alternating polarity. As the rotor revolves, an alternating magnetic field is produced, and the rate of revolution determines the frequency of the alternating magnetic field. When a conductor, such as a metallic disc in the illustration, is placed in the alternating magnetic field, a closed loop current flow occurs. The current loop in the conductor produces a magnetic field that is a mirror image of the alternating magnetic field. At any point in time, the induced magnetic field in the conductor directly opposes the alternating magnetic field. This opposition of magnetic fields produces an instantaneous repulsion in the conductor. The conductor is consequently repelled from the rotor. The alternating magnetic field has no effect on nonmetallic materials as they pass through the magnetic field and discharge the rotor in a natural trajectory. [ ]

Jan 1, 1992

By D. A. Norrgran

The term "secondary recovery" has recently brought on a new meaning in view of the depletion of natural resources, energy conservation, plant optimization, and the environmental consciousness that has led to hazardous waste management, recycling, and secondary processing. Many secondary recovery processes are being developed applying mineral processing technology. Gravity separation, magnetic separation, and flotation have all emerged as implicit methods for recovering residual values from various process streams and hazardous constituents from waste streams. Recently, a technique for concentrating metallics has been successfully reintroduced. Although the concept of the eddy-current separator was developed over a century ago, (Patent 400317 issued to Thomas Edison on March 26, 1889) it was not until this last decade that it gained prominent acceptance. The evolution of permanent magnets has provided a cost effective alternative for the generation of high intensity magnetic fields. High energy permanent magnets have substantially reduced the capital and operating costs over the electromagnetic circuits employed in antecedent eddy-current separators. Specifically, in recent years, the strength of permanent magnets has increased several fold with neodymiun-boron-iron rare earth magnets now providing an energy product of 35 million gauss-oersted. Figure 1 shows the evolution in the strength of permanent magnets. The development of these rare earth magnets has led to the design of circuits possessing a magnetic force an order of magnitude greater than that of conventional permanent magnetic circuits.

Jan 1, 1991

By Thomas J. Neil, O&apos

Mine land reclamation is a comparatively new science-Although some mining companies point with pride to reclamation efforts of 20 to 30 years ago these were the exception rather than the rule. In the last ten years the skyrocket of environmental awareness has been awesome to behold. Future shock gripped mine operators everywhere as they struggled to cope with rapidly changing and escalating demands. The initial result was that two divergent points of view became dominant. Environmentalists said, "Put it back the way it was," and the miners responded, "Let's grow some weeds and hide it." These views are not surprising as they represent rather obvious alternative responses, albeit at opposite ends of the decision spectrum. The former case has prevailed more often than the latter, as most state and federal legislation -- both proposed and passed -- has required drastic alteration of the post-mining landscape so that evidence of prior mining is largely obliterated. An exception to this has been in porphyry copper country where the infrequent abandonment of mines has given emphasis to the second philosophy -establishing vegetative cover on mine waste materials. Now, it should come as no revelation to most mining people that both of these approaches to mine reclamation suffer from serious drawbacks when applied to open pit copper mines. First, whereas waste dumps and tailings dams can be vegetated with some aesthetic benefit, the massive presence of copper mining operations remains very prominent. It is difficult to conceal an open pit copper mine. Second, returning open pit copper mines lands to their original topography and productivity is simply not a reasonable alternative.

Jan 1, 1976

By Jaeheon Lee, Jai‑Won Byeon, Junmo Ahn, Jun‑Jae Lee, Eun‑Woo Kim, Yoo‑Jin Kim, Jiajia Wu, Jae‑Yeon Kim

Growing demand for valuable battery materials and environmental issues from battery disposal make the recycling of spent lithium-ion batteries (LIBs) essential. Specifically, the green approaches using organic reagents have garnered many attentions for battery recycling. In this study, a synergetic organic leaching system using methanesulfonic acid (MSA) of strong organic acid and citric acid (CA) with good chelating ability was investigated to extract valuable metals from LiCoO2. Hydrogen peroxide was used as a reducing agent to enhance leaching kinetics. Cobalt extraction of 98% and lithium extraction of 97 % were achieved in the optimized condition; 2.4M MSA, 1.6M CA, 1.0 vol% H2O2, S/L ratio 80 g/L, 85 °C, and 1 h. The optimal leaching condition of the MSA-CA mixed leaching system exhibited good applicability to various cathode scraps, such as LiCoO2, LiNixMnyCo1- x-yO2, and LiNixCoyO2. The dissolved Co and Li ions in the MSA-CA leachate were selectively recovered with high recovery efficiencies of 99 % and 97 % as Co3O4 and Li3PO4, respectively. The recovered Co3O4 and Li3PO4 were utilized to regenerate cathode materials. LiCoO2 and LiFePO4 were also synthesized through a solid-state reaction and hydrothermal method. The recycling process based on the MSA-CA-H2O2 synergetic leaching system was proposed, and it might be applied as a green and economical organic leaching system for the recycling of various types of spent LIBs.

Sep 20, 2023

By Jaeheon Lee, Junmo Ahn, Jae-Yeon Kim, Yoo-Jin Kim, Jiajia Wu, Eun-Woo Kim, Jai-Won Byeon, Jun-Jae Lee

The surge in demand for battery materials, coupled with environmental challenges linked to battery disposal, underscores the need to recycle spent lithium-ion batteries (LIBs). Green recycling approaches, in particular, have garnered attention for battery recycling. In this study, a hydrometallurgical method using a synergetic organic lixiviant combining methanesulfonic acid (MSA) and citric acid (CA) as an alternative to inorganic mineral acids was introduced as a green approach to recycle cathode materials of LIBs. The conditions for leaching and recovery processes were optimized. Cathode materials were regenerated using the recovered materials. Moreover, the leaching performance and economic feasibility of this leaching system were compared with those of various other organic acids.

Feb 1, 2024

By Paul B. Queneau, Barry J. Hansen, D. Erik Spiller

Most lead and zinc secondaries are recycled pyrometallurgically. However, many problems encountered in secondary smelters have been solved by addition of physical concentration and/or hydrometallurgical processing steps, with resulting important environmental benefits. U.S. secondary lead and zinc operations are described, covering conventional smelters, EAF-dust treaters, and zinc sulfate/fertilizer producers, including plant capacities, technologies, and outputs. During the past two decades, remarkable advances have been achieved by recycling spent lead-acid battery components. Interaction between primary and secondary zinc producers, the fertilizer industry, and the zinc chemical industry has substantially decreased waste generation.

Jan 1, 1993

By Nikhil Dhawan, Shrey Agrawal

India’s most extensive renewable energy expansion program targets 280 GW of solar energy by 2030. Due to the massive generation of photovoltaic waste (expected 34,600 T by 2030), stringent recycling effort to recover metal resources from endof- life PVs is required for resource recovery, circular economy, and subsequent reduction in the environmental impact. The present study investigates the recycling potential of end-of-life silicon solar modules. The feed characterization reveals that most of the values in PV modules are concentrated in the frame (pure Al), Si wafer (72–84% Si, 9–12% Al, and 0.13–0.71% Ag), and electrical connections (Cu wire coated with Sn). The Si and Ag values in the feed were beneficiated using water fluidization, and concentrate with 90% Si and 2% Ag was attained in the underflow concentrate. Ag values were recovered in the form of AgCl by leaching in nitric acid and precipitation. After the purification step, the residue containing 99% Si can be further utilized to fabricate Si wafer and Al-Si alloy. The preliminary cost estimations suggest that the proposed process is economically viable for the recycling of solar panels with the maximum value generated from the AgCl precipitate followed by Al panels and Si wafers.

Nov 14, 2022

By Elif Emil-Kaya, Bernd Friedrich, Merve Papakci

Samarium (Sm), one of the rare earth elements (REEs), and cobalt (Co) are used in the production of SmCo permanent magnets, which have excellent temperature stability, corrosion resistance and oxidation resistance. Of the two types of SmCo magnets, one contains a high amount of iron, approximately 15.2 percent. This paper focuses on the recycling of iron (Fe)-bearing SmCo. In this study, an oxidative leaching process with nitric acid was developed to eliminate iron through in situ hydrolysis and to dissolve REEs and Co. The influence of experimental conditions on the formation of an amorphous iron compound through the hydrolysis of Fe3+ in a nitric acid environment was thoroughly examined based on a Taguchi orthogonal array. The optimal parameters for oxidative leaching were determined to be an acid concentration of 3 mol/L, a solid-to-liquid ratio of 1/10, and a process temperature of 60 °C.

Jul 1, 2024

By Bernd Friedrich, Elif Emil‑Kaya, Merve Papakci

In the production of SmCo permanent magnets with excellent temperature stability, corrosion resistance, and oxidation resistance, samarium (Sm), one of the rare earth elements (REEs), and cobalt (Co) are employed. Cobalt (Co) is a crucial component in tool materials, nickel-based alloys, tablet and smartphone batteries, and electric car batteries. REEs and Co have been listed as critical raw materials by the European Union Commission for many years. Due to the ever-growing demand for Co and REEs in technological applications, the recovery of these elements from secondary sources has garnered significant interest. There are two types of SmCo magnets, one of which contains a high amount of iron, approximately 15.2%. This paper focuses on the recycling of Fe-bearing SmCo. In this study, an oxidative leaching process with nitric acid was developed to eliminate iron through in situ hydrolysis and to dissolve REEs and Co. The influence of experimental conditions on the formation of an amorphous iron compound through the hydrolysis of Fe3+ in a nitric acid environment was thoroughly examined based on a Taguchi orthogonal array. The optimal parameters for oxidative leaching were determined to be an acid concentration of 3 mol/L, a solid-to-liquid ratio of 1/10, and a process temperature of 60 °C.

Feb 15, 2024

By F. Ferella

In this paper several leaching tests were per-formed to optimize the leaching section of a hydrometallurgical process for the recycling of alkaline and zinc-carbon batteries. Zinc and manganese oxides were dissolved by an acidic-reductive leaching using sulphuric acid and oxalic acid as reductant. Leaching tests were developed according to a full factorial design. The operational variables were pulp percentage, sulphuric acid concentration, temperature and oxalic acid concentration. Additional tests were performed to evaluate the precipitation rate of Mn and Zn oxalates. Finally a hydrometallurgical process were proposed for the recycling of alkaline and zinc-carbon batteries, in which Zn and MnO2 are recovered from purified solution by electrowinning: Zn is recovered as metallic compound, while Mn can be recovered as electrolytic manganese dioxide (EMD), but recovery of further manganese compounds is possible with simple process changes.

Jan 1, 2006

By Rod L. Norfleet

Cemented tungsten carbides are a sintered powder - metallurgical product essential to modern industry. Because of their moderate unit price and our dependence upon foreign sources for the component raw materials, a growing recycling industry has developed in the United States. There are two basic approaches taken to recycling cemented carbides; those which leave constituting materials unaltered or direct-reuse and those which separate the constitutes back to the raw components. To separate the carbides back to their raw components usually requires expensive chemical processing and is thus confined to the lower value materials such as grinding sludges. The direct-reuse methods recycle cemented carbides back to an intermediate level, a powder capable of being recompacted and resintered into a functional end-product. The three most commonly used methods of direct-reuse recycling, the coldstream process, bloaching and the Bernard or zinc process, are reviewed,

Jan 1, 1984

By K. Park, J. Sohn

Recovery of industrially useful metals from various secondary sources is an important issue in Korea whose natural resources are limited and needs in the strategic metals are on the rise. In order to meet such needs, researchers at the Korea Institute of Geoscience and Mineral Resources have launched a number of projects to help the nation to recover various metals from secondary sources. In this study, silver is successfully recovered from spent silver-oxide batteries first by distillation to remove mercury. The distilled residue was next subjected to leaching of silver using nitric acid. The study involves finding optimum conditions to leach silver from the distilled residue and subsequently to recover silver from the leach liquor by chemical precipitation. The chemically precipitated products are then subjected to reduction roasting to recover silver metal.

Jan 1, 2002

By N. S. Kim

Economically favored Cr and Cu leaching out process from spent power plant fly ash (PPFA) had been investigated. PPFA, bearing of C, S, V, Ni, Cu and Cr, has been widely used as an assistant fuel in cement industry. Recent environmental regulation in S. Korea prohibits using PPFA as a fuel. Many researchers have also studied on extraction V and Ni from PPFA. Due to low concentration of V and Ni, 2% and 1%, respectively, economical and environmental friendly process could not be found. In this study, Cu and Cr have been removed in an economical way and which satisfied with KS Extraction Test. The rest unburned carbon, V2O5 and NiO2 in residue were found to be applicable for indoor and outdoor colored bricks or deodorant panel. Various parameters such as pH, lixiviates and time on leaching behavior were investigated in order to leach Cr and Cu remaining C, V and Ni. Keywords: Fly ash; Selective extraction; Ammonia; Deodorant panel

Jan 1, 2009

By F. Ikumapayi

In order to predict and minimize detrimental production problems due to the recycling of process water in sulfide ore processing, the influence of major species, calcium and sulfate in process water on sphalerite flotation was investigated through Hallimond tube flotation, zeta potential, diffuse reflectance Fourier transform infrared spectroscopy (FTIR) and X-ray photoelectron spectroscopy (XPS) measurements using sphalerite mineral sample. Assessment of process water species in flotation was done using deionized water, process water and simulated water containing calcium and sulfate ions in experiments. Hallimond flotation shows increased sphalerite float-ability in process water compared to deionized water, but no significant effect on the presence of calcium and sulfate ions in deionized water using isobutyl xanthate as a collector. The presence of calcium ions reduced the sphalerite?s negative zeta potential, while at higher concentrations, a charge reversal occurred, at about pH 11. FTIR and XPS studies revealed the presence of surface-oxidized sulfoxy and carbonate species on sphalerite at pH 11.5 in deionized water, process water and water containing calcium and sulfate ions. These surface species do not influence xanthate adsorption.

By F. Ikumapayi

Hydrogen peroxide production was measured during the grinding of a complex sulfide ore, and its oxidizing effect on solid surfaces was investigated using Fourier transform infrared spectroscopy (FTIR) with diffuse reflectance attachment measurement. In turn, an attempt was made to correlate the formation of hydrogen peroxide, surface oxidation and sphalerite flotation. Additionally, in order to predict and minimize detrimental production problems due to the recycling of process water in sulfide ore processing, the effects of major components of calcium and sulfate species present in recycled process water and the effect of temperature on sphalerite flotation were investigated through bench-scale flotation tests using complex sulfide ores. The significance of process water species in flotation was studied using tap water, process water and simulated water containing calcium and sulfate ions. Formation of hydrogen peroxide was revealed during the grinding of the complex sulfide ore, and its formation was counteracted by diethylenetriamine (DETA). The FTIR spectrum of the pulp solid fraction showed varying degrees of oxidized surface species, which are related to the concentration of H2O2 analyzed in pulp liquid. Bench-scale flotation using two different complex sulfide ores showed that sphalerite recovery is better in process water than in tap water. Flotation results also indicated a varied recovery of sphalerite at different temperatures in either tap water or process water.