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During the last decades the material composition of buildings has become increasingly diverse. However, largely sorted material flows are needed for generating high quality secondary building materials. The use of secondary building materials can meet the requirements of sustainability in several ways: the extended time availability of primary raw materials and, thereby, the preservation of natural resources as well as the conservation of landfill sites.
Recycling of gypsum (calcium sulfate) can be a good example for the environmental benefits of closed-loop recycling. The content of sulfates in other secondary building materials, in particular in recycled concrete aggregates, should be minimized for quality reasons. In contrast, separated gypsum can also be used in gypsum production if the high quality requirements for the recycled gypsum are met. Since almost all processing steps in the recycling process are associated with environmental impacts, an environmental evaluation of the use of recycled gypsum as a substitute in gypsum production has to be carefully conducted.
This paper focusses on the techniques for generating recycled gypsum from gypsum plasterboards, the related quality requirements and a comprehensive environmental evaluation of the complete process.
Gypsum is widely used in the construction sector, and its worldwide consumption has been increasing now for several decades. Currently, the gypsum demand is met up to 60% by FGD gypsum (a by-product from coal-fired power plants) in Germany. The natural gypsum deposits cover the remaining gypsum demand. Due to national climate protection goals and the related shutdown of coal-fired power plants, the FGD gypsum supply will decrease significantly in the coming years and, therefore, other gypsum sources must be found.
Depending on the lifetime of the used gypsum products in the construction sector, an increase of gypsum in construction and demolition waste is to be expected. With regard to an upcoming shortage of gypsum, several approaches are being tested to recover gypsum from construction and demolition waste. Gypsum plasterboard recycling is already implemented on an industrial scale. Furthermore, new processes to recycle different types of gypsum products from construction and demolition waste are being examined. Of particular interest are different types of gypsum boards because they are well suited for selective dismantling. Therefore, they can be recovered comparatively free of impurities which is most important for the gypsum recycling.
In the research project “GipsRec 2.0”, funded by the Federal Ministry of Education and Research, recycling methods for gypsum fiberboards are being investigated. Additionally, the suitability of different types of synthetic gypsum as substitutes for FGD gypsum is being considered. Currently, the quantities of recycled gypsum are not sufficient with regard to the reduction of FGD gypsum. An increase of gypsum recycling should be achieved to narrow the future gypsum gap that will occur in the near future.
The use of secondary building materials can meet the requirements of sustainability in several ways: the extended time availability of primary raw materials and, thereby, the protection of natural ressources as well as the conservation of landfill sites. Regarding the predicted decrease of gypsum supply in Germany, particularly the recycling of gypsum (calcium sulfate) is of growing importance. Currently, the gypsum demand is fulfilled (at least 60%) by gypsum as side product from coal-fired power plants (FGD Gypsum). Germany’s natural gypsum deposits fulfil the remaining gypsum demand. Due to national climate protection goals the gypsum supply from coal power plants will decrease significantly in the future.
In addition, the content of sulfates in other secondary building materials, in particular in recycled concrete aggregates, should be minimized for quality reasons. Separated gypsum can be used in gypsum production if the high quality requirements for recycled gypsum are met. Accordingly, there have been significant advancements in the processing of gypsum residues in the last years. Since almost all processing steps in the recycling process are associated with environmental impacts, an evironmental evaluation of the use of recycled gypsum as a substitute in gypsum production has to be carefully conducted.
The presentation focusses on the techniques for generating recycled gypsum from gypsum plaster boards, the related quality requirements and a comprehensive environmental evaluation of the complete process.
Ausgehend von der aktuellen Situation in Deutschland werden die Themen Baustoffaufbereitung, Ressourceneffizienz vorgestellt und Möglichkeiten zur Verbesserung der Baustoffqualität von Baurestmassen vorgestellt. Zielkonflikte und Beispiele dazu aus dem Baubereich (z.B. Mantelverordnung) werden benannt.
Gips gehört zu den nachgefragtesten Baustoffen und entsprechend steigt der Gipsverbrauch weltweit schon seit Jahrzehnten an. In Deutschland wird der Gipsbedarf seit vielen Jahren zu einem guten Teil durch REA-Gips, einem Nebenprodukt aus der Abgasreinigung von Kohlekraftwerken, gedeckt. Die weitere Gipsversorgung erfolgt größtenteils durch die Nutzung natürlicher Gipsvorkommen. Ein geringer, aber steigender Anteil an RC-Gips aus dem Baustoffrecycling und die Nutzung synthetischer Gipse aus Nebenprodukten anderer Industriezweige sind ebenfalls zu verzeichnen. Aufgrund der nationalen Klimaschutzziele und der damit verbundenen Abschaltung von Kohlekraftwerken wird das REA-Gipsangebot in den nächsten Jahren jedoch weiter deutlich zurückgehen, so dass andere Gipsquellen erschlossen werden müssen.
Abhängig von der Lebensdauer der verwendeten Gipsprodukte im Bausektor ist infolge des in den vergangenen Jahren erfolgten Anstiegs des Gipsverbrauchs auch mit einer Zunahme von Gipsresten in Bau- und Abbruchabfällen zu rechnen. Im Hinblick auf eine bevorstehende Verknappung von Gips wird die Rückgewinnung dieser Gipse aus Bau- und Abbruchabfällen immer wichtiger. Das Recycling von Gipskartonplatten ist mittlerweile eine etablierte Technik und wird bereits seit einigen Jahren in industriellem Maßstab durchgeführt. Außerdem werden neue Verfahren zur Wiederverwertung weiterer Gipsprodukte aus Rück- und Umbaumaßnahmen untersucht. Von besonderem Interesse sind verschiedene Arten von Gipsplatten, da sie gut für selektiven Rückbau geeignet sind. Daher können sie vergleichsweise frei von Verunreinigungen oder Störstoffen zurückgewonnen werden, was für das Gipsrecycling besonders wichtig ist.
In dem vom Bundesministerium für Bildung und Forschung geförderten Forschungsprojekt "GipsRec 2.0" werden technische, wirtschaftliche und ökologische Aspekte des Recyclings von Gipsfaserplatten sowie von verschiedenen Synthesegipsen untersucht und bewertet. Die Aufbereitung von Gipsfaserplatten erfolgte im halbtechnischen Maßstab, an verschiedenen potentiellen Ausgangsstoffen für synthetische Gipse wurden Laborversuche durchgeführt. Erfolgversprechende Verfahrenswege werden ökobilanziell bewertet. Ziel dieser Arbeiten ist die Erschließung der Sekundärrohstoffpotenziale von weiteren Quellen für die RC-Gipsproduktion um mit einer Steigerung des Gipsrecyclings die in naher Zukunft durch die Reduktion der REA-Gips-Bereitstellung entstehende Lücke in der Rohstoffversorgung zu verringern.
In order to protect natural gypsum deposits and to compensate for the decreasing amount of Flue Gas Desulfurization (FGD) gypsum it is necessary to develop and explore new sources of gypsum. For this purpose, the potentials of different gypsum wastes are investigated in the study “GipsRec 2.0”, funded by the Federal Ministry of Education and Research (Germany).
On the one hand, the project worked on a new processing technology for gypsum fiberboards (GFB). While the recycling of gypsum plasterboards has already been carried out on an industrial scale for several years, the recycling of gypsum fiberboards (GFB) has proven to be challenging. Gypsum fiberboards from demolition sites and offcuts from GFB production were used for these investigations. The tests were conducted on a technical scale. Furthermore, various synthetic gypsums are being investigated with regard to their suitability for gypsum production. The analyses are carried out on production residues.
In this project, a promising process for gypsum fiberboard recycling could be developed, as well as other waste gypsums are investigated and evaluated with regard to their potential as secondary raw material. In addition, selected process routes are assessed for their environmental impact using a life cycle assessment (LCA) approach.
Dust deposition is an important source of phosphorus (P) to many ecosystems. However, there is little evidence of dust-derived P-containing minerals in soils. Here we studied P forms along a well-described climatic gradient on Hawaii, which is also a dust deposition gradient. Soil mineralogy and soil P forms from six sites along the climatic gradient were analyzed with bulk (X-ray diffraction and P K-edge X-ray absorption near edge structure)
and microscale (X-ray fluorescence, P K-edge X-ray absorption near edge structure, and Raman) analysis methods. In the wettest soils, apatite grains ranging from 5 to 30 μm in size were co-located at the micro-scale with quartz, a known continental dust indicator suggesting recent atmospheric deposition. In addition to colocation with quartz, further evidence of dust-derived P included backward trajectory modeling indicating that dust particles could be brought to Hawaii from the major global dust-loading areas in central Asia and northern Africa. Although it is not certain whether the individual observed apatite grains were derived from long-distance transport of dust, or from local dust sources such as volcanic ash or windblown fertilizer, these observations offer direct evidence that P-containing minerals have reached surface layers of highly-weathered grassland soils
through atmospheric deposition.
The aim of this study was to investigate the passive sampler method Diffusive Gradients in Thin-films (DGT) for ammonium and nitrate in amended soils. Therefore, we used soils from a pot experiment with maize where nitrogen (N) was supplied as ammonium sulfate nitrate (ASN), without and with a nitrification inhibitor (NI). The additional use of a NI can delay the nitrification in the soil and making the ammonium available for a longer period in the soil solution after its application. Homogenized soil samples were collected directly from each pot after one week of incubation before sowing and after harvesting the maize. Nitrate and ammonium in these soil samples were extracted using DGT devices equipped with a Putolite A520E (for nitrate) and Microlite PrCH (for ammonium) binding layer. Ammonium DGT which determined the mobile and labile ammonium forms based on diffusion and the resupplies from the solid soil phase, only showed a significantly higher amount of extractable ammonium with NI compared to that without NI for some samples. However, significantly lower values were found for nitrate of treatments with NI compared to without NI after harvest. Thus, the lower nitrate amounts for treatments with NI compared to the treatments without NI after harvest indicated the delay of the nitrification process by the NI. Furthermore, we compared also the ammonium and nitrate
DGT results to chemical extraction with KCl solutions. The results demonstrated that the trends of DGT results and chemical extraction were complimentary through all the treatments.
Phosphorus (P) fertilizers from secondary resources became increasingly important in the last years. However, these novel P-fertilizers can also contain toxic pollutants. Chromium in its hexavalent state (Cr(VI)) is regulated with low limit values for agricultural products due to its high toxicity, but the determination of Cr(VI) in these novel fertilizer matrices can be hampered by redox processes that lead to false results. Thus, we applied the passive sampler technique Diffusive Gradients in Thin-films (DGT) for the determination of Cr(VI) in fertilizers and compared the results with the standard wet chemical extraction method (German norm DIN EN 15192) and Cr K-edge X-ray absorption near-edge structure (XANES) spectroscopy. We determined an overall good correlation between the wet chemical extraction and the DGT method. DGT was very sensitive and in most cases selective for the analysis of Cr(VI) in P-fertilizers. However, hardly soluble Cr(VI) compounds cannot be detected with the DGT method since only mobile Cr(VI) is analyzed. Furthermore, Cr K-edge XANES spectroscopy showed that the DGT binding layer also adsorbs small amounts of mobile Cr(III) compounds which leads to overestimated Cr(VI) values. The results of certain types of P-fertilizers containing mobile Cr(III) or partly immobile Cr(VI), showed that optimization of the DGT method is required to avoid over- or underestimation of Cr(VI).
Recycling-Düngemittel auf Basis von sekundären Ressourcen (Gülle, Gärreste, Klärschlamm, Tiermehl etc.) gewinnen in den letzten Jahren zunehmend an Bedeutung in der Landwirtschaft. Die in den Recycling-Düngemitteln enthaltenen P-Spezies weichen oft stark von denen in konventionell hergestellten Düngemitteln aus Rohphosphat ab, zudem enthalten Recyclingdünger oft mehrere verschiedene P-Formen. Die Pflanzenverfügbarkeit des P in ist ganz wesentlich von der enthaltenen P-Form abhängig. Derzeit gibt es außer zeitaufwendigen und kostspieligen Gefäß- und Feldversuchen keine zufriedenstellende Testmethode zur Analyse der P-Pflanzenverfügbarkeit von unterschiedlichen Recycling P-Düngemitteln. Die im europäischen Düngemittelrecht normierten chemischen Extraktionsmethoden (Wasser, Zitronensäure, Ameisensäure, neutral Ammoniumcitrat etc.) zeigen oftmals keine oder nur sehr geringe Korrelation zu der P-Aufnahme von Pflanzen in Gefäßversuchen mit Recycling-Düngemitteln (Kratz et al. 2010, Steckenmesser et al. 2017, Vogel et al. 2017). Eine grundlegende Schwäche chemischer Extraktionsmethoden liegt darin, dass es sich dabei um statische Methoden handelt, die nicht in der Lage sind, die im System Boden/Düngemittel-Bodenlösung-Pflanze stattfindenden dynamischen Prozesse wie P-Freisetzung und Entzug durch die Pflanzenwurzeln abzubilden.
Einen Lösungsansatz bieten hier sog. P-Senken-Methoden. Bereits in den 1950er Jahren wurden erstmals P-Senken zur Analyse des Boden-P angewendet (Chardon et al. 1996). In den darauffolgenden Jahrzehnten wurden verschiedene P-Senken auf der Basis von Eisenoxid-Papier entwickelt (Chardon et al. 1996). Jedoch konnten diese Ansätze auch nur begrenzt zur Bestimmung der P-Pflanzenverfügbarkeit des Boden-P eingesetzt werden. Mitte der 1990er Jahre wurde die DGT (engl. diffusive gradients in thin films) Methode entwickelt (Zhang et al. 1998). Bei der DGT Methode diffundiert P aus der Bodenlösung des angefeuchteten Bodens durch einen Membranfilter und die Diffusionsschicht und wird anschließend an einer Bindungsschicht absorbiert. Durch den Diffusionsgradienten wird das Gleichgewicht in der Bodenlösung permanent gestört, wodurch auch labiles P im Boden gelöst wird. Die stetige Entnahme von P aus der Bodenlösung über die Diffusions-/Bindungsschicht simuliert dabei den Entzug von P durch die Pflanzenwurzel. Die an die Bindungsschicht adsorbierte Menge an P korreliert stark mit der P-Aufnahme von Pflanzen (u.a. Mason et al. 2005, 2013; Menzies et al. 2005, Six et al. 2012). Im Gegensatz zu chemischen Extraktionsmethoden werden bei der DGT Methode Mischungen an Düngemittel und Boden für mehrere Tage inkubiert (Vogel et al. 2017; Duboc et al. 2017), da ansonsten wasserlösliche P-Dünger den DGT Adsorber sättigen und wasserunlösliche P-Dünger unterschätzt werden. Ein bis zwei Wochen Inkubation sind ausreichend, damit sich pflanzenverfügbares P in die Mischungen bildet.
In letzter Zeit haben verschiedene Forschungsgruppen gezeigt, dass die DGT Methode auch eine sehr gute Korrelation mit der Pflanzenverfügbarkeit verschiedener Typen von (Recycling-)P-Düngemitteln aufweist (Vogel et al. 2017; Duboc et al. 2017; Foereid 2017; Haarstad and Bavor 2017; Lemming et al. 2017). Bei Gefäßversuchen mit verschiedenen Recycling P-Düngemitteln konnte die DGT Methode den Ertrag bzw. die P-Aufnahme von Mais deutlich besser vorhersagen als herkömmliche chemische Extraktionsmethoden (Vogel et al. 2017; Duboc et al. 2017).
Daher kann die DGT Methode im Vorfeld der Zulassung von neuen Düngermitteltypen als zuverlässige und robuste Methode zum Screening von Produktvarianten eines Düngemittelherstellers verwendet werden. Um dieses Messverfahren im Rahmen des Düngemittelrechts als Bewertungsinstrument für die Abschätzung der Pflanzenverfügbarkeit unterschiedlicher Düngemittel zu verwenden, muss es allerdings zunächst standardisiert werden. Zu diesem Zweck bietet sich der Einsatz eines „standardisierten“ Bodens bzw. Bodenrezepts an. Zur Kalibrierung der Methode im jeweiligen Labor könnten auch chemisch definierte P-Verbindungen mit bekannter Löslichkeit/Pflanzenverfügbarkeit als Referenz-substanzen verwendet werden.
Previous research shows that analytical methods based on Diffusive Gradients in Thin films (DGT) provide very good correlations to the amount of bioavailable nutrients and pollutants in the environmental samples. However, these DGT results do not identify which compound of the specific element has the high bioavailability. Using various spectroscopic techniques (infrared, XANES and NMR spectroscopy) to analyze the dried DGT binding layers after deployment could allow us to determine the specific elements or compounds. Nutrients such as phosphorus and nitrogen are often, together with other elements, present as molecules in the environment. These ions are detectable and distinguishable by infrared and NMR spectroscopy, respectively. In addition, XANES spectroscopy allows for the specification of nutrients and pollutants (e.g. chromium) on the DGT binding layer. Furthermore, microspectroscopic techniques make it also possible to analyze compounds on the DGT binding layer with a lateral resolution down to 5 µm2. Therefore, species of elements and compounds of e.g. a spatial soil segment can be mapped and analyzed, providing valuable insight to understand the dynamics of nutrients and pollutants in the environment. Here we will present the advantages and limitations of this novel combination of techniques.
Phosphorus (P) plays an essential role in the global food security. However, the global P reservoirs have a statistic lifetime of about 385 years only. Due to the scarcity of P and the increasing world population an efficient and sustainable recycling management is required. A few biogenic waste materials are high in P contents such as sewage sludge and meat and bone meal. Thus, they are suitable for P recycling and fertilizer production. But besides the high P content sewage sludge is often highly contaminated with organic pollutants and toxic heavy metals which have to be eliminated before agricultural field application. In this presentation we show the potential of sewage sludge as secondary resource for fertilizers. This includes our developments in thermochemical processes for the production of novel P-fertilizers from recycled materials. Furthermore, for these novel P-fertilizers common extraction tests to determine the plant-available P are often unusable. Therefore, we successfully applied the Diffusive gradients in thin-films (DGT) techniques to analyse the plant-availability of P-fertilizers from recycled materials.
Per- and polyfluoroalkyl substances (PFAS) are chemicals which were developed to improve humanity’s quality of life. Due to their high chemical stability and resistance to degradation by heat or acids, PFAS were used in a variety of consumer products. The continuous use of PFAS in household products and the discharge of PFAS from industrial plants into the sewer system resulted in the contamination of effluents and sewage sludge from wastewater treatment plants (WWTPs) (Roesch et al. 2022). Since sewage sludge is often used as fertilizer, its application on agricultural soils has been observed as a significant entry path for PFAS into the environment, specifically in our food chain. In Germany the sewage sludge/biosolid application on agricultural land was banned with the amendment of the German Sewage Sludge Ordinance and by 2029 sewage sludge application will be totally prohibited. However, phosphorus (P) from sewage sludge should still be recycled in WWTPs of cities with a population larger than 50,000 residents. To produce high-quality P-fertilizers for a circular economy, PFAS and other pollutants (e.g. pesticides and pharmaceuticals) must be separated from sewage sludge. Due to the strong diversity of industrial PFAS usage it is not clear if a safe application of novel recycled P-fertilizers from WWTPs can be guaranteed. Therefore, we analyzed various sewage sludges and wastewater-based fertilizers. Sewage sludge (SL) samples from various WWTPs in Germany and Switzerland, six sewage sludge ashes (SSA) from Germany, six thermally treated SL and SSA samples with different additives (temperatures: 700-1050 °C), two pyrolyzed SL samples (temperature: 400 °C) and two struvite samples from Germany and Canada were analyzed. The goal was to quantify PFAS in sewage sludges and wastewater-based P-fertilizers with the sum parameter extractable organic fluorine (EOF) by combustion ion chromatography (CIC). The results were compared with data from classical LC-MS/MS target analysis as well as selected samples by HR-MS suspect screening. The EOF values of the SLs mainly range between 154 and 538 µg/kg except for one SL which showed an elevated EOF value of 7209 µg/kg due to high organofluorine contamination. For the SSA samples the EOF values were lower and values between LOQ (approx. 60 µg/kg) and 121 µg/kg could be detected. For the pyrolyzed SLs no EOF values above the LOQ were detected. Moreover, the two wastewater-based struvite fertilizers contain 96 and 112 µg/kg EOF, respectively. In contrast to the EOF values, the sum of PFAS target values were relatively low for all SLs. Additional applied PFAS HR-MS suspect screening aimed to tentatively identify PFAS that could contribute to the hitherto unknown part of the EOF value. The majority of the detected fluorinated compounds are legacy PFAS such as short- and long-chain perfluorocarboxylic acids (PFCA), perfluorosulfonic acids (PFSA), polyfluoroalkyl phosphate esters (PAPs) and perfluorophosphonic acids (PFPA). Moreover, fluorinated pesticides, pharmaceutical as well as aromatic compounds were also identified, which are all included in the EOF parameter. Our research revealed that the current PFAS limit of 100 µg/kg for the sum of PFOS + PFOA in the German Fertilizer Ordinance is no longer up to date. Since the number of known PFAS already exceeds 10,000, the ordinance limit should be updated accordingly. Recent regulations and restrictions on using long-chain PFAS (≥C8) have resulted in a significant shift in the industry towards (ultra-)short-chain alternatives, and other, partly unknown, emerging PFAS. Ultimately, also fluorinated pesticides and pharmaceuticals, which end up as ultrashort PFAS in the WWTPs, have to be considered as possible pollutants in fertilizers from wastewater, too.
Lightweighting as a cross-cutting technology contributes significantly to achieve the European Green Deal goals. Based on, but not limited to, advanced materials and production technologies, the demand for natural resources and CO2 emmissions are reduced by lightweighting during production, as well as use phase. Therefore, lightweighting is a crucial transformation technology assisting in decoupling economic growth from resource consumption. In this manner, lightweighting contributes significantly as a key technology of relevance for many industrial sectors such as energy, mobility, and infrastructure, towards resource efficiency, climate action and economic strength, as well as a resilient Europe. To strengthen international partnerships, addressing global issues of today at the edge of science with high performance lightweight material based on carbon fibers, an overview about the BAM expertise in carbon fiber reinforced materials is given.
Optimierung eines pyrometallurgischen Tantal- und Niob- Recyclingprozesses mithilfe von On-Line LIBS
(2018)
Die Entwicklung von Hochleistungselektronik zu immer kleineren Bauformen ohne Leistungseinbußen ist ohne den Einsatz von Technologiemetallen wie Niob und Tantal heute praktisch nicht mehr realisierbar. Besonders in technischen Geräten wie Smartphones und Tablets sind Tantal- und Niobkondensatoren aufgrund ihrer hohen Leistungsdichten bereits unverzichtbar geworden. Für die nachhaltige Produktion von Elektronik stellt jedoch vor allem das Tantalerz Coltan als sogenanntes „conflict mineral” ein großes Problem dar.
Um den Wirtschaftsstandort Europa unabhängiger von Primärrohstoffimporten aus Krisenregionen zu machen, ist die Entwicklung von effizienten Recyclingverfahren heute wichtiger denn je. An der Bundesanstalt für Materialforschung und -prüfung (BAM) findet daher zurzeit die Optimierung eines pyrometallurgischen Industrieprozesses zur Niob- und Tantalrückgewinnung statt, welchem hauptsächlich niedrigkonzentrierte metallurgische Rückstände aus der Tantal- und Niob- bzw. der Zinngewinnung als Einsatzstoffe dienen.
Zu diesem Zweck werden im kleintechnischen Lichtbogenofen der BAM (480 kVA, max. Materialdurchsatz ca. 150 kg/h) Versuche mit einem neuen innovativen Messgerät durchgeführt, welches eine On-Line Analyse von Hochtemperaturprozessen ermöglicht. Der eingesetzte Prototyp nutzt das Verfahren der laserinduzierten Plasmaspektroskopie (LIBS), um die chemische Zusammensetzung der Schlackephase noch im Schmelzbad und während eines Schlackeabgusses zu bestimmen. Nach einer Kalibrierung auf das vorliegende Stoffsystem ermöglicht dieser On-Line-LIBS Prototyp der BAM daher eine in-situ Bestimmung der Elementverteilung in der Schmelze. Die hier gewonnenen Daten sollen helfen, die aktuelle Prozessführung zu verbessern und die Tantal- und Niobausbeute noch weiter zu erhöhen.
Tantalum and niobium are essential for the development of electronics towards a more and more compact design, but without reducing their performance today. Especially in smart phones and tablets, tantalum and niobium capacitors with high charge densities have already become almost indispensable. However, tantalum as a critical raw material is still a problem for the sustainable production of electronics. Due to this fact, the existence of efficient recycling processes especially in Europe is becoming even more important nowadays.
The Bundesanstalt für Materialforschung und -prüfung (BAM) is currently working on the optimisation of an existing pyrometallurgical tantalum recycling process. Optimisation of this industrial process is carried out in a small-scale electric arc furnace (480 kVA, capacity approx. 150 kg/h) at BAM using a new and innovative equipment for on-line analysis of high temperature processes.
The aim of this project is to identify the best timing for an optimum slag tapping, when the slag is lower than minimum targeted tantalum concentration. Hence, LIBS (Laser induced breakdown spectroscopy) is used to identify the chemical composition of the slag layer and during slag tapping. The on-line-LIBS prototype of BAM enables an in-situ measurement of the element distribution in the melt after calibration on the slag system.
First results of this joint research project will be presented including on-line-LIBS-measurements and thermodynamic and kinetic aspects of the process.
An existing pyrometallurgical process for tantalum and niobium recovery, mainly from low grade pyrometallurgical residues, was investigated. Series of melting experiments were carried out in a pilot-scale electric arc furnace to study how the amount, the grain size and the way of feeding affect the activity of carbon as a reducing agent. During the pyrometallurgical treatment refractory metals such as tantalum and niobium are reduced to their carbide form and enriched in the molten iron-based metal phase. The cooled down slag and metal phase were analysed to investigate thermodynamic and kinetic conditions of the carbide formation. FACT Sage simulations were also used to investigate the material system in state of thermodynamic equilibrium. Results show that mass transfer and kinetics may play an important role if compared to equilibrium analyses using FACT Sage.
Since the recycling of tantalum bearing post-consumer waste is practically not existent, metallurgical residues are the most important feed for the tantalum recycling. Most tin ores naturally contain significant quantities of refractory metals. During the smelting process in primary tin production these elements are enriched in the slag phase. This slag is a highly valuable raw material for tantalum production due to its considerable concentration of tantalum and its functioning as an additional slag former in further pyrometallurgical treatment.
In this paper the first process stage of an existing pyrometallurgical process for tantalum recovery, mainly from low grade pyrometallurgical residues, is discussed. Smelting trials were carried out in a pilot-scale electric arc furnace to analyse the effect of feeding on the activity of carbon as a reducing agent. Therefore, blowing petroleum coke through an iron lance and the manual adding of coke into the melting bath were tested. During the pyrometallurgical treatment elements with a high affinity to carbon were reduced to their carbide form and enriched in the molten iron-based metal phase. The objective of the process was to reduce the oxidic tantalum completely and to enrich it into the metal phase. Furthermore, the transfer of unwanted elements such as titanium into the metal phase was aimed to be avoided.
Spoon test specimens were taken from the liquid mineral melt to follow the evolution of the reduction process. The cooled down solidified melting bath was investigated by using the XRD and EDX method to characterise the slag system and to identify relevant mineral phases.
Calcium sulfate hemihydrate (CaSO4ᐧ0.5H2O), also known as bassanite, has been used as a precursor to produce gypsum (dihydrate, CaSO4ᐧ2H2O) for various construction and decorative purposes since prehistoric times. The main route to obtain hemihydrate is a thermal treatment of gypsum at temperatures typically between 150 °C and 200 °C to remove some of the structural water.
In this contribution, we introduce (Fig. 1) a more efficient and sustainable method (T < 100 °C) that enables the direct, rapid, and reversibly conversion of gypsum to bassanite using reusable high salinity aqueous solutions (brines with c[NaCl] > 4 M). The optimum conditions for the efficientproduction of bassanite in a short time (< 5 min) involve the use of brines with c(NaCl) > 4 M and maintaining a temperature, T > 80 °C. When the solution containing bassanite crystals is cooled down to around room temperature, eventually gypsum is formed. When the temperature is raised again to T > 80 °C, bassanite is rapidly re-precipitated. This contrasts with the typical behaviour of the bassanite phase in low salt environments.
Traditionally, hemihydrate is obtained through a solid state thermal treatment because bassanite is considered to be metastable with respect to gypsum and anhydrite in aqueous solutions, and therefore gypsum-to-bassanite conversion should not occur in water. Its very occurrence actually contradicts numerical thermodynamic predictions regarding solubility of calcium sulfate phases. By following the evolution of crystalline phases with in situ and time-resolved X-ray diffraction/scattering and Raman spectroscopy, we demonstrated that the phase stability in brines at elevated temperatures is inaccurately represented in the thermodynamic databases. Most notably for c(NaCl) > 4 M, and T > 80 °C gypsum becomes readily more soluble than bassanite, which induces the direct precipitation of the latter from gypsum. The fact that these transformations are controlled by the solution provides extensive opportunities for precise manipulation of crystal formation. Our experiments confirmed that bassanite remained the sole crystalline structure for many hours before reverting into gypsum. This property is extremely advantageous for practical processing and efficient crystal extraction in industrial scenarios.
The challenge of the project ASHES is focused on the recycling of nutrients from residues of thermochemical processing of by-products of sugar cane industry (bagasse/straw) in Brazil to increase the energy efficiency of thermal conversion and to enable the recycling of process ashes as fertilisers. Dry lignocellulosic biomass (straw, bagasse) are combusted, gasified and subsequently combined with post-thermochemical treatment in the AshDec process to increase the plant availability of phosphorus. Different fertilizer formulations are granulated/pelletized and tested regarding their storage/handling characteristics.
Hydrogen plasma treatment of iron ores or iron oxide containing wastes can be an efficient option to produce green iron e.g. for steel production. This way iron oxide is reduced to metallic iron in the liquid form by the highly reactive species that are formed in a hydrogen plasma. Hydrogen plasma can be used at the same time to remove undesired gangue elements. The presentation shows the experimental setup, shows first results of iron ore reduction by hydrogen plasma and gives an outlook for industrial application of the technology.
For the European sewage sludge ash monitoring ash samples from sewage sludge incineration plants were requested from all over Europe. First results of the received samples regarding main and trace element contents were presented at ESPC4. Moreover, a list of all known European facilities for sewage sludge monoincineration was presented.
Analyseverfahren und Messhäufigkeit zur Bestimmung des Phosphorgehalts im Klärschlamm nach AbfKlärV
(2022)
Auf dem Betreiberforum der DWA-Plattform P-Rück wurden die Empfehlungen für den Vollzug der Phosphorrückgewinnungspflicht aus Klärschlamm vorgestellt. Diese Empfehlungen behandeln die Häufigkeit der Phosphoruntersuchungen im Klärschlamm, wo ein Jahresgang empfohlen wird und eine Empfehlung der Phosphorbestimmung über Aufschluss der Probe in der Mikrowelle und Messung mit ICP-OES. Untermauert wurden die Empfehlungen mit den Ergebnissen von Klärschlamm-Monitoring, Ringversuch und Analytikvergleich aus dem Vorhaben extraWERT.
Der Vortrag liefert eine Zusammenfassung der wichtigsten Ergebnisse des extraWERT-Vorhabens mit Schwerpunkt auf den Umsetzungsfragen zur Klärschlammverordnung. Bei diesen Punkten handelt es sich um die Untersuchung von monatlichen Phosphorschwankungen in kommunalem Klärschlamm und die Gleichwertigkeit verschiedener Verfahren zur Phosphorbestimmung in Klärschlamm.
In Deutschland ist ab 2029 eine Phosphorrückgewinnung aus Klärschlamm verpflichtend. Ausgenommen sind Klärschlämme mit weniger als 20 g P/kg TM. Für die Phosphorbestimmung sind verschiedene Methoden nach Klärschlammverordnung als gleichwertig zugelassen: Der Königswasseraufschluss in der Mikrowelle und am Rückfluss sowie die Messung an ICP-OES, ICP-MS und die photometrische Bestimmung mittels Ammoniummolybdaten. An der BAM wurden die unterschiedlichen Methodenkombinationen aus Aufschluss- und Messmethode an 15 Klärschlämmen überprüft und in einem Ringversuch mit einem Klärschlamm getestet. Die Ergebnisse werden in diesem Vortrag zusammengefasst. Als Folge der Untersuchungen wird für die Phosphorbestimmung in Klärschlamm die ICP-OES-Messung nach Königswasseraufschluss in der Mikrowelle empfohlen.
Agricultural sewage sludge utilization becomes less important in Germany. In 2017, new fertilizer and waste laws caused the agricultural sewage sludge utilization to collapse by more than a quarter. From 2029, in German wastewater treatment plants (WWTPs) phosphorus (P) must be recovered from sewage sludge ifit contains more than 2 wt % P. Agricultural utilization will be prohibited for large WWTPs > 100,000 population equivalents (pe) from 2029 and > 50,000 pe from 2032. In Germany, each federal state must annually report amounts and quality of agriculturally utilized sewage sludge which was 17 % of the total disposal in 2019. The reports of 10 States were evaluated for 2016 and 2017 representing approx. 60 % ofthe total agriculturallyused sludge volume. Whereas phosphorus recovery is mandatory this does not apply to other nutrients. However, many P recovery processes recover other nutrients, too. Considering three differentscenariosfor future German sewage sludge disposal shows that 70 - 77 % ofthe P load in sewage sludge will probably be recovered in the future. At the same time, this applies for about 0 - 16 % of nitrogen, 36 - 52 % of calcium, 31-53 % of potassium, and 40 - 52 % of magnesium. However, these recovered nut rient loads can substitute only 1 % or less ofthe commercial fertilizer demand except from phosphorus which is about 45 % ofthe demand.
Die Ergebnisse des extraWERT-Vorhabens wurden Vertreter*innen des Umweltministeriums von Bund und Ländern vorgestellt und im Zusammenhang mit dem Vollzug der AbfKlärV diskutiert. Es ging um die Phosphorschwankungen in kommunalem Klärschlamm und eine Empfehlung der Untersuchungshäufigkeit, um den Phosphorgehalt rechtssicher festzustellen. Des weiteren wurde die Performance verschiedener nach Verordnung gleichwertiger Analyseverfahren für Phosphor in Klärschlamm diskutiert anhand von Ringversuchsergebnissen und Eigenuntersuchungen an 15 Klärschlammproben.
Gleichwertigkeit der nach AbfKlärV zulässigen Verfahren zur Phosphorbestimmung in Klärschlamm
(2021)
In dem Meeting wurde den Notifizierern und Ausrichtern des jährlichen länderübergreifenden Ringversuchs Klärschlamm die Ergebnisse zu Untersuchungen hinsichtlich der Gleichwertigkeit verschiedener nach AbfKlärV zulässiger Verfahren zur Phosphorbestimmung in Klärschlamm vorgestellt. Die Untersuchungen an 15 Klärschlammproben ergaben die höchsten Ergebnisse für das Messverfahren ICP-OES und das Aufschlussverfahren in der Mikrowelle. Diese Ergebnisse wurden im Ringversuch bestätigt.
Die landwirtschaftliche Klärschlammverwertung ist in der Bundesrepublik Deutschland seit Jahren rückläufig. Neben den Risiken durch Schadstoffeinträge gibt es in Deutschland Regionen mit einem stark erhöhten Nährstoffüberschuss. Um die Grundwasserbelastung zu verhindern wurde u.a. das Düngerecht verschärft, was die Flächenkonkurrenz zwischen Klärschlamm und Wirtschaftsdünger vergrößern wird.
Es ist davon auszugehen, dass sich die neuen Regelungen im Düngerecht und der Klärschlammverordnung massiv auf die landwirtschaftliche Verwertung von Klärschlamm und damit auf die Kreislaufwirtschaft verschiedener Nährstoffe auswirken werden. In diesem Beitrag werden erste Ergebnisse des Projekts extraWERT vorgestellt.
Es wurden erste Ergebnisse des Projekts extraWERT vorgestellt. Im Projekt werden monatlich Klärschlammproben von 10 kommunalen Kläranlagen untersucht, deren P-Gehalt im Grenzbereich der AbfKlärV liegt zwischen 1,7 und 2,3%. Die ersten Ergebnisse lagen zu fünf Kläranlagen vor, es wurden Daten zum TS-Gehalt, zur oTS und zu den Nährstoffgehalten präsentiert.
New developments in legislation and technology development for P-recovery were presented with focus on the situation in Germany.
Im Projekt extraWERT geht es um die Ermittlung von Nährstoffpotenzialen in Abwasser und Klärschlamm. Neben kommunalen Kläranlagen soll auch die Industrie als Quelle für nährstoffreiche Abfallströme betrachtet werden. Mit dem Vortrag sollten Mitglieder des MIV zu einer Projektbeteiligung bewegt werden. Es sollen rohes und gereinigtes Abwasser von direkt einleitenden Betrieben auf Makronährstoffe untersucht werden, neue Erkenntnisse werden insbesondere für die Nährstoffe Calcium und Magnesium erwartet.
Vorstellung des REFOPLAN-Projekts extraWERT Erhebung zusätzlicher Wertstoffpotenziale in Klärschlamm
(2019)
Auf dem Regionalgruppentreffen wurden erste Projektergebnisse vorgestellt und die Probenahmestrategie diskutiert. Vorgestellt wurde eine Rückberechnung der mittleren Wertstoffgehalte aus dem Klärschlamm-Monitoring 2014 (Krüger und Adam) und erste Auswertungen der Klärschlammbericht-Rohdaten aus NRW und Hessen.
Basic oxygen furnace slag (BOFS) is a by-product of steelmaking of which about 10.4 Mt are produced annually in the EU. BOFS is mostly used in road construction, earthwork and hydraulic engineering. However, in this use, the iron bound in BOFS is lost and the opportunity to produce higher value products from BOFS is forgone.
In recent decades, many researchers have investigated a thermochemical process to reduce iron oxides to metallic iron in molten BOFS. The metallic iron formed separates from the reduced slag due to its higher density and can be recovered. An advantage of this process is that simultaneously the chemical composition of the reduced slag is adapted to that of the Portland cement clinker and the hydraulic reactive mineral alite is formed.
In this study, BOFS was reduced in a small-scale electric arc furnace using petrol coke as reducing agent, and the hydraulic properties of the reduced, low-iron BOFS were investigated. Despite a chemical and mineralogical composition similar to that of Portland cement clinker, the reduced BOFS produced less heat of hydration, and its reaction was delayed compared to Portland cement. However, the addition of gypsum, as is also done in cement production from Portland cement clinker, has been found to accelerate the hydration rate of reduced BOFS.
Further research to improve the hydraulic properties of the reduced slag is essential. If successful, the production of a hydraulic binder and crude iron from BOFS could have economic and ecological benefits for both the cement and steel industry.
Steelmaking slags are a by-product of steel production, that are currently used primarily in road construction, earthwork, and hydraulic engineering. In this use, the iron bound in the steelmaking slags (< 30 wt.%) is lost.
Recovery of iron from steelmaking slags is possible by thermochemical reductive treatment. The reductive treatment of liquid steelmaking slags causes iron oxides to be reduced to metallic iron, which separates from the mineral phase due to its higher density. The chemical composition of the mineral phase is thus adapted to that of the Portland cement clinker and the mineral alite, the most important component of Portland cement, is formed. This way, crude iron can be recovered, and at the same time a hydraulic binder can be produced.
This process, however, is uneconomical due to the high temperatures required (~1800 °C). In the current project, the process is to be adapted so that the reduction of liquid steelmaking slag can be carried out at ~1600 °C. The chemical composition is to be modified in such a way that the melting temperature of the slags as well as their viscosity are in a technically suitable range and still a product with good cementitious properties is obtained.
Basic oxygen furnace slags (BOFS) are a by-product of steel production. In 2016, 10.4 Mt of BOFS were produced in the European Union (EU). The main part of BOFS is used in road construction, earthwork and hydraulic engineering. A smaller part is returned to the metallurgical circle, used as fertilizer or landfilled. However, it is also possible to produce higher value products from BOFS. For example, many researchers have investigated the possibility of producing Portland cement clinker and crude iron from BOFS by a carbothermal post-treatment.
In this study, German BOFS was reduced in a small-scale electric arc furnace using petrol coke as reducing agent. The carbothermal treatment reduces the iron oxides in the BOFS to metallic iron, which accumulates at the bottom of the furnace by density separation. In addition to metallic iron, the process generates a mineral product rich in the tricalcium silicate solid solution alite. As the main constituent of Portland cement clinker, the hydraulic reactive mineral alite is of high economic importance.
In previous studies, the hydraulic reactivity of the mineral product was investigated by testing the compressive strength of blends with 70 wt.% ordinary Portland cement (OPC). Recent investigations focused on the hydraulic properties of the pure mineral product from the reduced BOFS. The heat of hydration of the mineral product was measured by isothermal calorimetry and compared with the heat of hydration of a synthetic low-iron slag and OPC. In addition, the formation of hydration products was investigated with differential scanning calorimetry (DSC) and x-ray diffraction analysis (XRD) on freeze-dried samples after defined curing times. The results of the calorimetric measurements indicate that the mineral product produced less heat of hydration and its reaction was delayed compared to the synthetic low-iron slag and OPC. Hydration products such as portlandite and calcium silicate hydrates (C-S-H) formed later and in lower amounts.
The production of a hydraulic material from BOFS by reductive treatment is of great interest to both the cement and steel industries. The substitution of cement clinker in OPC with a hydraulic material such as reduced BOFS leads to a reduction in greenhouse gas emissions from cement production. The steel industry benefits from an application for its by-products that avoids cost expensive landfilling and may even bring economic advantages. Furthermore, it may be possible to return the recovered crude iron to production.
Basic oxygen furnace slag (BOFS) is a by-product of the steelmaking process, of which about 10.4 Mt are produced annually in the European Union. Besides its predominant use in road construction, earthwork, and hydraulic engineering, it is also possible to use BOFS as a source material for Portland cement clinker.
The main difference in the chemical composition of BOFS from the chemical composition of Portland cement clinker is its high content of iron oxides (7-50 wt.%). In recent decades, many researchers have investigated the production of both Portland cement clinker and crude iron from BOFS via thermochemical reductive treatment. Carbothermal treatment of liquid BOFS causes reduction of iron oxides to metallic iron, which separates from the mineral phase due to its higher density.
In this study, German BOFS was reduced in a small-scale electric arc furnace using petrol coke as reducing agent. The produced low-iron mineral product was chemically similar to Portland cement clinker and contained the most important Portland cement mineral alite (Ca3SiO5) as main component. Besides alite, the mineral product contained other Portland cement clinker constituents such as belite (β-Ca2SiO4) and tricalcium aluminate (Ca3Al2O6).
The production of Portland cement clinker and crude iron from BOFS has economic and ecological benefits for both the cement and steel industry. Cement clinker from reduced BOFS may be used as a substitute for cement clinker from conventional cement production, thereby CO2 emissions will be reduced. The steel industry benefits from a high-value application for its by-products that avoids cost expensive landfilling and may even bring economic advantages. However, reductive treatment requires high temperatures and, for economic reasons, has to be carried out immediately after casting of the liquid BOFS, which is a logistical challenge for most steel plants. A cost-benefit analysis is therefore essential.
Die Klinkerphasenbildung durch Sinterung in Drehrohröfen bei der Herstellung von Portlandzementklinker (PZK) ist gründlich erforscht und optimiert. Im Hinblick auf mög-liche ökonomische und ökologische Vorteile befassen sich aktuelle Forschungsvorha-ben darüber hinaus mit der Herstellung von Klinkermineralen aus Stahlwerksschla-cken, die eine vergleichbare chemische Zusammensetzung aufweisen.
Neuste Untersuchungen zeigen, dass nach der reduzierenden Behandlung schmelz-flüssiger Linz-Donawitz-(LD)-Schlacken und Abscheidung des gebildeten metallischen Eisens eine mineralische Schlacke entsteht, die unabhängig von ihren Abkühlbedin-gungen ca. 50–60 Gew.% des wichtigsten Klinkerminerals Alit (C3S) enthält und eine hohe hydraulische Reaktivität aufweist.
Die Stabilität des Alits auch nach langsamer Abkühlung deutet auf eine Stabilisierung des Minerals durch Nebenelemente aus den LD-Schlacken hin. Ein sinkender Anteil an LD-Schlacke durch Zusatz synthetischer Schlackemischung, die sich hinsichtlich ihrer Hauptkomponenten wie eine ausreduzierte LD-Schlacke zusammensetzt, führt zu einem Rückgang des Alitgehaltes und dem Zerfall der Schlacke beim Erstarren.
Steelmaking slag is a by-product of steel production of which 4.5 Mt were produced in 2020 in Germany alone. It is mainly used in road construction, earthwork and hydraulic engineering. A smaller part is returned to the metallurgical circle, used as fertilizer or landfilled.
With this use, iron oxides still contained in steelmaking slag are lost. In addition, the possibility of producing higher-grade products from steelmaking slag is foregone. In recent decades, many researchers have investigated the production of Portland cement clinker and crude iron from basic oxygen furnace slags (BOFS) via a reductive treatment. Carbothermal treatment of liquid BOFS causes a reduction of iron oxides to metallic iron, which separates from the mineral phase due to its higher density. Simultaneously, the chemical composition of the reduced slag is adapted to that of the Portland cement clinker.
In this study, German BOFS was reduced in a small-scale electric arc furnace using petrol coke as a reducing agent. The resulting low-iron mineral product had a similar chemical composition to Portland cement clinker and was rich in the tricalcium silicate solid solution alite (Ca3SiO5). Based on its chemical and mineralogical composition, similar to that of Portland cement clinker, the reduced BOFS has the potential to react comparably. In our study, the reduced BOFS produced less heat of hydration compared to OPC and its hydraulic reaction was delayed. However, adding gypsum has been shown to accelerate the hydration rate of the reduced BOFS compared to that known from the calcium silicates of Portland cement clinker.
Further research to improve the hydraulic properties of the reduced slag is essential. If successful, producing a hydraulic binder and crude iron from BOFS could have economic and ecological benefits for both the cement and steel industry.
Basic oxygen furnace slag (BOFS) is a by-product of steelmaking of which about 10.4 Mt are produced annually in the EU. BOFS is mostly used in road construction, earthwork and hydraulic engineering. However, in this use, the iron bound in BOFS is lost and the opportunity to produce higher value products from BOFS is forgone.
In recent decades, many researchers have investigated the production of both Portland cement clinker and crude iron from BOFS via a thermochemical reductive treatment. The reductive treatment of liquid BOFS causes a reduction of iron oxides to metallic iron, which separates from the mineral phase due to its higher density and can be recovered. An advantage of this process is that simultaneously the chemical composition of the reduced BOFS is adapted to that of Portland cement clinker and the hydraulic reactive mineral alite (Ca3SiO5) is formed.
In this study, German BOFS was reduced in a small-scale electric arc furnace and a low-iron mineral product rich in alite was produced. Despite a chemical and mineralogical composition similar to that of Portland cement clinker, the reduced BOFS produced less heat of hydration, and its reaction was delayed compared to Portland cement. However, adding gypsum accelerated the hydration rate of the reduced BOFS.
Further research to improve the hydraulic properties of the reduced BOFS is essential. If successful, the production of a hydraulic material and crude iron from BOFS could have economic and ecological benefits for both the cement and steel industry.
Despite its contribution to tackling climate change by lightweight design, growing CFRP production also results in a global waste generation of 62 kt/a. Accordingly, the energy-intensive production process of carbon fibers (CF) necessitates sustainable recycling solutions.
Herein we will give an overview of current recycling processes, discuss their limitations and present a novel approach for safe treatment of CF unsuitable for material recovery . Our project CF Pyro examines feedstock recycling in pyrometallurgical processes, focusing on reactivity of CF, process stability and prevention of hazardous WHO fiber release. Besides fundamental experimental breakthroughs, their broader impact on circular economy will be presented.
CFK-Abfälle werden trotz der bestehenden Verfahren zur Rückgewinnung der Carbonfasern zukünftig vermehrt anfallen. Für diese Abfälle wird nach technischen Lösungen der energetischen oder stofflichen Verwertung gesucht. Eine Möglichkeit ist die Nutzung der CFK-Abfälle als Primärkohleersatz im Lichtbogenofen bei der Stahlherstellung.
During iron and steel production, several by-products such as slags, dusts and sludges are generated in addition to pig iron and steel as primary products. While established recycling routes exist for slags, there are still considerable recycling problems for other residual materials, especially for filter dusts and sludges containing zinc and lead from waste gas purification. However, the high heavy metal contents make landfilling these dusts and sludges cost-intensive and ecologically problematic. In addition, the relatively high zinc and iron loads represent a valuable material potential, which can make reprocessing of the material with recovery of the zinc and iron loads as secondary raw materials ecologically as well as economically attractive. Against this background, a process is being developed in a cooperative project between Ferro Duo GmbH and the Federal Institute for Materials Research and Testing (BAM), in which the heavy metals (zinc, lead, cadmium, etc.) contained in the filter dusts and sludges are selectively converted into chlorides in a thermochemical process after the addition of a chlorine donor and evaporated at temperatures between 650 and 1100 °C. This process can be used to recover zinc and iron as secondary raw materials.
Experiments to date in a batch reactor show that >99% of the zinc and lead can be removed from the treated material. However, a continuous process is necessary for an economical process, which is why this process is transferred to a rotary kiln and relevant process parameters are identified and optimized. The results of these investigations will be presented here.