Process and technology evaluation and optimization
A sustainable raw materials production not only requires the development of novel extraction and recycling technologies but also the development of digitalized models of single processes and routes to evaluate efficiency, impact, and optimization potentials of any novel technology.
Based on our in-depth process understanding, we generate these digital process twins, test them together with our partners in pilot-scale, and benchmark them against currently existing options. When evaluating new recycling routes for end-of-life products, we also create design-for recycling concepts to improve their recyclability.
Process and technology evaluations are carried out adopting the following methods:
- Techno-economical assessment, which includes evaluation of process, energy consumption or cost/benefit data analysis associated with production.
- Sustainability assessment, using life cycle assessment (LCA), life cycle costing assessment (LCCA), and social LCA.
Sankey diagram of the complete life cycle of metals embedded in a PCB. Scenario 2050. Units in kWh, Source: Torrubia et al., 2024
Linking renewable energy systems to metal production
The mining and recycling sector is at the core of energy transition. The manufacturing of renewable energy systems is metal-intensive. The metals production itself is highly energy-intensive and a major contributor to the global greenhouse gas emissions. To lower emissions and establish a fossil-free metal production, renewable energies will have to be integrated into the raw materials value chain. In order to do so, electrical energy has to be transformed into heat or chemical energy by using so called Power-to-X technologies.
To boost the coupling of these two systems, we draw our research focus on:
- Assessing the potential of applying Power-to-X technologies in existing metal production processes such as copper recycling
- Identifying technical bottlenecks and solutions related to the decarbonization and sustainability of metal production processes but also related to the process flexibilization potential caused by large fluctuations in the power supply with renewables
