RAPID MCPI - Energy Efficient Technology for Metals Separation

Executive Summary

This project addresses the demonstration of a low-cost and low-energy pathway for the separation of metals from mixed scrap based on ionic liquids. The goal of the project is to develop and demonstrate a novel electrochemical process for the separation of metals from mixed scrap using ionic liquids (ILs) at low temperatures. For example, conventional separation of aluminum involves scrap melting at 800 °C resulting in high losses in metal values, high energy consumption and the generation of greenhouse gases including CO2 and fluorides that require post-combustion and flue gas cleaning processes. In the proposed electrochemical separation process, the separation will be carried out at low temperatures (<120°C), high metal recovery (>99%), low energy consumption, and no greenhouse gases generation. The electrolyte and residue of the process are recycled. This project will take the technology from bench to pilot scale.

Technical Challenge

  • Keeping the rate of ionic liquid consumption low
  • Preventing operational losses of the ionic liquid due to decomposition, contamination, and side reactions with impurities

Potential Impact

Separation of aluminum from mixed scrap using ionic liquids will result in major energy saving. The new aluminum separation technology developed in this project will have an energy consumption of 9.5 kwh/kg of Al ($1.10/kg of Al) as compared to the industrial best process is 13.64 kwh/kg of Al ($1.64/kg of Al) which translate to 30.4% energy reduction in US industrial energy intensity. The energy savings of 38.1% and a carbon dioxide reduction of 56.1% are estimated from the commercialization of this project.

Resources

Idaho National Laboratory (INL) provides expertise in electrochemical studies, process modeling and pilot-scale testing. Secat Inc. (SC) provides modular reactor and development and demonstration of modular process intensification, and assists with the design of experiments, materials characterization, process optimization, and lab to pilot scale test transition, and successful development and demonstration of modular process intensification. Schneider Electric Software, LLC (SE) (now AVEVA) specialized in process simulation software for project mathematical modeling, techno-economic analysis (TEA) and life cycle assessment (LCA). The AVEVA provides modeling activity of the project producing physical/chemical, economic and environmental impact models of the technology.

Investigator
Date Approved
Project Number
-
Initial TRL Level
-
Current TRL level
5
Project Funding
5,700,000
Focus Areas
Partner Organizations