How much sorting is required for a circular low carbon aluminum economy?

Aluminum recycling follows a downcycling dynamic where wrought alloys are transformed into cast alloys, accumulating tramp elements at every cycle. With the saturation of stocks of aluminum and the reduction of the demand for cast alloy due to electrification of transport, improvement in the recycling system must be made to avoid a surplus of unused recycled aluminum, reduce the overall environmental impacts of the industry, and move toward a circular economy. We aim to evaluate the potential environmental benefits of improving sorting efforts by combining operations research, prospective material flow analysis, and life cycle assessment. An optimization defines the optimal sorting to minimize climate change impacts according to different sorting efforts, dismantling conditions, and collection rates. Results show how the improvement of sorting can reduce by around 30% the greenhouse gas emissions of the industry, notably by reducing unused scrap generation and increasing the recycled content of the flows that supply the demand of aluminum. The best performance is achievable with four different sorting pathways. Further improvements occur with a better dismantling and an increase of collection rates, but it requires more sorting pathways. Results point to different closed-loop recycling initiatives that should be promoted on priority in specific sectors, like the building and construction sector and the aluminum cans industry. To implement a better material circularity, the mobilization of different stakeholders is needed. From a wider perspective, the article shows how operations research can be used to project a circular future in a specific industry. This article met the requirements for a Gold–Gold JIE data openness badge described at http://jie.click/badges .      

Modeling Metal Flow Systems

Substance flow analysis (SFA) is a frequently used industrial ecology technique for studying societal metal flows, but it is limited in its ability to inform us about future developments in metal flow patterns and how we can affect them. Equation‐based simulation modeling techniques, such as dynamic SFA and system dynamics, can usefully complement static SFA studies in this respect, but they are also restricted in several ways. The objective of this article is to demonstrate the ability of agent‐based modeling to overcome these limitations and its usefulness as a tool for studying societal metal flow systems. The body of the article summarizes the parallel implementation of two models—an agent‐based model and a system dynamics model—both addressing the following research question: What conditions foster the development of a closed‐loop flow network for metals in mobile phones? The results from in silico experimentation with these models highlight three important differences between agent‐based modeling (ABM) and equation‐based modeling (EBM) techniques. An analysis of how these differences affected the insights that could be extracted from the constructed models points to several key advantages of ABM in the study of metal flow systems. In particular, this analysis suggests that a key advantage of the ABM technique is its flexibility to enable the representation of societal metal flow systems in a more native manner. This added flexibility endows modelers with enhanced leverage to identify options for steering metal flows and opens new opportunities for using the metaphor of an ecosystem to understand metal flow systems more fully.     

What Do We Know About Metal Recycling Rates?

The recycling of metals is widely viewed as a fruitful sustainability strategy, but little information is available on the degree to which recycling is actually taking place. This article provides an overview on the current knowledge of recycling rates for 60 metals. We propose various recycling metrics, discuss relevant aspects of recycling processes, and present current estimates on global end‐of‐life recycling rates (EOL‐RR; i.e., the percentage of a metal in discards that is actually recycled), recycled content (RC), and old scrap ratios (OSRs; i.e., the share of old scrap in the total scrap flow). Because of increases in metal use over time and long metal in‐use lifetimes, many RC values are low and will remain so for the foreseeable future. Because of relatively low efficiencies in the collection and processing of most discarded products, inherent limitations in recycling processes, and the fact that primary material is often relatively abundant and low‐cost (which thereby keeps down the price of scrap), many EOL‐RRs are very low: Only for 18 metals (silver, aluminum, gold, cobalt, chromium, copper, iron, manganese, niobium, nickel, lead, palladium, platinum, rhenium, rhodium, tin, titanium, and zinc) is the EOL‐RR above 50% at present. Only for niobium, lead, and ruthenium is the RC above 50%, although 16 metals are in the 25% to 50% range. Thirteen metals have an OSR greater than 50%. These estimates may be used in considerations of whether recycling efficiencies can be improved; which metric could best encourage improved effectiveness in recycling; and an improved understanding of the dependence of recycling on economics, technology, and other factors.     

Valorization of Foundry Sand in Clay Bricks at Industrial Scale

In this article, foundry sand as waste material has been valorized in ceramic brick manufacturing at industrial scale. The employment of a waste coming from one industry as an input for another is one of the key concepts of industrial ecology. To study the environmental behavior of the ceramic bodies in different life cycle stages, three leaching tests have been developed. We used an EN 12457 equilibrium leaching test with distilled water and a Wastewater Technology Centre acid neutralization capacity (WTC‐ANC) leaching test with different acidic leachates to carry out the environmental evaluation under different granular scenarios to ascertain the possibilities of the reuse or disposal of this granular material at the end of its useful life (end‐of‐life stage). Finally, we used a NEN 7345 diffusion leaching test for construction materials, with the aim of studying the environmental assessment at the use stage. Regulated pollutants in both stages have been evaluated. Furthermore, other soluble salts have been analyzed because they are closely related to the efflorescence phenomenon in bricks. Results indicate that core and green sand from the foundry industry can be used to replace clay content in construction materials, and that these foundry‐sand‐based ceramics improve some soluble salt results. Despite this fact, at the end‐of‐life stage in an inert waste landfill, lead, arsenic and chromium can be an environmental problem, both for commercial bricks and for foundry‐sand‐based bricks. This work can contribute to the determination of viability of sustainable processes of brick manufacturing that use foundry wastes as raw materials.     

Industrial Recycling Networks as Starting Points for Broader Sustainability‐Oriented Cooperation?

Closing loops by intercompany recycling of by‐products is a core theme of industrial ecology (IE). This article considers whether industrial recycling networks or industrial symbiosis projects can be used as a starting point for much broader intercompany cooperation for sustainable development. Evidence presented is based on the results of an empirical investigation of the recycling network Styria in Austria, the recycling network Oldenburger Münsterland in Germany, and the manufacturing sector in Austria. Statistical analysis shows that the percentage of by‐products that are passed on to other companies for recycling purposes is not higher in member companies of the recycling networks than in the other companies of the manufacturing sector in Austria. In terms of cooperation, the relationships with the respective recycling partners are found to be very similar to regular customer relations. Furthermore, the companies of the recycling networks remain unaware of the network to which they belong. Instead, one of the main findings of this study is that intercompany recycling activities are regarded by the company representatives as bilateral market transactions, not as collaborative network activities. This has potentially significant implications for the use of industrial symbiosis networks as starting points for sustainability networks with broader cooperation toward sustainability. The findings raise interesting questions as to whether such broader cooperation might result from a conscious planning process or might emerge largely spontaneously as part of normal market coordination. In any case, intercompany recycling is clearly considered to be a very important field of collaborative action for sustainability in industry.     

Product/Service‐Systems for a Circular Economy: The Route to Decoupling Economic Growth from Resource Consumption?

Product/service‐systems (PSS) that focus on selling service and performance instead of products are often mentioned as means to realize a circular economy (CE), in which economic growth is decoupled from resource consumption. However, a PSS is no implicit guarantee for a CE, and CE strategies do not necessarily lead to decoupling economic growth from resource consumption in absolute terms. Absolute resource decoupling only occurs when the resource use declines, irrespective of the growth rate of the economic driver. In this forum paper, we propose a two‐step framework that aims to support analyses of PSS and their potential to lead to absolute resource decoupling. In the first step, we present four PSS enablers of relative resource reduction that qualify as CE strategies. In the second step, three subsequent requirements need to be met, in order to successfully achieve absolute resource decoupling. Conditions and limitations for this accomplishment are discussed. Danish textile cases are used to exemplify the framework elements and its application. We expect that the framework will challenge the debate on the necessary conditions for CE strategies to ensure absolute resource decoupling.