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minerals

Review
A Review of the Carbon Footprint of Cu and Zn
Production from Primary and Secondary Sources
Anna Ekman Nilsson 1 , Marta Macias Aragonés 2,3 , Fatima Arroyo Torralvo 3 , Vincent Dunon 4 ,
Hanna Angel 5 , Konstantinos Komnitsas 6 ID and Karin Willquist 5, *
1 Research Institutes of Sweden, Division of Bioscience and Materials, Agrifood and Bioscience, Ideon,
SE-22370 Lund, Sweden; anna.ekman.nilsson@ri.se
2 Fundación Corporación Tecnológica de Andalucía (CTA), C/Albert Einstein, Edif. Insur, 4th Floor,
41092 Seville, Spain; marta.macias@corporaciontecnologica.com
3 Departamento de Ingeniería Química y Ambiental, Escuela Superior de Ingeniería, Universidad de Sevilla,
Camino de los Descubrimientos S/N, 41092 Seville, Spain; fatimarroyo@us.es
4 ARCHE Consulting, Liefkensstraat 35D, BE-9032 Ghent, Belgium; vincent.dunon@arche-consulting.be
5 Research Institutes of Sweden, Division of Build Environment, Energy and Circular Economy, Ideon,
SE-22370 Lund, Sweden; hanna.angel@ri.se
6 School Mineral Resources Engineering, Technical University Crete, GR-73100 Chania, Greece;
komni@mred.tuc.gr
* Correspondence: karin.willquist@ri.se; Tel.: +46-10-5165963

Received: 13 July 2017; Accepted: 9 September 2017; Published: 13 September 2017

Abstract: Copper (Cu) and zinc (Zn) with their unique properties are central for economic growth,
quality of life, and the creation of new jobs. The base-metal producing sector is, however, under
growing public pressure in respect to energy and water requirements and needs to meet several
challenges, including increased demand and lower ore grades, which are generally associated with
larger resource use. The development of technologies for metal production from secondary sources is
often motivated by increased sustainability, and this paper aims to provide further insights about
one specific aspect of sustainability—namely, climate change. The paper presents a review of carbon
footprints (CF) for Cu and Zn produced from primary and secondary raw materials by analyzing
data taken from scientific literature and the Ecoinvent database. Comparisons are carried out based
on the source of data selected as a reference case. The data available in the literature indicate that
secondary production of Cu and Zn has the potential to be more beneficial compared to primary
production regarding the impact on climate change. However, the technologies used today for the
production of both metals from secondary sources are still immature, and more research on this
topic is needed. The general variation of data suggests that the standardization of a comparison is
needed when assessing the environmental benefits of production in line with the principles of waste
valorization, the zero waste approach, and circular economy.

Keywords: Cu; Zn; circular economy; carbon footprint; mining; secondary materials; metal production

1. Introduction
The sector of non-ferrous metals, with a turn-over of EUR 116.09 billion (1.8%) in 2010, accounts
for 1.25% (EUR 19.91 billion) of EU manufacturing. Among non-ferrous metals, copper (Cu) and zinc
(Zn) are very important for the EU’s industry, and their smooth supply guarantees economic growth,
quality of life, and the creation of new jobs. Cu and Zn possess unique physical, chemical, thermal,
electrical, and isolating properties and are used in many industrial sectors including automotive,
aerospace, construction, electricity, energy, electronics, and mechanical engineering. They differentiate
from steel due to their high conductivity (valid for Cu) and resistance to corrosion and non-magnetic

Minerals 2017, 7, 168; doi:10.3390/min7090168 www.mdpi.com/journal/minerals


Minerals 2017, 7, 168 2 of 12

properties (valid for Zn). Cu is considered the third most important metal for industry after iron
and aluminum, with a yearly production of 10 Mt. It has been predicted that the market of Cu will
reach 30 Mt during the period 2030–2040, which is approximately 8% higher than the predicted metal
production for the same period [1]. By taking into account the decreasing ore grades, some studies
indicate that Cu mining will reach its peak around 2050 [1–3], giving economic incentives to mine
secondary sources. Primary and secondary Cu sources considered in this review are summarized in
the Supplmentary Materials.
Zn has been identified as one of the fifty-four metals that are important to the EU’s economy.
China (39%), Australia (11%), and Peru (10%) are the top three producers of Zn, predominantly by
primary mining. Europe has produced approximately 1 Mt of Zn in 2014, which is 8% of the total
worldwide output [4]. In the developing world, Zn demand is expected to grow at an average rate of
2.2% per annum until 2035 [5]. A summary of Zn sources considered in this review is provided in the
Supplmentary Materials.
The EU’s non-ferrous metal sector depends mainly on imported raw materials; thus, its longevity
relies on continuous supply, the use of innovative and energy efficient technologies for the production
of the respective metals, and the maximization of the use of secondary raw materials. Probably this
is one of the reasons that the European recycling industry is among the most advanced in the world
when compared to other developed countries such as the US, Canada, and Japan [6]. Also, by taking
into account their high recycling potential, their continuous utilization will definitely contribute to
an improvement of the sustainability of several industrial sectors, as well as in achieving the EU’s
resource efficiency and energy goals [7].
For instance, while the global average demand for secondary raw materials for Cu production
was approximately 35% in 2011, the respective figure in the EU was close to 40% [8]. In the case of
Zn, nearly 70 per cent of Zn is recycled from end-of-life products in the EU [9]. Regarding Cu, almost
40% of the world´s demand is met using recycled material [10] and, at present, approximately 30% of
global Zn production comes from secondary sources. In Europe, these figures are higher, 50% in the
case of Cu [11] and 60%–70% in the case of Zn [12].
The future challenges of the sector, in order to maintain its competitiveness, minimize carbon and
water footprint [13], and achieve sustainable growth include aspects related to exploitation and access
of new resources, trade, research and innovation activities, and the reduction of energy and water
requirements [14].
Moreover, the decreasing ore grades result in environmental concerns such as large waste/metal
ratio and larger resource use in respect to the use of energy, explosives, and water [14]. The metal
producing sector is, on the one hand, under growing public pressure, while on the other hand it
needs to overcome several burdens such as, for example, increased demand for metals and the
treatment of lower ore grades [15]. This increases the environmental incentives for mining secondary
sources. Primary Cu is mined both from open pit and underground mines [16]. Cu ores normally
occur as either oxides or sulfides [17]. Upgrading processes to produce high-grade Cu include the
stages of concentrating, smelting, and refining [18]. Cu can also be recovered from the majority of
its end-products and returned to the production process without loss of quality during recycling.
The production of secondary Cu is based on the direct melt of “new scrap” (waste resulting from
either metals discarded in semis fabrication or generated during the initial manufacturing process)
and/or the recycling of “old scrap” (obsolete end-of-life products or structures) [19]. Old scrap is often
contaminated to a certain degree, depending mainly on its origin and the efficiency of its collection
systems [20]. Scrap metal recycling involves a number of steps such as recovery, sorting, brokering,
baling, shearing, and smelting [19]. Pyrometallurgical and hydrometallurgical processes are similar
to those used in primary metal production. A detailed description of the production technologies is
given in the Supplmentary Materials.
Primary Zn is also mined from underground and/or open pit mines [21] and extracted from
Zn-Pb ores, or from other ores containing Cu, Au, or Ag. Zn is mainly recovered through the
Minerals 2017, 7, 168 3 of 12

pyrometallurgical or hydrometallurgical route. In the case of ZnS ore, a hydrometallurgical approach is


followed, where the ore is concentrated by froth flotation and roasted to convert the zinc sulfide
to oxide, which is then leached out with sulfuric acid to provide a leach solution that can be
purified before recovering Zn by electrowinning. In the case of Zn-Pb ores, a pyrometallurgical
approach is followed in blast furnaces [21,22], and the main steps involve sintering, smelting, refining,
and casting. Zn can be also recovered from different secondary resources with different levels
of impurities including, among others, ash, zinc dross, flue dusts of the electric arc furnace and
brass smelting, automobile shredder scrap, rayon industry sludge, and cathodic tubes from WEEE.
Recovery from these sources eliminates the option of disposal, which today is considered expensive
and environmentally unacceptable because of the increasingly stringent environmental protection
regulations. Furthermore, most of these materials are classified as hazardous wastes due to their
increased toxicity as a result of the presence of different metals including Pb, Cd, As, and Cr. In view
of the above, there has been an increasing interest in developing new processes for the recovery of Zn
from these secondary sources in order both to valorize these wastes and reduce the environmental
risk associated with their disposal. Usually, pyrometallurgical and hydrometallurgical processes are
employed for treating such secondary materials, but they are not widely used for low-concentration
streams. Regarding the pyrometallurgical approach, its main concept relies on the reduction of zinc
oxide using carbon and the distillation of the metallic Zn from the resulting mix in a carbon monoxide
atmosphere. A detailed description of the production technologies is provided in the Supplmentary
Materials.
The development of new technologies for metal production from secondary sources should be
mainly motivated by increased sustainability, and this paper aims to provide further insights about
one specific aspect of sustainability: climate change. It presents a review of carbon footprints (CF)
for Cu and Zn produced from primary and secondary raw materials by analyzing data taken from
the scientific literature and the Ecoinvent database. All studies that are included have a cradle-to
gate perspective, which for primary metal production includes mining, concentration, and refining,
and for secondary sources collection of raw materials, concentration of the target metals, and upgrading.
Another objective of this paper is to identify key factors affecting the CF of Cu and Zn production by
comparing CO2 emissions based on country (for primary sources) and technology (for primary and
secondary sources).
During the life cycle of base metals production, a large share of the environmental impacts
is associated with the use of energy (thermal or electrical) in various processes. Thermal energy
is mainly produced from the combustion of fossil fuels, while electricity may be produced from
various sources in thermal, nuclear, and hydro power plants, as well as from renewable sources.
Thus, the overall environmental impact of energy generation may differ broadly among countries
and regions, even among different parts of the same country. Base metal production also contributes
considerably to other environmental impacts such as depletion of resources, water consumption, and
emissions of hazardous substances to the environment; these are, however, not included in this review.

2. Carbon Footprint and LCA


Life Cycle Assessment (LCA) is a methodological tool used to assess the potential environmental
impacts of a product or service through its life cycle [23]. LCA can also be used to calculate the
environmental impacts of an entire sector such as non-ferrous metals. The results generated by LCA
can be used for sustainability reporting and for exploring possibilities to improve environmental
performance by assessing and mapping environmental impacts and their causes. LCA is standardized
by ISO in the standards 14040 and 14044 and includes four main steps, namely, goal and scope
definition, life cycle inventory analysis, impact assessment, and interpretation [24,25].
According to ISO 14040-14044 standards, the Life Cycle Inventory (LCI) is an inventory of the
input/output data pertinent to the system studied. In this respect, energy, materials use, and associated
emissions over the life cycle of the entire metal production systems need to be identified and assessed.
Minerals 2017, 7, 168 4 of 12

Given the contribution of the base-metal sector, including Cu and Zn production to global warming,
mass flow analysis (MFA) and substance flow analysis (SFA) need to be properly defined and
integrated [26].
Since 2013, there has been a separate ISO standard for carbon footprint, ISO 14067 [27],
which defines the principles, requirements, and guidelines for its quantification and communication.
In general, it can be said that CF is often used for communication purposes because this specific
environmental impact category can be more easily grasped by the general public. Full LCAs are more
commonly used for research and development purposes when a more nuanced picture of a product or
process is required. The main difference between CF and LCA is that CF only considers the emissions
of CO2 -equivalents (CO
Minerals 2017, 2 -eq), while LCA covers a broader spectrum of impact categories.
7, 168 According to
4 of 12
the ISO standard, CF is expressed as global warming potential, in CO2 -eq. This means how potent a
Since 2013, there has been a separate ISO standard for carbon footprint, ISO 14067 [27], which
GHG is compared to CO2 . GWP
defines the principles,
factors recommended in ISO 14067 [27] are derived from the IPCC
requirements, and guidelines for its quantification and communication. In
Fourth Assessment Report. Examples
general, it can be said that CF is ofoften
GHGs usedconsidered are CO
for communication 2, CH4 ,because
purposes N2 O, SF
this6 ,specific
HFCs, and PFCs.
The product environmental footprint (PEF) and the organization environmentalmore
environmental impact category can be more easily grasped by the general public. Full LCAs are footprint (OEF)
commonly used for research and development purposes when a more nuanced picture of a product
were inaugurated by the European Commission as a way to measure environmental
or process is required. The main difference between CF and LCA is that CF only considers the
performance.
Between 2013 and 2016,
emissions of COPEF and OEF
2-equivalents (COhave beenLCA
2-eq), while tested inaabroader
covers variety of pilots,
spectrum of which
of impact the production
categories.
Metal SheetsAccording
is one pilot to theforISOPEF
standard,
andCF theis Cu
expressed
sector as is
global
onewarming
pilot forpotential,
OEF [28].in CO2-eq. This means
how potent a GHG is compared to CO2. GWP factors recommended in ISO 14067 [27] are derived
from the IPCC Fourth Assessment Report. Examples of GHGs considered are CO2, CH4, N2O, SF6,
Methodology
HFCs, and PFCs.
The product
The data used in this environmental
review paper footprint
were (PEF) and the
mainly organization
obtained environmental
through searchesfootprint (OEF) databases
in scientific
were inaugurated by the European Commission as a way to measure environmental performance.
such as Science Direct
Between 2013 and and
2016,Scopus.
PEF and OEF Also, Google
have been tested Scholar
in a varietyand commonly
of pilots, of which theused LCI databases
production
were used to extract
Metal data.
Sheets is Several
one pilot combinations
for PEF and of key
the Cu sector is one words
pilot for were considered to extract the
OEF [28].
most appropriate publications. Data for the production of Cu and Zn from primary sources was
Methodology
extracted from scientific papers and the Ecoinvent v3.3 database. For Cu and Zn production from
The data used in this review paper were mainly obtained through searches in scientific databases
secondary sources, data were extracted from the scientific literature. It is important to mention that no
such as Science Direct and Scopus. Also, Google Scholar and commonly used LCI databases were
pertinent datausedwas founddata.
to extract in databases such as Ecoinvent
Several combinations of key wordsv3.3, were Open LCAtonexus
considered extract Web,
the mostthe European
appropriate(ELCD),
Life Cycle Database publications.
theData
CPM for the production
database of Cu
from andSwedish
the Zn from primary sourcesCenter,
Life Cycle was extracted
and the United
from scientific papers and the Ecoinvent v3.3 database. For Cu and Zn production from secondary
States LCI database. Data from non-scientific reports published by, e.g., professional and industrial
sources, data were extracted from the scientific literature. It is important to mention that no pertinent
organizations,datawere not included
was found in databasesin this
such as review.
Ecoinvent v3.3, Open LCA nexus Web, the European Life Cycle
Database
This study (ELCD),the
reviews the CPM databaseliterature
available from the Swedish Life Cycle
pertinent toCenter, and the United of
the calculation States
theLCICF of metal
database. Data from non-scientific reports published by, e.g., professional and industrial
production using a “cradle-to-gate” approach and does not consider other impact categories. As the
organizations, were not included in this review.
produced metalThis canstudy
be anreviews
intermediate
the available product,
literaturemost CF to
pertinent reports and scientific
the calculation of the CFliterature
of metal are based
on this approach, which considers all production processes involved, from raw materials
production using a “cradle-to-gate” approach and does not consider other impact categories. As the extraction
produced metal can be an intermediate product, most CF reports and scientific literature are based
(i.e., the cradle) to the production in the form of Cu anode, Cu cathode, Cu blister, or Zn which are
on this approach, which considers all production processes involved, from raw materials extraction
available to a(i.e.,
manufacturing
the cradle) to thesector (i.e.,inthe
production the gate)
form of[29]. For Zn,
Cu anode, metal at
Cu cathode, Cuthe factory
blister, or Zn gate
whichin the reviewed
are
studies refers to refined Zn, Zn ingot, and special, high-grade Zn with a purity of more than 99.99%.
available to a manufacturing sector (i.e., the gate) [29]. For Zn, metal at the factory gate in the
reviewed studies refers to refined Zn, Zn ingot, and special, high-grade Zn with a purity of more than
The functional unit used for the comparisons is 1 kg metal. Figure 1 shows the system boundaries for
99.99%. The functional unit used for the comparisons is 1 kg metal. Figure 1 shows the system
studies included in this
boundaries for review.
studies included in this review.

Figure 1. System boundaries used for base-metal production Life Cycle Assessment (LCA) studies.
Figure 1. System boundaries used for base-metal production Life Cycle Assessment (LCA) studies.
Minerals 2017, 7, 168 5 of 12

3. Results and Discussion


Minerals 2017, 7, 168 5 of 12

3.1. Copper
3. Results and Discussion
A great variety of LCA publications on Cu production from primary sources are available, however
3.1. Copper
only a few describe the production of Cu metal in a cradle-to-gate approach. Therefore, both the
A great variety
pyrometallurgical of LCA publicationsprocesses
and hydrometallurgical on Cu production
are includedfrominprimary sources
this review, are produce
which available,either
however only a few describe the production of Cu metal in a cradle-to-gate approach. Therefore, both
anode or cathode copper. Figure 2 shows the calculated CF for Cu production according to the
the pyrometallurgical and hydrometallurgical processes are included in this review, which produce
geographical region and the metallurgical production process. The CF ranged from 1.1 to 8.5 kg
either anode or cathode copper. Figure 2 shows the calculated CF for Cu production according to the
CO2 -eq/kg Cu. Average CFs retrieved from the Ecoinvent 3.3 database [30] ranged from 2.1–8.0
geographical region and the metallurgical production process. The CF ranged from 1.1 to 8.5 kg CO2-
kg CO 2 -eq/kg Cu, and
eq/kg Cu. Average CFsthis range from
retrieved is consistent with3.3
the Ecoinvent what was [30]
database retrieved
rangedfrom
from the literature.
2.1–8.0 kg CO2- Data
on the contributions of the different process steps is scarce for high-grade Cu
eq/kg Cu, and this range is consistent with what was retrieved from the literature. Data on the production, and the
reviewed data did
contributions notdifferent
of the show any correlations
process between
steps is scarce the geographical
for high-grade production
Cu production, and the of Cu and the
reviewed
databetween
CF, nor did not show any correlations
the metallurgical between the
production geographical
process and CF.production
Northey etofal.Cu[1]and the CF, nor
concluded that the
mainbetween
factors the metallurgical
for the variationproduction
in CF values process anduse
are the CF.ofNorthey
differentet ore
al. [1] concluded
grades thatsources
and fuel the mainfor the
factors for the variation in CF values are the use of different ore grades and fuel
heating and generation of electrical energy. The type of the ore, the mining method, and the smelting sources for the
heating and generation of electrical energy. The type of the ore, the mining method, and the smelting
technology used were identified as critical factors determining the overall energy consumption by
technology used were identified as critical factors determining the overall energy consumption by
Norgate et al. [22]. A similar observation was made by Adachi and Mogi [31], showing the high CF
Norgate et al. [22]. A similar observation was made by Adachi and Mogi [31], showing the high CF
variability of Cu production from different mining sites. The authors also found that 30%–70% of
variability of Cu production from different mining sites. The authors also found that 30%–70% of the
the CF resulted fromthe
CF resulted from themining
mining andand processing
processing processes.
processes. Overall,
Overall, more harmonization
more harmonization of CF for of
Cu-CF for
Cu-production
production is is needed,
needed,ininorder
ordertoto provide
provide moremore detailed
detailed information
information on theon the different
different processprocess
steps. steps.

6
kg CO2 -eq/kg Cu

0
C H H C C C C C C H P C P P P H H H H H H C C H P H H P C P
Global Asia Latin North Australia Canada Chile Japan Laos Papua South Sweden USA
Pacific America America New Africa
Guinea

Adachi & Mogi (2007) Ecoinvent 3.3 Northey et al. (2013) Nuss & Eckelman (2014) Norgate et al. (2007)

Figure
Figure 2. Overview
2. Overview of carbon
of carbon footprints
footprints (CFs)
(CFs) of copper
of copper (Cu)(Cu) production
production (cradle-to-gate)
(cradle-to-gate) fromfrom
primary
primary sources. The CFs are grouped by geographical region. X axis indicates the type of
sources. The CFs are grouped by geographical region. X axis indicates the type of metallurgicalmetallurgical
processes used in each case: Pyrometallurgy, P; Hydrometallurgy, H; and Combined, C.
processes used in each case: Pyrometallurgy, P; Hydrometallurgy, H; and Combined, C.
Recently, there has been growing interest in the study of secondary Cu production, but only a
Recently, there has been growing interest in the study of secondary Cu production, but only a
few studies estimated the CF of these processes. The processes used for obtaining secondary Cu are
few studies estimated the CF of these processes. The processes used for obtaining secondary Cu are
similar to those used in primary metal production (Figures 1 and 2). The main differences are linked
similar to those usedofin
to the first steps primary
the metal
processes, production
namely, mining and(Figures 1 and 2).
beneficiation (inThe
the main
case ofdifferences
primary Cuare andlinked
to the first steps
collection), of the processes,
disassembly, namely, mining
sorting (according and beneficiation
to different (inand
levels of purity), thetransportation
case of primary Cu and
(in the
collection),
case of disassembly,
secondary Cu sorting (according
production). to different
A summary of CFslevels
for Cuofproduced
purity), and
fromtransportation
secondary sources (in the
is case
of secondary Cu production). A summary of CFs for Cu produced from secondary sources is given
given in Figure 3. CF values vary from 0.2 to 1.9 kg CO 2 -eq/kg Cu. The data indicates that the variation
depends
in Figure on the
3. CF quality
values of the
vary source
from 0.2 material
to 1.9 kgandCOthe metallurgical
2 -eq/kg Cu. Theprocess
dataused. In addition,
indicates studies
that the variation
have on
depends shown
the that transport
quality of theissource
a key factor in secondary
material and the Cu production in
metallurgical terms of
process CF, and,
used. depending
In addition, studies
have shown that transport is a key factor in secondary Cu production in terms of CF, and, depending
Minerals 2017, 7, 168 6 of 12
Minerals 2017, 7, 168 6 of 12

on the
on the transport
transport distance
distance of
of the
the raw
raw materials,
materials, recycling
recycling may
may not
not be
be as
as environmental
environmental friendly
friendly as
as
expected [32].
expected [32].

Figure 3. CFs of Cu production from


Figure 3. from secondary
secondary sources
sources grouped
grouped byby source
source material.
material. Waste
Waste electrical
electrical
and
and electronic
electronic equipment,
equipment, WEEE;
WEEE; municipal
municipal solid waste incinerator,
incinerator, MSWI;
MSWI; low
low grade,
grade, LG;
LG; high
high
grade,
grade, HG;
HG;mixed
mixedgrade,
grade,MG;
MG;at at
refinery, AR;AR;
refinery, LEDLED
lamp, LL; mechanical
lamp, dismantling
LL; mechanical in Europe,
dismantling MDE;
in Europe,
manual dismantling
MDE; manual in Europe,
dismantling in HDE;
Europe,mechanical dismantling
HDE; mechanical in India, MDI;
dismantling and manual
in India, dismantling
MDI; and manual
in India, HDI.
dismantling in India, HDI.

Grimmes
Grimmes et et al.
al. [33]
[33] showed
showed that that the
the CFCF of of processing
processing low low grade
grade scrap
scrap was
was approximately
approximately three three
times
times higher
higher than
than that
that ofof high
high grade
grade scrap. Slightly higher
scrap. Slightly higher is is the
the value
value estimated
estimated by by Nuss
Nuss and and
Eckelman [34], based on a Cu recovery process considered by Nassar
Eckelman [34], based on a Cu recovery process considered by Nassar et al. [35]; however, transport et al. [35]; however, transport
was
was not
not included
included in in the
the assessment.
assessment. In In the
the work
work of of Giurco
Giurco and and Petrie
Petrie [36],
[36], the
the CFCF toto obtain
obtain 11 kg kg of
of CuCu
from an ore (0.45% Cu) was estimated to be 7kg CO -eq; however,
from an ore (0.45% Cu) was estimated to be 7kg CO2-eq; however, when Cu was obtained from a mix
2 when Cu was obtained from a mix
of
of 25%
25% Number
Number 11 scrap
scrap (99%
(99% Cu),
Cu), 37.5%
37.5% of of Number
Number 22 scrap scrap (95%
(95% Cu),Cu), and
and 37.5%
37.5% of of low
low quality
quality scrap
scrap
(30%
(30% Cu),
Cu), the
the CF
CF was
was estimated
estimated to to be
bereduced
reducedto to0.65
0.65kgkgCO CO22-eq.
-eq.
Various
Various recycling methodologies for
recycling methodologies for e-waste
e-wastewere wereanalyzed
analyzedininthe thework
workofof Eisinger
Eisinger et et
al.al. [37],
[37], in
in
which the manual and mechanical dismantling of personal computers was compared for India and
which the manual and mechanical dismantling of personal computers was compared for India and
Europe.
Europe. TheThelowest
lowestCFs CFswerewere calculated
calculated when when mechanical
mechanical dismantling
dismantling was performed
was performed in Europe in Europe
(Figure
(Figure 4). Almost the same CF was reported by Reuter and Van Schaik
4). Almost the same CF was reported by Reuter and Van Schaik [38] in the case of producing Cu from an [38] in the case of producing
Cu from an eco-designed,
eco-designed, light-emittinglight-emitting
diode lamp. The diode lamp.compared
authors The authors the compared
results with thethe results with the
environmental
environmental
impact of obtainingimpact1 kg ofof
obtaining
blister Cu1 kg
from of ablister
1% ore Cu infrom a 1% country
an EU-27 ore in anwith EU-27thecountry with the useand
use of concentrator of
concentrator and smelter (Flash smelting and Flash Converting). The highest
smelter (Flash smelting and Flash Converting). The highest CF, 1.9 kg CO2-eq/kg Cu, was 2reported by CF, 1.9 kg CO -eq/kg Cu,
was reported
Boesch by Boesch
et al. [39], et al. [39],
who assessed thewho assessed
recovery the recovery
of metals from theof metals
fly ashfrom
and the theflyslag ashproduced
and the slag in a
produced in a municipal solid wastes incinerator in Switzerland. The
municipal solid wastes incinerator in Switzerland. The Cu content in the MSWI slag was 1 kg Cu/t. Cu content in the MSWI slag
was 1Tokgthe
Cu/t.
best of our knowledge, there are only two publications regarding the recovery of Cu from
To the
printed bestboard
circuit of our(PCB)
knowledge,
using thethere are only two publications
electrochemical processes. Inregarding
the work the recovery
of Soares of [40],
et al. Cu fromtwo
printed circuit board (PCB) using the electrochemical processes.
electrochemical processes for recovering Cu from PCB scrap were compared using LCA In the work of Soares et al. [40],
two electrochemical
methodology; processes
one involves for acid
sulfuric recovering
and theCu otherfrom
aqua PCB
regia scrap were
(nitric andcompared
chloridric acid).using In LCAthe
methodology; one involves sulfuric acid and the other aqua regia (nitric
paper of Fogarasi et al. [41], the environmental impacts related to direct electrochemical oxidation and chloridric acid). In the
paper of Fogarasi
were compared et al.
with the[41], the environmental
mediated electrochemical impacts related
oxidation using to direct
Fe2+/Feelectrochemical
3+ redox couple. oxidation

were The
compared with the mediated 2+ 3+ redox couple.
data presented in Figureselectrochemical oxidation to
2 and 3 are insufficient using Fe a /Fe
justify statistically viable benefit of
treating secondary materials in respect to primary sources due to the high variation in termsbenefit
The data presented in Figures 2 and 3 are insufficient to justify a statistically viable of purityof
treating secondary materials in respect to primary sources due to the high
and ease of processing. For example, the average CF calculated by Nuss and Eckelman [34] for global variation in terms of purity
and ease of processing.
production of Cu wasFor example, thelower
considerably average (2.80CFkg calculated
CO2-eq/kg by NussCu) and
thanEckelman
that derived [34] forfromglobal
the
production of Cu was considerably lower
Ecoinvent database (6.62–8.00 kg CO2-eq/kg Cu). Both (2.80 kg CO -eq/kg Cu) than that derived from
2 primary and secondary sources were included, the Ecoinvent
database
along with (6.62–8.00
variouskg CO2 -eq/kg
production Cu). BothThese
processes. primary and highlight
results secondaryclearlysourcesthe were included,inalong
complexity with
assessing
the benefits of Cu production from different sources.
Minerals 2017, 7, 168 7 of 12

various production processes. These results highlight clearly the complexity in assessing the benefits
of Cu production from different sources.

3.2. Zinc
The carbon footprints of Zn produced from primary sources are summarized in Figure 4. The CFs
are grouped either by technology used or by geographical region. However, there is not enough
data available to draw any clear conclusions about the importance of each factor. Data used by
van Genderen et al. [42], Qi et al. [43], and Ecoinvent 3.3 were obtained from the industry, while other
studies used only2017,
Minerals literature
7, 168 data. Van Genderen et al. [42] aimed for a representative7 of global
12 average
CF, but in certain regions too few producers provided data for the result to be fully representative
3.2. Zinc
and reliable. Qi et al. [43] used data from one specific production site in China. In the Ecoinvent 3.3
The carbon footprints of Zn produced from primary sources are summarized in Figure 4. The
database, different datasets are available for Zn production. However, only one dataset was considered
CFs are grouped either by technology used or by geographical region. However, there is not enough
representative and included
data available to draw anyin this
clear study.
conclusionsThisaboutrepresents a global
the importance of eachaverage
factor. DataCFusedforbyZn.van Since Zn is
not the single product
Genderen et al.produced from
[42], Qi et al. [43], the
and process,
Ecoinvent 3.3 allocation of environmental
were obtained from the industry,impact was applied in
while other
studies usedexcept
all studies reviewed only literature data. Vanand
for Adachi Genderen
Mogiet[31]. al. [42]Ecoinvent
aimed for a representative
3.3 applies global average alternative
as a default
CF, but in certain regions too few producers provided data for the result to be fully representative
the principle
andof allocation
reliable. Qi et al.at the
[43] usedpoint of substitution.
data from Nuss site
one specific production andinEckelman
China. In the [34] applied
Ecoinvent 3.3 economic
allocation, whereas the other
database, different studies
datasets are applied
available physical allocation
for Zn production. based only
However, on either mass was
one dataset [22,43] and/or
considered
metal content [42]. Inrepresentative
all studies,and included
it can in thisthat
be seen study. This production
metal represents a globalhas average
a largerCFcontribution
for Zn. to CF
Since Zn is not the single product produced from the process, allocation of environmental impact was
than ore mining and concentration. The contribution from metal production
applied in all studies reviewed except for Adachi and Mogi [31]. Ecoinvent 3.3 applies as a default
varied between 51% and
80% of the total CF. According
alternative the principle of toallocation
Norgateatet theal. [22],
point of 100% coal-based
substitution. Nuss andelectricity
Eckelman [34] was assumed for Zn
applied
production economic allocation,
in Australia, whichwhereas
could thecanother
why studies
these applied physicalare
emissions allocation
ratherbasedhigh.onNorgate
either masset al. [22] only
[22,43] and/or metal content [42]. In all studies, it can be seen that metal production has a larger
mention that metal production and refining stages made the greatest contribution to CF. In the study
contribution to CF than ore mining and concentration. The contribution from metal production
by Werder and
varied Steinfeld
between 51% [44],and
approximately
80% of the total20% of CF was
CF. According to caused
Norgate et byal.mining and
[22], 100% concentration and
coal-based
80% by refining. Of was
electricity the assumed
processfor stages used forinrefining,
Zn production Australia,electrolysis
which could can haswhythethese
single highest
emissions arecontribution.
rather high. Norgate et al. [22] only mention that metal production
Van Genderen et al. [42] calculated 30% of CF to be due to mining, 5% due to the transportation of and refining stages made the
greatest contribution to CF. In the study by Werder and Steinfeld [44], approximately 20% of CF was
concentrate,caused
and 65% due and
by mining to smelting.
concentration Inand
the80%study of Qi et
by refining. Ofal.
the[43],
process less thanused
stages 10% forwas due to mining,
refining,
65% were caused byhas
electrolysis electricity
the single production, and 25%
highest contribution. were due
Van Genderen et al.to[42]
thecalculated
use of natural
30% of CFgas.to beAdachi and
due to mining,
Mogi [31] studied the CF 5%of dueZnto the transportation
production from of concentrate,
importedand 65% due to smelting.
concentrate In the study
in a smelter of
in Japan, and they
Qi et al. [43], less than 10% was due to mining, 65% were caused by electricity production, and 25%
estimated that the contribution of mining was 40%–50% of the total,
were due to the use of natural gas. Adachi and Mogi [31] studied the CF of Zn production from
while the contribution of mineral
processing imported
was 20%–30%. Data derived from the EcoInvent Database
concentrate in a smelter in Japan, and they estimated that the contribution of mining was do not allow the accurate
assessment 40%–50% of the total, while
of the contribution of the contribution
single productionof mineral processing
phases. The was
CF 20%–30%. Data derivedinfrom
of Zn production Sweden is low,
the EcoInvent Database do not allow the accurate assessment of the contribution of single production
but the metal is considered as a by-product of the treatment of Au-Ag-Zn-Pb-Cu ore with the use of
phases. The CF of Zn production in Sweden is low, but the metal is considered as a by-product of the
low-carbontreatment
electricity.
of Au-Ag-Zn-Pb-Cu ore with the use of low-carbon electricity.

6
kg CO2 -eq/kg Zn

0
C C C E E P C H
Global Central Australia Japan China
Europe

van Genderen et al. (2016) Nuss & Eckelman (2014)


Norgate et al. (2007) Werder & Steinfeld (2000)
Ecoinvent 3.3 Adachi & Mogi (2007)
Qi et al. (2017)

Figure 4. Overview
Figure 4. Overview of CFsof CFs
of ofzinc
zinc (Zn)
(Zn)production (cradle-to-gate)
production from primary
(cradle-to-gate) sources.
from The CFs are
primary sources. The
grouped by geographical region. X axis indicates the type of metallurgical processes used:
CFs are grouped by geographical region. X axis indicates the type of metallurgical processes used:
Pyrometallurgy, P; Hydrometallurgy, H; Electrometallurgy, E; and Combined, C.
Pyrometallurgy, P; Hydrometallurgy, H; Electrometallurgy, E; and Combined, C.
Minerals 2017, 7, 168 8 of 12

During the last decade, many papers have been published on Zn production from secondary
sources focusing on process feasibility, sustainability, or economics. Since the number of
potential secondary sources is big, papers usually focus on some of them, for example, Ng and
Minerals 2017, 7, 168 8 of 12
co-workers [4] focused on wastes and conducted a multilevel sustainability assessment for Zn recovery.
Figure 5 presents
During the thelast
CFs of Znmany
decade, production
papers havefrom beensecondary
published sources groupedfrom
on Zn production by source
secondary material.
sources
Available focusing on
information process
about CF is feasibility, sustainability,
mostly related or economics.
to Zn recovery fromSince
scraptheand
number
fly ashof produced
potential after
secondary
municipal solid sources is big, papers
waste (MSW) usually focus
incineration, whileon some
only of them,
a few for example,
papers Ng and co-workers
are available [4]
for the production
focused on wastes and conducted a multilevel sustainability assessment for Zn recovery. Figure 5
of Zn from waste electrical and electronic equipment (WEEE) [45]. Boesch and co-workers [39]
presents the CFs of Zn production from secondary sources grouped by source material. Available
investigated the recovery of Zn from MSW fly ash considering combustion in a grate incinerator, the
information about CF is mostly related to Zn recovery from scrap and fly ash produced after
use and recovery
municipal from
solid slag(MSW)
waste and fly ash, and the
incineration, whilelandfilling
only a few of residues.
papers Until now,
are available for thethis approach has
production
been mostly
of Zn from followed
waste in Switzerland
electrical and Sweden.
and electronic equipment Concerning
(WEEE) [45]. theBoesch
rest ofandEurope, ash from
co-workers [39] MSW
incineration is also
investigated theincreasingly
recovery of Znrecognized
from MSW fly asash
a potential
considering source for materials
combustion of high importance
in a grate incinerator, the
to the use and recovery
economy [46]. from
Boesch slaget
and al.fly ash,studied
[39] and the landfilling of residues. of
also the sensitivity Until
LCA now, this approach
results has
to the electricity
been and
mix used, mostly followed in
concluded Switzerland
that the savings and from
Sweden. Concerning
energy recoverythe rest
vary of considerably
Europe, ash from MSW
depending on
incineration is also increasingly recognized as a potential source for materials of high importance to
assumptions related to the substituted energy production systems. Substituting the average Swiss
the economy [46]. Boesch et al. [39] studied also the sensitivity of LCA results to the electricity mix
electricity mix provides the lowest savings. Savings from substituting the average European electricity
used, and concluded that the savings from energy recovery vary considerably depending on
mix orassumptions
marginal electricity
related to the production
substituted (natural gas power
energy production plants
systems. in the case
Substituting theof Switzerland)
average Swiss are
considerably larger (by one order of magnitude). As for the metal recovery
electricity mix provides the lowest savings. Savings from substituting the average European approach, a hydro-chemical
processelectricity
can be applied, whichelectricity
mix or marginal involvesproduction
the use of the acidic
(natural scrubplants
gas power water obtained
in the from the wet flue
case of Switzerland)
are considerably
gas treatment to mobilizelarger and
(by one ordermetals
extract of magnitude).
from the Asalkaline
for the metal recovery
fly ash. Theapproach,
acidic flya ash hydro-leaching
chemical process can be applied, which involves the use of the acidic scrub
process produces a metalliferous filtrate and a low metal filter cake. The filtrate contains elevated water obtained from the
wet flue gas treatment to mobilize and extract metals from the alkaline fly ash. The acidic fly ash
concentrations of Zn, Pb, Cu, and Cd and can be further processed directly at a MSWI for Zn recovery
leaching process produces a metalliferous filtrate and a low metal filter cake. The filtrate contains
(FLUREC process)
elevated or sent to of
concentrations a specific
Zn, Pb, Cu, Zn-oxide
and Cdrecycling
and can befacility
further(FLUWA
processedprocess)
directly at [47]. When
a MSWI forLCIs of
fly ashZn
treatment
recoverywith (FLUREC and process)
withoutor metal recovery
sent to a specificare compared,
Zn-oxide metal
recycling recovery
facility (FLUWA through acidic
process) [47]. fly ash
scrubbing
When is LCIs
preferable
of fly ashover landfilling
treatment withofand
solidified
without fly ashrecovery
metal or underground
are compared, disposal
metal[39]. Moreover,
recovery
through
according to the acidic fly ash CFs
reviewed scrubbing is preferable
state-of-the art Znover landfilling
recovery, of solidified
directly fly ashisorthe
at the MSWI underground
environmentally
disposal
preferred process.[39]. The
Moreover,
largest according
benefitstoofthe reviewed
this approach CFs include
state-of-the art Znin
savings recovery, directly at
neutralization the and
agents
MSWI is the environmentally preferred process. The largest benefits of this approach include savings
credits for Zn recovery. The main differences in CFs between conventional (FLUWA) and integrated
in neutralization agents and credits for Zn recovery. The main differences in CFs between
Zn recovery at the MSWI (FLUREC) arise from the associated burdens and recovery efficiency of the
conventional (FLUWA) and integrated Zn recovery at the MSWI (FLUREC) arise from the associated
processes (pyro-metallurgical
burdens and electrowinning,
and recovery efficiency respectively)
of the processes [39]. Hence, and
(pyro-metallurgical whenelectrowinning,
considering the CF
of Zn production
respectively) [39]. Hence, when considering the CF of Zn production2in this case, figures values
in this case, figures averaged around 0.30 kg CO -eq/kg Zn, with averaged ranging
from 0.23 [48,49])
around 0.30 kgto CO0.33 kg CO
2-eq/kg Zn,2 -eq/kg Zn [50].
with values ranging from 0.23 [48,49]) to 0.33 kg CO2-eq/kg Zn [50].

FigureFigure
5. CFs5.ofCFs
Znofproduction
Zn production from
from secondarysources
secondary sourcesgrouped
grouped by
bysource
sourcematerial. In (A),
material. the the
In (A), CFs CFs of
of Zn production from scrap and waste electrical and electronic equipment (WEEE) are given.
Zn production from scrap and waste electrical and electronic equipment (WEEE) are given. (B) shows
(B) shows the CFs for Zn production from municipal solid waste incinerator (MSWI ash).
the CFs for Zn production from municipal solid waste incinerator (MSWI ash).
Minerals 2017, 7, 168 9 of 12

Regarding Zn production from scrap recycling and clean and mixed scrap can be treated
by sweating, whereby the scrap is heated at 360–420 ◦ C to melt and recover Zn (e.g., using dezincing,
Waelz Kiln, or DC-furnace based processes), directing other impurities such as Cu, Al, and Fe in slag.
Zn alloy scrap can also be processed by using a similar route to recover the metal as a new, pure alloy,
while Zn oxide residues can be converted to Zn by dissolving them in sulfuric acid and recovering the
metal by electrowinning, e.g., in the EZINEX process. It has been shown that the dezincing process has
a CF around 4.6 kg CO2 -eq/kg, while the EZINEX process accounts for 0.7–1.4 kg CO2 -eq/kg [33].
For WEEE, as recovery processes are still under development with only some of them going for
pilot scale, just a few references have been found, which highlight research activities carried out in
the frame of projects such as the HydroWEEE, funded by the European Commission [51]. An LCA
was applied to hydrometallurgical treatment carried out using the developed new portable prototype
plant for the recovery of valuable metals. The plant treated the WEEE residues derived from physical
processes applied for the recycling of fluorescent lamps, cathode ray tubes (CRTs), Li-ion accumulators,
and printed circuit boards (PCBs). Leaching with sulfuric acid, followed by metal recovery through
selective precipitation, were the main steps considered. The final step involved treatment of wastewater
with lime. The recovered metals included Y, Zn, Co, Li, Cu, Au, and Ag. In the case of Zn, which is
contained in CRTs (30–35% Zn, as oxide and sulfur compound), an estimated CF of 5.5 kg CO2 -eq/kg
Zn was calculated [45]. Concerning Zn production from steel dust, only one paper has been found,
while the CF analysis does not provide specific information [52].
In comparison to Cu, less information is available for the CF of Zn production. Based on
literature data, it seems that the CF of Zn produced from secondary sources is a magnitude lower than
the CF of Zn produced from primary sources. However, as in the case of Cu production, there is a
large variation of CF values depending on the source of data selected for comparison.

4. Conclusions
Cu and Zn are of great importance for the world economy and the increasing need for their
production contributes significantly, as the entire base-metal sector, to global warming, both due to the
extraction of resources and the production of metals. In this review, the production of both metals from
primary and secondary sources was studied and compared. In general, LCI-data for metals production
from primary sources is more often available in databases, whereas data for their production from
secondary sources solely derives from the scientific literature.
Production of metals from secondary sources is promising, but more research and development
in all stages of their life cycle is needed to provide truly sustainable solutions in the frame of
circular economy. From the analysis of data, it is deduced that no clear trend could be seen between
the CF for metals produced from primary sources and their geographical origin or the technology used
for processing. With few exceptions, the production of metals from secondary sources has generally
been reported to have lower CFs than the production from primary sources. However, the variations
in each case are large. For example, the CF of Cu production from MSWI slag was in the same range
as several of the reviewed CFs from primary sources, whereas the CF for Zn from MSWI fly ash was
significantly lower than all the reviewed CFs from primary sources. The variation is large, and depends
on the metal content in the resource and how easily it can be extracted.
The technologies used for the extraction of metals from secondary sources are less mature than
the technologies used for their extraction from primary sources, and this may have a negative impact
on the results. One can expect that as technology matures and systems are optimized, the CFs of
metal production from secondary sources will be reduced. On the other hand, as ore grades are
becoming lower, one can expect that the CFs for the production of metals from primary sources
will be increased over time. Similarly, as the technologies for the extraction and logistics needed for
efficient recovery of metals from secondary sources are improved, CFs for metals production from
secondary sources will most likely decrease over time. Hence, the general variation of data suggests
that standardization of the comparison approach is needed for the assessment of environmental
Minerals 2017, 7, 168 10 of 12

impacts of metal production, the reliable evaluation of the existing technologies used (in terms of water
and energy requirements), and the development of more environmentally friendly and cost-efficient
approaches. Finally, it is important to highlight that this review only presents literature data on CF
without the ambition of including other environmental impact categories such as marine and terrestrial
eco-toxicity, acidification, and water footprint. The inclusion of these categories may result in larger
differences between metal production from primary and secondary sources. However, the number
of studies that include, for example, water footprint is low and more studies are needed to provide
a more comprehensive picture of the environmental impact of metal production from primary and
secondary sources.
Supplementary Materials: The following are available online at www.mdpi.com/2075-163X/7/9/168/s1; Figure
SI1. Summary of Cu sources and main recovery process and Figure SI2. Summary of Zn sources and main
recovery methods.
Acknowledgments: The authors would like to acknowledge the financial support of European Commission in
the frame of Horizon 2020 project “Metal recovery from low-grade ores and wastes”, www.metgrowplus.eu,
Grant Agreement n◦ 690088.
Author Contributions: A.E.N. was responsible for the writing process and performed a literature research and
analyzed data of metal production from primary sources. K.W. took initiative to the paper and has contributed
to the literature search and composition of the paper. M.M.A. and F.A.T. drafted the sections corresponding to
secondary sources and contributed to literature search and paper review. V.D. and H.A. performed a literature
search and analyzed the data of primary resources. K.K. performed a literature search, critically analyzed results
and revised the paper.
Conflicts of Interest: The authors declare no conflict of interest.

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