2024.07.08
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Special feature : Cleanly creating metal and society Vol.1
Figuring out how to reduce the environmental burden of the process known as smelting, which creates metal from ore and other raw materials, has been a social issue for many years.
In the 1970s, Mitsubishi Materials succeeded with the practical application of the “Mitsubishi Process,” the world’s first environmentally friendly copper smelting process.
To this day, we have continued with various improvements to cleanly create metals while taking the environment into consideration.
We leverage our proprietary technologies to realize a sustainable society and to solve social issues.
In the 1970s, Mitsubishi Materials succeeded with the practical application of the “Mitsubishi Process,” the world’s first environmentally friendly copper smelting process.
To this day, we have continued with various improvements to cleanly create metals while taking the environment into consideration.
We leverage our proprietary technologies to realize a sustainable society and to solve social issues.
How is Mitsubishi Materials able to cleanly create metal resources?
Through the establishment of an environmentally friendly manufacturing process
When creating metal resources, Mitsubishi Materials contributes to the environment by utilizing all of its proprietary technologies and systems. Here we will introduce key points regarding Mitsubishi Materials’ environmental contributions, such as the collection and processing of E-Scrap, a manufacturing process with low environmental impact through the use of the Mitsubishi Process, the launch of the recycled metal brand, “REMINE,” and more, using simple questions.
Is it OK to put E-Scrap into a furnace as is?
It is first processed through incineration melting in a pretreatment furnace
Conventional copper smelting methods were only able to melt finely powdered raw materials, but the Mitsubishi Process has enabled the direct processing of E-Scrap around the size of gravel. E-Scrap larger than the size of gravel is processed using the Mitsubishi Process after being transformed into recycled scrap (a mixture of slag and metal) in granular form through water granulation following incineration melting in a pretreatment furnace. The pretreatment furnace helps to achieve an environmentally friendly process with no fossil fuels as it enables combustion (spontaneous combustion) and melting using only the heat of reaction from combustibles, which E-Scrap itself contains. Mitsubishi Materials handles E-Scrap with various properties through the combination of a pretreatment furnace and the Mitsubishi Process.
It is first processed through incineration melting in a pretreatment furnace
Conventional copper smelting methods were only able to melt finely powdered raw materials, but the Mitsubishi Process has enabled the direct processing of E-Scrap around the size of gravel. E-Scrap larger than the size of gravel is processed using the Mitsubishi Process after being transformed into recycled scrap (a mixture of slag and metal) in granular form through water granulation following incineration melting in a pretreatment furnace. The pretreatment furnace helps to achieve an environmentally friendly process with no fossil fuels as it enables combustion (spontaneous combustion) and melting using only the heat of reaction from combustibles, which E-Scrap itself contains. Mitsubishi Materials handles E-Scrap with various properties through the combination of a pretreatment furnace and the Mitsubishi Process.
What is the role of the pretreatment furnace?
Eliminating chlorine and bromine
E-Scrap, which contains many combustibles, is incinerated and melted in the pretreatment furnace. Through this process, E-Scrap is transformed into a mixture of slag and metal, and thermal recy- cling takes place. In-house power generation is carried out using the steam from thermal recycling.
Plastic parts from discarded circuit boards contain the halogens chlorine and bromine. The processing of large volumes of these compounds is the cause of equipment deterioration in the Mitsubishi Process. The pretreatment furnace serves the role of eliminating the halogens chlorine and bromine contained within E-Scrap.
Eliminating chlorine and bromine
E-Scrap, which contains many combustibles, is incinerated and melted in the pretreatment furnace. Through this process, E-Scrap is transformed into a mixture of slag and metal, and thermal recy- cling takes place. In-house power generation is carried out using the steam from thermal recycling.
Plastic parts from discarded circuit boards contain the halogens chlorine and bromine. The processing of large volumes of these compounds is the cause of equipment deterioration in the Mitsubishi Process. The pretreatment furnace serves the role of eliminating the halogens chlorine and bromine contained within E-Scrap.
Are there a lot of emissions when creating copper?
A pollution-free system has been established
In conventional copper smelting, sulfur dioxide (SO2) gas generated from molten metal would leak out as uncovered ladles (cauldrons) would be used to move molten metal from multiple furnaces. However, in the Mitsubishi Process, a pollution-free system has been established that prevents the leakage of SO2 gas through the use of enclosed furnaces connected by launders.
A pollution-free system has been established
In conventional copper smelting, sulfur dioxide (SO2) gas generated from molten metal would leak out as uncovered ladles (cauldrons) would be used to move molten metal from multiple furnaces. However, in the Mitsubishi Process, a pollution-free system has been established that prevents the leakage of SO2 gas through the use of enclosed furnaces connected by launders.
In what ways is this technology amazing?
It was the first in the world to succeed in commercial application
It is said that the realization of a continuous copper smelting process was a dream for metallurgical engineers. In 1974, this technology was applied practically for the first time in the world as the “Mitsubishi Process.” This world-renowned system was created after overcoming various hardships, such as construction difficulties due to the oil crisis.
Does this consume large amounts of energy?
There are ways to save energy
Continuous operation in a compact facility is a key point of the Mitsubishi Process. This allows for energy-saving, low-cost operation.
It was the first in the world to succeed in commercial application
It is said that the realization of a continuous copper smelting process was a dream for metallurgical engineers. In 1974, this technology was applied practically for the first time in the world as the “Mitsubishi Process.” This world-renowned system was created after overcoming various hardships, such as construction difficulties due to the oil crisis.
Does this consume large amounts of energy?
There are ways to save energy
Continuous operation in a compact facility is a key point of the Mitsubishi Process. This allows for energy-saving, low-cost operation.
Where is E-Scrap collected from?
World leader in volume processed
It is expected that the volume of E-Scrap handled will increase further due to an increase in the recycling rate of electronics in recent years. Mitsubishi Materials collects E-Scrap not only from Japan, but also from various regions around the world, such as Europe and North America. The volume processed leads the world at approximately 160,000 tons annually.
World leader in volume processed
It is expected that the volume of E-Scrap handled will increase further due to an increase in the recycling rate of electronics in recent years. Mitsubishi Materials collects E-Scrap not only from Japan, but also from various regions around the world, such as Europe and North America. The volume processed leads the world at approximately 160,000 tons annually.
Is it Possible to Increase the Amount Collected in the Future?
Our goal is to increase the volume collected to 240,000 tons annually
The volume of E-Scrap processed by Mitsubishi Materials accounts for around 20% of the approximately 800,000 tons generated worldwide. In light of the expectation that the E-Scrap market will expand going forward, Mitsubishi Materials is aiming to expand its processing capabilities to approximately 240,000 tons annually by the end of the fiscal year ending March 2031.
Our goal is to increase the volume collected to 240,000 tons annually
The volume of E-Scrap processed by Mitsubishi Materials accounts for around 20% of the approximately 800,000 tons generated worldwide. In light of the expectation that the E-Scrap market will expand going forward, Mitsubishi Materials is aiming to expand its processing capabilities to approximately 240,000 tons annually by the end of the fiscal year ending March 2031.
Naoshima Smelter & Refinery
Onahama Smelting and Refining Co., Ltd.’s Onahama Smelter and Refinery
How Do You Prove Use of Recycled Materials?
We Verify Our Use of Recycled Materials Through Third-Party Organizations.
Mitsubishi Materials launched Japan’s first recycled metal brand, “REMINE,” which specifies the recycled material content in non-ferrous metal products. REMINE offers reliable non-ferrous metal products, achieved through calculations of recycled material content in compliance with the international standard ISO 14021* and verification by third-party organizations.
*International standard that requires the elimination of ambiguous expressions and the disclosure of information necessary for verification regarding environ- mental information on products
We Verify Our Use of Recycled Materials Through Third-Party Organizations.
Mitsubishi Materials launched Japan’s first recycled metal brand, “REMINE,” which specifies the recycled material content in non-ferrous metal products. REMINE offers reliable non-ferrous metal products, achieved through calculations of recycled material content in compliance with the international standard ISO 14021* and verification by third-party organizations.
*International standard that requires the elimination of ambiguous expressions and the disclosure of information necessary for verification regarding environ- mental information on products
Isn't it enough to secure metal resources from mines?
It is necessary to recycle our limited resources for the future.
It is possible that supply and demand for metal resources will be out of balance in the future. Copper, in particular, is indispensable as a material that will support decarbonization as it is essential for xEVs and equipment used for generating renewable energy. However, it is predicted that the volume supplied from mines will decrease in the future, so it is necessary to recycle our limited metal resources. From the next page, we will introduce Mitsubishi Materials Group’s resource recycling initiatives using examples of home appliance recycling.
It is necessary to recycle our limited resources for the future.
It is possible that supply and demand for metal resources will be out of balance in the future. Copper, in particular, is indispensable as a material that will support decarbonization as it is essential for xEVs and equipment used for generating renewable energy. However, it is predicted that the volume supplied from mines will decrease in the future, so it is necessary to recycle our limited metal resources. From the next page, we will introduce Mitsubishi Materials Group’s resource recycling initiatives using examples of home appliance recycling.
