Metal Recycling Challenges from Waste Products in Japan

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Metal Recycling Challenges from Waste Products in Japan

1 Kyoto University Environment Preservation Research Center Shin-ichi Sakai, Dr. & Prof.

Taiwan Urban Mining Seminar 111021

Material Cycles &

Waste Management

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Metal Recycling Challenges from Waste Products in Japan

1. Backgrounds of Metal Recycling

2. Recycling Potential of Mobile Phones 3. Hazardous Characteristics of E-waste 4. E-Waste Recycling Policies in Japan

2 Taiwan Urban Mining Seminar 111021

Material Cycles &

Waste Management

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１．Backgrounds of Metal Recycling

3 Material Cycles &

Waste Management

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Stable mineral supplies in the medium & long term are secured by exploration/development of minerals, recycling promotion, finding alternative resources for minerals, and by stockpiling of rare metals.

＜Promotion of exploration development＞

Conduct

comprehensive

strategies for securing resources exploration among world-wide.

＜Promotion of recycling＞

Increase collection rate of nonferrous metals contained in collected used-

products by technological development.

＜Development of alternative sources＞

Develop technology for usage reduction of rare metals and find alternative materials.

＜Stockpile of rare metals＞

Conduct agile stocking & selling of rare metals on public- private partnership basis.

METI, Japan (2009)

Securing Policies of

Sustainable Mineral Supply

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List of Rare Metals

Lithium (Li) Niobium (Nb) ＊Rare earthes

Berylium (Be) Molybdenum (Mo) Scandium (Sc)

Boron (B) Palladium (Pｄ) Yttrium (Y)

Rare earthes (RE)* Indium (In) Lanthanum (La)

Titanium (Ti) Antimony (Sb) Cerium (Ce)

Vanadium (V) Tellurium (Te) Praseodymium (Pr)

Chrome (Cr) Cesium (Cs) Neodymium (Nd)

Manganese （Mn) Barium (Ba) Promethium (Pm)

Cobalt (Co) Hafnium (Hf) Samarium (Sm)

Nickel ( Ni) Tantalum (Ta) Europium (Eu)

Gallium (Ga) Tungsten (W) Gadolinium (Gd) Germanium (Ge) Rhenium (Re) Terbium (Tb)

Selenium (Se) Platinum (Pt) Dysporosium (Dy)

Rubidium (Rb) Thallium (Tｌ） Holmium (Ho)

Strontium (Sr) Bismuth (Bi) Erbium (Er)

Zirconium (Zr) Thulium (Tｍ）

Ytterbium (Yb)

Lutetium (Lu)

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Application of rare metals

• Rare metals in products are in a small amount;

however, they are the backseat players for various industries.

Some modification were made on the ref.erence of Baba,Y.: Metal Resources Report, Vol.35, No2, pp.189-197, 2005 6 Sophisticated

materials Smaller & lighter products Energy saving/

environmental measures

Iron & steel

industry Electronic industry Precision machinery &

processing industries Environmental & energy industries

Special steel

Liquid crystal

Electronic componen

t

Rare-earth magnet

(Nd/Fe/B), small motor

Portable secondary battery

(lithium-ion battery, nickel hydride battery)

Fuel cell Solar cell Purification

of exhaust gases

Light-emitting diode(LED) Carbide

tool

Ni, Cr, W, Mo, Mn, V

In

Ga, Ta, Ni Zr, Nb, Pt

Co, Ni, Rare earthes

W, Co, Mo, V

Rare earthes (Nd, Dy, Tb), Co

Pt, Pd, Rare earthes (Ce)

Pt, Mo, Ni, Ga, Ta

Ga

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– The concept of unban mines : introduced by Professor Nanjyo in last 1980s,

– In 2008，National Institute for Materials Science calculated the amount of metals which have been accumulated in Japan to date which are recyclable for use as metal resources in the future. These metals, called “urban mines”, are found in a wide range of products, but are generally not recycled when products are discarded. The results of this study revealed that Japan’s urban mines have reached a scale

comparable to natural reserves of the world’s leading resource nations.

Urban Mining Concept

According to these calculations, Japan’s urban mines of many metals exceed 10% of world reserves, including

Gold; 6,800 tons, or about 16% of the world’s current reserves of 42,000 tons Silver (60,000 tons, or 22%), indium (61%), tin (11%), and tantalum (10%).

Many other metals, including platinum, also rank in the top 5 in comparison

with reserves by country. (Source: Kohmei Harada)

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２．Recycling Potential of Mobile Phones

8 Material Cycles &

Waste Management

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9 Explosive growth of mobile phone use

Exceed one hundred million

Exceed 4 billion in 2008

・Domestic sales increased by about 5.5 times during 1995-2000.

・In 2006, number of subscription exceeded one hundred million; that is, one for each person on an average

・In 2008, number of subscription across the world exceeded 4 billions.

5.5time s

1) Communications and Information network Association of Japan http://www.ciaj.or.jp/content/info/dat.html 2) Telecommunications carriers Association http://www.tca.or.jp/database/index.html

3) International Telecommunication Union http://www.itu.int/ITU-D/ict/statistics/at_glance/KeyTelecom99.html

Number of subscription across the world ³⁾ (million/ year) Domestic sales ¹⁾ / number of subscription ²⁾

(million/year)

Do mestic Sales (m illion/year) Cu m u lative subscription (m illion/year)

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10 Metals in Mobile Phone

Motor for mobile phone

W: Tungsten

Contains various useful

metals such as rare metals and precious metals

Ref)Koden recycle ＨＰ http://www.coden.jp/rare- metal/use.html

Speaker : ferrite Vibrating motor: Nd

Chip resistor: Fe, Ag, Ni, Cu, Zn, Pb Chip coil: Cu

Crystal display: In, Sn Camera: Cu, Ni, Au

Glass epoxy board: Cu, SiO2, (Br) Solder: Pb, Sn

Crystal resonator: Si, Cu, Ni

Plastic: Sb

Button battery: Ag

Earphone jack, AC jack: Au

Written in red: rare metal Ceramic capacitor:

Tanalum capacitor:

Contacts

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Copper (Cu) in some mobile phones and other end-of-life E/Es ^（g/ton）

5,171g of Cu per 1t of the ore

・ small size appliances: 3-29 times higher than the raw mineral ore

・ Mobile phone: 13-29 times higher

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Gold (Au) in some mobile phones and other end-of-life E/Es ^（g/ton）

13.6g of Au per 1t of the ore

Extremely few！

Small size appliances: 1～38 times higher than the raw mineral

Mobile phone: 6~38 times higher

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Palladium (Pd) in some mobile phones and other end-of-life E/Es （g/ton）

・ 1.1g per 1t of the raw mineral ore

・Mobile phone: 13-29 times higher than the ore

・Cassette player: 241times higher 1997

1995

1990 (Note)

・Recent amount of Pd decreases is due to alternative use of Ni

・Old products contain

higher amount of these

metals

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Tungsten (W) in some mobile phones and other end-of-life E/Es （g/ton）

11,115g of tungsten per 1t of the ore

Mobile: 0.6-1.23 times higher if motor part is included

（Note）

①-⑤: Analyze only circuit board

⑥-⑧: Circuit board & motor

（⑨: No data for W）

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Indium (In) in some mobile phones and other end-of-life E/Es （g/ton）

10.0g of indium per 1t of ore.

Mobile: 0.7-8 times higher if liquid crystal display part is included

（Note）

Only circuit board part is analyzed.

Mobile⑥-⑧: including liquid

crystal display part

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３．Hazardous Characteristics of E‐waste

16 Material Cycles &

Waste Management

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17 Restriction of the use of certain

Hazardous Substances in electrical and electronic equipment (RoHS)

• Established in January 27, 2003. Will be applied to products appearing on market after July1, 2006.

• The purpose is to make common laws on usage restrictions of hazardous substances for electrical

and electronic equipment among EU countries and in order to collect & dispose waste electrical and

electronic equipment (WEEE) without affecting to human health and to the environment.

• EU nations have started to organize their own

domestic laws in response to RoHS.

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18 RoHS Directive of 27 January 2003 preamble (5)

The available evidence indicates that measures on the collection, treatment, recycling and disposal of waste electrical and electronic equipment (WEEE) ･・・・・・ are

necessary to reduce the waste management problems linked to the heavy metals concerned and the flame retardants

concerned. In spite of those measures, however, significant parts of WEEE will continue to be found in the current

disposal routes. Even if WEEE were collected separately and submitted to recycling processes, its content of mercury,

cadmium, lead, chromium VI, PBB and PBDE would be likely

to pose risks to health or the environment.

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19 J-Moss (JIS C0950)

• “The Marking for presence Of the Specific chemical Substances for electrical and

electronic equipment”

• “Obligation to provide the information

contained” exactly means to show the orange mark of J-Moss and to list the information of the target chemicals on the web.

• In case the contents of these 6 substances

are below standard values, marking of the

green mark of J-Moss (no contamination) is

allowed.

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20 Targeted products that are under obligation of J-Moss by which information about their

constituent substances must be reported

• Targeted products

– ・Personal Computer

・Unit type air conditioner

・TV

・Microwave

・Cloth drier

・Refrigerator

・Washing machine

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21 Substances in products such as electric appliances and PC whose information

must be reported

Chemical substances Chemical symbols

Targeted substances for

calculation

Standard values (wt%)

Lead/lead compound Pb Lead 0.1

Mercury/mercury compound

Hg Mercury 0.1

Cadmium/cadmium compound

Cd Cadmium 0.01

Hexavalent chromium compound

Cr (VI) Hexavalent chromium

0.1 Polybromobiphehyl PBB Polybromobiphehyl 0.1

Polybrominated dipheny ethers

PBDE Polybrominated dipheny ethers

0.1 ◆Targeted 6 substances and their limit concentrations (if the concentration of these

substances is above the level, the examined materials are considered as “contained”)

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Al

1A 2A 3A 4A 5A 6A 7A 8 1B 2B 3B 4B 5B 6B 7B 0

1 H He

2 C N O F Ne

3 Si P S Cl Ar

4 Ca Br Kr

5 Tc I Xe

6 Os Au Po At Rn

7 Fr Ra **

Element with high acute toxicity （LD ₅₀ <10mg/kg bw)

Element with rather high toxicity （10<LD ₅₀ <100mg/kg bw) Element with rather low toxicity（100<LD ₅₀ <1000mg/kg bw) Element with low toxicity （1000mg/kg bw<LD ₅₀ )

Acute Toxicity Test of Metal Compounds by Oral Exposure to Rat (Yamamoto et al. of National Institute for Materials Science (NIMS))

Ge Se

Te B

Re Pt Sc

*

Boldface：rare metals

*lanthanoid

**actinoid

Li

Rb Sr Cs Ba

Zr Nb Mo Ta

Ti

Hf W

Y Ru

Fe

Pd

Mn Co Ni Cu Zn Ga In Cd

Ag Sn Sb

Pb Bi Tl

Ir Rh

Hg Cr

V Be

As K

Na Mg

•No data of acute toxicity for 12 elements among 33 rare metals

→ As they have not been used much up until now, so toxicology test was not necessary. Another reason is that those data are difficult to obtain due to high costs of toxicity test and from the viewpoint of consideration for animal care.

R. Yamamoto, Materia Japan, Vol.43, No.8, 639-642(2004)

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Al

1A 2A 3A 4A 5A 6A 7A 8 1B 2B 3B 4B 5B 6B 7B 0

1 H He

2 C N O F Ne

3 Na Mg Si P S Cl Ar

4 K Ca As Br Kr

5 Tc I Xe

6 Os Au Po At Rn

7 Fr Ra **

Elements with high cytotoxicity（IC ₅₀ <10 ^-5 )

Element with rather high cytotoxicity（10 ^-5 <IC ₅₀ <10 ^-4 ) Element with rather low cytotoxicity（10 ^-4 <IC ₅₀ <10 ^-3 ) Element with low cytotoxicity （10 ^-3 <IC ₅₀ )

Primary screening based on cytotoxicity assay for metal salts.

(Yamamoto et al. of National Institute for Materials Science (NIMS))

Ge Se

Te B

Pt Re

Sc

* Li

Rb Sr Cs Ba

Zr Nb Mo Ta

Ti

Hf W

Y Ru

Fe

Pd

Mn Co Ni Cu Zn Ga In Cd

Ag Sn Sb

Pb Bi Tl

Ir Rh

Hg Cr

V Be

Boldface：rare metals

*lanthanoid

**actinoid

A. Yamamoto et al. JBMR 39, 331-340, 1998.

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Hidden flow means…

Total amount of materials required including rocks and gravels when mining for obtaining a certain amount of minerals. It is also called Ecological Rucksack or Total Material Requirement (TMR)

Appeal the importance of “avoiding further mining of minerals” by “long- term use” and “recycling” ways

Though the amount of used mineral itself may be small, we can understand that a very heavy environmental load is

produced when considering TMR.

To obtain 1t of gold・・・

TMR will be over 1

million t.

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TMR in some products/ product weight

Cassete player:

1029 times higher

Video camera:

774 times higher

Indirect but large reduction of environmental burden can

be expected by long-term use and recycling of products.

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４．E‐Waste Recycling Policies in Japan

26 Material Cycles &

Waste Management

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Recycling Law of Specified Kinds of Home Appliances

Objective

Legally promotion of environmentally sound management of E‐waste and efficient use of recyclable resources

Mechanism

Shared responsibilities to all stakeholders:

• End users: payment of recycling fee

• Retailers: collection of used home appliances

• Manufacturers: recycling of collected appliances

Targets

Air conditioners

Televisions (CRTs, LCD/PDP TVs) Refrigerators and freezers

Washing machines and clothes dryers

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1.Payment of the fees for transportation and recycling

Ex. for recycling fee: Air conditioner: JPY 3,150; TV sets: JPY 1,785-2,835; Refrigerator/freezer: JPY 3,780-4,830; Washing machine: 2,520.

2.Proper transfer to retailers or others

1.Payment of the fees for transportation and recycling

Ex. for recycling fee: Air conditioner: JPY 3,150; TV sets: JPY 1,785-2,835; Refrigerator/freezer: JPY 3,780-4,830; Washing machine: 2,520.

2.Proper transfer to retailers or others

1. Target equipment that the retailer sold in the past

2. Target equipment which is requested for collection when new products are purchased.

1. Target equipment that the retailer sold in the past

2. Target equipment which is requested for collection when new products are purchased.

Retailers Retailers

Designated corporations Designated corporations

1. When there are no entities that are obliged to collect 2. Entrusted by small and

medium-sized companies

Ensuring reliable transport by

manifesto system Ensuring

reliable transport by

manifesto system

Designated collection sites Designated collection sites

Target equipment that the manufacturer made or the importer imported in the past

Manufacturers and importers Manufacturers and importers

Collection and transfer

Recycling

End users

End users Payment of fees

379 Designated collection sites 49 Recycling plants

Monitoring of implementation Monitoring of implementation

Waste Management and Public Cleansing Law

Issue and reference Issue and reference

Recycling fee covering area

Recycling Law of Specified Kinds of Home Appliances

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Small appliances & battery collection site in front of an administration office in Kyoto

Dec. 10

2009

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Collected mobile phone in the collection site of small appliances in Kyoto

Feb. 4

2010

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Subcommittee on Compact Digital Equipment Recycling, Central Environment Council

Priority Items

Mobile phones, game players, portable CD/MD players, portable digital audio players, digital cameras,

automobile navigation system, video cameras, DVD players, etc

Priority rare

earth metals Tungsten, Cobalt, Tantalum, Neodym, Palladium Option of

mechanism

Voluntarily mechanism, Utilization of current mechanism, Mandatory mechanism

Steps toward Legal Framework for Small Appliances

Potential of other urban mining = Compact digital gadgets

No. of Items 218 million units (45 kinds)/1.4 million tonnes

Potential value Base/precious metals: JPY 30 billion Rare earth metals: JPY 5 billion

Available for recovering technology of base/precious metals;

but no legal framework for collection/recovering

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Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magne

Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet t Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet

Substance Flow Analysis of Neodymium and Dysprosium in Neodymium Magnet

32 Major industries in Japan

Functional material Downsizing, energy saving design

Special steel

Liquid crystal

Electric parts

Rare earth magnet

Rechargeable battery

Carbide tool

Ni Cr W Mo Mn V In Ga Ta Ni Ti Zr N b Pt Nd Dy Tb C o Li Ro Pd

Rare earth

Essential to increase industrial

competitiveness

• China: from producer to consumer

• Increased demand for new tech

• Wild fluctuations in price Securing of

stable supply

Recovery from EOL products

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0%

1%

2%

3%

4%

5%

6%

7%

8%

HE V 駆動用モータ EP S 自動車その他 FA 家電製品 VC M MRI 音響光ピックアップ

Nd magnet ³³

Strongest magnetic force

Major producer: China, Japan

Major application:

VCM for HDD

Automobiles

Electric appliances

MRI (magnetic resonance imaging)

Others (speakers, FA, etc.)

Chemical formula : (Nd _1‐x Dy _x ) ₁₅ Fe ₁₇ B ₈

Nd, B: enhance magnetic force

Dy: improves heat resistance and durability

Fig. 2 Dy content by use ²⁾ Fig. 1 A composition

of Nd magnet (mass) ¹⁾

1）美濃輪武久，希土類磁石とその資源問題，金属，Vol77，No6，pp.592‐597，2007 2）神鋼リサーチ，希少性資源の3Rシステム化に資する技術動向調査，2006

3)財団法人クリーン・ジャパン・センター，循環型社会における3Rに関する調査研究

（産業機械分野の3Rに係るレアメタル対策推進に関する調査），2010 より作成

32% 34% 35% 37% 40% 44% 45%

36% 35% 32% 34% 34% 30% 31%

17% 15% 11% 11% 7% 5% 5%

15% 16% 22% 18% 19% 21% 19%

0%

20%

40%

60%

80%

100%

2002 2003 2004 2005 2006 2007 2008

モータ VCM MRI 音響他

Fig. 3 End use of Nd magnet ³⁾

Motor Audio etc.

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Result: Nd flow in 2009 ³⁴

Metal Nd import

2,100

Magnet alloy pro d uct io n

Magnet alloy

Magnet pr oduct io n

Domestic supply of magnet

27 ‐ 230

Magnet export 490 Magnet

import 50

Intermediate product import

33 ‐ 190

Intermediate product export

9 ‐ 68

Disposal 110 ‐ 260 1,260

1,300 ‐ 1,500

White goods 170 ‐ 420 MRI 38 ‐ 114 Small electrics 19 ‐ 58

Automobiles 140 ‐ 290

Other 410 ‐ 870

PC/peripherals 18 ‐ 76

Stock

Target year: 2009 Unit: ton‐Nd/year

Second hand product export

7.4 ‐ 15 Compressor

32 ‐ 260

Fina l pro d uct assembly

Final product import 130 ‐ 340

Final product export 130 ‐ 250

Domestic supply of magnet

1,000 – 1,200

2,100

2,300[t‐Nd] ‐ 5,600[t‐Nd]

Asse mbly

HDD 20 ‐ 80

Process scrap

400

(35)

Result: Nd flow in 2009 ³⁵

Metal Nd import

2,100

Magnet alloy pro d uct io n

Magnet alloy

Magnet pr oduct io n

Domestic supply of magnet

27 ‐ 230

Magnet export 490 Magnet

import 50

Intermediate product import

33 ‐ 190

Intermediate product export

9 ‐ 68

Disposal 110 ‐ 260 1,260

1,300 ‐ 1,500

White goods 170 ‐ 420 MRI 38 ‐ 114 Small electrics 19 ‐ 58

Automobiles 140 ‐ 290

Other 410 ‐ 870

PC/peripherals 18 ‐ 76

Stock

Target year: 2009 Unit: ton‐Nd/year

Second hand product export

7.4 ‐ 15 Compressor

32 ‐ 260

Fina l pro d uct assembly

Final product import 130 ‐ 340

Final product export 130 ‐ 250

Domestic supply of magnet

1,000 – 1,200

2,100

2,300[t‐Nd] ‐ 5,600[t‐Nd]

Asse mbly

HDD 20 ‐ 80

Process scrap

400 Demand : 2,100 ton

Process scrap + Domestic supply : 1,700 ‐ 1,900 ton

‐> Could supply 80% ‐ 90% of demand

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36 We estimated the Nd and Dy flow considering the intermediate products.

Process scrap and domestic supply constitute 80% ‐ 90% of the total demand.

White goods and automobiles constitutes 70% of domestic supply, stock, and disposal of Nd and Dy.

Nd and Dy would be recovered efficiently under the current framework of recycling systems.

Domestic recycling of the process scrap is desired.

¾ To refine the flow estimates, information on other products and Nd magnet is necessary.

Nd in the dead‐stock mobile phone constitutes 80% of the Nd in the dead‐stock small electric appliances.

Effective collection of the dead stock mobile phone is necesarry.

Substance Flow Analysis of Neodymium and

Dysprosium in Neodymium Magnet

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Conclusions

1. Regarding urban cities as urban mines and promotion of metal recycling are essential from the viewpoints of resources and environment conservation. Also,

ecological rucksack should be kept in mind at the stage of mining minerals.

2. Not only resource potential, but also adverse harmful effect should be considered. Balanced recycling system considering these two points is expected.

3. In addition to 4 items of home appliances (e.g.: TV and others), recycling policy for small household appliances like mobile phone is under discussion in Japan.

Recovery of metal like copper and rare metals like palladium is one of the hot issues.

37