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Journal of Cleaner Production 32 (2012) 32e44

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Journal of Cleaner Production


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Renewable energy in the minerals industry: a review of global potential


B.C. McLellan a, *, G.D. Corder b, D.P. Giurco c, K.N. Ishihara a
a
Graduate School of Energy Science, Kyoto University, Yoshida-honmachi, Sakyo-ku, Kyoto 606-8501, Japan
b
University of Queensland, Sustainable Minerals Institute, Centre for Social Responsibility in Mining, St Lucia, QLD 4072, Australia
c
Institute for Sustainable Futures, University of Technology Sydney, Ultimo, NSW 2007, Australia

a r t i c l e i n f o a b s t r a c t

Article history: This paper examines the major minerals producing countries and the potential that local energy mix and
Received 28 September 2011 renewable energy resources have for lowering the impact of the industry, with respect to carbon dioxide
Received in revised form emissions. Furthermore, it seeks to estimate the potential for new technologies, energy efficiency and
7 March 2012
demand-side measures to reduce emissions. Of total carbon dioxide emissions, 71% arise from fossil fuels
Accepted 10 March 2012
Available online 23 March 2012
used in thermal applications and 29% from indirect electricity generation. We find the highest theoretical
potential for reduction of emissions from thermal applications is from the increased use of renewable
biofuels and charcoal instead of fossil fuels (up to 46% of total industry net emissions), while conversion
Keywords:
Minerals
of various applications to use renewable hydrogen may reduce emissions by 28%. Electricity generation
Mining emissions could be “substantially reduced” by switching to electricity generation from cleaner sources,
Greenhouse gas with hydropower a key potential contributor (reduction of 22% of total industry emissions). Solar thermal
Renewable energy and electrical production may only be capable of 2e7% reduction in the industry’s emissions.
Energy Ó 2012 Elsevier Ltd. All rights reserved.

1. Introduction mitigating GHG emissions. Whilst there is already in the literature


some work on energy use for specific commodities and technologies
Growth in population, affluence and associated consumption (e.g. (Norgate and Haque, 2010; Worrell et al., 2001a, 2001b)) and
over the past century, coupled with increasing trends of urbani- renewable energy in mining has been based discussed in relation to
sation and electrification (among other factors), have led to an specific countries (e.g. Australia (Corder et al., 2011)), specific tech-
increase in the global demand for materials (Krausmann et al., nologies such as wind (Sarder, 2010), or the influence of future global
2009) which is anticipated to continue over the coming century scenarios on renewable energy uptake by mining (Memary et al.,
(Krausmann et al., 2008). Moreover, the production of materials e 2011), there has yet to be a quantitative, top-down, global analysis
especially bulk minerals and construction materials e is a major of renewable potential in mining and minerals processing.
contributor to global energy usage and corresponding greenhouse The production of steel and cement have been the focus of much
gas (GHG) emissions (Allwood et al., 2010; IEA, 2010a; UNSTATS, attention in regards to greenhouse gas production, due to their
2010). In the specific case of minerals, it is also expected that ore predominant contribution to industrial emissions (Krausmann
grades will continue to decline and that, as a consequence, the use et al., 2009; Allwood et al., 2010; Worrell et al., 2009). Energy
of standard minerals processing routes will require higher energy efficiency through improved technology and process integration,
inputs and therefore higher costs and emissions (Mudd, 2007, 2010; and fuel switching have been the key elements in the efforts to
Mason et al., 2011). reduce the greenhouse gas impacts of cement and steel production
Consequently, a global perspective on the current energy use and (Worrell et al., 2009). In the case of cement, there has been
GHG emissions arising from minerals production is required. The a specific focus on the use of alternate feedstocks, including the
aim of this study is to analyse the industry baseline for energy use waste fly ash and slags from power production and minerals pro-
and identify where the potential lies for improving energy efficiency cessing (McLellan et al., 2011). Some cases of industrial ecology or
and utilising renewable energy sources. From this we aim to identify regional synergies between the minerals industry and other
key sectoral renewable energy routes and their potential for industries or the residential sector have also been examined as an
opportunity to reduce overall environmental impacts and energy
* Corresponding author. Tel.: þ81 75 753 9173; fax: þ81 75 753 4775.
usage (Keikkala et al., 2007; van Beers et al., 2007).
E-mail addresses: b-mclellan@energy.kyoto-u.ac.jp, b.mclellan@yahoo.com.au Some sectors, such as the aluminium industry which is heavily
(B.C. McLellan). dependent on electricity in the smelting process, have globally

0959-6526/$ e see front matter Ó 2012 Elsevier Ltd. All rights reserved.
doi:10.1016/j.jclepro.2012.03.016
B.C. McLellan et al. / Journal of Cleaner Production 32 (2012) 32e44 33

been moving new greenfields operations to countries where they 1. Estimation of energy usage attributable to the minerals
can take advantage of cheap and secure energy supply. In particular, industry using a top-down sectoral estimation based on
some countries that have large renewable energy supplies have International Energy Agency (IEA) data
seen a significant increase in market share (e.g. Iceland, Norway 2. Order-of-magnitude verification of the estimation from (1.) by
and Canada). However, there is a limitation to how much industrial a bottom-up estimation of the energy usage in the production
processing can be moved to such countries. Furthermore, for cycles of major minerals
mining (as opposed to smelting) there is a physical limitation tying 3. Estimation of greenhouse gas emissions (GHG) from the energy
the mining and primary processing stages to the geographical used
location in which the ore is found. 4. Estimation of the potential requirement for renewable energy
Emissions from transportation are also important. For bulk resources, and identification of the magnitude of potential
transportation, emissions are related to the mass and distance of substitution and key barriers to for the countries that are major
transportation. The larger the geographical separation between the producers of the major metals and minerals
point of production and the processing site, the more non-valuable 5. Analysis to identify any limitations or synergies for renewable
components contribute to the life cycle emissions of the product (Li energy in the industry, and enablers and barriers to uptake.
et al., 2011). The current emissions from transportation of bulk
minerals are estimated to be between 2 and 9% of the life cycle Data on the production of major minerals was obtained from the
emissions of key minerals, but the elimination of the transportation United States Geological Survey (USGS) (USGS, 2010) and cross-
of ores and concentrates (by onsite processing) could reduce this (Li checked with the British Geological Survey (BGS) (BGS, 2010)
et al., 2011). By contrast, global emissions from iron ore mining are using the basis year of 2008. Data on energy usage in the minerals
roughly <1% of the global emissions from steel making (Norgate industry (top-down perspective in Stage 1) was obtained from the
and Haque, 2010). IEA (IEA, 2010b). Fig. 1 shows the global level industrial energy
This study investigates the potential for reducing greenhouse usage, highlighting the minerals-related energy usage, broken
gas emissions in the minerals industry using synergistic opportu- down by energy source. Fig. 1(a) indicates the total energy usage by
nities with the development of renewable energy. The approach energy source, while (b) shows the corresponding percentage
taken is to estimate the energy usage and emissions attributable to contribution e highlighting that the minerals industry is a major
the minerals industry in the major producing countries, followed user of energy in industry e especially fossil fuels. Fig. 1(c) shows
by an assessment of the potential in those countries for renewable the same information grouped by sector (rather than energy
energy usage to supplement the needs of mining and minerals source) and the relative percentage representation in Fig. 1(d).
processing. If the demand for minerals increases as forecast, Table 1 gives a brief description of the sub-sectors as used in the IEA
renewable energy utilisation, energy efficiency and other initiatives statistics, with reference to the relevant division under the Inter-
would be essential to moving towards a carbon neutral minerals national Standard Industrial Classification of all economic activities
industry. (ISIC) (United Nations, 2008).
Globally, the minerals industry accounts for 15% of total elec- The data are not provided at a lower level of aggregation, so
tricity usage, 11% of total final energy consumption and 38% of caution needs to be taken in applying assumptions and interpreting
industrial final energy consumption (IEA, 2010b). Including the the results. Particularly important to note are the exclusion of coal
conversion of coal to coke and use in blast furnaces, as well as direct mining and the inclusion of quarrying in “mining and quarrying”
usage, the industry uses 19% of coal and coal products and 5% of all and the inclusion of cement in “non-metallic minerals”. The
gas and 2% of all oil supplied globally (IEA, 2010b). The large scale of exclusion of coal mining means that a significant consumer of
this draw on natural energy resources as well as other impacts to energy and producer of greenhouse gas emissions is not included in
society and environment have been key drivers in the push for mining and quarrying, but as shown in Fig. 1(c), this sector is not
sustainable minerals and mining which has received significant particularly large compared with the processing sectors. The
attention over the past decade (Hilson and Murck, 2000; McLellan inclusion of cement, as the largest volume non-metallic mineral
et al., 2009; Azapagic, 2004; Giurco and Cooper, 2012). This has product is important, but it must also be noted that the emissions
been exemplified by reported energy efficiency initiatives in the related to cement are not only due to the energy use, but also the
mining and minerals industry that utilise proven technologies such chemical release of CO2 in the calcining process. (This chemical
as waste heat re-use, capture and re-use of coal seam methane and component is not included in this analysis due to the focus on
a program of innovations to reduce energy and carbon dioxide energy.)
emissions (Guerin, 2006). In addition, industry bodies such as the
International Council on Mining and Metals have through their 10 3. Results
principles framework promoted initiatives to improve energy effi-
ciency and reduce greenhouse gas emissions across the industry It is apparent from Fig. 1(b) that the iron and steel and non-
(ICMM, 2010). The current paper highlights one key element of metallic minerals sectors dominate the energy usage attributable
sustainability (energy) but an examination of other aspects would to the minerals industry e especially the direct usage of fossil fuels.
also promote a broader picture of the potential for sustainable Non-ferrous minerals have the highest percentage of electricity
development in this industry. usage, but still trail iron and steel slightly in absolute terms. Mining
and quarrying utilises around half as much energy globally as the
2. Methodology processing of non-ferrous metals, or 6% of the total minerals
industry (IEA, 2010b). Tables 2and 3 give the data on global
The ultimate aim of this study is to estimate the current usage of production of non-ferrous metals and non-metallic minerals
energy and production of greenhouse gas emissions of the minerals products respectively, while world crude steel production for 2008
industry globally, and to examine the potential for the emissions to was 1330 Mt (USGS, 2010). Applying emissions factors for fuel
be mitigated through the substitution of renewable or low net combustion (DCC, 2010) and electricity consumption (IEA, 2010a)
carbon energy. to the energy use data by sector for each country, the emissions
To achieve this aim, the study was undertaken in the following from the industry, the specific emissions and energy usage per
stages: tonne of production are given in Table 4. The energy ratios can be
34
B.C. McLellan et al. / Journal of Cleaner Production 32 (2012) 32e44
Fig. 1. Final energy consumption (FEC) by global industry showing contribution of minerals sub-sectors (Note: FEC here does not include coal inputs to coke ovens or blast furnaces, which are accounted for under primary energy).
B.C. McLellan et al. / Journal of Cleaner Production 32 (2012) 32e44 35

Table 1 Table 3
Industrial sector definitions as used by the IEA. Global non-metallic mineral production (2008).

Designation General inclusions Significant exclusions Non-metallic minerals Production 2008 (kt) % of total
Industry (See sub-sectors) Energy used for (offsite) Asbestos 2090 0.1%
Iron and steel Manufacture of basic iron transport by industry. Barite 15,646 0.4%
and steel through to casting. Embodied energy of Boron 4346 0.1%
[ISIC Rev. 4 Group 241 and consumables. Fluorspar 14,042 0.4%
Class 2431] Graphite 1120 0.03%
Non-ferrous [ISIC Rev. 4 Group 242 and Gypsum 158,780 4.0%
metals Class 2432] Kyanite 470 0.01%
Non-metallic Glass, ceramic, cement, clay, Lime 295,960 7.5%
minerals refractory products, etc. Magnesite 5426 0.1%
[ISIC Rev. 4 Division 23] Phosphate 161,060 4.1%
Mining and Mining (excluding fuels) and Coal mining. Potash 44,753 1.1%
quarrying quarrying. Titanium mineral concentrates 12,388 0.3%
[ISIC Rev. 4 Divisions 07 and Clays 51,280 1.3%
08 and Group 099] Feldspar 21,900 0.6%
Non-minerals Sum of all remaining industry Pumice 19,300 0.5%
industry Soda Ash 4600 0.1%
Salt 258,000 6.6%
Cement 2,850,000 72.7%
Total 3,921,161 100.0%
converted to primary energy ratios, using estimated efficiency rates
for conversion of fuel to electricity (35% and 50% as shown in
Table 5). (Primary energy is the amount of energy directly used as
fuel plus the fuel energy used to generate electricity e as opposed for non-ferrous metals are difficult to compare because of the wide
to final energy usage which includes the direct energy use in terms variety of minerals included.
of fuel plus the electrical energy provided to the user). The calcu- As a further important element of the analysis, Tables 6and 7
lated values (in Table 5) compare well with other published values show the contribution of each mineral sector and energy source
(Worrell et al., 2001a, 2001b; IAI, 2007), although the energy ratios to the entire minerals industry final energy usage and GHG emis-
sions. These indicate that the largest contribution to both energy
and emissions is from fossil fuel usage however, the contribution of
electricity to emissions is larger than its energy contribution. This
Table 2 higher contribution is mainly due to the use of fossil fuels in elec-
Global non-ferrous metal production (2008). tricity production. As shown in Table 6, renewables and waste heat
Metal Production 2008 (kt) % of total
usage were considered to be zero-GHG-emissions sources of
energy.
Aluminium 39,584 51%
Antimony 197 0.3% Table 8 results from combining the minerals production figures
Arsenic 53 0.1% (USGS, 2010) and the energy usage by the minerals sectors (IEA,
Beryllium <0.2 0.0% 2010b), and shows the breakdown of production figures for the
Bismuth 8 0.0% key minerals products. In particular, it highlights that the 5 highest
Cadmium 20 0.0%
Chromium 34 0.0%
production non-metallic minerals and non-ferrous metals
Cobalt 76 0.1% contribute the vast majority (95%) of tonnage for their respective
Copper 15,427 20% sectors. In addition, the top 10 producing countries for each of the
Germanium <0.2 0.0% sectors produce a combined total of more than 70% of each of these
Gold 2 0.0%
minerals, with the top 20 countries producing approximately 80%
Indium <0.6 0.0%
Lead 3840 5% or more of the minerals products in each sector. This trend flows on
Lithium 25 0.0% to the energy usage and carbon dioxide emissions figures, with
Magnesium metal 672 0.9% more than 80% and 90% of emissions produced by the top 10 and 20
Manganese 1130 1.5% countries respectively. Based on the figures in Table 8 e with special
Mercury 1 0.0%
Molybdenum 218 0.3%
note that it was not possible to obtain data from some non-
Nickel 1574 1.9% reporting energy nations such as Iran e that consideration of the
Niobium 63 0.1% top 5 minerals and the top 20 countries should ensure coverage of
Platinum Group Metals <0.6 0.0% approximately three quarters of all mineral production and 85% of
Rare earths 124 0.2%
energy and emissions.
Rhenium <0.2 0.0%
Selenium 2 0.0%
Silver 21 0.0% 4. Discussion
Strontium 496 0.6%
Tantalum 1 0.0%
Tellurium <0.2 0.0%
The potential for reduction of carbon dioxide emissions in the
Thallium <0.2 0.0% minerals industry has a number of components which are dis-
Thorium <0.2 0.0% cussed in this section. The key strategies are energy efficiency and
Tin 299 0.4% decarbonisation of energy. Before discussing potential strategies, it
Titanium Sponge Metal 155 0.2%
is important to raise some general comments on technologies to
Tungsten 56 0.1%
Vanadium 56 0.1% improve energy efficiency and reduce GHG emissions.
Yttrium 9 0.0% Energy efficiency initiatives, equipment and technologies will
Zinc 11,598 15% vary substantially between different commodities and at different
Zirconium and Hafnium 1282 1.7% steps in the value chain. Employing mass mining methods
Total 73,054 100%
compared with more conventional drill and blast methods, using
36 B.C. McLellan et al. / Journal of Cleaner Production 32 (2012) 32e44

Table 4
Summary of production, energy usage and carbon emissions from minerals industry.

Sector Production (Mt) Energy usagea CO2 emissionsb Energy ratio Carbon ratiob
(PJ) (Mt CO2) (GJ/t production) (t CO2/t production)
Iron and steel 1330 25,043 2551 18.8 1.92
Non-ferrous metals 73 4638 508 60.1 6.58
Non-metallic minerals 3921 13,155 1120 3.4 0.29
Mining and quarryingc 20,000e40,000 2651 241 0.07e0.13 0.006e0.012
a
Final energy consumption. (In the case of iron and steel, this includes coal used in blast furnaces and coke ovens.)
b
CO2 emissions and carbon ratio are based only on the combustion of fuel. This is particularly significant in the case of non-metallic minerals, in which cement production
dominates. (Non-energy CO2 emissions from cement production are estimated at 1500 Mt CO2).
c
There is high uncertainty around the production figures for mining and quarrying. Estimates of aggregate production vastly outweigh the production of other products
however these figures are difficult to verify due to poor global reporting of production.

Table 5 a useful graphical method of identifying the most appropriate


Primary energy ratios for given electric conversion efficiencies (h) typical of gas method. We can interpret Fig. 2 by considering the following
combined cycle (50%) and coal (35%).
guidelines on where to focus effort from a global perspective:
Sector Primary energy ratio (GJ/t)

h ¼ 50% h ¼ 35% 1. If, % Energy > % Production then energy efficiency is an impor-
Iron and steel 20.8 23.0 tant strategy, because the majority of the rest of the world’s
Non-ferrous metals 95.5 127.0 production uses less energy per unit (see Discussion below for
Non-metallic minerals 3.7 4.0 significant limitations in non-ferrous metals).
Mining and quarrying 0.2 0.2 2. If, % Emissions > % Energy then decarbonising the fuel mix is
important, because the rest of the world’s production uses
high pressure grinding rolls instead of conventional grinding semi- lower carbon energy.
autogenous mills and ball mills or installing efficient pumps are
examples that are being currently implemented in mining and Graphically, the higher performing countries are those which
mineral processing operations. Other examples of currently feasible show a decrease in height of the bars from left to right, while the
or emerging technologies include dry granulation of blast furnace opposite trend indicates the poorest performing countries. While
slag, drained cathodes in aluminium smelting, use of fly ash in this holds true as an overall trend, on the specific country basis, the
cement production and geo-polymer binders based on alumino- particular mix of minerals and the impact of secondary metal
silicate waste materials (Lund et al., 2008). Several of these processing must also be considered. For example, with particular
approaches, like others, are technically feasible but often are not focus on guideline 1, minerals such as aluminium and nickel have
implemented as the economics, the additional capital costs versus high energy requirements for processing, whereas zinc and lead
operating cost savings, are not currently favourable. have much lower processing energy (Norgate et al., 2007). Due to
Likewise, numerous electricity generating feasible technologies the lack of separation of the energy data on the global scale, it is not
such as solar, wind, hydroelectric and nuclear have lower green- possible to show the energy usage by country and metal. Further-
house gas emissions compared with the more conventional coal, more, and particularly of importance in aluminium and steel e due
diesel or gas technologies. There are also technologies still in the to the large tonnage and process impact e the recycling of metal
development phase, such as charcoal from biomass for steel scrap can affect the technology mix applicable and the energy
production and a range of low-grade heat recovery technologies usage per tonne of product. This mix is available for many countries
(Lund et al., 2008), which could significantly contribute to lowering for steel (OECD, 2010), but not for other sectors. In regards to non-
the industry carbon footprint. However, similar to energy efficiency ferrous metals, the energy usage is highly dependent on the metal
technologies, without the appropriate incentives, such as the mix, so caution should be used in applying guideline 1. However, for
necessary regulatory schemes, these technologies have difficulty in iron and steel and non-metallic minerals it may be assumed to be
being adopted. While this is an important factor this paper is not a reasonably fair first estimate.
aimed at analysing the policies and regulatory aspects that could These broad strategies are considered sector by sector and
lead to improving energy efficiency and reducing the carbon foot- country by country in Table 9. It should be highlighted that these
print of the minerals industry. Instead, the focus for the remainder strategies only direct the reduction of emissions towards the global
of the Discussion is on strategies and possible technology average, while the specific technologies, renewable energy and
approaches that could deliver lower carbon dioxide emissions other measures that could contribute to a much lower carbon
across the industry from a global perspective. footprint from the minerals industry are discussed later in this
If we wish to know what general approaches could be used to section. China, the largest contributor to all minerals production,
target particular countries and industrial sectors, Fig. 2 offers performs poorly on both efficiency and carbon ratio, and thus offers

Table 6 Table 7
Contribution to total greenhouse gas emissions by sector and energy product. Contribution to total final energy consumption by sector and energy product.

Sector Electricity Fossil fuel Combustible waste, Percentage Sector Electricity Fossil fuel Combustible Heat Percentage
usage usage renewables of total usage usage waste and of total
and heat renewables
Iron and steel 11% 46% 0% 58% Iron and steel 7% 46% 0.5% 1.1% 55%
Non-ferrous metals 9% 3% 0% 12% Non-ferrous metals 6% 4% 0% 0.2% 10%
Non-metallic minerals 6% 20% 0% 25% Non-metallic minerals 4% 24% 0.7% 0.3% 29%
Mining and quarrying 3% 2% 0% 5% Mining and quarrying 2% 3% 0% 0.2% 6%
Percentage of Total 29% 71% 0% 100% Percentage of Total 19% 78% 1% 2% 100%
B.C. McLellan et al. / Journal of Cleaner Production 32 (2012) 32e44 37

Table 8
Contribution of top 10 countries and top 5 materials to global minerals production, energy and emissions.

Sub-sector of minerals industry

Iron and Non-ferrous metals (NFM) Non-metallic minerals (NMM)


steel
Al Cu Ni Zn Pb Top 5 All Cement Gypsum Lime Phosphate Salt Top 5 All
NFM NFM NMM NMM
Percentage of industry sector e production 100% 54% 21% 2% 16% 5% 94% 100% 73% 4% 8% 4% 7% 95% 100%
Top 10 countries (% of specified material 78% 78% 83% 90% 83% 90% 74% 74% 71% 75% 85% 91% 75% 70% 69%
production)
Top 20 countries (% of specified material 89% 89% 87% 97% 83% 92% 84% 84% 79% 90% 91% 95% 85% 79% 78%
production)
Category “other” (% of specified material 3% 7% 13% 3% 17% 8% 10% 9% 13% 8% 9% 5% 15% 12% 12%
production)
Percentage of industry sector e energy usage 100% 100% 100%
Top 10 countries (% of energy usage) 84% 81% 79%
Top 20 countries (% of energy usage) 92% 90% 91%
Category “other” (% of energy usage) 2% 3% 2%
Percentage of industry sector e emissions 100% 100% 100%
Top 10 countries (% of CO2 emissions) 85% 87% 82%
Top 20 countries (% of CO2 emissions) 93% 94% 92%
Category “other” (% of CO2 emissions) 2% 2% 2%

significant potential for future carbon reductions. In light of the majority of renewable energy technologies, and thus requires
limitations of guideline 1 discussed above, a few examples from serious consideration. As shown in Table 10, the contribution of
Table 9 are useful illustrations. Brazil, Germany and Russia all have electricity in the non-ferrous metals industry is particularly high. If
very high proportions of aluminium and nickel in their mix of non-carbon electricity sources could be used to provide electricity
produced metals. Thus they may reasonably be expected to have for iron and steel and non-ferrous metals production, both would
a higher energy per tonne of non-ferrous metals. However, the reduce their specific carbon dioxide emissions to approximately
United States of America has just below the global average of these 1.5 t CO2/t. While still being far from carbon neutral, this would be
two key metals in their mix e indicating that inefficiency in their a considerable marketing advantage for aluminium and other non-
production is probably real. Moreover, Australia has a much lower ferrous metals which are being pushed as substitutes for steel e
component of nickel and aluminium smelting than the world especially in transportation applications in which their light weight
average (38% of non-ferrous metal production compared to 51% also offers potential for further operational emissions reductions.
globally) e indicating again that inefficiency is most likely a real In the non-metallic minerals, zero-carbon energy would reduce
opportunity. the energy-based emissions of CO2 to an even lower level however,
Hereafter, we discuss how renewable energy technologies could the key emissions challenges of cement lie in the chemical emis-
be used in the minerals industry, with some estimation of the sions that are associated with limestone calcining e which are
overall potential for application and subsequent reduction in higher than the energy emissions.
emissions. The major challenge of decarbonising minerals pro- Electrolytic processing of minerals has some potential to
cessing is the significant amount of energy supplying high increase adoption of renewable energy. For example, approxi-
temperature thermal energy rather than electricity. Even for elec- mately 90% of global zinc production is estimated to be via the
tricity, usage of solar panels, with some highly conservative electrolytic route (Norgate and Rankin, 2002), with approximately
assumptions (10e15% panel efficiency, 1e3 MJ/m2 daily insolation, 85% of the final energy consumption as electricity. The substitution
installation of 300% annual required capacity), might require of this electricity for renewables in Australia and China in particular
between 5 and 15% of all mined land (assuming an average 10 ha/kt could reduce a significant proportion of the emissions from zinc
annual metal or mineral production as based on Australian figures production. The ability to utilise renewable electricity could actu-
(ABARES, 2010; ACLUMP, 2009)) to be covered with panels in order ally improve the emissions from production e a trend that could be
to provide the required electricity for the entire minerals industry. utilised to counteract the ongoing decline in grade of ores (lower
Further discussion of renewable electricity potential for the grade ores tend to be those that are processed by hydrometallurgy
minerals industry follows below, however electricity represents and therefore currently have higher emissions per tonne).
only 29% of the overall emissions of the industry’s energy-based However, the additional embodied energy and emissions in the
emissions. So the key concern is how to substitute the carbon- increased usage of reagents and other consumables associated with
based fuels that dominate e especially for the production of iron this shift in technology may lead to a significant increase in offsite
and steel and cement (bulk of non-metallic minerals). These emissions that could offset some of the gains from renewable
industries have been addressed from the perspective of technology energy usage. This would be an issue worth investigating in future,
efficiency improvements and product substitution elsewhere but is not within the scope of the current work.
(Worrell et al., 2001a; Worrell et al., 2001b; Worrell et al., 2009; One key consideration of the usage of renewable electricity in
McLellan et al., 2011; de Beer et al., 1998; Johansson and the minerals industry is reliability and stability of supply. Under
Söderström, 2011; Oggioni et al., 2011) and such analyses do not current operational paradigms and with existing technology, fluc-
form part of this paper. tuations in power from electrical sources would be unacceptable.
Additional gas-power or intermittent steps such as pumped-hydro
4.1. Electrical energy storage could potentially mitigate this risk. Alternatively,
geothermal and hydropower sources, which can supply constant
Although only one fifth of the energy usage and one third of the electrical output day and night could be preferred. Hydrogen has
total minerals industry emissions, electricity is the key focus of the also been widely considered as a useful energy carrier for the
38 B.C. McLellan et al. / Journal of Cleaner Production 32 (2012) 32e44

Fig. 2. Percentage contribution to global production, energy and emissions of the top 20 producing countries for each mineral sector.
B.C. McLellan et al. / Journal of Cleaner Production 32 (2012) 32e44 39

Table 9 current thermal energy usage, coal and coal products contribute
Broad strategies identified for energy-based CO2 emissions reduction from selected 74% of the energy consumed in the minerals industry (coal and coke
major producing countries.a
in the steel sector are 51% of the total industry).
Sector Key strategies for specified countries Fundamentally, of the renewable sources of energy, heat is
Energy efficiency Decarbonisation produced from biomass, solar and geothermal only. Geothermal
Iron and steel China, India energy is typically at the lower end of the temperature require-
Brazil; Russia; Ukraine Japan; Korea ments for industrial processing e although it could be used for
Non-ferrous metals Australia; China electricity production, the raising of low-grade steam will not be
Brazil; Germany Russia; United States
sufficient for most thermal requirements in the minerals industry.
Non-metallic minerals China; Japan; Spain
Brazil; Italy; Russia United States; India
Concentrating solar energy can typically raise the temperature of
a
a transfer fluid up to around 350  C (Hu et al., 2010) and can thus be
Selected strategies are based on Fig. 2 and the guidelines described in the text.
utilised for some of the lower temperature materials e e.g. gypsum
Generally, Energy efficiency is prescribed for countries with higher than global
average energy use per tonne of product in a sector, while decarbonisation is for (300 w 350  C) and salt (>100  C). Solar boosting of processes to
countries with higher than global average emissions per unit of energy. alleviate a fraction of the fossil fuel load could also be used. Addi-
tionally, concentrating solar towers could be used for low
throughput materials processing at very high temperatures, but
storage and transmission of renewable energy (Abbott, 2010) and to currently would be unable to provide the required combination of
smooth fluctuations from intermittent renewable electricity sour- temperature and throughput. One example is a solar thermal route
ces such as wind power (Sherif et al., 2005; Carton and Olabi, 2010). to syngas and zinc that has been described (Werder and Steinfeld,
Hydrogen could be a useful energy storage mechanism, but the 2000) to displace the electrolytic route to zinc however, this still
efficiency losses and the competition for water that may occur in requires high temperature heat in the conventional roasting
the remote, dry areas of some of the key minerals producing production of ZnO as a precursor, and therefore is not significantly
nations e such as Chile and Australia e may not enable widespread beneficial in comparison with electrolytic processes using renew-
usage. Other forms of energy storage that may have particular able electricity.
synergies with renewable energy and mining include compressed Thermal energy usage in calcining of lime, cement and alumina,
air (often stored in underground caverns) (Saidur et al., 2010) and roasting of zinc, and smelting of nickel, copper is typically high
pumped-hydro storage which could be a value-add to mine temperature. Lower temperature heat for the Bayer process in
dewatering. alumina production may be able to be substituted with solar or
Some technologies may also be unsuited to the conditions that boosted geothermal, but this is not a major contributor to energy
surround mine sites in particular e photovoltaic cells for example, consumption. Of perhaps most interest in the non-ferrous metals is
may not perform well under dusty mine site conditions. Wind the potential for hydrometallurgy as a substitute for pyrometal-
power in many countries is also not particularly strong in inland lurgy, and the potential to then utilise renewable electricity to
areas (WEC, 2010) apart from mountainous regions. If the pro- a greater extent. Nickel, copper and zinc all have alternative
cessing of minerals is located further from the mine or renewable hydrometallurgical routes to production, although in some cases
energy sites located elsewhere, these problems could likely be the ore characteristics may be unfavourable.
avoided e potentially at the expense of higher costs, higher emis- In iron and steel, charcoal from renewable biomass has been
sions from transport and loss of the convenient use of mining land. posited as a potential replacement fuel. It is estimated that up to
Ultimately, renewable energy has a very site-specific element to its 20% charcoal can readily be substituted for coke (Norgate and
development. Langberg, 2009), and perhaps all of the injected coal (maybe 40%
of total energy) can be substituted (Gielen and Moriguchi, 2002).
4.2. Thermal energy Ultimately, this means that perhaps up to 60% of the fuel energy
requirement for steel making may be substituted by charcoal e as
The thermal energy usage from fossil fuels in the production of long as there is enough charcoal produced, and therefore enough
steel and non-metallic minerals combined contributes to 70% of land area for biomass plantations. From assessments elsewhere, it
energy consumption and 66% of emissions (Tables 6and 7), and is would appear that there is sufficient biomass potential at minimum
thus of high importance. In the non-metallic minerals, significantly to supply the entire minerals industry, or at maximum to supply the
cement production, there is unlikely to be a limitation on the industry approximately 15e30 times over (Hoogwijk et al., 2003). If
substitution of fossil fuels with other sources of heat e as long as we compare the amount of land required under conservative
the required temperatures can be achieved. However, in the assumptions (at 10 t biomass/t charcoal; 10 t biomass/ha; 300 kg
production of steel using current large scale blast furnace tech- charcoal/t steel) with the amount of mined land worldwide, the
nology, it has been found to be difficult to entirely substitute for required land would be around 400 Mha, or approximately 1e2
non-coke fuels (Gielen and Moriguchi, 2002; Norgate and times the mined land. A significant contribution at least could
Langberg, 2009) (these authors give an excellent detailed analysis come from the remediation of post-mined land (Bungart and Hüttl,
and for more detail the reader is directed to these papers). Of the 2001). However, current production of charcoal is limited and if
only current wood waste was considered, only roughly 10% of the
global need from the steel industry could be provided (WEC, 2010).
Table 10 Biofuels at present are only low carbon emissions energy, rather
Contribution of electricity to minerals industry energy usage and emissions by sub- than carbon neutral, with estimates that up to approximately 85%
sector.
mitigation of emissions is possible by substituting current fuels
World data Total Energy as CO2 CO2 from with biofuels (Cuevas-Cubria, 2009). Competition for land and
energy GJ/t electricity % t CO2/t electricity % water with food production, and competition for biofuel products
of total of total
with other industries may make their use practically less feasible,
Iron and Steel 18.8 13% 1.9 20% but this is not considered in detail in this work.
Non-ferrous metals 60 61% 7 78%
Non-metallic minerals 3.3 12% 0.3 22%
Another way that emissions could be reduced is by a substitu-
tion of coal and oil products with natural gas. Assuming this to be
40 B.C. McLellan et al. / Journal of Cleaner Production 32 (2012) 32e44

technically feasible, this would offer potential reductions of 32% of utilised as storage materials for hydrogen (although high temper-
current minerals industry emissions, but would require an addi- atures tend to release the hydrogen from these compounds). If
tional 18% of the world’s gas production (a total of 23% of produc- appropriate processes utilising hydrogen as the heat source and
tion). Moreover, this is utilising a non-renewable resource. reductant are developed, the emissions from the thermal energy
Hydrogen has been examined elsewhere as a source of energy component of minerals production could be mitigated.
for the minerals industry in Australia (McLellan, 2009). The
potential for utilising hydrogen for thermal energy substitution was 4.3. Transportation
considered to be likely for mitigating oil and gas usage, but not for
metallurgical coal applications using current technology. On the Some of the major mineral ore producing countries do not
global scale hydrogen could be a useful energy substitute in the process the ore to metal domestically, but export it. For some
minerals industry e especially for driving mechanical equipment. countries, the emissions from the transportation of this ore can be
The benefit of its application with renewable energy sources highly significant in terms of minerals industry emissions (Li et al.,
producing the hydrogen e via electrolysis or from biomass e could 2011). The onsite or domestic processing of this ore could
be reinforced through its benefit as an energy storage medium contribute to reduction of CO2 emissions from transportation itself
(although hydrogen itself must be stored). The ability to produce it and, if there is a domestic mix of lower carbon fuel and electricity
from various local sources of energy is an advantage that may suit than the importing nations, there can be reduction in the pro-
remote applications such as mines. cessing emissions. Estimates for these two emissions reduction
The use of hydrogen in direct-contact combustion situations for sources are made below.
high temperature metallurgical applications should be considered Calculations using the production data for iron ore, steel,
as a possibility. However, in conjunction with the thermal contri- bauxite, alumina and aluminium (USGS, 2010; OECD, 2010), and the
bution, the implications of hydrogen-metal chemical interactions energy mix of countries involved in their production (IEA, 2010b),
must be considered. For instance, hydrogen embrittlement of steel as well as transport distance estimates (Fearn Research, 2005), can
is a serious concern for its transportation in pipelines. Design of be used to estimate the impact of onsite processing of minerals that
processes for its use in steel production would be required to are currently shipped offshore (McLellan, 2011). If the exports of
ensure that no weakening of steel would occur. Furthermore, iron ore were to be stopped, and instead the ore processed to steel
nickel, iron, manganese and magnesium are among the key metals onsite, the savings in terms of emissions from transportation and

Table 11
Summary of electricity usage in the top 20 minerals producing countries and renewable electricity potential (Note: * indicates that data has not been reported; electrical energy
usage only shown (and only included in Total) for sectors in which the country is in the top 20 producers e others marked with x).

Country Minerals industry electricity usage (PJ/yr) (IEA, 2010b) Grid CO2 emissions Hydropower potential Ranking on Ranking
(IEA, 2010b) capacity (WEC, 2010) electricity on total
emissions electricity
Iron and Non-ferrous Non-metallic Total (g CO2-eq/kWh) PJ/yr Sufficiency (%)
reduction usage in
steel metals minerals
potential minerals
(Ang et al.,
2011)
Australia x 177 15 193 883 108 56% 5 8
Belgium 23 x x 23 249 e e 23
Brazil 99 141 30 269 89 2945 >100% 5
Canada 38 209 8 255 181 1930 >100% 6
Chile x e* e* e* 412 349 e
China 1330 904 706 2940 745 6311 >100% 1 1
France 44 x 41 85 83 252 >100% 14
Germany 102 62 46 211 441 72 34% 7
Iceland x 42 x 42 1 144 >100% 20
India e* e* e* e* 968 1591 e 3
Indonesia x e* e* e* 726 144 e 9
Iran e* x e* e* 582 180 e 10
Italy 78 x 50 128 398 173 >100% 11
Japan 227 x 82 309 436 490 >100% 4
Kazakhstan x 34 x 34 439 104 >100% 8 22
Korea 159 x x 159 459 68 43% 9
Mexico 30 3 21 54 440 119 >100% 17
Morocco x x 9 9 718 18 >100% 25
Norway x 83 x 83 5 742 >100% 15
Peru x e* x e* 225 936 e
Poland 24 11 15 50 653 25 51% 7 18
Russia 220 359 71 651 326 3067 >100% 4 3
Saudi Arabia x x 2 2 754 e e 26
South Africa 16 58 x 74 835 18 24% 6 16
Spain 63 41 46 150 326 133 89% 10
Turkey 58 x 32 90 495 504 >100% 13
Ukraine 105 x x 105 386 61 59% 12
United Kingdom 18 x 28 45 487 50 >100% 19
USA 287 293 152 732 535 1354 >100% 2 2
Venezuela x 41 x 41 203 360 >100% 21
Zambia x 14 x 14 3 72 500% 24
Other 135 45 x 180 516 e 0%
World 3372 2841 1548 7761 516 57,438 740%
B.C. McLellan et al. / Journal of Cleaner Production 32 (2012) 32e44 41

from change in fuel mix for processing are estimated to be equiv- already widely used in aluminium smelting and is a relatively
alent to 6% and 8% of iron and steel emissions respectively. If cheap and constant form of renewable energy if the location is
bauxite were processed to aluminium in its country of origin, the appropriate. The table also shows that all of the top ten countries
global processing emissions would likely increase in the order of with potential for reducing emissions from their electricity grid, as
14% of the non-ferrous metals emissions from the change in energy ranked by other authors (Ang et al., 2011), are major mineral
mixes, which would counteract the 20% of transportation emissions producers.
that would be eliminated (2% of the non-ferrous metals emissions). Comparing the emissions rates per kWh of electricity supplied,
Altogether, the emissions change from this shift in processing for we can see that a number of countries have good renewable energy
steel and aluminium would result in an increase of the equivalent of potential or already have very low emissions rates e for example,
10% of current minerals industry emissions. For the production of Brazil, Iceland and Norway due to their renewable energy and
aluminium, the benefits would be more if aluminium smelting was France due to the high nuclear energy usage. These countries’
undertaken with renewable energy at just about any location in the potential for expansion of use of renewables in minerals processing
world (McLellan, 2011). may be less important than the possibility of expanding the pro-
cessing of minerals in these countries e that is, where possible and
4.4. Renewable potential examined where the potential of reduced emissions can be verified over the
life cycle, transportation of intermediate mineral products to these
The potential of renewable energy has been examined by many countries may be an important step in reducing global carbon
authors, with some notable recent studies concluding that dioxide emissions from metal production.
renewable energy could be used to power all global needs e at least Table 12 focuses on the thermal energy usage in the minerals
in terms of the overall balance (Abbott, 2010; Delucchi and industry’s top 20 producing nations for each sub-sector. The
Jacobson, 2011; Jacobson and Delucchi, 2011). potential for waste wood biomass conversion to charcoal and the
Table 11 shows the reported usage of electricity in the minerals appropriateness of solar thermal applications was compiled to
industry for the top producing nations, and the potential for new examine these two key thermal energy substitutes. In major
hydropower capacity from the World Energy Council’s 2010 Survey minerals producing countries it was estimated that over 2000 PJ of
of Energy Resources (WEC, 2010) (economic potential in most biomass fuel from wood waste and forestry production was avail-
cases e technical potential if no economic potential given). In able (WEC, 2010). This is roughly 11% of the requirement for the
comparison to minerals electricity demand, hydropower potential iron and steel sector, meaning there would be a significant shortfall
is seen to be more than sufficient in many cases. Hydropower is unless production was ramped up or wood from other uses was

Table 12
Summary of thermal energy usage in the top 20 minerals producing countries and renewable energy potential (Note: * indicates that data has not been reported; thermal
energy usage only shown (and only included in Total) for sectors in which the country is in the top 20 producers).

Country Minerals industry thermal energy usage (PJ/yr) (IEA, 2010b) Charcoal capacity: wood waste Appropriateness Ranking on
(wood cropping) (WEC, 2010) for solar thermal total thermal
(WEC, 2010) energy usage
Iron and Non-ferrous Non-metallic Total Mt/yr Sufficiency (%)
in minerals
steel metals minerals
Australia x 225 95 320 2.5 11% Good-excellent 14
Belgium 112 x x 112 Not appropriate 21
Brazil 658 107 298 1063 0.36 (9) 0.4% (10%) Reasonable 6
Canada 183 37 7 227 3.6 8% Not appropriate 17
Chile x e* x e* Reasonable
China 10,266 680 5491 16,437 Reasonable 1
France 234 x 132 366 0.6 (1.6) 1% (4%) Not appropriate 12
Germany 549 36 235 820 Not appropriate 8
Iceland x 0 x 0 Not appropriate
India 1219 23 403 1646 Good 4
Indonesia x 8 219 227 Reasonable 18
Iran 30 x x 30 Excellent 24
Italy 224 x 284 508 Reasonable 10
Japan 1333 x 266 1599 0.04 0.01% Not appropriate 5
Kazakhstan x 16 x 16 0.0002 0.00% Reasonable 25
Korea 595 x x 595 0.01 0.00% Not appropriate 9
Mexico 212 8 169 389 14.5 3% Good-excellent 11
Morocco x x 30 30 Good 23
Norway x 4 x 4 Not appropriate 26
Peru x e* x e* 1.1 3% Reasonable
Poland 136 17 97 251 7.5 3% Not appropriate 16
Russia 1812 0 599 2411 4.3 0.2% Not appropriate 2
Saudi Arabia x x e* e* Excellent
South Africa 190 x x 190 11.2 4% Excellent 20
Spain 99 12 224 336 Good 13
Turkey 161 x 55 217 Good 19
Ukraine 836 x x 836 0.7 0.1% Not appropriate 7
United Kingdom 187 x 72 259 1.4 0.3% Not appropriate 15
USA 939 262 1011 2211 46.4 1.7% Reasonable 3
Venezuela x 32 x 32 2.5 Not appropriate 22
Zambia x 2 x 2 Good 27
Other 368 84 265 717 e e e
World 21,672 1797 11,558 35,027 e 11% e e
42 B.C. McLellan et al. / Journal of Cleaner Production 32 (2012) 32e44

Table 13
Summary of renewable energy technologies, enablers and barriers for implementation in the minerals industry.

Energy strategy Potential for mitigation Enablers Barriers


of emissions (% of thermal
or electricity based emissions)
Thermal energy (71% of total minerals industry emissions)
Solar thermal Low (3 w 7%) Remote locations and large areas available Low throughput;
in countries where solar thermal is suitable Need for overnight shut down or fuel-boosting
Geothermal Low e Low temperature applications only
Biomass e charcoal Good (w65%) Utilisation of waste product; Land area for cropped biomass;
and biofuels Agricultural synergies or improved economics Availability and competition for food and water;
Suitability in technology e e.g. charcoal in steel
production
Hydrogen Moderate (w40%) Wide variety of renewable energy sources can be used; Water usage e scarcity in some mineral regions;
Can transform electrical energy into thermal e useful Minimal existing infrastructure;
for the renewable case in minerals Potential problems in processing;
Current cheapest routes to hydrogen are via fossil fuels
Electrical energy (29% of total minerals industry emissions)
Solar Low (w8%) Remote locations and large areas available in Dust interference in mining locations;
countries where solar thermal is suitable Instability needing back-up smoothing capacity or;
Wind Moderate Currently the largest expanding renewable source High wind power mostly coastal or in mountainous
regions e may not match the mine locations, but
perhaps the processing locations
Hydropower Good (w75%) Source of stable electricity supply; Environmental impacts of mining and hydropower
Minerals producing countries still have combined may be a project-killer
large hydropower capacity;
Some potential synergies of mine dewatering
and pumped-hydro storage of energy

directed to the manufacture of charcoal. Assuming that solar 5. Conclusions


thermal energy could be used to substitute for all thermal energy in
those countries where a “good” or “excellent” rating was applied, The contribution of the minerals industry is more than one third
the global potential would be equivalent to around 9% of the of global industrial final energy usage e and with the inclusion of
minerals industry’s thermal energy usage. Apart from the issue of coke oven and blast furnace energy consumption it is greater than
throughput, the potential of solar energy may well be limited by the all other industry put together. Furthermore, the increasing
ability to store thermal energy. High temperature applications demand for minerals products makes it apparent that this industry
would not be able to store thermal energy for use overnight, in cannot be overlooked in the consideration of reducing global
which case the operation would either have to shut down or carbon dioxide emissions from energy usage.
substitute solar energy with standard fuel combustion (probably There are also peculiarities of the industry that give it an
the more likely case). In the case where fuel was utilised, this would important role in the choice and provision of energy services. In
reduce the renewable proportion of the energy use to at best 30% e particular, for remote locations where most mines are located,
or around 3% of the minerals industry’s thermal energy needs. a mining/energy combination can be useful in many situations. The
Disregarding any potential process problems with hydrogen, it benefits of mines using locally-sourced renewable energy (perhaps
is feasible to assume that approximately 80e100% of all thermal on post-mined land) can offer socio-economic benefits and non-
energy could be mitigated by hydrogen in the non-ferrous metals mining industrial growth opportunities for example (Corder et al.,
sector, and perhaps 100% of coal in the non-metallic minerals and 2012).
mining, as well as all oil and gas across all sectors. The split of energy usage across the minerals industry is 19%
In Table 13 we examine some of the enablers and barriers for key from electricity and the remainder from thermal sources e of
renewable energy sources in the minerals industry, along with which renewables and heat currently play a minor part (combined
a broad estimate of potential. The potential has been estimated approximately 3%). In terms of emissions, 29% arise from electricity
from the information presented earlier on the technological and usage and 71% from fossil fuels.
locational potential of the selected renewables. From the table it is Contributions to the energy and greenhouse gas emissions from
apparent that there are some strong enablers and barriers for most energy consumption are shown to be highest from iron and steel
of the technologies. Biofuels and hydrogen present the best (59% of energy, 55% of CO2) and non-metallic minerals (29% of
opportunities for the thermal energy provision, while hydropower energy and 25% of CO2). With the additional CO2 emissions
and wind are the most attractive in electricity production. chemically released in the production of cement bringing the CO2
One final but important note for discussion is that the non- emissions of non-metallic minerals up to a similar level as iron and
energy emissions of CO2 can be highly significant e especially in steel, this concentration of impacts on these two sectors justifies
the case of cement production. The chemical release of CO2 in the level of research into mitigation of these emissions. Mining and
calcinations of limestone in the production of cement produces quarrying and non-ferrous metal production contribute only 5e6%
approximately 0.53 t CO2/t cement (DCC, 2010). This correlates to and 10e12% of energy and emissions respectively. Furthermore, the
around 1500 Mt CO2 pa globally e more than the energy emissions concentration of production in a number of countries (most notably
of the non-metallic minerals industry as a whole. A switch to China, with the largest share in all categories) leads to the top 10
renewable energy would not mitigate this emission source e which countries sharing >70% of production and >80% of energy and
is one of the key reasons why cement alternatives and substitution emissions, while the top 20 countries share >80% of production and
of supplementary cementitious materials are so important >90% of energy and emissions. This fairly tight concentration of
(McLellan et al., 2011; O’Brien et al., 2009). production indicates that the potential to influence overall industry
B.C. McLellan et al. / Journal of Cleaner Production 32 (2012) 32e44 43

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