Sustainability analysis in the mining sector: a case study on new recycling technologies for sulphidic mine residues valorisation

Research has demonstrated that mining activities can cause serious impacts on the environment, as well as the surrounding communities, mainly due to the unsafe storage of mine tailings. This research focuses on the sustainability assessment of new technologies for the recovery of metals from mine residues. The assessment consists in the evaluation of the environmental, economic, and social impacts through the Life Cycle based methods: Life Cycle Assessment (LCA), Life Cycle Costing (LCC), and Social Life Cycle Assessment (SLCA). The analyses are performed on the Mondo Minerals bioleaching project, which aim is to recover nickel and cobalt from the Sotkamo and Vuonos mine tailings. The LCA demonstrates that the project contributes to the avoided production of nickel and cobalt concentrates from new resources, hence reducing several environmental impacts. The LCC analysis shows that the company’s main costs are linked to the bioleaching process, caused by electricity consumption and the chemicals used. The SLCA analyses the impacts on three main stakeholder categories: workers, local community, and society. The results demonstrated that a fair salary (or the absence of it) impacts the workers the most, while the local community stakeholder category impacts are related to the access to material resources. The health and safety category is the most impacted category for the society stakeholder. The environmental and economic analyses demonstrate that the recovery of mine tailings may represents a good opportunity for mine companies both to reduce the environmental impacts linked to mine tailings and to increase the profitability. In particular, the project helps reduce the amounts of metals extracted from new resources and demonstrates that the use of the bioleaching technology for the extraction of metals can be economically profitable.

Design, fabrication and mechanical characterization of a structural node made using Wire and Arc Additive Manufacturing (WAAM) technology

Additive Manufacturing (AM), also known as “3D printing”, is a recent production technique that allows the creation of three-dimensional elements by depositing multiple layers of material. This technology is widely used in various industrial sectors, such as automotive, aerospace and aviation. With AM, it is possible to produce particularly complex elements for which traditional techniques cannot be used. These technologies are not yet widespread in the civil engineering sector, which is slowly changing thanks to the advantages of AM, such as the possibility of realizing elements without geometric restrictions, with less material usage and a higher efficiency, in particular employing Wire-and-Arc Additive Manufacturing (WAAM) technology. Buildings that benefit most from AM are all those structures designed using form-finding and free-form techniques. These include gridshells, where joints are the most critical and difficult elements to design, as the overall behaviour of the structure depends on them. It must also be considered that, during the design, the engineer must try to minimize the structure's own weight. Self-weight reductions can be achieved by Topological Optimization (TO) of the joint itself, which generates complex geometries that could not be made using traditional techniques. To sum up, weight reductions through TO combined with AM allow for several potential benefits, including economic ones. In this thesis, the roof of the British Museum is considered as a case study, analysing the gridshell structure of which a joint will be chosen to be designed and manufactured, using TO and WAAM techniques. Then, the designed joint will be studied in order to understand its structural behaviour in terms of stiffness and strength. Finally, a printing test will be performed to assess the production feasibility using WAAM technology. The computational design and fabrication stages were carried out at Technische Universität Braunschweig in Germany.