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32.6 Implementation and Approach
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The segregation of metal dust and scrap by type is the best method to increase the value of the metals for resale. When on-site recycling is not possible due to space or economic constraints, utilize a subcontractor most will take these materials at no cost due to the relatively high resale value.
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CASE STUDY ALUMINUM RECYCLING
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32.7 Case Study Aluminum Recycling
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The recycling of aluminum scrap has signi cant economic, energy, environmental, and resource-savings implications. Compared with the primary aluminum production, aluminum recycling has a great advantage due to lower production cost (Campbell, 1996; Henstock, 1996). In order to ef ciently recycle metals the industry is faced by various issues which include scrap sampling, scrap purchasing, metal recovery (based on recoverable metal in scrap) and yield (based on total mass of scrap), production cost and hence pro t margins, product quality, environmental issues, and regulation. The chemical composition of the molten aluminum product is controlled not only by the process operation, but also to a large extent by proper selection of charged aluminum scrap. As the real metal content of the scrap remains unknown, metal yield becomes a crucial factor for the recycling of aluminum scrap. Unfortunately, due to aluminum s high reactivity, metal yield of aluminum is a function of numerous parameters such as surface area to-volume ratio (due to oxidized surface), shape of the scrap, type of alloy, scrap history, contaminants (e.g., oxides, water, oil, and paint), and amount of required ux additives in the melting process. For example, any increased level of contamination on scrap reduces metal recovery due to reaction with aluminum, and further lowers the metal yield. Figure 32.1 shows a metal scrap pile commonly found in the United States.
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Metal scrap.
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PRIMARY AND FABRICATED METAL INDUSTRIES
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32.8 Additional Information
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1 Sibley, Scott and Butterman, William, Metal Recycling in the US, Resources,
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Conservation, and Recycling, vol. 15, 1995, pp. 259 267.
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ELECTRONICS, SEMICONDUCTORS, AND OTHER ELECTRICAL EQUIPMENT
33.1 Industry Overview
NAICS code: all 33400s
INDUSTRY SNAPSHOT
6499 electronic manufacturing operations in the United States 494,370 employees $102.9 billion in annual sales 3.1 tons of solid waste generation per employee Major waste streams: papers, plastics, and metals
Industries in the computer and electronic product manufacturing subsector group include establishments that manufacture computers, computer peripherals, communications equipment, and similar electronic products, and establishments that manufacture components for such products. The computer and electronic product manufacturing industries have been combined in the hierarchy of the North American Industry Classi cation System (NAICS) because of the economic signi cance they have attained. Their rapid growth suggests that they will become even more important to the economies of all three North American countries in the future, and in addition their manufacturing processes are fundamentally different from the manufacturing processes of other machinery and equipment. The design and use of integrated circuits and the application of highly specialized miniaturization technologies are common elements in the production technologies of the computer and electronic subsector. Convergence of technology motivates this NAICS
ELECTRONICS, SEMICONDUCTORS, AND OTHER ELECTRICAL EQUIPMENT
subsector. Digitalization of sound recording, for example, causes both the medium (the compact disc) and the equipment to resemble the technologies for recording, storing, transmitting, and manipulating data. Communications technology and equipment have been converging with computer technology. When technologically related components are in the same sector, it makes it easier to adjust the classi cation for future changes, without needing to rede ne its basic structure. The creation of the computer and electronic product manufacturing subsector will assist in delineating new and emerging industries because the activities that will serve as the probable sources of new industries, such as computer manufacturing and communications-equipment manufacturing, or computers and audio equipment, are brought together. As new activities emerge, they are less likely therefore, to cross the subsector boundaries of the classi cation. Semiconductors are electrical devices that perform functions such as processing and display, power handling, and conversion between light and electrical energy. Semiconductor production processes involve over 100 proprietary solutions and 200 generic materials to achieve the nal product. This industry generates signi cant quantities of spent solvents and liquids containing metals. The economic and liability incentives caused by increasing disposal costs and more stringent regulations are resulting in efforts to minimize such wastes at the source. Semiconductors are unique substances, which, under different conditions, can act as either conductors or insulators of electricity. Semiconductor processors turn one of these substances silicon into microchips, also known as integrated circuits. These microchips contain millions of tiny electronic components and are used in a wide range of products, from personal computers and cellular telephones to airplanes and missile-guidance systems. To manufacture microchips, semiconductor processors start with cylinders of silicon called ingots. First, the ingots are sliced into thin wafers. Using automated equipment, workers or robots polish the wafers, imprint precise microscopic patterns of the circuitry onto them using photolithography, etch out patterns with acids, and replace the patterns with conductors, such as aluminum or copper. The wafers then receive a chemical bath to make them smooth, and the imprint process begins again on a new layer with the next pattern. A complex chip may contain more than 20 layers of circuitry. Once the process is complete, wafers are then cut into individual chips, which are enclosed in a casing and shipped to equipment manufacturers. The manufacturing and slicing of wafers to create semiconductors takes place in clean rooms production areas that are kept free of all airborne matter because the circuitry on a chip is so small that even microscopic particles can make it unusable. All semiconductor processors working in clean rooms must wear special lightweight outer garments known as bunny suits. These garments t over clothing to prevent lint and other particles from contaminating the clean room. There are two types of semiconductor processors: operators and technicians. Operators start and monitor the equipment that performs the various production tasks. They spend the majority of their time at computer terminals, monitoring the operation of equipment to ensure that each of the tasks in the production of the wafer is performed correctly. Operators may also transfer wafer carriers from one station to the next, though the lifting of heavy wafer carriers is done by robots in most new fabricating plants.
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