In the program, Seco provides manufacturers with small, medium or large storage containers to place within their facilities. Small 1-pint containers hold approximately 11 lbs (5 kg) of carbide, medium 1-gallon containers hold approximately 50 lbs (23 kg), and the large 30-gallon drums accommodate approximately 2,000 lbs (910 kg). As tools reach the end of their useful life they are placed in the containers, which are then collected by Seco. Any carbide products from any manufacturer can be submitted, including carbide inserts, solid drills, solid endmills, wear parts and PCD/PCBN-tipped inserts. Manufacturers are paid at the market rate when the carbide is returned.

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Any machining process used to part metal or other material or give a workpiece a new configuration. Conventionally applies to machining operations in which a cutting tool mechanically removes material in the form of chips; applies to any process in which metal or material is removed to create new shapes. See metalforming.

The process of separating cemented carbide inserts from the steel body of the drill bit is done through an elaborate heating process. The inserts are then gathered and shipped to Terelion’s recycling partner – saving more than 90% of shipping emissions in the process (compared to shipping the complete drill bits).

Rio Tinto Kennecott’s (Salt Lake City, USA) site has joined Terelion’s Circularity Program in what the drill bits company says marks a significant milestone in delivering on its ambitious goal of achieving circularity throughout the whole value chain.

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Cutting tool manufacturer Seco Tools, Troy, Mich., released the results of its North American Carbide Recycling Program for 2013. The company collected and processed 125,919 lbs (57,235 kg) of used carbide tools. Of the total, 110,585 lbs (50,265 kg) were returned to Seco Tools AB for processing into grade powder. Over the life of the carbide recycling program, Seco Tools has returned an average of over 10,100 lbs (4,100 kg) of tools per month for recycling.

Rio Tinto Kennecott General Manager Minerals, Brendan Murphy, said: “We’re always looking for new and inventive ways to reduce our carbon footprint and cut waste. We are excited to support this innovative circularity program and look forward to seeing the difference it can make.”

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Major customers taking advantage of the recycling program include John Deere, GE, Haas Automation, American Axle, Cummins Engines, Royal Oak Industries, Caterpillar, MessierDowty and GTTC de Mexico. Manufacturers interested in participating in the Seco Tools Used Carbide Recycling Program can visit www.secotools.com/recycling for more information, or contact Vic Bruni at vbruni@secotools.com.

The used products are collected on site at Kennecott and transported to a partner where the dull tungsten carbide drill bits are separated from the steel. The used carbide inserts are then sent to a process plant in Austria where they are transformed back to its original powder form, and then made into new tungsten carbide inserts that are used as the raw material for making new drill bits.

Cemented carbide is a key component in high-quality drill bits. One important ingredient in the manufacturing is tungsten, a rare mineral difficult to come by. Through Terelion’s Circularity program, it is now possible to recycle all cemented carbide inserts on a drill bit back to virgin material – pure tungsten – which can then be used in manufacturing new cemented carbide inserts. Tools from recycled solid carbide require 70% less energy which results in 40% less CO2 emissions.

Graeme McKenzie, Operations Director at Terelion, said: “At Terelion, we are committed to working towards a more sustainable mining future. Doing so will benefit all: our planet, our customers and our business. Our aim is 90% circularity by 2030. Key in achieving this is our Circularity Program. We are very happy that Rio Tinto Kennecott shares this ambition and has decided to join our program – a clear testament also to their commitment in this area. We look forward to a successful partnership that ultimately encourages others to join this exciting initiative.”

A ceremony taking place at the Rio Tinto Kennecott Mine on May 23, 2023, marked the start of the circularity program between the two companies.

Partially in response to the program, Seco Tools was named in the August issue of Corp! magazine's list of "Michigan's Best and Brightest Sustainable Companies" for 2013. The reflects the company's efforts to support sustainability and minimize its impact on the environment. "We scored particularly high in community outreach and the promotion of sustainable practices," said Kurt Nordlund, president of Seco Tools North America. "We are committed to sustainability and taking a leadership role on environmental initiatives. That is evident through programs like our Carbide Recycling Program."

The Terelion Circularity program for tungsten carbide drill bits at the Rio Tinto Kennecott mine is estimated to reduce CO2 emissions related to carbide drill bits by 64%. The energy consumption will be reduced by 70% compared with sourcing tungsten carbide via conventional mining methods.

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In addition to the environmental benefits of recycling, Seco's carbide recycling program helps to address the growing global demand for tungsten, which comprises 75 percent of cemented carbide tools. Up to 95 percent of the material in a typical carbide insert can be reclaimed, helping to ensure the long-term sustainability of the metalcutting industry. Seco says recycling reduces related energy consumption by 35 percent and cuts CO2 emissions by 40 percent.