exploiting our urban mine in electronic products · exploiting our urban mine in electronic...
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Exploiting our urban mine in electronic products – a good opportunity and a complex challenge
materialsolutionsMetals
Applicationknow-how
Recycling
Materialsolutions
ChemistryMaterial science
Metallurgy
NGU Day Trondheim 6.02.2014
Dr. Christian Hagelüken
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 2
Umicore – a materials technology company
14,400 people in ~ 80 industrial sites worldwide, turnover 2012 €: 12.5 Billion (2.4 B excl. metals)
Ø 50% of metal needs from Recycling material
solutionsMetals
Applicationknow-how
Recycling
Materialsolutions
ChemistryMaterial science
Metallurgy
Top 10 ranking in global index companies (Jan. 2014)
Significance of technology metals
Recycling opportunities & challenges – the system approach
Technical & economical challenges in extractive metallurgy
Conclusion – overall requirements & way forward
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 4
Achzet et al., Materials critical to the energy industry, Augsburg, 2011
Booming product sales drive demand for (technology) metals
0200400600800
100012001400160018002000
1997
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2009
2010
2011
Annual global sales of mobile phones Source: after Gartner statistics (www.gartner.com)
Million units
300170
470SmartPhones
forecast
Accumulated global sales until 2010 ~ 10 Billion units
& increasing functionality
Drivers: • growing population (Asia!) • growing wealth • technology development & product
performance
… next wave: tablet computer:
• 2013 tablets will overpass laptops
• 2015 more tablets than laptops + PC
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 5
Massive shift from geological resources to anthropogenic “deposits”
• Electric & electronic equipment (EEE) Over 40% of world mine production of copper, tin, antimony, indium, ruthenium & rare earths are annually used in EEE
• Mobile phones & computer account for 4% world mine production of gold and silver and for 20% of palladium & cobalt.
• Cars > 60% of PGM mine production used for autocatalysts, increasing significance for electronics (“computer on wheels“) and light metals
• In the last 30 years we extracted > 80% of the REE, PGM, Ga, In, … that have ever been mined
• Clean energy technologies & other high tech applications will further accelerate demand for technology metals (precious metals, semiconductors, rare earths, refractory metals, …) without access to these metals no sustainable development
% mined in 1980-2010
% mined in 1900-1980
Mine production since 1980 / since 1900
0%10%20%30%40%50%60%70%80%90%
100%
Re Ga In Ru Pd Rh Ir REE Si Pt Ta Li Se Ni Co Ge Cu Bi Ag Au
% mined in 1980-2010
% mined in 1900-1980
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 6
Resource scarcity ? Earth crust is rich in elements, but some occur in very low concentrations only …
no mid term absolute exhaustion of metal resources, but frame conditions continue to deteriorate:
Declining ore grades Increasing ore complexity More difficult mining conditions
(depths; mine location; water & energy access) Mining in ecological sensitive
areas (rain forest, ocean, Antarctica, …) Quelle: USGS
Rising economic & environmental costs of primary supply
Christian Hagelüken – NGU Day Trondheim, 6.02.2014
High footprint of primary metals production
• Energy needs & related climate impact • Other burden on environment (land, water, biodiversity)
Market imbalances already today cause temporary scarcity, due to: • Supply restrictions → political, trade, speculation; regional
or company oligopolies, by-product challenges, …
• Limits of substitution
• Surges in demand
→ critical metals identification for the EU & others
Recycling offers solutions for both challenges 7
How to achieve clean solutions without dirty feet?
Cu
Co
Au
Pt
In
Sn
Ag
Pd
Ru
t CO2/ t primary metal
10 000
200
10
0
≈
≈
10 000
200
10
0
≈
≈
How to secure a sustainable supply?
Significance of technology metals
Recycling opportunities & challenges – the system approach
Technical & economical challenges in extractive metallurgy
Conclusion – overall requirements & way forward
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 9
Focus circular economy - metals can be recycled „eternally“ without losses of properties
Residues
Residues
Residues
Residues
Historic wastes (tailings, landfills)
Dissipation
Residues
Residues
Residues
Residues
Historic wastes (tailings, landfills)
Dissipation
End-of-LifeProductmanufacture
Use
Natural resources
Metals, alloys& compounds
New scrap
Raw materials production
Recyclingfrom
industrial materials
from Concentrates
& ores
productreuse
reduce metal losses along all steps of lifecycle
•Reduce generation of residues •Collect residues comprehensively & recycle these efficiently
• Improve metal yields by using high quality recycling processes
Based on: C.E.M. Meskes: Coated magnesium, designed for sustainability?, PhD thesis Delft University of Technology, 2008
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 10
Recycling of most technology metals still lags way behind …
End-of-Life recycling rates for metals in metallic
applications WEEE: precious metal recycling rates below 15%
UNEP (2011) Recycling Rates of Metals – A Status Report, A Report of the Working Group on the Global Flows to the International Resource Panel.
New report (April 2013): Metal Recycling: Opportunities, Limits, Infrastructure http://www.unep.org/resourcepanel/Publications/MetalRecycling/tabid/106143/Default.aspx
http://www.unep.org/resourcepanel/Publications/AreasofAssessment/Metals/Recyclingratesofmetals/tabid/56073/Default.aspx
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 11
Recycling & circular economy as key contributors
Primary mining • ~ 5 g/t Au in ore • Similar for PGMs
Urban mining • 150 g/t Au, 40 g/t Pd & Ag, Cu, Sn, Sb, …
in PC motherboards • 300 g/t Au, 50 g/t Pd … in cell phones • 2,000 g/t PGM in automotive catalysts
factor 40 & more
State-of-the-art recycling … • improves access to raw material • is for many technology metals far less energy intensive
than mining
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 12
What is Recycling? Million € loss by „Recycling“ of coinage scrap in China
“…old 1 & 2 € coins were shipped… as scrap metal to China. But there – instead of smelting and refining – the coin rings and centres were „repaired“ and shipped back. They were then exchanged at the German Bundesbank against real money“
More transparency needed about real activities – not only for coin scrap
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 13
Is this recycling? example “low tech” gold recycling in India …
photo: EMPA/CH
Gold-yield ≈ 25%, dramatic impacts on health & environment (Rochat, Keller, EMPA 2007)
… “Standard” for many backyard processes
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 15
Recycling needs a chain, not a single process - system approach is crucial
Collection 10,000’s
Prepro- cessing
1000‘s
100‘s
Example recycling of WEEE Recovery of technology metals
from circuit boards
<10
Number of actors in Europe
Dismantling
Total efficiency is determined by weakest step in the chain Make sure that relevant fractions reach most appropriate refining processes
Global smelting & refining of technology metals (metallurgy)
Example: 30% x 90% x 60% x 95% = 15%
products
components/ fractions
metals Inve
stm
ent n
eeds
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 16
:
Challenge 1: relevant products/fractions don‘t reach suitable recycling processes
a) Low collection
b) “Deviation” of collected goods dubious exports low quality ”recycling”
ambitious targets & new business models are required
“Tracing & Tracking“, controls & enforcement, stakeholder responsibility, transparency
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 17
Bottle glass
Green glass
White glass
Brown glass
Steel scrap
+
Circuit boards Autocatalysts
• “Mono-substance” materials without hazards • Trace elements remain part of alloys/glass
Recycling focus on mass & costs
• ”Poly-substance” materials, incl. hazardous elements
• Complex components as part of complex products Place focus on trace elements & value
Technology metals need smart recycling - traditional mass focussed recycling does not fit
PM & specialty metals PGMs
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 18
source: Markus Reuter, Outotec & Antoinette Van Schaik, MARAS (2010)
Challenge 2: How to recover low concentrated technology metals from complex products?
Product manufacturing manual/mechanical metallurgical recovery preprocessing
Technical-organisational improvement needs along entire chain: Inappropriate product design Insufficient alignment within recycling chain (system & interface management) Insufficient use of recognised high-quality recycling installations Laws of nature (thermodynamics) prohibit recovery of all metals in some
complex “inappropriate” material mixes (“composition conflict”)
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 19
Pre-processing
Precious + special metals
Fe- recovery
Al- recovery
Cu- recovery
PM- recovery
plastics- recycling
Disposal of hazardous materials
Slags & other
residues
EoL product
Rare Earth recycling
from magnets
Co-Li recycling from
rechargeable batteries
Indium from
LCD screens
„versatile“ integrated smelter processes for Cu, PM & some
special metals Dedicated processes for certain components & special metals
Avoid dissipation of trace elements Gold losses of up to 75% if PC- mother- boards are not removed prior to shredding 100% gold losses in a car shredder
End-
proc
essi
ng
The mechanical pre-processing challenge - materials separation for final metallurgical recovery
Multi-metal recycling with modern technology High tech & economies of scale
• Recovery of 20 metals with innovative metallurgy from WEEE, catalysts, batteries, smelter by-products etc. Au, Ag, Pt, Pd, Rh, Ru, Ir, Cu, Pb, Ni, Sn, Bi, Se, Te, Sb, As, In (via versatile multi feed process). Co, REE (via specialised process for battery materials)
• Value of precious metals enables co-recovery of specialty metals (‘paying metals’) • High energy efficiency by smart mix of materials and sophisticated technology • High metal yields, minimal emissions & final waste
Umicore‘s integrated smelter-refinery in Hoboken/Antwerp Treatment of 350 000 t/a, global customer base
ISO 14001 & 9001, OHSAS 18001
Significance of technology metals
Recycling opportunities & challenges – the system approach
Technical & economical challenges in extractive metallurgy
Conclusion – overall requirements & way forward
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 22
Umicore Precious Metals Refining flowsheet - pyrometallurgy as initial process for most materials
The Precious Metals Operations (PMO) focus on fast throughput and maximized yields at optimized cost. The Base Metals Operations (BMO) focus on flexibly processing by-products from the PMO at low cost and with optimal throughput times.
? What happens with al these elements
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 24
Element distribution at the smelter
Sulfuric acid
Removed to deposit
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 25
Element distribution at the Pb blast furnace
In Recovered out of Flue dust
As, Sb, Sn, Bi Recovered from
Pb bullion
Ni As Recovered out of speiss
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 26
Elements reporting to the end slag
Zn, Ga, Ge, Co, Rare Earths, V, Cr, Zr, Nb, Mo, W, Ta need to be separated before entering the main flowsheet and/or need to be treated in a separate process.
⇒ Make sure that beforehand separation of such elements does not lead to unintended co-separation of precious metals etc.
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 27
Example:Umicore Battery Recycling Plant
Special process for recycling of cobalt, copper, nickel, generation of REE concentrates
Inauguration Sept. 2011
Capacity 7000 t/a
Christian Hagelüken – NGU Day Trondheim, 6.02.2014
Recycling success factors - products & treatment processes must match
Product: Sufficient (extractable) value • Composition (what is in?) • Concentration (how much of it?) • Material prices
Process: Performance & costs • Technological efficiency for value
recovery (yields, energy, …) • Process robustness & flexibility • Environmental & social compliance • Available volumes
→ Economies of scale • Factor costs (labour, energy, capital) • Process chain organisation / interface
management
Depending on:
Product & technology development
28
Process quality
Legal, societal & other frame conditions
Market development →
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 29
- Metal prices of Sep. 2013 - indicative compositions
Plastics, Cu, Fe, Al dominate the weight
Precious metals dominate the value
<1% 1- 5 % 5 -10 % 10 - 20% 20 - 50% 50 - 70 % > 70%
weight-% plastics Fe Al Cu Au [ppm] Ag [ppm] Pd [ppm]TV-boards dismantled 39% 6% 9% 16% 20 450 14
printed circuit board 26% 8% 5% 19% 150 815 40
mobile phone handset 41% 10% 2% 12% 350 1600 50
value-share plastics Fe Al Cu Au Ag Pd Sum PMTV-boards dismantled <1% <1% 3% 36% 27% 10% 10% 47%
printed circuit board 0 <1% <1% 14% 65% 6% 9% 80%
mobile phone handset <1% <1% <1% 5% 81% 6% 6% 94%
Value vs. weight distribution in electronics
Precious metals + copper = “paying metals”, can enable co-recovery of other metals in case of metallurgical (thermodynamical) fit
Pb, Ni, Sn < 2% Sb, Bi, Ga, As, Ta in ppm level Pt, REE, In = negligible → In in LCD screens → REE in magnets
Negligible value Contribution from other metals
Christian Hagelüken – NGU Day Trondheim, 6.02.2014
Extractable metals value - a closer look on economic challenges in metallurgy
Metals that follow the paying metals, e.g. Te, Se, Bi, PGMs • Some extra separation & refining steps • modest extra costs (major part already covered)
Metals extractable from intermediates, e.g. Pb, Ni, Sn, Sb, (In, As) • Additional smelting, extraction & refining steps • Higher extra costs
Metals reporting to slag, e.g. Ta, Ga, REE, W, (In) • Technical hurdles to overcome
→ pre-, inter- or post-metallurgy process • High extra costs (capex + opex)
→ supply & price security is key for investment • Beware of counter-effects (compositon conflicts)
→ e.g., don’t lose Pd/Ag to recover Ta
30
• Sufficient concentration or value?
• Sufficient contribution potential to metals supply or better focus on lower hanging fruits?
• Sufficient societal value for R&D efforts
Significance of technology metals
Recycling opportunities & challenges – the system approach
Technical & economical challenges in extractive metallurgy
Conclusion – overall requirements & way forward
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 32
source: UNEP Resource Panel, press conference presentation, New York City, May 13, 2010
Closing the loop - example palladium – business models are key → challenge for consumer applications
„Closed loop“, benefits of an industrial business model & built-in transparency
„Open loop” high & avoidable losses
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 33
Channelling into high quality* processes along the entire recycling chain
Secure supply of valuable and critical raw materials & avoid environmental damage
Creating a level playing field
Positive differentiation for quality recyclers (on all steps)
Allows reporting & documentation of real flows
Provides security for manufacturers, municipalities and consumers
Objective: Transparent flows & high quality recycling Certification of recycling processes down to end-processing
* Covering technical, environmental & social performance
Christian Hagelüken – NGU Day Trondheim, 6.02.2014
Need for more responsibility & business ethics - a role to play for all stakeholders in the chain Manufacturers, retailers, municipalities: • Don’t take just the cheapest way, secure quality recycling for your products/streams • Understand & check downstream activities, require real transparency on flows • Support recycling by appropriate business models and improving product design
Recyclers (collection – pre-processing – end-processing) • Follow the rules & walk the talk • Take real responsibility for your own outflows
Authorities: • Set appropriate legal frame conditions and ensure their enforcement • Take international responsibility and stop illegal/dubious exports • Be consequent in own procurement policy
Consumers: Give products into recycling & buy preferentially sustainable products
34
Achieving more quality & transparency is key in recycling chains (as in food & textiles, finance flows, mining of conflict metals, …)
Metals sourced from quality recycling are inherently “conflict free”. → New approach for extended producer responsibility
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 35
Metallurgy
Mechanical processing
Costs & revenues Collection
& logistics
Product design & business models Consumer- behaviour
Material & technology perspective
Product perspective
Concluding – Overall recycling success factors
Prerequisites: 1. Technical recyclability as basic
requirement 2. Accessibility of relevant
components → product design 3. Economic viability
intrinsically or externally created
4. Completeness of collection business models, legislation, infrastructure
5. Keep within recycling chain → transparency of flows
6. Technical-organisational set-up of chain → recycling quality
7. Sufficient recycling capacity
Complex products require a systemic optimisation & interdisciplinary approaches (product development, process engineering, metallurgy, ecology, social & economic sciences)
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 36
Focus circular economy - significant improvements still needed at every step
Improve collection Increase transparency of flows Ensure quality recycling Go beyond mass recycling (more
focus on technology metals) Develop innovative technologies
to cope with technical recycling challenges
End-of-LifeProductmanufacture
Use
Geological resources
Metals, alloys& compounds
New scrap
Recycling
Reuse
RM production
from Industrial materials
from ores
End-of-LifeProductmanufacture
Use
Geological resources
Metals, alloys& compounds
New scrap
Recycling
Reuse
RM production
from Industrial materials
from ores
Residues
Residues
Residues
Dissipation
Residues
Residues
Residues
Dissipation
Improve range & yields of recovered metals
Improve efficiency of energy & water use
Consider recycling in product design
Develop business models to close the loop
Recycle production scrap
Avoid dissipation Minimise residue streams at all
steps & recycle these effectively Take a holistic system approach
Mining & Recycling are complementary systems!
Thanks for your attention! Contact: [email protected] www.umicore.com; www.preciousmetals.umicore.com
For more information: Hagelüken, C., C.E.M. Meskers: Complex lifecycles of precious and special metals, in: Graedel, T., E. van der Voet (eds): Linkages of Sustainability, Cambridge, MA: MIT Press, 2010 Hagelüken, C.: Recycling of (critical) metals, in: Gunn, G. (ed): Critical Metals Handbook, Wiley & Sons, 2014
ERA-MIN Research Agenda, 2014, www.era-min-eu.org
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 38
H
K
Be
Sc Ca
Li
Na
Ti
Mg
V Mn Cr Fe Co Cu Ni Zn Ga Ge As Br Se Kr
Al Si P Cl S Ar
B C N F O Ne
He
Rb Y Sr Zr Nb Tc Mo Ru Rh Ag Pd Cd In Sn Sb I Te Xe
Cs La-Lu Ba Hf Ta Re W Os Ir Au Pt Hg Tl Pb Bi At Po Rn
K Ac-Lr Ca Rf Db Bh Sg Hs Mt
Precious Metals (PM)
Rare Earth Elements (REE)
Technology metals: descriptive expression, comprising most precious and special metals • crucial for technical functionality based on their often unique physical & chemical properties (conductivity; melting point; density; hardness; catalytic/optical/magnetic properties, …) • mostly used in low concentrations and a complex substance mix (‘spice metals’) • Key for “Hi-Tech” and “Clean-Tech”
Semi- conductors
Technology metals
Edelmetalle Seltene Erden Halbleiter
Ce Pr Nd Pm Sm Eu Gd Tb Dy Ho Er Tm Yb Lu
Confusion in public debate about metals – ? critical metals – rare metals – rare earths - …?
*
Be
Sc
Li
Co Ga Ge As Se
Si
Mo Ru Rh Ag Pd Cd In Sn Sb Te
Re Ir Au Pt Bi La*
Ac-Lr
Ta
Nb Y Zr
Hf
Mg
W
EU critical metals
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 39
a) Mobile phones
1800 million units/ year X125 mg Ag ≈ 225 t Ag X 25 mg Au ≈ 45 t Au X 5 mg Pd ≈ 9 t Pd X 9 g Cu ≈16,000 t Cu
1800 million Li-Ion batteries X 3.8 g Co ≈ 6,800 t Co
a+b) Urban mine
Mine production / share Ag:23,500 t/a ► 3% Au: 2,800 t/a ► 4% Pd: 230 t/a ► 17% Cu: 16 Mt/a ► 1%
Co: ~100,000t/a ►21%
b) PCs & laptops
365 Million units/year X1000mg Ag ≈ 365 t Ag X 220 mg Au ≈ 80 t Au X 80 mg Pd ≈ 29 t Pd X~500 g Cu ≈183,000 t Cu
~220 million Li-ion batteries X 65 g Co ≈ 14,300 t Co
Low metal content per unit but volume counts Example: Metal use in electronics
• Containing additionally many other technology metals. • Other electr(on)ic & equipment (and cars!) add to these figures → significant total demand. • Intrinsic value per mobile phone < 1 € little economic recycling incentive per unit
Global sales 2011
Christian Hagelüken – NGU Day Trondheim, 6.02.2014 40
technical solutions to improve resource efficiency & mitigate climate impact will need more, not less technology metals (PV, EV, catalysis etc.)
Many technology metals are by-products from “carrier” base metals, their supply will drop in case of: Successful decoupling for base metals (Cu, Zn, Ni, Al, Pb) Improved recycling of base metals Supply restrictions for lead, nickel etc.
Double challenge to secure supply of technology metals
source: Next steps for EU waste and resource policies, R. v.d.Vlies, DG Env., Brussels 17.6.2009
EU-strategy useful & realistic for base metals, especially if used in infrastructure
Decoupling of resource use from GDP growth is unlikely for technology metals
PGM