The role of the Chemical Industry in Critical Raw Materials

Prof. Dr. Michael Röper, BASF SEIndustrial Technologies 2012, Aarhus

June 20, 2012

The chemical industry is the key enabler of sustainable industrial production

Raw materials present about 30 % of the costs of a chemical product; sourcing at competitive prices is essential

Carbon feedstocks – oil, gas, coal, renewables, and CO2 – are the base of organic chemistry that creates about 90% of the value of the chemical industry

Some inorganic feedstocks are regarded as critical: Noble metals, some rare earth elements, indium, lithium, phosphate, …

The chemical industry helps to overcome the tightness of critical raw materials through improving the exploitation of deposits, improving the efficiency in processing, recycling, and substitution

Raw Materials are of Key Importance Raw Materials are of Key Importance to the Chemical Industryto the Chemical Industry

Critical Inorganic FeedstocksCritical Inorganic Feedstocks

UseNoble metals: contacts in the electronic industry, catalysts in exhaust gas converters, fuel cells, oil refining, chemical conversionsSome rare earth elements: magnets, phosphors, ceramics, alloys, glass & polishing, catalystsIndium: transparent conductor for lighting & displays, touch screensLithium: batteries, glass, ceramics, pharmaceuticalsPhosphates: fertilizers, detergents, animal feed

Strategies to improve the availabilityImproving the exploitation of depositsImproving the efficiency in processingReducing the use by improved design & materials scienceRecycling after useSubstitution by more abundant feedstocks

Estimated global reserves of 100 million metric tons REO are sufficient to meet demand for the next 100 years (USGS, 2010)

97% of REO mining and purification is today done in China

Negligable capacity outside China due to costs and environmental issues (significant Th amounts in ores)

4

Rare earth oxides (REO)Rare earth oxides (REO)Reserves

7%

22% all other countries 13% USA5% Australia

38% China19% CIS

3% India

5

Ore

Mineral concentrate

RE/Th/U concentrate

Individual REO

Grinding, magnetic/gravity separation, flotation

Mixed RE concentrate

Cracking (acids or bases)

Separation of Th and/or U

Separation of REO

In situ mining(Ion adsorption clays)

RE metals

Metallothermic or electrolytic reduction

REE ProcessingREE ProcessingFrom ores to REO (RE oxides) and RE metals

Beneficiation/CrackingBeneficiation/Cracking

Challenges• Similar chemical properties of

REE• Environmental issues

Possible Improvements• Improved extraction to reduce

energy consumption and use of chemicals

• Chemicals & processes for waste water treatment

• Novel separation processes

Challenges• Recovery not quantitative• Tailings are not used today• High energy demand in cracking

step

Possible Improvements• Improved beneficiation of

minerals by tailor-made chemicals

• process intensification for cracking

Separation of the individual REO‘sSeparation of the individual REO‘s

Enhanced REE ProcessingEnhanced REE Processing

Reduction of CRM Use in CatalysisReduction of CRM Use in Catalysis

Better Catalyst Design to Reduce CRM UseBetter Catalyst Design to Reduce CRM Use

Catalysts are essential for exhaust gas cleaning, oil refining, and chemical production.Many catalysts are based on noble metals (Pt, Pd, Rh, ...) on supports and some contain rare earths as co-catalysts – improved design can reduce the use of these materials:Reduction of active particles size on the support increases the catalytically active surface and allows reduction of metal content while maintaining or improving the catalyst propertiesIncrease of catalyst life-time (service life) reduces the need for replacement and decreases the down time for catalyst replacementRational catalyst design enhances product yields and selectivities (e.g. by improved supports, promoters or geometry)Replacement of CRMs by less critical materials (e.g. platinum by nickel)

Substitution of CRMs

Application Subcatagory CRM Substitute

Electrics Batteries Cobalt Iron, organic polymers, manganese

Graphite Silicon (nano)

Lanthanum Zinc-air, lithium-air, aluminium-air, super-capacitors

Fuel cells Platinum Silver, biocatalysts

Electronics Semiconductors, LED, OLED, photovoltaics

Gallium ZnO/MgS, organic polymers, zinc, tin

Indium (ITO)

Organic polymers, graphene, carbon nontubes, ZnO with metal grids

Materials Catalysts Platinum Nickel, iron, biocatalysts

Tungsten Iron oxide

Metals, alloys Cobalt Nickel, carbides, nitrides, chromium, boron, titanium

Tungsten Silicon carbide, molybdenum

Graphene as a Substitute for ITO Graphene as a Substitute for ITO as Transparent Electrodesas Transparent Electrodes

Graphene

Graphite

Preparation of Graphene transparent Preparation of Graphene transparent films by CVDfilms by CVD

The chemical industry is the key enabler of sustainable industrial production and relies heavily on a reliable raw materials supply at competitive conditions (carbon & inorganic feedstocks)

Some inorganic feedstocks are regarded as critical: Noble metals, some rare earth elements, indium, lithium, phosphate, …

The chemical industry helps to overcome the tightness of critical raw materials through improving the exploitation of deposits, improving the efficiency in processing, recycling, and substitution

Redesign of materials and products through material science is an efficient tool to reduce CRM utilization and to improve the sustainability of industrial production

ConclusionsConclusions

Back-upBack-up

The role of the Chemical Industry in Critical Raw Materials

Prof. Dr. Michael Röper, BASF SEIndustrial Technologies 2012, Aarhus

June 20, 2012

Carbon Feedstocks for the Chemical Carbon Feedstocks for the Chemical Industry in GermanyIndustry in Germany

Coal1%

Naphtha, Oil Derivatives

72%

Renewable Feedstocks

13%

Natural gas14%

Total: 21,2 Mill. t (2008)Source: VCI, FNR 2010

15

Availability of Fossil Feedstocks

Situation Base for power&fuel industries: fuels for

mobility, electrical power, heating&cooling

Mineral oil the most important feedstock of the chemical industry, but is used almost exclusively in the energy sector

Goal: Material use rather than burning! Better energy efficiency by

electromobility, better heat insulation and light weight construction

Use of renewable energy Increase mineral oil & gas reserves by

improved recovery methods

146

60

41

Range: Reserves / yearly consumption*

* Source: Bundesanstalt für Geowissenschaften und RohstoffeMineral oil Gas Coal

Years

16

Raw Material Change in Carbon Feedstocks

To enable the chemical industry to replace or supplement oil, the conventional chemical raw material, with alternatives

GOALTo develop new technologies for entry into the existing value-adding chains

Examples: Reduction of CO2 by use of renewable energy, improved & new catalytic conversions

STRATEGY

Natural gasOil Coal Carbon dioxideBiomass