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Transcript of Strategies for More Effective Critical Materials Use 3 December 2010 Trans-Atlantic Workshop on Rare...
Strategies for More Effective Critical Materials Use
3 December 2010Trans-Atlantic Workshop on Rare Earth Elements and Other Critical Materials
for a Clean Energy Future
Peter C. DentVP Business DevelopmentElectron Energy Corporation
924 Links Avenue, Landisville, PA 17538www.electronenergy.com
Real World Views
“The purpose of a business is to serve a customer” Peter F. Drucker • “Effective” – “Do the Right Thing”• Provide customer value
– Fulfill a need– Better Performance– Lower Cost– Realistic expectations
• Solutions MUST make sense commercially• Sustainable manufacturing & supply chains• Environmentally responsible
204/11/23 2
EEC’s Beginnings• Marlin Walmer - innovator and pioneer in magnet materials Founded
Electron Energy Corporation in 1970• First non-captured commercial Samarium Cobalt (SmCo) producer in the
world• Last US Rare Earth magnet producer (Samarium Cobalt or Neodymium
Iron Boron - NdFeB)
Marlin Walmer
1/11/29 – 12/12/99
About EEC• Landisville, PA – 40,000 sq ft single site• 118 employees • Small Business• One Modern Manufacturing Site• Samarium Cobalt magnet producer• ISO 9001:2000 Certified• Compliance with DOD Domestic Preferences of Specialty
Metals (DFARS 225.252-7003, 7008, 7009)• Defense Directorate of Trade Controls Registered
5
Real World View of Magnet Materials Production
WW Total Market Size $7B 2010, $15B by 2020
NdFeB magnets 72%
Rare Earth Oxide Ore production 97%
Rare Earth pure Metals nearly 100%
Hard ferrites 66+ %
Alnico ½
SmCo 63%
Japan, US, European producers close plants, move production
CHINA
5/18/2010 IVEC 201004/11/23 5
Typical Manufacturing Process for SinteredRare Earth Magnets – Labor is predominant cost
Magnetizing & Testing
Induction Melting or co-
reduction
Ball milling or Jet milling
To m scales
Sintering, Solution and
Heat treatment
~ 200 - 500 m
Crush into
Pressing
Grinding, lapping, honing, Or wire EDM
Machining
Raw MaterialsSm, Co, Fe,Cu, Zr (SmCo)
Nd, Pr, Dy, Fe, Co, B (NdFeB)
Crushing
Criticality Matrix (US National Academies, 2008)This matrix was devised by the U.S. National Academies and published in 2008 in Minerals, Critical Minerals, and the U.S. Economy (2008). The matrix preceded by a detailed explanation of the conclusions from which it was created is (free) on the Internet at http://books.nap.edu/openbook.php?record_id=12034&page=165#p200140369960165001
-Increase use of periodic table of elements
-Semiconductors- 24 plus new elements used in 2000 and beyond
-11.3 Tons/year per person non-fuel minerals in USA, - ? T/yr developing world
-New inventions
-Changing demographics
04/11/23 7
Magnet Sales Worldwide• Market is growing due to automotive &
more uses, miniaturization• People pay lots more for better magnet
performance ($5.4/kg Ferrite, $90/kg Nd)• Smaller magnets make smaller less costly
systems• Lower systems costs will increase market• “More electric” means more magnets
Data courtesy of Webmagnetics.com
Permanent Magnet Material Sales by Type
$0
$2,000
$4,000
$6,000
$8,000
$10,000
$12,000
$14,000
$16,000
$18,000
1985 1990 1995 2000 2005 2010 2015 2020
Year
US
Do
llars
(in
mill
ion
s)
AlNiCo Rare Earth Ferrite Total
9
Material Usage
• Perspective 30 years ago?
• Mother nature’s gifts
• Unique properties• Benefits vs. cost of
replacement
9IVEC 20105/18/2010 Light Rare Earths (LRE’s)
Heavy Rare Earths (HRE’s)
9
Item 2008 Mine Prod.
(Metric Tonnes)
Item 2008 Mine Prod.
(Metric Tonnes)
Raw Steel 1,360,000,000 Uranium (2007) 41,279
Pig Iron 958,000,000 Lithium 27,400
Aluminum 39,700,000 Silver 20,900
Copper 15,700,000 Cadmium 20,800
Manganese 14,000,000 Bismuth 5,800
Zinc 11,300,000 Boron 4,100
Lead 3,800,000 Gold 2,330
Nickel 1,610,000 Selenium 1,590
Magnesium 808,000 Zirconium 1,360
Strontium Materials 512,000 Tantalum 815
Molybdenum 212,000 Yttrium (2001) 600
Antimony 165,000 Indium 568
Rare Earths (mixed, oxides)
124,000 Palladium 206
Cobalt 71,800 Platinum 200
Vanadium 60,000 Rhenium 45
Niobium (Columbium) 60,000 Rhodium 30
Tungsten 54,000 Hafnium 25
Global Metal Production 2008 - Record Year
Courtesy:
Jack Lifton04/11/23 10
-A steel world
-Recycling effectiveness of large vs. small,
mid size -expectations
-Large users volume, mature
recycle
-Rare metals have high price
and big incentives
Rare Earth Mineral Production
• China REE worldwide reserves– 2 years ago over 50% – today substantially less– Reason, more discoveries
• 100 plus potential sites for REE’s discussed for development worldwide
• 5-6 new non-Chinese mining operations will likely be developed
• Lots of investment is flowing to major REE producers – well funded– Downstream supply chain needs– Non-Chinese customers, OEM’s
04/11/23 1111
Rare Earth Oxide Demand Supply/Production REO Tonnes % REO Tonnes %
Lanthanum 51,050 28.40% 54,750 26.90%Cerium 65,750 36.50% 81,750 40.20%Praseodymium 7,900 4.40% 10,000 4.90%Neodymium 34,900 19.40% 33,000 16.30%Samarium 1,390 0.80% 4,000 2.00%Europium 840 0.50% 850 0.40%Gadolinium 2,300 1.30% 3,000 1.50%Terbium 590 0.30% 350 0.20%Dysprosium 2,040 1.10% 1,750 0.90%Erbium 940 0.50% 1,000 0.50%Yttrium 12,100 6.70% 11,750 5.70%Ho-Tm-Yb-Lu 200 0.10% 1,300 0.50%Total 180,000 100% 203,500 100.00%
Forecast Global Demand for Individual Rare Earths in 2014 (±15%) (Im)balance of Supply-Demand
04/11/23 IVEC 2010 12
Source: Dudley J KingsnorthIMOCA 2009
04/11/23 12
- Air Products O2, N2 -steel
-Reduce use of higher demand
-Increase use of lower demand (Ce, Sm) – unsold material = cost, wildcard
-Thorium?
Rare Earth Supply-Demand
Source: Industrial Minerals Company of Australia
04/11/23 13
Rare Earth Prices
04/11/23 14
-Fe, Co, Tb, Ce, Au, Re price comparisons
-REE price disparities ($3/kg-$500/kg pre July 8, 2010, $10-12/kg avg.)
Core Issues• What will be impact of new RE applications
(wind power, Li vs. NiMH batteries, lighting, MCE refrigeration, To Be Invented) ?
• 1000’s of REE applications, how many can be helped?
• Who will make it to market profitably & sustainably grow over time?
• What will China do? –Wildcard factor, SEO’s• Can private sector fix problems alone?
04/11/23 15
REE Supply Core Strategies-Market Driven-
• Stockpile raw materials – price/availability disruptions• Mitigate/Replace REE usage (short-medium term)
– Incremental Process improvements (Kaizen – Japan NdFeB)– Better magnet technology (same flux with less material) => mitigate
• Hi electrical resistivity NdFeB, SmCo (DOE)• Nanocomposites (NdFeB, SmCo) add 30% Fe• New magnet systems (non REE)
– Leapfrog, disruptive technologies • Develop / Adopt Recycling with ROI• Develop applications for Ce, Sm, Pr and others in over supply – grow business• Secure long term reliable, sustainable supply• Develop & recruit people to innovate• Engage with US government to affect appropriate REE policies • Move from Studies => Resource Allocation & Action• Multi faceted, balanced, realistic public policy approaches & expectations• Be EFFECTIVE
04/11/23 16
Peter C . Dent(717) 459-1001 direct(610) 349-5525 [email protected]
Electron Energy Corporation
924 Links Avenue
Landisville, PA 17538
(717) 898-2294
04/11/23 17
www.electronenergy.comwww.usmagnetmaterials.com
Questions
17