Dr. Matthias Buchert, Öko-Institut e.V., Germany
envietech2008, Vienna 1st February 2008
Precious Metals Recycling in a Global Perspective
PGM are crucial in modern industrial societies
• PGM usage in today‘s key technologies (chemical catalysis, emission purification, electronics, fuel cells, ...)
• 85% of mankind‘s cumulative PGM-mine production (> 7000 t) took place from 1980 onwards
• German PGM-gross demand will rise by 30% until 2020
• Germany today: gross usage 40 t/a (1.2 Billion $), inventory > 250 t (> 7.5 Billion $)
• High price volatility severely impacts demand segments
• PGM-recycling shows significant ecological benefits compared to PGM-mining (about 10 times better in the case of CO2 equiv.)
• Global dependence on South Africa and Russia, no PGM mining in Europe
• PGM usage in today‘s key technologies (chemical catalysis, emission purification, electronics, fuel cells, ...)
• 85% of mankind‘s cumulative PGM-mine production (> 7000 t) took place from 1980 onwards
• German PGM-gross demand will rise by 30% until 2020
• Germany today: gross usage 40 t/a (1.2 Billion $), inventory > 250 t (> 7.5 Billion $)
• High price volatility severely impacts demand segments
• PGM-recycling shows significant ecological benefits compared to PGM-mining (about 10 times better in the case of CO2 equiv.)
• Global dependence on South Africa and Russia, no PGM mining in Europe
The research report
“Stoffströme der Platingruppenmetalle”GDMB Medienverlag, Clausthal Zellerfeld 2005ISBN 3-935797-20-6234 S., über 70 Abbildungen und Tabellen, 45 €
“ Materials Flow of PGM in Germany”English edition with introduction by GFMSGFMS Ltd, London 2005ISBN 0-9543293-7-6300 pages, 100 €
Authors: Hagelüken, Buchert, Stahl
Material flows of PGM
Significance of PGMSecondary material flows & PGM-lifecycle
efficienciesResults of a research project
oil refining & chemical catalystsautomotive catalystsOther applications
Summary & conclusionsConsequences for the recycling industry
The global mine production of Platinum Group Metals (PGM) fits into a small room
|- 2,6 m -| |- 2,2 m -| |- 1,25 m -| |-1,50 m -| |0,55 | m
Pd230 t/a
(17.9 m³)
density: 12.0 t/m³
Pd230 t/a
(17.9 m³)
density: 12.0 t/m³
Pt210 t/a
(9,5 m³)
21.5
Pt210 t/a
(9,5 m³)
21.5
Rh25 t/a
12.4
Ru40 t/a
12.5
Ru40 t/a
12.5
Ir
22.7
4 t/a
Ir
22.7
4 t/a
Mine Production PGM:> 85% South Africa & RussiaPGM Concentration < 10 g/tValue: 14 Billion $ (2006)
Global mine production of PGM
Data: Christian Hagelüken, Umicore
Global PGM net demand 2006
Rhothers
chemical
autocat
Pdothers
electronics
jewellery
dental
autocat
Pt
autocat
jewellery
chemical
others
global net demand 2006
Data: Christian Hagelüken, Umicore, Numbers based on JM
PGM-flows of Pt/Pd catalysts used in the oil refining industry
Process incl. regeneration PGM-refining
Catalyst fines from regeneration(5-10%)
Process losses incl. charge/discharge(1-2%)
Pt/Pd recovered(96-98% yield)
PGM-refining
Refining loss
Refining loss
Pt/Pd recovered(96-99% yield)
Total Pt/Pd - recovered: 97%- lost: 3%
Pt/Pd
Pt/Pd
all %-numbers at single flows refer to 100% initial material; refining yields on input into PGM refinery
Werte nach JM Platinum
Mine above ground
0
20
40
60
80
100
120
1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004 2006
Pt
Pd
RhΣ 1980-2006:Input Recycling
Rh 87 t - 10 t
Pd 473 t - 21 t
Pt 516 t - 32 t
Σ PGM/ t a-1
Data: Christian Hagelüken, Umicore, Numbers based on JM
Automotive catalysts: gross demand Pt,Pd,Rh in Europe
Motivation to use this “Mine above ground”
Catalyst recycling ....
... secures a sustainable supply of PGM
... contributes to stabilise PGM-prices
... decreases the dependence on primary producers
(mainly South Africa and Russia)
... has a much lower ecological impact than
PGM-mining
PGM-flow and loss distribution for ELV- auto catalysts in Germany, 2002
RefinerDe-registrationsof catalyst-cars Dismantler Collector Decanner
RecoveredPGM
41%
33%
31%
30%
29%
Shredder
Used cars
Loss 4%
4%
Loss 1-2% Loss 1-2% Loss 1%
Unidentifiedoutflows(exports etc.)
Stolen vehicles
57%
2%- yellow: outflow from system boundary (e.g. export of ELV); recycling abroad or re-import of catalyst is theoretically possible
All %-numbers refer to 100%PGM-input into catalyst cars
A substantial part of cars are exported into regions without an adequate recycling infrastructure and awareness, which leads finally to real losses of the PGM‘s
ELV monitoring 2004, D• 3,1 Mio car de-registrations• 1,2 Mio out of these
collected/first treated in D• 540 000 only final treatment
in D
Statistical data by year, emission level and engine size
New registrations
Car inventory
De-registrations
Calculation model
PGM-loading by emission level and engine size
Transfer into an „Excel“-model
De-registered catalyst cars PGM potential
from catalyst recycling
Project findings, actual market data and forecast
Field study
PGM recovered from catalysts in
Germany
Losses
Auto catalyst - methodology
PGM-Refining
decanning
Collection logistic
Sources for spent catalystsfrom end-of-live vehicles (ELV) І from cat exchange (workshops)
cat-converter
cat-converter
cat-ceramic
Ca. 1.000dismantlers+ 60.000 workshops
< 10 decanners
< 10 smelters/refinersglobally (1 fully integrated in Europe)
< 100 catalyst collectors(including
subcollectors)
Catalyst-cars
Catalytic converters
Catalyst ceramic
System boundary Germany
Recycling chain for automotive catalysts - the physical PGM recovery is limited to a few specialists worldwide
Green numbers refer to Germany
Challenge for PGM-recycling from many export cars
exports mainly to Eastern Europe (& beyond) & Africa; Middle East
in many of these countries no emission legislation /-control in place
insufficient car maintenance, bad road conditionshigh probability for destruction of catalyst
→ emission of ceramic/PGM (misfire, bumps on converter ...)
Usually high vehicle lifetime, catalyst has rather no significance (as long as car is still driving)
insufficient recycling infrastructure, missing awareness for catalyst recycling
difficult logistical frame conditions
PGM-recycling potential from automotive catalysts in D until 2020 („reference scenario“)
PGM beim Auto-Kat. (ELV+Ersatz)
0
5.000
10.000
15.000
20.000
25.000
1993
1995
1997
1999
2001
2003
2005
2007
2009
2011
2013
2015
2017
2019
PGM
in k
g
PGM PotentialPGM Recycling
PGM from auto catalysts (ELV & exchange catalyst)
0
3.000
6.000
9.000
12.000
15.000
18.000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
PGM
in k
g
Auto-Kat.-Kreislaufw.Auto-Kat.
A linear increase of the dynamic recycling rate to 70% (“loop scenario”) would double the
PGM recycling volumesReference scenario
“loop” scenario*
Deficit analysis: PGM lifecycle efficiencies for main segments
0% 20% 40% 60% 80% 100%
electroplating
Homogeneous Catalysts Pt
dental
electronics
Automotive Catalysts
Homogeneous Catalysts Pd
Homogeneous Catalysts Rh
jewellery
Oil Refining & Chemical Catalysts
glass industry
PGM-lifecycle efficiency = dynamic recycling quota
0,20,50,20,060,049,81,71,81,20,115,6
Lifecylelosst/a
5,06,43,50,40,115,02,42,51,50,437,2
Gross-demand
t/a
Σ
low
h igh
?? What makes the difference ??
Direct recycling loops
Product manufacturingPGM-
precursorPGM-
product
Product use in process
Charge Use (regeneration)
Dis-charge
Product RecyclingCondi-tioning
PGM-refining
PGM‘sE.g. Oil-refining catalysts, chemical catalysts, glass-equipment
Direct relationship along lifecycle(manufacturer, industrial user, PGM-refiner)
No change of PGM-ownership after initial delivery to end user (weight account transfer)
Industrial parties, professional handling, transparent material flows
PGM content of product is known through entire cycle
High PGM recycling ratio (usually > 90%)
User 1 finaluser n
Change of PGM component
Manufacturing Use Recycling-Logistics physical Recycling / Refining
PGM-Refining
Production scrap
Indirect recycling loops
E.g. car catalysts, PGM in electronics, (dental)
PGM-precursor
assemblyPGM-component
End-product
PGM -salt
Coated monolith Cat. converter car
Return point/ Collection
Dismantling(possibly multistep)
Componentcollection
(possibly multistep)Conditioning
Decanning Car dismantler
Loss
es/ S
yste
m o
utflo
ws
for p
rodu
ct
Losses / System outflows (component / PGM’s)
No removal of PGM component
No direct business relations between industrial parties involved, loop is broken by private end-users and non-industrial parties.
Multiple changes of PGM-ownership, component value fluctuates with PGM-prices.
No professional handling along entire chain, in-transparent material flows after production, “grey and black channels” occur in end-of-life and scrap chain.
PGM lifecycle losses difficult to detect, information on PGM-content gets lost.
In certain areas dilution of PGM in end product to an extend, that recycling is not economically viable by itself (electronics).
Low PGM recycling ratio (usually < 50%).
Indirect recycling loops II
User 1 Finaluser n
PGM-Refining
PGM-precursor
assemblyPGM-component
End-product
Return point/ Collection
Dismantling(possibly multistep)
Componentcollection
(possibly multistep)Conditioning
E.g. car catalysts, PGM in electronics
0
5.000
10.000
15.000
20.000
25.000
30.000
35.000
40.000
45.000
50.000
55.000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
PGM
in k
g
Auto-Kat.B rennsto ffzelleSonstigeIndustrie-Ka t.SchmuckDentalE lektronikGlasGalvanik
PGM gross demand
0
5.000
10.000
15.000
20.000
25.000
30.000
2001
2003
2005
2007
2009
2011
2013
2015
2017
2019
PGM
in k
g
PGM-recycling
0
5 .0 0 0
1 0 .0 0 0
1 5 .0 0 0
2 0 .0 0 0
2 5 .0 0 0
3 0 .0 0 0
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
PGM
in k
g
Au to -Ka t.
E le k tro n ik
Bre n n s to ffze l leSo n s tig e
In d u s tr ie -K a t.Sch m u ck
D e n ta l
Gla sGa lva n ik
PGM net demand
0
5.0 00
1 0.0 00
1 5.0 00
2 0.0 00
2 5.0 00
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
PG
M in
kg
PGM losses
Forecast PGM-balance D, reference scenario)
Growth trends per PGM-segment
Stable- oil refining catalysts
(reforming, isom., hydrocracking)- gauze & fixed bed catalysts
(HNO3, HCN, ...)- industrial emission catalysts- dental & jewellery- electroplating
Stable- oil refining catalysts
(reforming, isom., hydrocracking)- gauze & fixed bed catalysts
(HNO3, HCN, ...)- industrial emission catalysts- dental & jewellery- electroplating
Moderate- Glass industry- Heterogeneous powder catalysts
(e.g. Pd/C)- homogeneous catalysts- automotive catalysts- electronics- sensors & spark plugs
Moderate- Glass industry- Heterogeneous powder catalysts
(e.g. Pd/C)- homogeneous catalysts- automotive catalysts- electronics- sensors & spark plugs
Strong- niche heterogeneous catalysts- special homogeneous catalysts- automotive electronics- auto catalyst-scrap- electronic scrap
Strong- niche heterogeneous catalysts- special homogeneous catalysts- automotive electronics- auto catalyst-scrap- electronic scrap
Importance of PGM in industrial societies confirmed, range of applications is further widening
PGM-gross demand will rise significantly, but no significant impact of fuel cells up to 2020
PGM recycling is a necessity (sustainability, price volatility, ecological benefit). ≈ 50% of PGM-gross demand covered by recycling
Efficient PGM-recovery processes & sufficient refining capacity available, some new materials require technical innovations
Industrial PGM-applications achieve high PGM-lifecycle efficiencies (direct loops between professional parties)
Significant PGM-losses occur in consumer applications with indirect loops (not collected; non-professional chains; grey business practises)
Without significant improvements in collection of auto catalysts & electronics a huge PGM-recycling potential will be lost inevitably: export challenge!
Importance of PGM in industrial societies confirmed, range of applications is further widening
PGM-gross demand will rise significantly, but no significant impact of fuel cells up to 2020
PGM recycling is a necessity (sustainability, price volatility, ecological benefit). ≈ 50% of PGM-gross demand covered by recycling
Efficient PGM-recovery processes & sufficient refining capacity available, some new materials require technical innovations
Industrial PGM-applications achieve high PGM-lifecycle efficiencies (direct loops between professional parties)
Significant PGM-losses occur in consumer applications with indirect loops (not collected; non-professional chains; grey business practises)
Without significant improvements in collection of auto catalysts & electronics a huge PGM-recycling potential will be lost inevitably: export challenge!
Project summary & conclusions
How to Transform Existing Systems?
Example “low tech” – Gold recycling in Bangalore/India …
foto: EMPA/CH
Total Au-recovery efficiency only ≈ 25%, while environmental & health damage is dramatic (Rochat, Keller, EMPA 2007)
… this takes place in large parts of the world today!Let us work for future co-operation in an internationally operating and optimized closed-cycle materials economy!
Thank you for your attention!
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