dr. christian hagelüken, umicore precious metals refining. hagelueken.pdf · dr. christian...
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Dr. Christian Hagelüken, Umicore Precious Metals Refining
Material flows of car related PGM
2nd Roundtable on the Sustainable Production & use of
Platinum Group Metals
Brussels, Dec. 12, 2007
2Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
PGM = Platinum Group Metals
|- 2,6 m -| |- 2,2 m -| |- 1,25 m -| |-1,50 m -| |0,55 | m
The global annual mine productionfor PGMs fits into a 15 m² room (31m³)
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 & Russiaore grade < 10 g/tvalue: 14 billion $ (at 2006-prices)
9 billion $ (at 2005-prices)
$/g Pd Pt Rh Ru Ir M $ Pd Pt Rh Ru Ir total M $2006 10,29 36,75 146,13 6,16 11,22 2006 2366 7717 3653 185 45 139662005 6,46 28,84 66,01 2,38 5,43 2005 1486 6056 1650 71 22 92862004 7,39 27,20 31,51 2,06 5,98 2004 1701 5712 788 62 24 82862003 6,43 22,22 17,04 1,13 2,99 2003 1479 4665 426 34 12 6616
Ag20000 t/a Au
2500 t/aPGM500 t/a
|3.2 m | |- 12.3 m -| |- 5.1 m -|
density: 10.5 t/m³
19.3
Pt+Pd+Rh+Ru+Ir(15.1)
> 85% of all PGMs ever mined were extracted after 1980!
3Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
Platinum t/a % Palladium t/a % Rhodium t/a %autocatalyst 104 48 autocatalyst 107 52 autocatalyst 21 84jewellery 50 23 jewellery 23 11 chemical 2 7chemical+petroleum 20 9 electronics 34 17 others 2 9investment 2 1 dental 19 9 total demand* 25others 40 18 others 22 11total demand* 215 total demand* 205 * net demand
total PGM for autocat (net) = 232 52% = gross demand - recyclingtotal demand* Pt+Pt+Rh: 446
Pdothers
electronics
jewellery
dental
autocat
Rh
otherschemical
autocat
Ptautocat
jewellery
chemical
others
Num
bers
base
don
JM
200
7PGM demand 2007 worldwide– autocatalyst > 50% of net demand
4Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
There are more precious metals in automotive applications
Automotive is most important segment for Platinum Group Metals (PGM). Recycling only takes place for car catalysts, but hardly for sensors/spark plugs or car electronics
global annual gross demand in t* Pt Pd Rh Ir Au Ag
Catalysts & DPF 131,7 136,2 26,8 (x)Sensors & spark plugs 5 XElectronics X X Xtotal automotive 136,7 >129 26,8 1 ? ?total mine supply* 207,2 230 25 4 2.500 20.000% of mine supply 66% >56% 107% 25%
--
catalyst recycling in t/a* 28 29,4 6% catalyst demand covered by recycling 20% 23% 21%*2007, Based on JM & GFMS figures
DPF= Diesel Particulate Filter
5Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
0
20
40
60
80
100
120
1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004 2006
Pt
Pd
RhΣ PGM/ t a-1
0
50
100
150
200
250
1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004 2006
OthersPetroleumJewelleryInvestmentGlasElectronicsChemicalAutocat.-net
*net-demandt a-1
Pt
Europe
Autocat is the main driver for PGMs
0
50
100
150
200
250
300
1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004 2006
jewelleryotherselectronicsdentalchemicalautocat net
Pd*net demandt a-1
0
50
100
150
200
250
300
350
19801982 198419861988 19901992 199419961998 200020022004 2006
ΣPGM/ t a-1
Pt
Pd
Rh
global
gross demand
– Europe: 27% of total demand & 33% of autocat
6Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
Autocat demand & technology impact PGM prices – which impact catalyst costs …
M
0
2 0 0
4 0 0
6 0 0
8 0 0
1 0 0 0
8 1 8 2 8 3 8 4 8 5 8 6 8 7 8 8 8 9 9 0 9 1 9 2 9 3 9 4 9 5 9 6 9 7 9 8 9 9 0 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8
1 troz = 31 .1035 g
$ 100 /troz = $ 3215 /kg
M
0
2000
4000
6000
90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08
R hod ium
26.01.01: $ 1094 troz-1
$ troz-1 P t/ P d : London fix ing , R h:JM -base
P a llad ium
11.5.07$ 6350 troz-1
M
200
400
600
800
1000
1200
1400
81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08
P la tinum
PGM value autocat (2006)
Europe: 3.6 billion US-$World: 10.3 billion US-$
7Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
0
20
40
60
80
100
120
1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004 2006
Pt
Pd
RhΣ 1980-2007:Input Recycling
Rh 91 t - 14 t
Pd 499 t - 30 t
Pt 581 t - 38 t
Σ 1171 t - 82 t
Σ 1980-2007:Input Recycling
Rh 91 t - 14 t
Pd 499 t - 30 t
Pt 581 t - 38 t
Σ 1171 t - 82 t
Global / Europecumulative demand 3770 t / 1170 t recycling until 2007 500 t / 80 tstill „on the road“ 2300 t / 900 tlosses ≈ 1000 t / 200 t ?
Annual PGM gross demand for autocat
Main catalysts recycledtoday are from the early 1990’s.
How much of the later increase will become available for recycling ?
What needs to be done to secure these resources ?
CO2 primary equivalent:30 Mt for still “on the road”13 Mt for losses
Autocatalysts – an above ground PGM-stock to be mined with a 10-15 years delay
0
50
100
150
200
250
300
350
1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004 2006
Σ 1980-2007:Input Recycling
Rh 356 t - 43 t
Pd 1776 t - 176 t
Pt 1640 t - 285 t
Σ 3772 t – 504 t
Σ PGM/ t a-1
Pt
Pd
Rh
2007 M$ cum Mt CO2 Mt CO2 cumPd 18.275 1,3 16,7Pt 60.270 1,8 22,9Rh 52.022 0,8 10,9
130.567 3,9 50,4
1000 M$*130
1580 35
*global at 2006prices
Europe
global
8Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
Sources for spent catalystsfrom end-of-live vehicles (ELV) І from cat exchange (workshops)
PGM-Refining
Decanning
Collection logistic
SmeltingPGM-conc.
numbers for Germany
Ca. 1.000dismantlers+ 60.000 workshops
< 10 decanners
< 100 catalyst collectors
(incl. subcollectors)
< 10 smelters/refiners globally (1 fully integrated in Europe)
cat-c
eram
ic
cat-c
onve
rter
Refined metals arechemically/physically
identical with metals frommining (no “downcycling”)
The same recycling chaincould also be used for car
electronics
Recycling chain for autocatalysts -PGM-refining takes place at the very end
9Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
Example for “high-tech” metals recovery- Umicore’s Hoboken plant near Antwerp
• Unique flowsheet, focus on secondary materials
• Recovering 17 metals: Au, Ag, Pd, Pt, Rh, Ir, Ru, Cu, Pb, Ni, Sn, Bi, Se, Te, Sb, As, In
• Annual PGM-output > 30 t ≈ 7% of world mine prod.
• Wide range of complex precious metals bearing feed materials
• Market leader (EU) for car catalysts & circuit boards
• Global customer base
• Minimizing waste
• World class environ-mental standards (BAT)
Pt/Pd yield 98%
10Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
Recycling reality for autocatalysts: 50% PGM-losses globally with Europe even worse
Material flows of PGM‘s from autocatalysts in Germany 2001
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
11Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
User 1 finaluser n
Change of PGM component
PGM-Refining
Production scrap
E.g. car catalysts,PM in electronics,(dental)
PGM-precursor
assemblyPGM-component
End-product
PGM -salt
Coated monolith Cat. converter car
Return point/ Collection
Dismantling(possibly multistep)
Component collection
(possibly multistep)Conditioning
Decanning Car dismantler
Loss
es /
Sys
tem
out
flow
sfo
r pro
duct
Losses / System outflows (component / PGM’s)
No removal of PGM component
The challenge of “open cycles” - recycling from consumer durables
• Multiple changes of ownership, no connection between final owner and manufacturer • High product mobility & long life time, no defined EOL, reuse in other regions than 1st use• Intransparent material flows, “informal” participants in early “recycling” stages• High exports of old cars, computers etc. to less developed countries with poor recycling
infrastructure/awareness• Highly complex structures with numerous opportunities for failure of metals-recovery
→ Inherently inefficient, PGM recycling rate < 50% for entire lifecycle
12Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
Much better results are achieved in industrial, „closed loop“ cycles
Process incl. regeneration PGM-refining
Catalyst fines fromregeneration(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
Process incl. regeneration PGM-refining
Catalyst fines fromregeneration(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
Example: PGM-flows of Pt/Pd catalysts used in oil refining
→ Inherently efficient>90% measured efficiency
• PGM-product remains physically located at industrial plant
• Provider, user & refiner of PGM product work closely together
• User typically retains ownership of the PGMs
• transparent material flows• Industrial, professional attitude
among all stakeholders,
13Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
The report
Some books for more info:„Autoabgaskatalysatoren“ (2nd ed.)• Expert Verlag, Kontakt & Studium• ISBN 3-8169-2488-3• 400 S, 56 €
“Stoffströme der Platingruppenmetalle”• GDMB Medienverlag, Clausthal Zellerfeld 2005• ISBN 3-935797-20-6• 234 S., über 70 Abbildungen und Tabellen, 45 €
“ Materials Flow of PGMs in Germany”• English edition with intoduction by GFMS• GFMS-Verlag, London 2005• ISBN 0-9543293-7-6• 300 S., 100 €
14Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
The European autocat lifecycle - what steps can be influenced by whom?
cat-/car
production
1st user
“ELV”export
ELV
disman
tling
“2nd” user
lastuser
cat
collectioncatdecanning
PGM
refining
PGMmining
Σ 5-15%
Σ<<5%
> 40%
<< 5%
car industry
legislation
business ethics*
impact area
*authorities, recycling & car industry to increase
transparency & fight criminal activities
15Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
There is much more in cars than PGM
other metals contained (in kg/vehicle)*built (Europe): 1990 → 2004weight/vehicle 900kg 1350kg
• Cu ≈ 1.2%: 11kg → 16kg
• Al ≈ 8%: 70kg → 120kg
• Pb ≈ 1%: 9kg → 13kg
• Steel ≈ 65%: 590kg → 870kg
• + Zn, Sn, Cr, special metals
• + Ag, Au, Pd in car-electronics
• + Pt, Ir in spark plugs & sensors built 1990 ≈ deregistered in 2006
2004 ≈ deregistered in 2020
*source: Daniel Goldmann, VW Sicon
16Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
PGM recycling has significant benefits …
• less environmental burden to „mine the catalyst“ (> factor 5 in CO2 impact)
• huge intrinsic PGM value that can be recovered (> 50 billion US-$)
• improved supply security• Relief of supply / demand balance
mitigates price increase and volatility cat-converter catalyst ceramic
150t
2t 0,5t
Mine ore cat-converter catalyst ceramic
150t
2t 0,5t
Mine ore
1kg PGM is contained in …
Car companies can establish internal collection systems for catalysts from contract workshops → weight account model with catalyst recycler/producer, recovered PGMs can be used for fresh catalystsCar companies should support an effective recycling of ELV-cars & catalysts in their own interest. ELV-exports out of Europe reduce the supply base for recycling PGMs and other metals significantly. They indirectly contribute to tightness of supply and rising metal prices.
A company which follows a sustainable business approach must not ignore the effects of current ELV-exports (image risk)
… which can be of vital interest for the car industry
17Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
What needs to be done
Car industry
• consider ELV more as a resource opportunity and less as a waste problem. Spent catalysts can have a strategic impact on future raw material supply
• select the right partners for creating effective loops
• mid-/long-term: rethink business model – how to transfer an open cycle into a closed loop system? → ownership of car? (e.g. for fuel cell cars)
Authorities / legislation
• better monitor ELV flows / prevent export* of real scrap cars (minimum standards)
• recycling quotas which only consider the recycled cars and ignore the exports are meaningless
• improve resource policy for secondary raw materials (from an EU-perspective)
All: car & recycling industry; authorities
• create professional multi stakeholder co-operations to close the loop• set up effective, industry driven and transparent ELV & autocat flows
*out of Europe
18Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGMThank you for your attention Umicore Precious Metals Refiningchristian.hagelueken@eu.umicore.comwww.preciousmetals.umicore.com
19Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
Questions ?
Annex
21Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
0
200
400
600
800
1000
1200
1900 1910 1920 1930 1940 1950 1960 1970 1980 1990 2000
Pt PdUS-$/troz
Industrial demandConsumer demandJewellery & investment
-> 1920‘sPt-catalyst nitric acid
Mid 1950‘sPt-reforming cat.
-> 1975autocat. US
-> late 1960‘sPt- jewellery
Japan
1900-1930Pt-cat.H2SO4
-> 1989Pt in PC-harddisks
-> 1985Pd in MLCC
-> mid 1980‘s: Pt for LCD glass
-> 1985: autocat. Europe
1988: high Pt-investment Japan
-> mid 1990‘sPt- jewellery China
-> 2000 Europe Diesel boom
-> 2004 Pd-jewellery
China
1995-2001 Pd-dominated
autocat
→ 1900: Pd/C-cat. (fine chemistry)
annual averages until 2006-08
Fuel Cells?
Historic milestones in Pt & Pd applicationsand corresponding price development
22Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
A market partially beyond industrial control– Some practices in autocat recycling• Fake converters sold into market (with unloaded bricks, cement filling, iron, …).
• Leaching of PGMs from converters/ceramics with subsequent sale of leached ceramic to market at “normal” cat-prices.
• Selling of used converters as spare parts.
• Backdooring of low value converters against too high telquel prices to less educated market participants.
• Tax-free cash purchase.
• Money laundering (one of the reasons for overpricing ?).
• Hidden deals/bribing of contract partners.
• Assay skimmings: manipulation of weights, moisture content, biased samples, false report of analytical results, ….
• Theft:...of new catalysts from cars on a parking lot or a manufacturer’s plant, spent catalysts from collectors/decanners, ... Concealment of stolen catalysts - it seems not to be difficult to feedback these materials into the recycling chain.
• Interpol listed criminals temporarily dominating local markets and always finding a „refining“ outlet.
23Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
A market partially beyond industrial control– Why could assay skimming be attractive?
A manipulation of 3% (0.223% vs 0.23% PGM) means a fraud of 36 k$ !.This already reaches the magnitude of refining charges of ≈ 50 k$.
⇒ A company could almost offer treatment free of charge and take the profit on assay / weight skimming.
⇒ often it’s even more than 3% (5 up to 10%).
These malicious practices create a heavily distorted playing field for those who strictly follow ethical business standards.
10 t/a spent autocatalyst at 0.12% Pt, 0.08% Pd, 0.03% Rh→Σ 0.23%) makes 12 kg Pt + 8 kg Pd + 3 kg Rh
at Pt=1400 $, Pd = 350 $; Rh = 6000 $/troz
means 1.2 Mio $ intrinsic value
24Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
Low probability for future PGM-recycling from many export cars
• exports mainly to Eastern Europe (& beyond) & Africa
• in most of these countries no emission legislation /-control in place
• insufficient car maintenance, bad road conditions
• high probability for destruction of catalyst → emission of ceramic/PGMs (misfire, bumps on converter ...)
• Usually high vehicle lifetime, catalyst has rather no significance (as long as car is still driving)
• insufficient recycling infrastructur, missing awareness for catalyst recycling
• difficult logistical frame conditions
• exports mainly to Eastern Europe (& beyond) & Africa
• in most of these countries no emission legislation /-control in place
• insufficient car maintenance, bad road conditions
• high probability for destruction of catalyst → emission of ceramic/PGMs (misfire, bumps on converter ...)
• Usually high vehicle lifetime, catalyst has rather no significance (as long as car is still driving)
• insufficient recycling infrastructur, missing awareness for catalyst recycling
• difficult logistical frame conditions
Europe: ca. 1/3 of ELVs are exported(ACEA 2004) → today it could be close to 50%
25Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
Known PGM-Reserves, being minable economically in theory at 1997 price levels
0
5.000
10.000
15.000
20.000
25.000
30.000
Platinum Palladium Rhodium
Tons
Others North-America Russia South Africa
PGM availability – sufficient reserves* at even higher resources**
130 *114 *
* Multiple Total Consumption 2005
119 *
* Could be economically extracted at a given price level**known or assumed PGM content in ore deposits
USD/g 1997 2007*Pt 12,73 40,41
Pd 5,72 11,41Rh 9,58 195,12
* Jan-Sept.
26Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
Different dimensions of resource scarcity
Absolute resource scarcity: depletion of geological resources that can be extracted even at higher prices
Relative resource scarcity: supply can (temporarily) not follow an increasing demand
• Time lag & investment risk for new mines and smelters• Political unrest, war, natural disasters, …
Continuous degradation of the natural resource base• Declining ore grades• More difficult mining conditions (mine depth, geographical location, political
frame conditions, …)• Number of deposits/mines & their global distribution
⇒ increasing costs, energy demand, environmental burden, …⇒ impact on biosphere (rain forest, Antarctic, ocean mining, …)⇒ regional dependences – „battle for resources“ ?
Structural resource scarcity: constraints from “coupled production” of „minor metals“ (Rh, Ru, Ir, … In, Bi, Se, Te …) with „major metals“ (Pt, Ni, Cu, Zn, Pb, …)
27Christian Hagelüken, 12.12.2007 2nd PGM-roundtable: Material flows of car related PGM
The Umicore recycling loop for automotive companies
coating of freshcatalysts with PGM
at Umicore
collection of spentcatalysts/scrap
catalyst manufacturing e.g. by the automotive
industry
recycling of PGMof spent catalysts
at Umicore
PGM-credit oncustomer weight
account
spent catalyststo Umicore