Magnetic Materials for Energy

Magnetic Materials for Energy ISC-IWKS Resources and distribution Criticality Prices Value chain Applications Material cycles Reduction Substitution Recycling Oliver Gutfleisch Technical University of Darmstadt, Material Science, Germany and Fraunhofer IWKS Hanau Materials Recycling and Resource Strategy TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 1

DAY - NIGHT CYCLE Renewable Energy is intermittent in nature CONVERSION of WWS RESIDENTIAL Heat / Cool / Light I DAY STORAGE I I SEASONAL CYCLE YEAR Geographical ENERGY DISTRIBUTION of WWS TRANSPORT CONVERSION into I MOBILITY Work DAY/WEEK INDUSTRY Heat / Work / Light LATITUDE (adapted from A. Züttel, EMPA) TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 2

The EFFICIENCY PARADOX Thomas Savary (1698) Thomas Newcomen (1712) James Watt (1769) Ref.: Jeff Rubin and Benjamin Tal, "Does Energy Efficiency Save Energy?" CIBC World Markets, InC. StrategEcon - November 27, 2007 TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 3

Demand in resources increases dramatically more products europarl.europa.eu more people more elements per product - COMPLEXITY TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 4 ISC-IWKS

ABUNDANCE OF ELEMENTS IN THE EARTH CRUST PER MILLION OF SI ATOMS http://pubs.usgs.gov/fs/2002/fs087-02/ Abundance of the chemical elements in Earth s upper continental crust. (1) Rock-forming elements (major elements in green field and minor elements in light green field); (2) Rare earth elements (lanthanides, La Lu, and Y; labelled in blue); (3) Major industrial metals (global production > 3 10 7 kg/year; labelled in red); (4) Precious metals (purple); (5) The nine rarest metals the six platinum group elements plus Au, Re, and Te (a metalloid). TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 5

CRUSTAL ABUNDANCES OF IRON AND OTHER MAGNETIC ELEMENTS, SHOWN ON A LOG-SCALE J.M.D. Coey, Magnetism and Magnetic Materials Cambridge, 2009 TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 6

Critical Metals (UNEP 2009) united nations environment programme TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 7

TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 8 New Scientist

Criticality Matrix TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 9

Rare earth metals Science News, August 27, 2011 TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 10

World wide production of rare earth oxides TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 11 ISC-IWKS

RE metal life cycle Du and Graedel, Rare Earth Stocks in NdFeB Magnets, Journal of Industrial Ecology, 2011 TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 12

Global estimates of end-of-life recycling rates for 60 metals and metalloids (2008) T. E. Graedel et al., J. Ind. Ecol. 15, 355 (2011). TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 13

Permanent Magnet Growth World production of sintered NdFeB in 2011: ~100.000 t (estimated 80% China, ~18% Japan, 2% Europe) The motor/generator in a hybrid electric vehicle contains 2 kg of NdFeB. Set to grow to between 10 million and 20 million vehicles by 2018. New designs of wind generators use NdFeB magnets at a rate of ~600 kg per mega-watt. This application alone has potential to increase RE demand by 25% per year above current production. Hard disc drives cannot function without RE permanent magnets. Formerly 70% of the NdFeB market this is now diluted by the other major applications. Solid state energy efficient cooling: Magnetocalorics 1kg MCE and 4 kg NdFeB per kilo-watt cooling power Adv. Mat. (Review) 23 (2011) 821 TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 14

Wind power World Wind Energy Association, http://www.wwindea.org, report from March 2010. TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 15

Percentages of NdFeB magnets production per region Du and Graedel, Rare Earth Stocks in NdFeB Magnets, Journal of Industrial Ecology, 2011 TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 16

WHICH ARE THE 17 RARE EARTHS? TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 17

THE RE INDUSTRY FOCUSES ON 15 ELEMENTS TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 18

TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 19

Rare Earth applications TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 20

Rare Earths in the car Science News, August 27, 2011 TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 21

APPLICATIONS OF RES TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 22

MAIN USAGES Sc Y La Ce Pr Light aluminium-scandium alloy for aerospace components, additive in Mercury-vapor lamps Yttrium-aluminium garnet (YAG) laser, yttrium vanadate (YVO4) as host for europium in TV red phosphor, YBCO high-temperature superconductors, yttrium iron garnet (YIG) microwave filters, energyefficient light bulbs High refractive index glass, flint, hydrogen storage, battery-electrodes, camera lenses, fluid catalytic cracking catalyst for oil refineries Chemical oxidizing agent, polishing powder, yellow colors in glass and ceramics, catalyst for self-cleaning ovens, fluid catalytic cracking catalyst for oil refineries, ferrocerium flints for lighters Rare-earth magnets, lasers, core material for carbon arc lighting, colorant in glasses and enamels, additive in didymium glass used in welding goggles, ferrocerium firesteel (flint) products. TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 23

MAIN USAGES Nd Sm Gd Tb Rare-earth magnets, lasers, violet colors in glass and ceramics, ceramic capacitors Rare-earth magnets, lasers, neutron capture, masers Rare-earth magnets, high refractive index glass or garnets, lasers, X-ray tubes, computer memories, neutron capture, MRI contrast agent, NMR relaxation agent Green phosphors, lasers, fluorescent lamps Dy Rare-earth magnets, lasers Lu PET Scan detectors, high refractive index glass TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 24

THE RES CAN BE DIVIDED IN SUBGROUPS TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 25

THE ALPHABET SOUP OF RES TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 26

RARE-EARTH ELEMENTS: DISCOVERY AND EARLY HISTORY Y -1794, Er -1842, Tb -1842, Yb -1878 Ytterby quarry Rare earth elements became known with the discovery of the black mineral "ytterbite" by Lieutenant Carl Axel Arrhenius in 1787, Oxides of: Gd Sm Pr Nd La Ce Memorial plaque of the ASM International society at the entrance of Ytterby mine TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 27

THE DISCOVERY OF EACH REE TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 28

ORIGIN OF EACH NAME TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 29

Carl Auer von Welsbach was not only the discoverer of neodymium and praseodymium, but was also the inventor of the light-mantle (using thorium), and of the rare earth industry. He built a factory to manufacture his mantles, and had discovered that the necessary thorium was available from monazite sand. But after the 6-10% thorium content had been extracted from the monazite, he had a lot of lanthanides left over, for which there was no commercial use. Thus, he began exploration for applications to which the rare earths might be put. Among his first discoveries/inventions to bear practical fruit turned out to be Mischmetal and the lighter flint, both of which continue in use a century later. Wikipedia TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 30

MISCH METAL misch metal, alloy consisting of about 50 percent cerium, 25 percent lanthanum, 15 percent neodymium, and 10 percent other rare-earth metals and iron. Misch metal has been produced on a relatively large scale since the early 1900s as the primary commercial form of mixed rare-earth metals. Misch metal alloyed with iron is the flint (spark-producing agent) in cigarette lighters and similar devices. Misch metal is also used as a deoxidizer in various alloys and to remove oxygen in vacuum tubes. As an alloying agent in magnesium, it contributes to high strength and creep resistance. TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 31

WHERE DOES THE DEMAND FOR RES ORIGINATE FROM? TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 32

WHERE DOES THE DEMAND FOR RES ORIGINATE FROM? TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 33

WHERE DOES THE DEMAND FOR RES ORIGINATE FROM? TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 34

FROM WHERE DOES THE SUPPLY FOR RES ORIGINATE? TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 35

China s approach 1992: Deng Xiaoping there is oil in the Middle East; there is rare earth in China. 1999 Jiang Zemin : Improve the development and applications of rare earth, and change the resource advantage into economic superiority. China s White Paper on rare earths 20-06-2012: http://news.xinhuanet.com/english/business/2012-06/20/c_131665123.htm TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 36

RARE EARTH MINING MADE IN CHINA TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 37

Rare earth production Cost vs environmental and safety standards Chinese Society of Rare Earths: One ton of RE elements creates 2,000 tons of mine tailings. Tailings are the ground up materials left behind once the RE has been extracted from the ore. Often, these tailings can contain thorium, which is radioactive. One ton of RE produced generates 8.5 kg of fluorine and 13 kg of dust; and using concentrated sulfuric acid high temperature calcination to produce one ton of calcined RE ore generates ~10,000 m 3 of waste gas containing dust concentrate, hydrofluoric acid, sulfur dioxide, and sulfuric acid, 75 m 3 of acidic wastewater plus about one ton of radioactive waste residue (containing water). Processing Rare Earth Oxides in China TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 38

Ranking of raw materials - reports Minerals, Critical Minerals and the US Economy (National Academics 2008) Critical Metals for Future Sustainable Technologies and their Recycling Potential (Öko-Institut für UNEP, 2009) Rohstoffe für Zukunftstechnologien (Fraunhofer ISI und IZT für BMWi, 2009) Critical raw materials for the EU - Report of the Ad-hoc Working Group on defining critical raw materials (EC 2010) TU Darmstadt Materialwissenschaften Funktionale Materialien Prof. O. Gutfleisch ESM 2013 39