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Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
Critical raw materials – the industry perspective with focus on recycling
KU Leuven EmeritiforumFaculty Club
31.01.2013, Leuven, Belgium
Christian Hagelüken & Egbert Lox, Umicore
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
Introduction to Umicore
Significance of critical raw materials/technology metals
„Urban Mining” – recycling opportunities & challenges
Conclusions
3Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
Umicore’s history: the roots
1853 Asturienne des Mines
1805 Vieille-Montagne
1928
1908 Soc. Gén. Métallurgique de Hoboken
1887
1919 Société Générale de Minerais
1959 Mechim
1906 Union Minière du Haut-Katanga
1981
1901 ACEC
1919 SIBEKA
1873 Degussa (DM)
1800 1850 1900 1950 2000
1985
1989
1985
Union Minière
1990
1970
Usine de Désargentation
Compagnie des Métaux d’Overpelt
1981
1989
2003DMC² PMG
2010
1919
2001
2007 Nyrstar
2005 Cumerio
2005 Traxys
MHO
UM
1989
(Degussa)
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
Umicore’s transformation:A change in the business profile
Capital intensivemetal refiner
R&D intensivematerials technology
company
1.036
1.725
2.1242.000
2.290
1.919 1.9101.902
1.358
1.723
9,3%
2,5%3,2%
4,8%5,7% 5,4% 5,8%
7,0% 6,9%6,0%
6,8%
8,6%
10,2%
8.0%7,2%
11,1%8,7% 8,4%
14.6%
10.5%
0
500
1.000
1.500
2.000
2.500
2002 2003 2004 2005 2006 2007 2008 2009 2010 2011
DiscontinuedUmicore
Core Umicore
Capex /revenues
R&D /revenues
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013 5
Umicore – a materials technology companyour business approach
• We transform metals into hi-tech materials
• We use application know-how to create tailor-made solutions in close collaboration with our customers
• We close the loop and secure supply by recycling production scrap and end-of-life materials
materialsolutionsMetals
Applicationknow-how
Recycling
Materialsolutions
ChemistryMaterial science
Metallurgy
14,600 people in 79 industrial sites worldwide, turnover € 2.3 billion excl. metal
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
Our elementsUmicore’s products and services cover 26 different metals and materials
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
Key megatrends for Umicore
· More stringent emission control
· Resource scarcity
· Renewable energy
· Electrification of the automobile
More stringent emission control
Resource scarcity Renewable energy
Electrification of the automobile
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
Introduction to Umicore
Significance of critical raw materials/technology metals
„Urban Mining” – recycling opportunities & challenges
Conclusions
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013 10
Source: Achzet et al., Materials critical to theenergy industry, Augsburg, 2011
Booming product sales & increasingfunctionality boost demand for (technology) metals
Drivers:• growing population (Asia!)• growing wealth• technology development & product
performance
0200400600800
100012001400160018002000
199719981999200020012002200320042005200620072008200920102011
Annual global sales of mobile phones Source: after Gartner statistics (www.gartner.com)
Million units
300170
470SmartPhones
forecast
Accumulated global mobile phone sales until 2010 ~ 10 billion unitscontaining in total 2500 t Ag, 240 t Au, 90 t Pd, 38,000 t Co, 90,000 t Cu, …
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
From waste to secondary resourcesProducts, infrastructure and residues form huge urban mine
• EEE Over 40% of world mine production of copper, tin, antimony, indium, ruthenium & rare earths are annually used
• Mobile phones & computeraccount for 4% world mine production of gold and silver and for 20% of palladium & cobalt.
• Cars> 60% of PGM mine production goes into autocatalysts increasing significance for electronics (“computer on wheels“)
• In the last 30 years we extracted > 80% of the REE, PGM, Ga, In, … that have ever been mined
• Massive shift from geological to anthropogenic deposits “URBAN MINE” with large amounts of technology metals
% mined in 1980-2010
% mined in 1900-1980
Mine production since 1980 / since 1900
0%10%20%30%40%50%60%70%80%90%
100%
Re Ga In Ru Pd Rh Ir REE Si Pt Ta Li Se Ni Co Ge Cu Bi Ag Au
% mined in 1980-2010
% mined in 1900-1980
Composition of mobile phones
mobile phone substance (source Nokia)
Composition of mobile phones
mobile phone substance (source Nokia)
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013 12
Much more technology metals mined in the last 3 decades than in the entire history of mankind
% mined in 1980-2010
% mined in 1900-1980
Mine production since 1980 / since 1900
0%10%20%30%40%50%60%70%80%90%
100%
Re Ga In Ru Pd Rh Ir REE Si Pt Ta Li Se Ni Co Ge Cu Bi Ag Au
% mined in 1980-2010
% mined in 1900-1980
REE = Rare Earth Elements
Many of these still sitting in our products and infrastructurehuge anthropogenic „ore deposit“ for current & future exploitation
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013 13
Efficient production and use of energy will further boost demand for technology metals
Fuel CellsLight Emitting Diodes (LED)
Photovoltaic (solar cells) Electric vehicles & batteriesGermaniumGalliumSeleniumIndiumSilver
LithiumCobaltNickel Rare Earth ElementsCopper
GalliumIndiumGermaniumSilver
Platinum IridiumCobalt
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
Critical raw materials (EU Commission)materials for which a threat to supply could involve harm to the national economy, and for which the risk is higher than for most other raw materials in the coming 10 years
minor metal
Source: Critical Raw Materials for the EU – European Commission Enterprise & Industry, July 2010
precious metal
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
Potential metal scarcity ?
Absolute= resource depletion → not in near future, but:
Natural resource base degrades continuously (ore grades, mining conditions) → increasing costs, energy & water demand, environmental burden
Temporary = mismatch demand supply → ongoing
• Sudden demand increase (new applications, market surges, speculative, …) • Time lag & investment risk for new mines and smelters • Trade barriers, political unrest, war, natural disasters, …• Special vulnerability in case of concentrated supply (deposits, mining companies)
Structural= supply constraints from “coupled production” → ongoing
• typical for many technology metals• Supply of „minor metals“ (In, Bi, Se, Te …Rh, Ru, Ir, … ) depends on
mining of „major metals“ (Ni, Cu, Zn, Pb, Pt, …)
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
1 Price explosion by ITO boom for LCDs (2003-2006). Increased primary supply & recycling of production scrap drove prices down again (amplified by & economic crises)
Temporary & structural scarcity
Temporary scarcity → price volatilitye.g. LCD impact on indium prices1
PGMPGM
Structural scarcity:supply constraints by coupled production (→ price inelastic)
2 Increased demand can only be met if demand for carrier metals rises accordingly → places an absolute cap on availability.
Source: Hagelüken/Meskers (2010), in: Linkages of sustainability,
Temporary scarcity:
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
Substitution vs Recycling system approach is needed
Substitution:• No sustainable solution if substitutes
are from same metal family → problem shifting
• Difficult for hi-tech applications based on specific material properties
• Can lead to supply constraints& price surges for substitute
• Consider impact of substitute on recyclability
Not competing but complementary approaches, set the right priorities:• Recycling potential sometimes easier to realise than substitution (e.g. PGM in autocat)• Focus on substitution of dissipative applications of critical metals (e.g. Ag in RFID)• Look for substitutes with abundant availability
Source: Hagelüken/Meskers (2010), in: Linkages of sustainability,
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
Introduction to Umicore
Significance of critical raw materials/technology metals
„Urban Mining” – recycling opportunities & challenges
Conclusions
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013 19
Consensus on benefits of a circular economy mining & recycling are complimentary to secure metal supply for infrastructure & products
Reduce metal losses and boost recycling along all steps of the lifecycle
Securing access to scarce resourcesReducing impact on energy/climate, biosphere & water resourcesInducing innovation & creating jobs
Residues
Residues
Residues
Residues
Historic wastes (tailings, landfills)
Dissipation
Residues
Residues
Residues
Residues
Historic wastes (tailings, landfills)
Dissipation
End-of-LifeProductmanufacture
Use
Natural resources
Metals, alloys& compounds
New scrap
Raw materials production
Recyclingfrom
industrial materials
from Concentrates
& ores
productreuse
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013 20
Source: UNEP (2011) Recycling Rates of Metals
Still far away from closing the loop for most technology metals
End-of-Life recycling rates for metals in metallic applications
WEEE:precious metal recycling rates below 15%
technical & non-technical innovation is crucial for success
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013 21
Urban mining “deposits”can be much richer than primary mining ores Primary mining
• ~ 5 g/t Au in ore• Similar for PGMs
Urban mining• 200 g/t Au, 80 g/t Pd & Cu, Sn, Sb, …
in PC motherboards• 300 g/t Au, 100 g/t Pd … in cell phones• 2,000 g/t PGM in automotive catalysts
factor 40& more
Challenge : how to accumulate millions of discarded EoL product into „urban mines” of a reasonable (= economically viable) size
Low grade, high volume, fixed location High grade, millions of units, global dissemination
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013 22
Recycling needs a chain, not a single process- system approach is crucial
Collection10,000’s
Prepro-cessing
1000‘s
100‘s
Example recycling of WEEERecovery of technology metals
from circuit boards
3
Number of actors in Europe
Dismantling
Total efficiency is determined by weakest step in the chain Make sure that critical fractions reach these plants
Smelting & refining of technology metals (metallurgy)
Example: 30% x 90% x 60% x 95% = 15%
products
components/fractions
metals Inve
stm
ent n
eeds
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013 23
Bottle glass
Green glassWhite glassBrown glass
Steel scrap
+
Circuit boards Autocatalysts
• “Mono-substance” materials without hazards• Trace elements remain part of alloys/glass
Recycling focus on mass & costs
• ”Poly-substance” materials, incl. hazardouselements
• Complex components as part of complex products
Focus on trace elements & value
Technology metals need smart recycling - traditional mass focussed recycling does not fit
PM & specialty metals PGMs
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
Multi-metal recycling with modern technologyHigh tech & economies of scale thermodynamic limits exist
• Recovery of 20 metals from WEEE, catalysts, batteries, smelter by-products etc. Au, Ag, Pt, Pd, Rh, Ru, Ir, Cu, Pb, Ni, Sn, Bi, Se, Te, Sb, As, In (from universal process).Co, REE, (Li); Ga (from specialised processes)
• Value of precious metals enables co-recovery of specialty metals (‘paying metals’)• High energy efficiency by smart mix of materials and sophisticated technology• High metal yields, minimal emissions & final waste
Umicore‘s integrated smelter-refinery in Hoboken/AntwerpTreatment of 350 000 t/a
ISO 14001 & 9001, OHSAS 18001
Collection Pre-processing
Dis-mantling
Materialsrecovery
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
Business Group Recycling Business unit Jewellery & Industrial Metals
• Provides gold and other precious metals containing products to the jewellery sector and for industrial applications
• Closed loop offering for precious metals products, refining and related supply services
• Multi-regional business concept, strong in Europe and expanding worldwide
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013 26
Umicore BatteryRecycling Plant
Special process for recycling of cobalt, copper, nickel, generation of REE (& Lithium) concentrates
Inauguration Sept. 2011
Capacity 7000 t/a
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013 27
From: Disney/Pixar www.wall-e.com
Metal recycling from complex products- technical* & non-technical** challenges to overcome
*Accessibility of relevant components/materials- Electronics in cars, REE magnets in electric motors, …
„Design for Disassembly“, mechanical processing, „Pre-shredder“-technology
*Thermodynamic limits & difficult substance combinationsfor „trace elements“
- Rare Earths, Gallium/Germanium, Lithium, Tantalum, …„Design for Recycling,“ fundamental metallurgical research, pilot plants
**Severe deficits in closing the loop for consumer goods- Electronics, cars, batteries, lamps, …
better collection, tracing & tracking of material flows, prevention of dubious exports, creating transparency, economic incentives, …
Complex products require a systemic solution & interdisciplinary approaches (Product design, mechanical processing, metallurgy, economics, ecology, social sciences)
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013 28
Dismantling &pre-processingCollection Smelting &
refining
Deficits in closing the loop for consumer goods- relevant materials don‘t reach best suited processes
Collect more & better• Legislative support & ambitious targets• Awareness & infrastructure• New business models (leasing, deposit systems …)• Better data (inventory of the urban mine)• Number and type of collection categories, interplay logistics recycling technology
Feed into & keep within appropriate recycling channels• Measure & monitor global product/material flows down to final process• Smart tracking & tracing technology to prevent illegal exports• More transparency & combined stakeholder responsibility along chain• Process certification to ensure use of high quality processes
More focus on critical/technology metals than on mass only
Dismantling &pre-processingCollection Smelting &
refining
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
Introduction to Umicore
Significance of critical raw materials/technology metals
„Urban Mining” – recycling opportunities & challenges
Conclusions
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013 31
Metallurgy
Mechanical processing
Costs &revenuesCollection
& logistics
Product design &business models
Consumer-behaviour
Material perspective
Product perspective
Recycling success factors
Recycling requirements 1. Technical recyclability as
basic requirement2. Accessibility of relevant
component3. Economic viability
intrinsically or externally created
4. Completeness of collection business models, legislation, infrastructure
5. Channelling & keeping within recycling chain
6. Technical-organisational set-up of chain
7. Sufficient recycling capacity
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
Research & developmentKey figures
Research & development headcount• 889 people currently
of which 236 in associates
Patents• 569 patent families• 215 Filings the last 5 years
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
Research & development Locations
Group R&Denergy materials
catalysts
recycling
performance materials energy materials
R&D in the BU’s
Group R&D
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
External Science & TechnologyOverview of partners – academia & RTO’s (non-exhaustive)
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
The European Institute of Innovation and Technology
• Increase sustainable growth and competitiveness by reinforcing the innovation capacity of the EU
• Interaction in the knowledge triangle: education – research – industry
• Entrepreneurship is the keyword
• Towards an EIT labelledmaster or PhD diplome
Higher Education
Research & Technology
Industry & SMEs
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
Knowledge and Innovation Community (KIC)
• The objectives of the KIC are to:• put the innovation web into practice,• create new jobs,• educate and develop entrepreneurs, • while addressing current societal challenges.• Each KIC is a legal entity consisting of several innovation hotspots
(co-location centres) and must become self-sustainable.• Three KICs are currently running on:
• climate change• information and communication technologies• sustainable energy
• Next potential KICs (start in 2014):• Healthy living and active ageing• Food• Raw Materials
Christian Hagelüken, & Egbert Lox, Umicore, KU Leuven Emeritiforum, Leuven, 31.01.2013
Thank you !
Contact:[email protected]@umicore.comwww.umicore.com;www.preciousmetals.umicore.com
For background information:Hagelüken, C., C.E.M. Meskers: Complex lifecycles of precious and special metals, in: Graedel, T. , E. van der Voet (eds): Linkages of Sustainability. Strüngmann Forum Report, vol. 4. Cambridge, MA: MIT Press, 2010