Dr. Christian Hagelüken, Umicore Precious Metals Refining. Hagelueken.pdf · Dr. Christian Hagelüken, Umicore Precious Metals Refining ... Platinum t/a % Palladium t/a % Rhodium

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!

http://www.platinum.matthey.com/cgi-bin/dynamic.pl?template=popup&page_id=none&suffix=&page=africa

http://www.platinum.matthey.com/cgi-bin/dynamic.pl?template=popup&page_id=none&suffix=&page=industry_links


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


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


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


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-$World: 10.3 billion US-$


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


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


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%


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


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


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


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%)


PGM-refining

Refining loss

Refining loss


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,


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 €


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


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


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


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


Questions ?

Annex


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


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.


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


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%


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.


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, …)


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

Documents

Dr. Christian Hagelüken, Umicore Precious Metals Refining. Hagelueken.pdf · Dr. Christian Hagelüken, Umicore Precious Metals Refining ... Platinum t/a % Palladium t/a % Rhodium