Post on 18-Dec-2015
The role of the Chemical Industry in Critical Raw Materials
Prof. Dr. Michael Röper, BASF SEIndustrial Technologies 2012, Aarhus
June 20, 2012
The chemical industry is the key enabler of sustainable industrial production
Raw materials present about 30 % of the costs of a chemical product; sourcing at competitive prices is essential
Carbon feedstocks – oil, gas, coal, renewables, and CO2 – are the base of organic chemistry that creates about 90% of the value of the chemical industry
Some inorganic feedstocks are regarded as critical: Noble metals, some rare earth elements, indium, lithium, phosphate, …
The chemical industry helps to overcome the tightness of critical raw materials through improving the exploitation of deposits, improving the efficiency in processing, recycling, and substitution
Raw Materials are of Key Importance Raw Materials are of Key Importance to the Chemical Industryto the Chemical Industry
Critical Inorganic FeedstocksCritical Inorganic Feedstocks
UseNoble metals: contacts in the electronic industry, catalysts in exhaust gas converters, fuel cells, oil refining, chemical conversionsSome rare earth elements: magnets, phosphors, ceramics, alloys, glass & polishing, catalystsIndium: transparent conductor for lighting & displays, touch screensLithium: batteries, glass, ceramics, pharmaceuticalsPhosphates: fertilizers, detergents, animal feed
Strategies to improve the availabilityImproving the exploitation of depositsImproving the efficiency in processingReducing the use by improved design & materials scienceRecycling after useSubstitution by more abundant feedstocks
Estimated global reserves of 100 million metric tons REO are sufficient to meet demand for the next 100 years (USGS, 2010)
97% of REO mining and purification is today done in China
Negligable capacity outside China due to costs and environmental issues (significant Th amounts in ores)
4
Rare earth oxides (REO)Rare earth oxides (REO)Reserves
7%
22% all other countries 13% USA5% Australia
38% China19% CIS
3% India
5
Ore
Mineral concentrate
RE/Th/U concentrate
Individual REO
Grinding, magnetic/gravity separation, flotation
Mixed RE concentrate
Cracking (acids or bases)
Separation of Th and/or U
Separation of REO
In situ mining(Ion adsorption clays)
RE metals
Metallothermic or electrolytic reduction
REE ProcessingREE ProcessingFrom ores to REO (RE oxides) and RE metals
Beneficiation/CrackingBeneficiation/Cracking
Challenges• Similar chemical properties of
REE• Environmental issues
Possible Improvements• Improved extraction to reduce
energy consumption and use of chemicals
• Chemicals & processes for waste water treatment
• Novel separation processes
Challenges• Recovery not quantitative• Tailings are not used today• High energy demand in cracking
step
Possible Improvements• Improved beneficiation of
minerals by tailor-made chemicals
• process intensification for cracking
Separation of the individual REO‘sSeparation of the individual REO‘s
Enhanced REE ProcessingEnhanced REE Processing
Better Catalyst Design to Reduce CRM UseBetter Catalyst Design to Reduce CRM Use
Catalysts are essential for exhaust gas cleaning, oil refining, and chemical production.Many catalysts are based on noble metals (Pt, Pd, Rh, ...) on supports and some contain rare earths as co-catalysts – improved design can reduce the use of these materials:Reduction of active particles size on the support increases the catalytically active surface and allows reduction of metal content while maintaining or improving the catalyst propertiesIncrease of catalyst life-time (service life) reduces the need for replacement and decreases the down time for catalyst replacementRational catalyst design enhances product yields and selectivities (e.g. by improved supports, promoters or geometry)Replacement of CRMs by less critical materials (e.g. platinum by nickel)
Substitution of CRMs
Application Subcatagory CRM Substitute
Electrics Batteries Cobalt Iron, organic polymers, manganese
Graphite Silicon (nano)
Lanthanum Zinc-air, lithium-air, aluminium-air, super-capacitors
Fuel cells Platinum Silver, biocatalysts
Electronics Semiconductors, LED, OLED, photovoltaics
Gallium ZnO/MgS, organic polymers, zinc, tin
Indium (ITO)
Organic polymers, graphene, carbon nontubes, ZnO with metal grids
Materials Catalysts Platinum Nickel, iron, biocatalysts
Tungsten Iron oxide
Metals, alloys Cobalt Nickel, carbides, nitrides, chromium, boron, titanium
Tungsten Silicon carbide, molybdenum
Graphene as a Substitute for ITO Graphene as a Substitute for ITO as Transparent Electrodesas Transparent Electrodes
Graphene
Graphite
The chemical industry is the key enabler of sustainable industrial production and relies heavily on a reliable raw materials supply at competitive conditions (carbon & inorganic feedstocks)
Some inorganic feedstocks are regarded as critical: Noble metals, some rare earth elements, indium, lithium, phosphate, …
The chemical industry helps to overcome the tightness of critical raw materials through improving the exploitation of deposits, improving the efficiency in processing, recycling, and substitution
Redesign of materials and products through material science is an efficient tool to reduce CRM utilization and to improve the sustainability of industrial production
ConclusionsConclusions
Back-upBack-up
The role of the Chemical Industry in Critical Raw Materials
Prof. Dr. Michael Röper, BASF SEIndustrial Technologies 2012, Aarhus
June 20, 2012
Carbon Feedstocks for the Chemical Carbon Feedstocks for the Chemical Industry in GermanyIndustry in Germany
Coal1%
Naphtha, Oil Derivatives
72%
Renewable Feedstocks
13%
Natural gas14%
Total: 21,2 Mill. t (2008)Source: VCI, FNR 2010
15
Availability of Fossil Feedstocks
Situation Base for power&fuel industries: fuels for
mobility, electrical power, heating&cooling
Mineral oil the most important feedstock of the chemical industry, but is used almost exclusively in the energy sector
Goal: Material use rather than burning! Better energy efficiency by
electromobility, better heat insulation and light weight construction
Use of renewable energy Increase mineral oil & gas reserves by
improved recovery methods
146
60
41
Range: Reserves / yearly consumption*
* Source: Bundesanstalt für Geowissenschaften und RohstoffeMineral oil Gas Coal
Years
16
Raw Material Change in Carbon Feedstocks
To enable the chemical industry to replace or supplement oil, the conventional chemical raw material, with alternatives
GOALTo develop new technologies for entry into the existing value-adding chains
Examples: Reduction of CO2 by use of renewable energy, improved & new catalytic conversions
STRATEGY
Natural gasOil Coal Carbon dioxideBiomass