Paper submitted to the 3rd International Conference “Platinum Metals in the Modern Industry, Hydrogen Energy and Life Maintenance of the Future” (XI`AN-PM`2008)

Platinum Engineered Materials of Umicore

Jürgen Neumann, Sven Jantzen, Andreas Panowitz and Jürgen Leyrer

Umicore AG & Co. KG, Rodenbacher Chaussee 4, P.O. Box 1351; 63403 Hanau, Germany

Abstract:

Umicore's business unit Platinum Engineered Materials (PEM) is one of the world’s leading producers of platinum equipment for the production of high quality glass and platinum based catalysts for the chemical industries.

Our philosophy is value creation for our customers and partners in any of our business areas is the overriding goal that we are driven by:

• Managing complexity by applying a comprehensive business approach

• Providing sustainable benefits by innovation & technology

• Striving for long-term relationships enabling joint learning

• Applying market & application driven technical & commercial processes

PEM`s ability to offer complementary competences and resource-saving processes has made us an attractive partner for numerous companies of high reputation around the globe. Our long-lasting experience of more than 100 years in many of our target markets does certainly support this, reinforced by our company's overall history that is dating back for more than 200 years!

Deriving our business model from the various application and market requirements, we do not limit ourselves to precious metal materials only. We also provide a non-PGM based complementary product & service portfolio - all out of one hand!

This paper will give an overview about Umicore activities in the field of platinum based products and catalysts, especially where it knows its expertise in materials science, chemistry and metallurgy can make a real difference.

Key Words: Umicore; Platinum Engineered Materials; PEM; Glass Industry Applications, Nitric

Acid; Catalysts; Performance Catalysts; Industrial Specialties; Bushings ==========================================================================

Umicore Group

Umicore is a materials technology group. Its activities are centred on four business areas:

Advanced Materials, Precious Metals Products and Catalysts, Precious Metals Services and Zinc

Specialties. Each business area is divided into market-focused business units.

Umicore focuses on application areas where it knows its expertise in materials science, chemistry

and metallurgy can make a real difference, be it in products that are essential to everyday life or

those at the cutting edge of new technological developments. Umicore`s overriding goal of

sustainable value creation is based on this ambition to develop, produce and recycle materials in a

way that fulfils its mission: materials for a better life.

The Umicore Group has industrial operations on all continents and serves a global customer base;

it generated a turnover of EUR 8.3 billion (€1.9 billion excluding metal) in 2007 and currently

employs some 14,800 people.

Figure 1: Umicore approach to materials technology

Umicore's business unit Platinum Engineered Materials (PEM) is one of the world’s leading

producers of platinum equipment for the production of high quality glass and platinum based

catalysts for the chemical industries.

Our philosophy is value creation for our customers and partners in any of our business areas is

the overriding goal that we are driven by:

• Managing complexity by applying a comprehensive business approach

• Providing sustainable benefits by innovation & technology

• Striving for long-term relationships enabling joint learning

• Applying market & application driven technical & commercial processes

PEM`s ability to offer complementary competences and resource-saving processes has made us

an attractive partner for numerous companies of high reputation around the globe. Our long-lasting

experience of more than 100 years in many of our target markets does certainly support this,

reinforced by our company's overall history that is dating back for more than 200 years!

Deriving our business model from the various application and market requirements, we do not limit

ourselves to precious metal materials only. We also provide a non-PGM based complementary

product & service portfolio - all out of one hand!

Figure 2: Platinum Engineering Materials: Value creation

Performance Catalysts

Following Ostwald’s approach to apply very practical considerations regarding catalyst and

operating conditions on his ammonia conversion process, Umicore started already long time ago to

consider an engineering approach towards this topic rather than an isolated view on catalyst

gauzes. Consequently the focus was steadily directed on the complexity and interactivity of various

process aspects and hence leads to the modular system concept that in the meantime is well

established and appreciated by many of our partners.

Adding value to the customer through the integrated consideration and perfecting of customers

process engineering by modelling and simulation

Figure 3: UHDE medium pressure ammonia converter and its flow characteristic under

operating conditions

To perfectly comply with our mission we have extended and improved our well-known MKS

(Modulares Katalysator System™) a wide range of sophisticated modules like our product modules

PLATINIT® and MULTINIT® structures, and especially the technology-based engineering and

service modules.

Adding value to the customer through customized catalyst & getter lay-out design focused on the

specific operating conditions for

� higher efficiency

� longer lifetime

� lower PGM inventory

Figure 4: MULTINIT® catalyst gauze and simulation of the reaction course of ammonia

oxidation

Our latest product innovation was certainly also triggered by the strong demand for N2O emission

control, but should not be seen as a solution to this issue only. Our new multifunctional ceramic

product family can serve the purpose to selectively decompose N2O. Depending on the process

characteristics it can also work on aspects of gas flow behaviour as a non-catalytically active

product line.

Adding value to the customer through a system approach, offering the industry exclusive expertise

in the integration of all components

� PGM catalyst & getter gauzes,

� Honeycombed ceramic based catalyst for N2O abatement

Figure 5: MULTICOMB GreenLine, Umicore’s catalyst for reduction of N2O emissions in

nitric acid industry

By means of numeric fluid mechanic (CFD), experimental research studies in lab, pilot and

industrial reactors, and a strong internal catalyst knowledge Umicore developed a unique new

multifunctional product family aiming at an overall improved performance of today’s Ostwald

process designs.

Glass Industry Applications

As one of the world’s leading engineers and suppliers of PGM components for the glass industry, we consider our main task to add value to our customers system by optimization of

• Efficiency

• Stability

• Security

We are proud to be considered as standing at the forefront of the development of ground-breaking materials and advanced component design, making us an expert partner for the glass industries in converting such achievements into individually planned solutions.

Our task is to manage complexity for our customers by

• Increasing PGM component functionality

• Increasing PGM component lifetime

• Decreasing PGM component weight

Engineering

Our engineers take into account all aspects relevant to the working life and steady function of a PGM component, such as the construction of the steel frame, insulation, temperature distribution and thrust and floating bearings. Their thinking is not driven in terms of components and singularities, but by the need to take a consistence approach to the comprehensive evaluation of the overall system.

Our unique engineering and design capabilities are dedicated to the pursuit of process excellence. To achieve this, we design the system and provide you with an accurate assessment of fundamental dimensions and with a detailed PGM component illustration.

Our component design is based on mathematical calculations and advanced methodologies for mathematical simulations and numerical analyses that ascertain the properties of all critical parameters, such as peripheral factors, mechanics, strength and thermal expansion.

Figure 6: Directly heated feeder system

Material

More than thirty years ago, Umicore found a way to grain-stabilize platinum and its alloys with the introduction of a unique ODS (Oxide Dispersion Strengthened) material. Such ODS materials stabilize the fine grain of platinum, thus significantly improving the properties of the platinum engineered components in terms of quality and endurance. They are characterized by

• High mechanical strength

• High creep resistance

• High level of corrosion resistance towards aggressive glass melts

A)

B)

Figure 7: (A) Grain structure

(B) Crucible

Superior ODS: Umicore’s FKS alloys

Only with in-depth scientific research, unique material knowledge and specialist production it is possible to develop, manufacture and improve a superior and outstanding ODS material.

It is proven that FKS possesses superior properties in comparison to other ODS materials and standard alloys

• Mechanical strength is 4 to 8 times higher than of a standard alloy

• Level of corrosion resistance and creep resistance is about 1,000 times higher than that of a standard alloy

• Superior forming behaviour at room temperature compared to other ODS materials

• Superior weldability compared to other ODS materials

The combination of understanding glass, engineering capabilities and materials know how enables us to add value to our customers systems.

Industrial Specialties

Besides our catalyst and special glass expertise we do also serve other high-temperature areas

that are essential to today’s key industries: Temperature measurement by means of thermo wires,

analytical devices such as labware, or sophisticated electrodes for high tech spark plugs that do

increase the lifetime of engines.

Figure 8: Mission statement for Industrial Specialties

Apart from this we are also serving a further segment of the glass industry, which is a significant

contributor to today’s quality of life: we are talking about fiber glass that is needed in composite

materials. And again we have a Pt based component appearing on stage: a so-called bushing.

Let’s take a closer look at this important component.

Figure 9: Mission statement for Performance Bushings

A bushing is a small furnace, usually electrically-heated, used for the attenuation of liquid glass into

continuous fibers. It is a rectangular box, open at the top, receiving molten glass from a fore-hearth

of a glass melting furnace. As it is made of PtRh alloys, it is the key component in fiber glass

production processes in terms of capital requirement.

The demand of the rapidly growing global FRP (Fiber Reinforced Plastics) composite markets

(Aerospace, Construction, Infrastructure, Automotive, Transportation, Consumer, Electronics) for

thinner glass fibers with improved mechanical strengths, higher glass manufacturing temperatures

and higher production yields (while at the same time lowering manufacturing cost), dictate the

strong need for engineered bushing solutions utilizing ODS (oxygen-dispersion-strengthened)

materials in particular for the base-plate of the bushings. The most crucial limitation of the bushing

lifetime is the problem of base-plate sagging that reduces the economy of the fiber glass

manufacturing process and increases the Platinum and Rhodium process losses and inventory.

Umicore is actually the only player in the market that can provide real added value by means of an

impressive portfolio – and by combining the right competencies to generate an excellent

performance of our customers’ processes: being efficient, stable, and secure !

Although the most striking assets of our portfolio are certainly our engineering & designing, our

advanced ODS material (named “FKS”), and our advanced technologies, it is really unique that

Umicore can offer all this out of one hand!

Figure 10: Simulations of base-plate sagging and thermal stress for a non-ODS bushing

And actually this is what does really make the difference, as our cost reduction tools provide very

concrete commercial advantages for our customers:

• PGM savings by thinner sheets

• PGM savings by Rh reduced and even Rh free solutions

• PGM savings by decreased process losses

• Increased bushing service time

• Energy savings

• Tooling cost savings

• Maintenance cost savings

Furthermore we make any external consultant redundant and of course do train and support on-

site for an improved understanding of how the bushing and its periphery do interact. Finally we

close the loop with our unique refining and recycling capabilities and restart all these

considerations when designing the next generation of bushings:

Life Cycle Management through close long-term cooperation for sustainable and impressive

results!

References

For more details please visit our websites

• www.umicore.com

• www.platinum-engineered-materials.com