Dr. Matthias Buchert, Öko-Institut e.V., Germany

m.buchert@oeko.de

envietech2008, Vienna 1st February 2008

Precious Metals Recycling in a Global Perspective

PGM are crucial in modern industrial societies

• PGM usage in today‘s key technologies (chemical catalysis, emission purification, electronics, fuel cells, ...)

• 85% of mankind‘s cumulative PGM-mine production (> 7000 t) took place from 1980 onwards

• German PGM-gross demand will rise by 30% until 2020

• Germany today: gross usage 40 t/a (1.2 Billion $), inventory > 250 t (> 7.5 Billion $)

• High price volatility severely impacts demand segments

• PGM-recycling shows significant ecological benefits compared to PGM-mining (about 10 times better in the case of CO2 equiv.)

• Global dependence on South Africa and Russia, no PGM mining in Europe

• PGM usage in today‘s key technologies (chemical catalysis, emission purification, electronics, fuel cells, ...)

• 85% of mankind‘s cumulative PGM-mine production (> 7000 t) took place from 1980 onwards

• German PGM-gross demand will rise by 30% until 2020

• Germany today: gross usage 40 t/a (1.2 Billion $), inventory > 250 t (> 7.5 Billion $)

• High price volatility severely impacts demand segments

• PGM-recycling shows significant ecological benefits compared to PGM-mining (about 10 times better in the case of CO2 equiv.)

• Global dependence on South Africa and Russia, no PGM mining in Europe

The research report

“Stoffströme der Platingruppenmetalle”GDMB Medienverlag, Clausthal Zellerfeld 2005ISBN 3-935797-20-6234 S., über 70 Abbildungen und Tabellen, 45 €

“ Materials Flow of PGM in Germany”English edition with introduction by GFMSGFMS Ltd, London 2005ISBN 0-9543293-7-6300 pages, 100 €

Authors: Hagelüken, Buchert, Stahl

Material flows of PGM

Significance of PGMSecondary material flows & PGM-lifecycle

efficienciesResults of a research project

oil refining & chemical catalystsautomotive catalystsOther applications

Summary & conclusionsConsequences for the recycling industry

The global mine production of Platinum Group Metals (PGM) fits into a small room

|- 2,6 m -| |- 2,2 m -| |- 1,25 m -| |-1,50 m -| |0,55 | m

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 & RussiaPGM Concentration < 10 g/tValue: 14 Billion $ (2006)

Global mine production of PGM

Data: Christian Hagelüken, Umicore

Global PGM net demand 2006

Rhothers

chemical

autocat

Pdothers

electronics

jewellery

dental

autocat

Pt

autocat

jewellery

chemical

others

global net demand 2006

Data: Christian Hagelüken, Umicore, Numbers based on JM

PGM-flows of Pt/Pd catalysts used in the oil refining industry

Process incl. regeneration PGM-refining

Catalyst fines from regeneration(5-10%)

Process losses incl. charge/discharge(1-2%)

Pt/Pd recovered(96-98% yield)

PGM-refining

Refining loss

Refining loss

Pt/Pd recovered(96-99% yield)

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

Werte nach JM Platinum

Mine above ground

0

20

40

60

80

100

120

1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004 2006

Pt

Pd

RhΣ 1980-2006:Input Recycling

Rh 87 t - 10 t

Pd 473 t - 21 t

Pt 516 t - 32 t

Σ PGM/ t a-1

Data: Christian Hagelüken, Umicore, Numbers based on JM

Automotive catalysts: gross demand Pt,Pd,Rh in Europe

Motivation to use this “Mine above ground”

Catalyst recycling ....

... secures a sustainable supply of PGM

... contributes to stabilise PGM-prices

... decreases the dependence on primary producers

(mainly South Africa and Russia)

... has a much lower ecological impact than

PGM-mining

PGM-flow and loss distribution for ELV- auto catalysts in Germany, 2002

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

Statistical data by year, emission level and engine size

New registrations

Car inventory

De-registrations

Calculation model

PGM-loading by emission level and engine size

Transfer into an „Excel“-model

De-registered catalyst cars PGM potential

from catalyst recycling

Project findings, actual market data and forecast

Field study

PGM recovered from catalysts in

Germany

Losses

Auto catalyst - methodology

PGM-Refining

decanning

Collection logistic

Sources for spent catalystsfrom end-of-live vehicles (ELV) І from cat exchange (workshops)

cat-converter

cat-converter

cat-ceramic

Ca. 1.000dismantlers+ 60.000 workshops

< 10 decanners

< 10 smelters/refinersglobally (1 fully integrated in Europe)

< 100 catalyst collectors(including

subcollectors)

Catalyst-cars

Catalytic converters

Catalyst ceramic

System boundary Germany

Recycling chain for automotive catalysts - the physical PGM recovery is limited to a few specialists worldwide

Green numbers refer to Germany

Challenge for PGM-recycling from many export cars

exports mainly to Eastern Europe (& beyond) & Africa; Middle East

in many of these countries no emission legislation /-control in place

insufficient car maintenance, bad road conditionshigh probability for destruction of catalyst

→ emission of ceramic/PGM (misfire, bumps on converter ...)

Usually high vehicle lifetime, catalyst has rather no significance (as long as car is still driving)

insufficient recycling infrastructure, missing awareness for catalyst recycling

difficult logistical frame conditions

PGM-recycling potential from automotive catalysts in D until 2020 („reference scenario“)

PGM beim Auto-Kat. (ELV+Ersatz)

0

5.000

10.000

15.000

20.000

25.000

1993

1995

1997

1999

2001

2003

2005

2007

2009

2011

2013

2015

2017

2019

PGM

in k

g

PGM PotentialPGM Recycling

PGM from auto catalysts (ELV & exchange catalyst)

0

3.000

6.000

9.000

12.000

15.000

18.000

2001

2002

2003

2004

2005

2006

2007

2008

2009

2010

2011

2012

2013

2014

2015

2016

2017

2018

2019

2020

PGM

in k

g

Auto-Kat.-Kreislaufw.Auto-Kat.

A linear increase of the dynamic recycling rate to 70% (“loop scenario”) would double the

PGM recycling volumesReference scenario

“loop” scenario*

Deficit analysis: PGM lifecycle efficiencies for main segments

0% 20% 40% 60% 80% 100%

electroplating

Homogeneous Catalysts Pt

dental

electronics

Automotive Catalysts

Homogeneous Catalysts Pd

Homogeneous Catalysts Rh

jewellery

Oil Refining & Chemical Catalysts

glass industry

PGM-lifecycle efficiency = dynamic recycling quota

0,20,50,20,060,049,81,71,81,20,115,6

Lifecylelosst/a

5,06,43,50,40,115,02,42,51,50,437,2

Gross-demand

t/a

Σ

low

h igh

?? What makes the difference ??

Direct recycling loops

Product manufacturingPGM-

precursorPGM-

product

Product use in process

Charge Use (regeneration)

Dis-charge

Product RecyclingCondi-tioning

PGM-refining

PGM‘sE.g. Oil-refining catalysts, chemical catalysts, glass-equipment

Direct relationship along lifecycle(manufacturer, industrial user, PGM-refiner)

No change of PGM-ownership after initial delivery to end user (weight account transfer)

Industrial parties, professional handling, transparent material flows

PGM content of product is known through entire cycle

High PGM recycling ratio (usually > 90%)

User 1 finaluser n

Change of PGM component

Manufacturing Use Recycling-Logistics physical Recycling / Refining

PGM-Refining

Production scrap

Indirect recycling loops

E.g. car catalysts, PGM in electronics, (dental)

PGM-precursor

assemblyPGM-component

End-product

PGM -salt

Coated monolith Cat. converter car

Return point/ Collection

Dismantling(possibly multistep)

Componentcollection

(possibly multistep)Conditioning

Decanning Car dismantler

Loss

es/ S

yste

m o

utflo

ws

for p

rodu

ct

Losses / System outflows (component / PGM’s)

No removal of PGM component

No direct business relations between industrial parties involved, loop is broken by private end-users and non-industrial parties.

Multiple changes of PGM-ownership, component value fluctuates with PGM-prices.

No professional handling along entire chain, in-transparent material flows after production, “grey and black channels” occur in end-of-life and scrap chain.

PGM lifecycle losses difficult to detect, information on PGM-content gets lost.

In certain areas dilution of PGM in end product to an extend, that recycling is not economically viable by itself (electronics).

Low PGM recycling ratio (usually < 50%).

Indirect recycling loops II

User 1 Finaluser n

PGM-Refining

PGM-precursor

assemblyPGM-component

End-product

Return point/ Collection

Dismantling(possibly multistep)

Componentcollection

(possibly multistep)Conditioning

E.g. car catalysts, PGM in electronics

0

5.000

10.000

15.000

20.000

25.000

30.000

35.000

40.000

45.000

50.000

55.000

2001

2002

2003

2004

2005

2006

2007

2008

2009

2010

2011

2012

2013

2014

2015

2016

2017

2018

2019

2020

PGM

in k

g

Auto-Kat.B rennsto ffzelleSonstigeIndustrie-Ka t.SchmuckDentalE lektronikGlasGalvanik

PGM gross demand

0

5.000

10.000

15.000

20.000

25.000

30.000

2001

2003

2005

2007

2009

2011

2013

2015

2017

2019

PGM

in k

g

PGM-recycling

0

5 .0 0 0

1 0 .0 0 0

1 5 .0 0 0

2 0 .0 0 0

2 5 .0 0 0

3 0 .0 0 0

2001

2002

2003

2004

2005

2006

2007

2008

2009

2010

2011

2012

2013

2014

2015

2016

2017

2018

2019

2020

PGM

in k

g

Au to -Ka t.

E le k tro n ik

Bre n n s to ffze l leSo n s tig e

In d u s tr ie -K a t.Sch m u ck

D e n ta l

Gla sGa lva n ik

PGM net demand

0

5.0 00

1 0.0 00

1 5.0 00

2 0.0 00

2 5.0 00

2001

2002

2003

2004

2005

2006

2007

2008

2009

2010

2011

2012

2013

2014

2015

2016

2017

2018

2019

2020

PG

M in

kg

PGM losses

Forecast PGM-balance D, reference scenario)

Growth trends per PGM-segment

Stable- oil refining catalysts

(reforming, isom., hydrocracking)- gauze & fixed bed catalysts

(HNO3, HCN, ...)- industrial emission catalysts- dental & jewellery- electroplating

Stable- oil refining catalysts

(reforming, isom., hydrocracking)- gauze & fixed bed catalysts

(HNO3, HCN, ...)- industrial emission catalysts- dental & jewellery- electroplating

Moderate- Glass industry- Heterogeneous powder catalysts

(e.g. Pd/C)- homogeneous catalysts- automotive catalysts- electronics- sensors & spark plugs

Moderate- Glass industry- Heterogeneous powder catalysts

(e.g. Pd/C)- homogeneous catalysts- automotive catalysts- electronics- sensors & spark plugs

Strong- niche heterogeneous catalysts- special homogeneous catalysts- automotive electronics- auto catalyst-scrap- electronic scrap

Strong- niche heterogeneous catalysts- special homogeneous catalysts- automotive electronics- auto catalyst-scrap- electronic scrap

Importance of PGM in industrial societies confirmed, range of applications is further widening

PGM-gross demand will rise significantly, but no significant impact of fuel cells up to 2020

PGM recycling is a necessity (sustainability, price volatility, ecological benefit). ≈ 50% of PGM-gross demand covered by recycling

Efficient PGM-recovery processes & sufficient refining capacity available, some new materials require technical innovations

Industrial PGM-applications achieve high PGM-lifecycle efficiencies (direct loops between professional parties)

Significant PGM-losses occur in consumer applications with indirect loops (not collected; non-professional chains; grey business practises)

Without significant improvements in collection of auto catalysts & electronics a huge PGM-recycling potential will be lost inevitably: export challenge!

Importance of PGM in industrial societies confirmed, range of applications is further widening

PGM-gross demand will rise significantly, but no significant impact of fuel cells up to 2020

PGM recycling is a necessity (sustainability, price volatility, ecological benefit). ≈ 50% of PGM-gross demand covered by recycling

Efficient PGM-recovery processes & sufficient refining capacity available, some new materials require technical innovations

Industrial PGM-applications achieve high PGM-lifecycle efficiencies (direct loops between professional parties)

Significant PGM-losses occur in consumer applications with indirect loops (not collected; non-professional chains; grey business practises)

Without significant improvements in collection of auto catalysts & electronics a huge PGM-recycling potential will be lost inevitably: export challenge!

Project summary & conclusions

How to Transform Existing Systems?

Example “low tech” – Gold recycling in Bangalore/India …

foto: EMPA/CH

Total Au-recovery efficiency only ≈ 25%, while environmental & health damage is dramatic (Rochat, Keller, EMPA 2007)

… this takes place in large parts of the world today!Let us work for future co-operation in an internationally operating and optimized closed-cycle materials economy!

Thank you for your attention!