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Dealing with complexity in developing new recycling<br />
technologies - the case of critical metals<br />
Kris Van den Broeck<br />
<strong>Umicore</strong> <strong>Precious</strong> <strong>Metals</strong> <strong>Refining</strong><br />
International Minor <strong>Metals</strong> Conference<br />
International Minor <strong>Metals</strong> Conference 2011<br />
Philadelphia 4 - 6 May 2011
Introduction to <strong>Umicore</strong><br />
• Global materials technology company<br />
• Mission: “materials for a better life”<br />
• Majority of growth comes from clean technologies:<br />
technologies that are specifically designed to optimize the use of<br />
natural resources and to reduce environmental impact<br />
• 2010: turnover €9.7 billion , 14,386 employees<br />
• Listed Euronext Brussels, market capitalization €4.5 billion<br />
• Visit us at www.umicore.com<br />
Dealing with complexity in developing<br />
new recycling technologies<br />
2<br />
International Minor <strong>Metals</strong> Conference 2011<br />
Kris Van den Broeck
Key megatrends for <strong>Umicore</strong><br />
Resource scarcity<br />
More stringent emission control<br />
Renewable energy<br />
Dealing with complexity in developing<br />
new recycling technologies<br />
3<br />
Electrification of the automobile<br />
International Minor <strong>Metals</strong> Conference 2011<br />
Kris Van den Broeck
Leading manufacturer of Special <strong>Metals</strong><br />
Tellurium<br />
Capacity: 150 t/y<br />
Quality: 2N5<br />
Form: powder<br />
Indium<br />
Capacity: 50 t/y<br />
Quality: 4N, 4N8<br />
Forms: ingots, shots, shells<br />
Selenium<br />
Capacity: 600 t/y<br />
Quality: 2N5, 3N, 4N5, 5N,<br />
5N+<br />
Forms: powder, shots<br />
Dealing with complexity in developing<br />
new recycling technologies<br />
4<br />
International Minor <strong>Metals</strong> Conference 2011<br />
Kris Van den Broeck
Roadmap<br />
● What are critical metals? Why recycling?<br />
● Complexitiy in recycling<br />
• Economic<br />
• Technological<br />
• Commercial<br />
● Case studies<br />
• ITO recycling<br />
• CIGS recycling<br />
• Battery recycling<br />
● Closing remarks<br />
International Minor <strong>Metals</strong> Conference 2011
Dealing with complexity in developing<br />
new recycling technologies<br />
6<br />
International Minor <strong>Metals</strong> Conference 2011<br />
Kris Van den Broeck
Critical raw materials (EU Commission)<br />
materials for which a threat to supply could involve harm to the national economy,<br />
and for which the risk is higher than for most other raw materials in the coming 10 years<br />
minor<br />
metal<br />
Source: Critical Raw Materials for the EU – European Commission Enterprise & Industry, July 2010<br />
Dealing with complexity in developing<br />
new recycling technologies<br />
7<br />
International Minor <strong>Metals</strong> Conference 2011<br />
Kris Van den Broeck
Critical raw materials (USA-DOE)<br />
importance to the clean energy economy and risk of supply disruption<br />
on short (0-5 years) and medium term (5-15 years)<br />
Source: U.S. Department of Energy – Critical materials strategy, December 2010<br />
Dealing with complexity in developing<br />
new recycling technologies<br />
8<br />
International Minor <strong>Metals</strong> Conference 2011<br />
Kris Van den Broeck
“Within the next five years (short-term perspective), Öko-Institut (DE)<br />
estimates metals tellurium, indium and gallium to be regarded as most<br />
critical due to rapid demand growth as well as serious supply risks<br />
combined with moderate recycling restrictions.”<br />
Source: UNEP report, July 2009<br />
Critical metals for future sustainable technologies and their recycling potential<br />
Dealing with complexity in developing<br />
new recycling technologies<br />
9<br />
International Minor <strong>Metals</strong> Conference 2011<br />
Kris Van den Broeck
Policies for secure access & materials efficiency<br />
EU Commission:<br />
US – Department Of Energy:<br />
• improve access to and extraction of<br />
primary resources<br />
• diversify global supply chains<br />
• level playing field in trade & investment<br />
• recycling<br />
• substitution<br />
• materials efficiency<br />
• reuse<br />
• recycling<br />
• substitution<br />
• materials efficiency<br />
Criticality factors & need for recycling do not come out of the blue<br />
Dealing with complexity in developing<br />
new recycling technologies<br />
10<br />
International Minor <strong>Metals</strong> Conference 2011<br />
Kris Van den Broeck
Clean tech applications: impact on demand<br />
Compound Annual Growth Rate by 2015 [%]<br />
50<br />
40<br />
30<br />
20<br />
10<br />
0<br />
Selenium Indium Tellurium Gallium<br />
Glass & pigments Metallurgy (incl alloys) Optics & electronics (incl LCD)<br />
Photovoltaics<br />
Others (incl chem & pharma)<br />
Source: <strong>Umicore</strong> scenario for PV: 80 GW/y in 2020, 35% share Thin Film PV<br />
Dealing with complexity in developing<br />
new recycling technologies<br />
11<br />
International Minor <strong>Metals</strong> Conference 2011<br />
Kris Van den Broeck
jan/11<br />
jul/10<br />
apr/11<br />
jan/11<br />
In,Se,Te,Ga - price evolution [$/kg] update 26-Apr-11<br />
150<br />
140<br />
130<br />
120<br />
110<br />
100<br />
90<br />
80<br />
70<br />
60<br />
50<br />
40<br />
30<br />
20<br />
10<br />
0<br />
jul/00<br />
jan/01<br />
jul/01<br />
jan/02<br />
jul/02<br />
jan/03<br />
jul/03<br />
jan/04<br />
jul/04<br />
jan/05<br />
jul/05<br />
jan/06<br />
jul/06<br />
jan/07<br />
jul/07<br />
jan/08<br />
jul/08<br />
jan/09<br />
jul/09<br />
jan/10<br />
jul/10<br />
jan/11<br />
jan/00<br />
jul/00<br />
jan/01<br />
jul/01<br />
jan/02<br />
jul/02<br />
jan/03<br />
jul/03<br />
jan/04<br />
jul/04<br />
jan/05<br />
jul/05<br />
jan/06<br />
jul/06<br />
jan/07<br />
jul/07<br />
jan/08<br />
jul/08<br />
jan/09<br />
jul/09<br />
jan/10<br />
1100<br />
1000<br />
900<br />
800<br />
700<br />
600<br />
500<br />
400<br />
300<br />
200<br />
100<br />
0<br />
Dealing with complexity in developing<br />
new recycling technologies<br />
12<br />
International Minor <strong>Metals</strong> Conference 2011<br />
Kris Van den Broeck<br />
jan/00<br />
450<br />
425<br />
400<br />
375<br />
350<br />
325<br />
300<br />
275<br />
250<br />
225<br />
200<br />
175<br />
150<br />
125<br />
100<br />
75<br />
50<br />
25<br />
0<br />
Indium, AvgMetalBulletin 2000-2011 Selenium, AvgMetalBulletin 2000-2011<br />
Tellurium, AvgMetalPrices 2004-2011 Gallium, LowMetalPages 2005-2011<br />
jan/04 jul/04 jan/05 jul/05 jan/06 jul/06 jan/07 jul/07 jan/08 jul/08 jan/09 jul/09 jan/10 jul/10 jan/11<br />
1000<br />
900<br />
800<br />
700<br />
600<br />
500<br />
400<br />
300<br />
200<br />
100<br />
0<br />
oct/10<br />
jan/05<br />
apr/05<br />
jul/05<br />
okt/05<br />
jan/06<br />
apr/06<br />
jul/06<br />
okt/06<br />
jan/07<br />
apr/07<br />
jul/07<br />
okt/07<br />
jan/08<br />
apr/08<br />
jul/08<br />
oct/08<br />
jan/09<br />
apr/09<br />
jul/09<br />
okt/09<br />
jan/10<br />
apr/10<br />
jul/10
continuously increasing demand for a.o.<br />
clean tech applications<br />
&<br />
government policies<br />
&<br />
consumer + producer policies<br />
<br />
need for recycling<br />
International Minor <strong>Metals</strong> Conference 2011
Recycling: clear benefits<br />
<br />
De-coupling from primary production<br />
production scrap is a significant, readily available resource<br />
<br />
Economically justifiable<br />
production scrap has an economic value<br />
<br />
<br />
<br />
<br />
Lower environmental impact<br />
recycling needs less energy & has lower CO 2<br />
emissions<br />
Mitigate metal scarcity by resource conservation<br />
special metals are reused in products, instead of landfilled<br />
Remove impact of metal price fluctuations<br />
the producer may remain owner of the metal in the scrap<br />
Secure access to raw materials<br />
you know the location, the recycler and the owner<br />
Dealing with complexity in developing<br />
new recycling technologies<br />
14<br />
International Minor <strong>Metals</strong> Conference 2011<br />
Kris Van den Broeck
Roadmap<br />
What are critical metals? Why recycling?<br />
● Complexitiy in recycling<br />
• Economic<br />
• Technological<br />
• Commercial<br />
● Case studies<br />
• ITO recycling<br />
• CIGS recycling<br />
• Battery recycling<br />
● Closing remarks<br />
International Minor <strong>Metals</strong> Conference 2011
Recycling: as easy as in the movies?<br />
Wall-E (Pixar movies)<br />
Dealing with complexity in developing<br />
new recycling technologies<br />
16<br />
International Minor <strong>Metals</strong> Conference 2011<br />
Kris Van den Broeck
Economic complexity<br />
Positive vs negative value materials<br />
Production scraps vs End-Of-Life materials<br />
Value<br />
Contained<br />
metals<br />
Positive value recycling<br />
Lost metals<br />
Recovered<br />
metals<br />
Supplier’s<br />
return<br />
Recycler’s<br />
return<br />
• e-scrap / printed circuit boards<br />
• spent automotive catalysts<br />
• spent industrial catalysts<br />
• spent ITO targets<br />
• CIGS production scraps<br />
Recycling cost<br />
The value of the material is sufficient to cover<br />
suppliers return + recyclers return + recycling cost<br />
no direct need for regulation or incentives<br />
Dealing with complexity in developing<br />
new recycling technologies<br />
17<br />
International Minor <strong>Metals</strong> Conference 2011<br />
Kris Van den Broeck
Recycling potential<br />
From production wastes -TODAY<br />
Very high<br />
High<br />
Medium<br />
Low<br />
Very low<br />
Selenium Indium Tellurium Gallium<br />
Glass & pigments Metallurgy (incl alloys) Optics & electronics (incl LCD)<br />
Photovoltaics<br />
Source: <strong>Umicore</strong><br />
Others (incl chem & pharma)<br />
Dealing with complexity in developing<br />
new recycling technologies<br />
18<br />
International Minor <strong>Metals</strong> Conference 2011<br />
Kris Van den Broeck
Economic complexity (2)<br />
Positive vs negative value materials<br />
Production scraps vs End-Of-Life materials<br />
Negative value recycling<br />
Value<br />
Lost metals<br />
Recycler’s<br />
return<br />
• rechargeable batteries<br />
• LCD displays<br />
• PhotoVoltaic (end-of-life) modules<br />
Contained<br />
metals<br />
Recovered<br />
metals<br />
Recycling cost<br />
Supplier’s recycling fee<br />
The value of the material is not sufficient to cover<br />
suppliers return + recyclers return + recycling cost<br />
financing models, government incentives or legislation is needed<br />
Dealing with complexity in developing<br />
new recycling technologies<br />
19<br />
International Minor <strong>Metals</strong> Conference 2011<br />
Kris Van den Broeck
Recycling potential<br />
From End-of-LIfe wastes –FUTURE<br />
Very high<br />
High<br />
Medium<br />
Low<br />
Very low<br />
Selenium Indium Tellurium Gallium<br />
Glass & pigments Metallurgy (incl alloys) Optics & electronics (incl LCD)<br />
Photovoltaics<br />
Source: <strong>Umicore</strong><br />
Others (incl chem & pharma)<br />
Dealing with complexity in developing<br />
new recycling technologies<br />
20<br />
International Minor <strong>Metals</strong> Conference 2011<br />
Kris Van den Broeck
Technological complexity<br />
Multi-metal (complex) materials require:<br />
• State-of-the-art technology;<br />
• combination pyro-& hydrometallurgy<br />
• Knowledge management (knowhow, IP)<br />
• R&D support;<br />
• continuous improvement<br />
• break-through ideas<br />
In<br />
Pb<br />
Au<br />
Pd<br />
Cu<br />
As<br />
Sb<br />
Bi<br />
Sn<br />
Se<br />
Ir<br />
Ru<br />
Ag Rh<br />
Te Pt<br />
Ni<br />
• Sampling & assaying essential to determine return distribution<br />
• Environmental management excellence;<br />
• resource efficiency (materials and energy)<br />
• eco-efficiency<br />
Dealing with complexity in developing<br />
new recycling technologies<br />
21<br />
International Minor <strong>Metals</strong> Conference 2011<br />
Kris Van den Broeck
Commercial complexity<br />
• Market intelligence;<br />
• supply market<br />
• metals market<br />
• worldwide sales network in order to secure access to scraps<br />
• ethical supply<br />
• Credit worthiness important in business where high (metal) values are in the<br />
loop<br />
• Control the costs<br />
• Offer a no-worries service (pick-up, customs formalities, metal account)<br />
• EHS support: MSDS, CLP, REACh-compliant<br />
• Auditing<br />
Dealing with complexity in developing<br />
new recycling technologies<br />
22<br />
International Minor <strong>Metals</strong> Conference 2011<br />
Kris Van den Broeck
Roadmap<br />
What are critical metals? Why recycling?<br />
Complexitiy in recycling<br />
• Economic<br />
• Technological<br />
• Commercial<br />
● Case studies<br />
• ITO recycling<br />
• CIGS recycling<br />
• Battery recycling<br />
● Closing remarks<br />
International Minor <strong>Metals</strong> Conference 2011
ITO target recycling<br />
Closed loop recycling of indium in Providence (US)<br />
• Spent ITO targets have a high value, which drives recycling<br />
• <strong>Umicore</strong> combines production of indium and ITO targets with recycling<br />
of spent targets, all in-house<br />
• Old target can easily be swapped for new target via regional centers in<br />
US, Taiwan and Liechtenstein<br />
• Indium (as ITO target) quickly enters the life cycle again<br />
Efficient material usage and a closed material loop<br />
Dealing with complexity in developing<br />
new recycling technologies<br />
24<br />
International Minor <strong>Metals</strong> Conference 2011<br />
Kris Van den Broeck
CIGS production scrap recycling<br />
New process in Hoboken (BE) [capacity 50 t/y]<br />
• <strong>Umicore</strong> has closed the cycle for production wastes<br />
from sputtering and evaporation chambers<br />
• Convert hazardous waste into valuable materials<br />
• Cu, In, Ga and Se are recovered for use in the PV or<br />
other industries<br />
• Business model:<br />
• Customer pays a treatment charge for the recycling service<br />
• <strong>Metals</strong> return is based on sampling and assaying of the<br />
production scrap<br />
• The customer may remain owner of the metals, so no<br />
impact of price fluctuations<br />
• Assistance with waste shipments etc. can be provided<br />
Dealing with complexity in developing<br />
new recycling technologies<br />
25<br />
International Minor <strong>Metals</strong> Conference 2011<br />
Kris Van den Broeck
Battery Recycling<br />
New process in Hoboken (BE) [capacity 7,000 t/y]<br />
First ever developed process with a specific focus<br />
on the need for rechargeable battery recycling<br />
Li-ion & NiMh<br />
• Unique recycling process with a maximum<br />
valorisation of valuable metals Co & Ni<br />
• Clean process with minimum energy use, CO 2 and<br />
waste generation<br />
• Safe and <strong>full</strong> service from battery transport to<br />
recycling, all complying with the strictest regulations<br />
First industrial pilot plant under construction, to be<br />
commissioned mid 2011<br />
• Future volume of this business is driven by the<br />
merging electrification of transport<br />
Dealing with complexity in developing<br />
new recycling technologies<br />
26<br />
International Minor <strong>Metals</strong> Conference 2011<br />
Kris Van den Broeck
Roadmap<br />
What are critical metals? Why recycling?<br />
Complexitiy in recycling<br />
• Economic<br />
• Technological<br />
• Commercial<br />
Case studies<br />
• ITO recycling<br />
• CIGS recycling<br />
• Battery recycling<br />
● Closing remarks<br />
International Minor <strong>Metals</strong> Conference 2011
Closing remarks<br />
• Present and expected future growth of the clean tech & high tech<br />
industry will place strong demand on specific “critical” materials<br />
that leads to a debate on their respective future availability<br />
• Recycling of production scraps (today) and End-of-Life modules<br />
(future) can make significant contributions to ensuring a secure<br />
metals supply<br />
• This recycling potential is found in currently minor applications,<br />
with high CAGR creating future material resources<br />
• <strong>Umicore</strong> operates appropriate technologies for efficient and<br />
environmentally sound recycling of production scraps<br />
• Effective recycling goes beyond technology aspects.<br />
Dealing with complexity in developing<br />
new recycling technologies<br />
28<br />
International Minor <strong>Metals</strong> Conference 2011<br />
Kris Van den Broeck
Thank you<br />
Contact<br />
Kris Van den Broeck<br />
Christina Meskers<br />
Address Adolf Greinerstraat 14<br />
2660 Hoboken<br />
Belgium<br />
e-mail<br />
kris.vandenbroeck@umicore.com<br />
christina.meskers@eu.umicore.com<br />
Website<br />
www.preciousmetals.umicore.com<br />
www.pvmaterials.umicore.com<br />
International Minor <strong>Metals</strong> Conference 2011
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