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Raw Material Status and New Developments in Processing ... - ABM Raw Material Status and New Developments in Processing ... - ABM

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Raw Material Statusand New Developments inProcessing and ApplicationsBernd GriebGregory KrollDavid Miller

<strong>Raw</strong> <strong>Material</strong> <strong>Status</strong><strong>and</strong> <strong>New</strong> <strong>Developments</strong> <strong>in</strong>Process<strong>in</strong>g <strong>and</strong> ApplicationsBernd GriebGregory KrollDavid Miller

Magnequench HistoryTimel<strong>in</strong>e• ’82 – General Motors, Sumitomo Special Metals <strong>and</strong> Ch<strong>in</strong>a Academy of Sciences discover a new permanent magnetmaterial composed of neodymium, iron <strong>and</strong> boron.• ’86 – GM forms MAGNEQUENCH as a bus<strong>in</strong>ess unit to commercialize Nd-Fe-B powder <strong>and</strong> builds 175,000 sq. ft. plant<strong>in</strong> Anderson, Indiana.• ‘95 – Ch<strong>in</strong>a National Non-Ferrous Metals Import & Export Corp. (CNIEC), San Huan <strong>and</strong> Sextant MQI Hold<strong>in</strong>gs acquireMAGNEQUENCH on September 30, 1995.• ‘98 – MAGNEQUENCH beg<strong>in</strong>s build<strong>in</strong>g 145,000 sq. ft. Tianj<strong>in</strong>, Ch<strong>in</strong>a powder manufactur<strong>in</strong>g facility.• ’00 – Production beg<strong>in</strong>s at Tianj<strong>in</strong> powder manufactur<strong>in</strong>g facility with 10 jet casters.• ‘01 – MAGNEQUENCH ceases powder production <strong>in</strong> Anderson <strong>in</strong> December <strong>and</strong> consolidates all production at Tianj<strong>in</strong>,Ch<strong>in</strong>a facility.• ‘04 – MAGNEQUENCH relocates all R&D together with sales <strong>and</strong> market<strong>in</strong>g to anew 17,000 sq. ft. facility <strong>in</strong> S<strong>in</strong>gapore Science Park.• ‘05 – MAGNEQUENCH merges with AMR Technologies, Inc. of Toronto, Canada;Neo <strong>Material</strong> Technologies, Inc is established• ’06 – 43,000 sq. ft Korat, Thail<strong>and</strong> facility is equipped with two MQ jet casters• ’07 – Production beg<strong>in</strong>s at Korat, Thail<strong>and</strong> manufactur<strong>in</strong>g facilityA Division of Neo <strong>Material</strong> Technologies Inc.

Overview<strong>Raw</strong> <strong>Material</strong> Supply <strong>and</strong> Dem<strong>and</strong> Update<strong>New</strong> <strong>Developments</strong> <strong>in</strong> <strong>Material</strong>s<strong>New</strong> <strong>Developments</strong> <strong>in</strong> Process<strong>in</strong>g<strong>New</strong> <strong>Developments</strong> <strong>in</strong> ApplicationsA Division of Neo <strong>Material</strong> Technologies Inc.

<strong>Raw</strong> <strong>Material</strong> Supply<strong>and</strong> Dem<strong>and</strong> UpdateA Division of Neo <strong>Material</strong> Technologies Inc.

Rare Earth Ore toMQP-Powder to MotorBastnasite Ore (CeFCO 3 )Flotation & Mill<strong>in</strong>g ProcessApply proprietary technologySeparation processChemicalTreatmentAMR bus<strong>in</strong>essAlloy<strong>in</strong>g FacilityHeat Treatment(Calc<strong>in</strong>ation)Shipped to MQTJHeated to 2,500CNd MetalRare Earth Oxide PowderAlloy is rapidlysolidifiedPowder shipped tocustomersEnd ApplicationsBonded NdFeB MagnetsEnd applicationsA Division of Neo <strong>Material</strong> Technologies Inc.

Extraction of Rare-EarthOxidesA Division of Neo <strong>Material</strong> Technologies Inc.

RE Environment<strong>and</strong> Production• Rare Earth Oxide (“REO”)output limited by Ch<strong>in</strong>a’s NDRC– Maximum output for 2007 isshown on the right– “Light Rare Earths” are found<strong>in</strong> the north– “Heavy Rare Earths” are found<strong>in</strong> the southTotal Rare Earth Oxide <strong>in</strong> Ch<strong>in</strong>a - By AreaSouthernCh<strong>in</strong>a, 35,773 ,27%Sichuan Area,22,059 , 17%Baotou &Sh<strong>and</strong>ong Area,75,000 , 56%~132,000 MTTotal NdPr Output <strong>in</strong> Ch<strong>in</strong>a - By AreaSichuanArea:Light REBaotou &Sh<strong>and</strong>ong:Light RESouthernCh<strong>in</strong>a:Heavy RESouthernCh<strong>in</strong>a, 7,870 ,29%Sichuan Area,3,750 , 14%Baotou &Sh<strong>and</strong>ongArea, 15,750 ,57%~27,500 MTA Division of Neo <strong>Material</strong> Technologies Inc.

The RE-Elements <strong>in</strong>different OresEu, 0.30%Gd, 0.70%Tb, 0.10%Sm, 1.50%Nd, 13.00%Dy, 0.20% Er, 0.00%Y, 0.90%Ho-Tm-Yb-Lu,0.00%Eu, 0.20% Dy, 0.01%Gd, 0.70%Tb, 0.01%Sm, 1.20%Baotou BastnasiteEr, 0.01%Y, 0.20%Ho-Tm-Yb-Lu,0.80%Pr, 4.10%La, 31.50%Nd, 16.70%La, 25.00%Ce, 47.70%SichuanBastnasitePr, 5.10%Er, 1.80%Y, 20.00%Ho-Tm-Yb-Lu,0.00%La, 30.40%Dy, 3.60%Ce, 50.07%Tb, 0.60%Gd, 4.80%Ce, 1.90%• The ma<strong>in</strong> RE elements areCe, La <strong>and</strong> YEu, 0.70%Sm, 5.20%Nd, 24.40%Pr, 6.60%Southern Clay (example)A Division of Neo <strong>Material</strong> Technologies Inc.

<strong>Raw</strong> <strong>Material</strong> Environment –Reduction of SupplyOrig<strong>in</strong>al Situation:Actual Situation:NDRC Quotas 2007REO (MT)Nd/Pr Oxide(MT)NDRC Quotas2007REO (MT)Nd/PrOxide (MT)Nd/Pr OxidReduction(MT)Baotou & Sh<strong>and</strong>ongArea75,00015,750Baotou &Sh<strong>and</strong>ong Area60,71412,750(3,000)Sichuan Area22,0593,750Sichuan Area--(3,750)Southern Ch<strong>in</strong>a35,7737,870Southern Ch<strong>in</strong>a35,7737,870-TOTAL131,78027,370TOTAL96,48720,620(6,750)• Production of REO <strong>in</strong> 2007 will be below NDRC quotas– Baotou Iron & Steel has temporarily halted production to performma<strong>in</strong>tenance on its tail<strong>in</strong>gs pond– Sichuan government has decided to stop production while attempt<strong>in</strong>g toconsolidate RE m<strong>in</strong><strong>in</strong>g <strong>in</strong>dustry• 6,750 MT reduction of Nd/Pr Oxide equals ~5,400 MT reduction of Nd/Pr metalA Division of Neo <strong>Material</strong> Technologies Inc.

<strong>Raw</strong> <strong>Material</strong>Environment - Dem<strong>and</strong>2007NdFeB Powder(MT)Nd/Pr Oxide Required(MT)Bonded Nd Market5,2001,850S<strong>in</strong>tered Nd Market50,00017,810TOTAL - Nd Magnet Mkt55,20019,660• 19,660 MT of dem<strong>and</strong> is almost equal to output (20,620 MT)– (When factor<strong>in</strong>g <strong>in</strong> other markets, such as phosphors, there isno excess supply)A Division of Neo <strong>Material</strong> Technologies Inc.

Activities Outsideof Ch<strong>in</strong>a• April 2007: MolyCorp announcesresumption of rare earthoperations• July 2007: Lynas commences rareearth m<strong>in</strong><strong>in</strong>g at Mt. Weld, Australia• July 2007: Avalon Venturesannounces cont<strong>in</strong>uation of drill<strong>in</strong>gat Thor Lake, Canada, to “fillCh<strong>in</strong>a void” Ventures outside of Ch<strong>in</strong>astarted becom<strong>in</strong>g moreactive when Nd metalprices started to approachthe $30/kg level –actually we were neverbelow $32/kg s<strong>in</strong>ce morethan one year• September 2007: NavigatorResources announces rare earthexploration at Cumm<strong>in</strong>s Range,AustraliaA Division of Neo <strong>Material</strong> Technologies Inc.

Rare EarthsSupply <strong>and</strong> Dem<strong>and</strong>A Division of Neo <strong>Material</strong> Technologies Inc.

The RE-Elements <strong>in</strong>different OresBaotou BastnasiteEu, 0.30%Gd, 0.70%Tb, 0.10%Sm, 1.50%Nd, 13.00%Dy, 0.20% Er, 0.00%Y, 0.90%Ho-Tm-Yb-Lu,0.00%Eu, 0.20% Dy, 0.01%Gd, 0.70%Tb, 0.01%Sm, 1.20%Er, 0.01%Y, 0.20%Ho-Tm-Yb-Lu,0.80%Pr, 4.10%La, 31.50%Nd, 16.70%La, 25.00%Ce, 47.70%SichuanBastnasitePr, 5.10%Er, 1.80%Y, 20.00%Ho-Tm-Yb-Lu,0.00%La, 30.40%Dy, 3.60%Ce, 50.07%Tb, 0.60%Gd, 4.80%Ce, 1.90%• The ma<strong>in</strong> RE elements areCe, La <strong>and</strong> YEu, 0.70%Sm, 5.20%Nd, 24.40%Pr, 6.60%Southern Clay (example)A Division of Neo <strong>Material</strong> Technologies Inc.

Compositions needed!Dy/ Nd = 0.05Sagawa (Pori 2007)A Division of Neo <strong>Material</strong> Technologies Inc.

Applications NdFeBSagawa (Pori 2007)A Division of Neo <strong>Material</strong> Technologies Inc.

The “Dy-Problem”• Total Heavy RE / Light RE 4.5 %• Composition of a NdFeB magnet for Temperatures > 120°C, typicalfor Hybrid Car Electrical Eng<strong>in</strong>e– Nd 24%– Dy 6%– Co 3%– B 1%– Small Additions of Ga, Cu, Nb (optional)– Fe balance• Total Need Dy / Nd 20 %Dy is <strong>and</strong> will become further a significant costfactor for RE magnet applicationsA Division of Neo <strong>Material</strong> Technologies Inc.

Extraction of Rare-EarthMetalsMischmetallA Division of Neo <strong>Material</strong> Technologies Inc.

$160$140$120$100$80$60$40$20$-Dy-Price DevelopmentJun-06Jul-06Aug-06Sep-06Oct-06Nov-06Dec-06Jan-07Feb-07Mar-07Apr-07May-07Jun-07Jul-07Aug-07Sep-07Oct-07Nov-07Dec-07Jan-08Feb-08Mar-08Apr-08May-08A Division of Neo <strong>Material</strong> Technologies Inc.May-06Apr-06Mar-06Feb-06Jan-06US$ / KG

The Dy - Problem• Dy will be a significant factor for the availability <strong>and</strong> cost of raw materialsfor future applications with s<strong>in</strong>tered (Nd,Dy)FeB magnets• At the exist<strong>in</strong>g situation <strong>in</strong> <strong>Raw</strong> <strong>Material</strong>s, processes <strong>and</strong> Applications theexpected volumes are not available!• Solutions can be– F<strong>in</strong>d new m<strong>in</strong>es with high Dy content– Develop new processes to get <strong>in</strong>creased coercivity to avoid Dy– Reduce the use of high coercive materials by changes <strong>in</strong> design ofapplications– Use of Bonded Isotropic Magnets where no Dy is used <strong>in</strong> the alloys forApplications where both <strong>Material</strong>s can be appliedA Division of Neo <strong>Material</strong> Technologies Inc.

<strong>New</strong> <strong>Developments</strong><strong>in</strong> <strong>Material</strong>sA Division of Neo <strong>Material</strong> Technologies Inc.

<strong>New</strong> Isotropic MQP <strong>Material</strong>sBr(mT)10501000MQP-16-7MQP-16-7A950MQP-15-7MQP-15-7AMQP-B+900MQP-B2MQP-B2+MQP-B3850MQP-14-12800MQP-13-9R1MQP-13-9R2MQP-OMQP-AMQP-C750MQP-S-11-9700400 500 600 700 800 900 1000 1100 1200 1300 1400Hci(kA/m)A Division of Neo <strong>Material</strong> Technologies Inc.

High Remanent <strong>Material</strong>Vacodym 722 HR - (BH)max = 53 MGOe - BR = app. 1.5 TeslaA Division of Neo <strong>Material</strong> Technologies Inc.

High Coercive <strong>Material</strong>Vacodym 890 AP - HcJ = 2600 kA/m -Tk = -0.090 %/°CA Division of Neo <strong>Material</strong> Technologies Inc.

<strong>New</strong> <strong>Developments</strong><strong>in</strong> Process<strong>in</strong>gA Division of Neo <strong>Material</strong> Technologies Inc.

<strong>New</strong> Process<strong>in</strong>gLow Pressure Press<strong>in</strong>gSagawa (Pori 2007)A Division of Neo <strong>Material</strong> Technologies Inc.

Low Pressure Press<strong>in</strong>g<strong>and</strong> result<strong>in</strong>g MagnetsSagawa (Pori 2007)(net shape)A Division of Neo <strong>Material</strong> Technologies Inc.

Dependency of ParticleSize <strong>and</strong> CoercivityCoercivity/kOe2,7 µm2,9µm5 µmSagawa (Pori 2007)A Division of Neo <strong>Material</strong> Technologies Inc.

Improvement ofCoercivity by PLPEnergy Product / MGOeINTERMETALLICSSagawa (Pori 2007)Coercivity / kOeA Division of Neo <strong>Material</strong> Technologies Inc.

Back-extrusion of radialoriented r<strong>in</strong>gsA Division of Neo <strong>Material</strong> Technologies Inc.

<strong>New</strong> grades by DAIDOElectronicsA Division of Neo <strong>Material</strong> Technologies Inc.

M<strong>in</strong>iature MQ3 r<strong>in</strong>gs byDAIDO ElectronicsA Division of Neo <strong>Material</strong> Technologies Inc.

Improved flux ag<strong>in</strong>g ofpretreated powders14 - 12 Powder Ag<strong>in</strong>g at 450C0%B Losses / %l-20%-40%-60%-80%Bare 14 -12 (+100mesh)14-12 G1 (+100mesh)14-12 G2 (+100mesh)-100%0 20 40 60 80 100 120Magnequench PowdersAg<strong>in</strong>g Time (hours)A Division of Neo <strong>Material</strong> Technologies Inc.

Improved Magnetsfrom pretreated powdersB Losses / %0%-2%-4%-6%-8%-10%-12%14-12 Magnet Ag<strong>in</strong>g at 180 ºC-100 = f<strong>in</strong>e powders+100 = coarse powders14-12STD( -100)14-12G1( -100)14-12G2( -100)14-12STD(+100)14-12G1(+100)14-12G2(+100)-14%0 100 200 300 400 500Ag<strong>in</strong>g Time (hours)A Division of Neo <strong>Material</strong> Technologies Inc.

<strong>New</strong> <strong>Developments</strong><strong>in</strong> ApplicationsA Division of Neo <strong>Material</strong> Technologies Inc.

Flywheel(Univ. Sheffield)StoredEnergy:400WhPower:30 kWA Division of Neo <strong>Material</strong> Technologies Inc.

Applications: Seat MotorsSeat MotorFerrite <strong>and</strong> NdFeB DesignToday up to 8 motors are <strong>in</strong> one seat- Consumption is neglectible- Weight <strong>and</strong> Volume are the key factors- With 200 g sav<strong>in</strong>gs/motor ...A Division of Neo <strong>Material</strong> Technologies Inc.

Comparison of technical data ofFerrite/Bonded Neo Seat MotorWeight [g]FerriteNdWeightReductionWeightratio:Nd toFerriteFerriteCostNdCostsav<strong>in</strong>gCostsav<strong>in</strong>gratio1Magnet96.640.755.942.1%$0.31$1.14-$0.83-272.2%2Yoke160.094.465.659.0%$0.27$0.24$0.029.1%3Core113.873.040.864.1%$0.29$0.23$0.0621.1%4Wire66.725.041.737.5%$0.71$0.24$0.4665.5%5Shaft39.531.08.578.5%$0.28$0.26$0.027.7%Total476.6264212.555.4%$1.85$2.11-$0.26-14.3%A Division of Neo <strong>Material</strong> Technologies Inc.

Applications: L<strong>in</strong>earCompressor(Univ. Sheffield)A Division of Neo <strong>Material</strong> Technologies Inc.

Developed <strong>and</strong> Realizedby EmbracoComparison of different compressor types, l<strong>in</strong>ear <strong>and</strong> rotat<strong>in</strong>g systemsA Division of Neo <strong>Material</strong> Technologies Inc.

Applications:Circulation PumpsHeat<strong>in</strong>g <strong>in</strong> Europe is different to USA or Asia, ma<strong>in</strong> systemsare work<strong>in</strong>g with radiation, not by blow<strong>in</strong>g.Facts:87 Mio. heat<strong>in</strong>g pumps with power <strong>in</strong>put less than250 W are <strong>in</strong>stalled <strong>in</strong> EuropeTotal consumption of electrical energy: 41 TW= 1’000’000’000’000 Wh/year = 1 Mio MWh/yearThis is the yearly energy of 4 power stations(each 1.2 GW)A Division of Neo <strong>Material</strong> Technologies Inc.

Comparison of “wet runner”motor- weight*105,07,78,6motor-weight (kg)13,22,01,42,40,9 1,01,61,10,80,54,3wet runner AC-Motorwet runner EC-motor0,11 10 100 1000 10000* Weight without electronic <strong>and</strong> pump-hous<strong>in</strong>gmotor shaft-power P2 (W)A Division of Neo <strong>Material</strong> Technologies Inc.

Solution: Heat<strong>in</strong>gPumpPermanent magnet rotor withsta<strong>in</strong>less steel sleeve(high efficiency, corrosionprotection)3D-Impeller(high efficiency)Electronics<strong>in</strong>e wavecommutation(low noise)Carbon fiber hybrid can(no eddy current losses)(WILO GmbH)A Division of Neo <strong>Material</strong> Technologies Inc.

Motors forCirculation Pumps2500kWh2000ConstantspeedSpeedselectorMa<strong>in</strong> quantities <strong>in</strong> <strong>in</strong> useuseEnergy Consumption150010005000Electronic differentialpressure control“Intelligent” pumpPumps with asynchronousmotor at at optimization limit limit?> 2000

Summary: CirculationPumpsElectronic controlled pumps reduce energyconsumption significantlyPumps based on wet runner EC motors show higherefficiency than AC motor pumpsGa<strong>in</strong> of efficiency <strong>in</strong>creases with lower motor powerExcellent part load performance of EC motor pumpenables large energy sav<strong>in</strong>g for different applicationsReplacement of of all all 87 87 Mio. Mio. heat<strong>in</strong>g circulators with with EC EC pumps pumpscould could lead lead to to energy energy sav<strong>in</strong>g sav<strong>in</strong>g of of more more than than 20 20 TWh/a TWh/a (which (whichmeans means 2 power power stations!)… <strong>and</strong> <strong>and</strong> create create a need need of of 5000 5000 tons tons of of magnetsA Division of Neo <strong>Material</strong> Technologies Inc.

<strong>New</strong> ApplicationsThe two bigdrivers <strong>in</strong>magnets aregreen.W<strong>in</strong>d EnergyHybrid CarsA Division of Neo <strong>Material</strong> Technologies Inc.

W<strong>in</strong>d Energy withSynchronous MotorsEstimated Growth for Installed Powerresults 2020 <strong>in</strong> 18 to 37 GW per year.Magnets: 20 – 40‘000 tons/yearA Division of Neo <strong>Material</strong> Technologies Inc.

Hybrid Car Eng<strong>in</strong>eA Division of Neo <strong>Material</strong> Technologies Inc.

A Division of Neo <strong>Material</strong> Technologies Inc.

Hybrids:Impact <strong>in</strong> 2020• GM stated that 80% will be Hybrids <strong>in</strong> 2020• Toyota stated that 100% will be Hybrids <strong>in</strong> 2020• At 70‘000 vehicles per year, each consum<strong>in</strong>g 1 kg of NdFeN magnets, thetotal additional requirement will be 60‘000 tons• If we assume, a NdFeB plant for s<strong>in</strong>tered magnets has a capacity of 2‘000tons/year, we would need 30 new plants just for this application!A Division of Neo <strong>Material</strong> Technologies Inc.

StatementSagawa 2007:A Division of Neo <strong>Material</strong> Technologies Inc.

THANK YOU !QUESTIONS?A Division of Neo <strong>Material</strong> Technologies Inc.

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