recycling of nimh and li -ion batteries - egvi jan tytgat_umicore.pdf · umicore battery recycling...
TRANSCRIPT
Umicore Battery Recycling Umicore Battery Recycling RecyclingRecycling of of NiMHNiMH and Liand Li--ion batteriesion batteries
a sustainable new businessa sustainable new business
December, 2011 December, 2011 Brussels Brussels
Joint EC / Green Cars Initiative PPP Joint EC / Green Cars Initiative PPP Expert Workshop 2011 Expert Workshop 2011
Dr. Jan Tytgat Dr. Jan Tytgat -- UmicoreUmicore
2Joint EC / Green Cars Initiative PPP Expert Workshop 2011 Brussels, Dec. 2011
Umicore Battery Recycling
Triple bottom line (J. Elkington, 1997)
UBR-model: from recycling drivers to new business
Social
Environmental
Economic
EHS
Volume Value
Economy
Ecology
How?Technology
Why?
A sustainable business model is:
- Economically sound
- Environmentally safe
- Socially responsible
3Joint EC / Green Cars Initiative PPP Expert Workshop 2011 Brussels, Dec. 2011
Waste Framework Directive
Battery Directive
(BD)
End of Life of Vehicles
(ELV)
Waste of Electrical and Electronic Equipment
(WEEE)
Economic aspects: Legal Framework as driver for recycling
Strong regulation of battery recycling is a basis for our ‘service model’: even for batteries having low intrinsic metal value, there is a service value
4Joint EC / Green Cars Initiative PPP Expert Workshop 2011 Brussels, Dec. 2011
Economic aspects: Proven market for Portable Rechargeable Batteries
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
90,000
2003
2005
2007
2009
2011
2013
2015
2017
(in MWh/ year)
Portable electronics Power tools (P)HEV / EVSource: IIT Takeshita 2009Source: IIT Takeshita 2009
In the EU, the market of PRB’s is about 35000 Tons/year an still growing.
• Collection target: 45 % by 2016 = target market volume of 20 000 ton
• collection today: +/- 6%
• Proven technology and position: UBR is running this business on pilot scale for 4 years before deciding in new, bigger and better installation
Power demand for Li-ion batteries
5Joint EC / Green Cars Initiative PPP Expert Workshop 2011 Brussels, Dec. 2011
Several business models expect up to 10 % (H)EV by 2020 (% of sales of new cars)
1 million e-cars =50 000 ton batteries
First wave:- production waste- warranty claims- accidents
0,0
1,0
2,0
3,0
4,0
5,0
6,0
7,0
8,0
2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018
year
HE
V c
ar s
ales
[M
io u
nits
/y]
0,0%
1,0%
2,0%
3,0%
4,0%
5,0%
6,0%
7,0%
8,0%
9,0%
10,0%
HE
V c
ar s
ales
as
% o
f new
car
sal
es w
orld
wid
e
EV = full Electrical Vehicle
PHEV = Plug in Hybrid Electrical Vehicle
HEV (NiMH) = NiMH Hybrid Electrical Vehicle
HEV (LiB) = Li-ion Hybrid Electrical Vehicle
Economic aspects: Expected market for (H)EV-batteries
Source: Takeshita
6Joint EC / Green Cars Initiative PPP Expert Workshop 2011 Brussels, Dec. 2011
• the only industrial Li-ion battery recycler worldwide • 7000 ton/year capacity up and running• Competition: < 200 t/y capacity and unsolved qualification issues with some
recycled fractions• Connects a new dedicated battery smelter technology with an existing large
scale refinery
• the only industrial NiMH-battery recycler worldwide that recovers Rare Earth Elements
• Unique collaboration with Rhodia: Umicore concentrates, Rhodia refines
• Intensive contacts with car-industry (Europe, US, Japan, Korea)
• Published relations, others under NDA
Economic aspects: UBR market position
7Joint EC / Green Cars Initiative PPP Expert Workshop 2011 Brussels, Dec. 2011
Compounds = “added value molecules” �Compound Cost > Σ Element Cost
e.g.: LiCoO2 cost > (Co + Li + O) cost
�Recycling model based on compound value recovery makes sense�But, due to:
�High diversity of battery materials�Rapidly changing specifications and long
lifetime for EV batteries�Contamination risks�Low risk minded battery industry, heavy
qualification processTheoretical compound value hard to valorize:
small market for recycled battery compounds
���� Umicore strategy = ‘element recovery’ and service
Economic aspects: compound � element � service
8Joint EC / Green Cars Initiative PPP Expert Workshop 2011 Brussels, Dec. 2011
• New UHT smelter in Hoboken, opened September 7, 2011 has a 7000 T/y capacity (= 140 000 (H)EV batteries or 250 Million cell phone batteries• Sufficient for EU- and world wide market for coming years• New installations will be geographical spread (N-America, Far East)• Plant size will be determined by
• Technology: physical limits, risks• Economy: investment and exploitations costs versus transport
costs• Ecology: LCA methodology to balance between recycling and
resource efficiency versus transport burden• Commitment to have installed capacity to cover all customer needs• Robust process, compatible with all Li-ion battery chemistries
Economic aspects: UBR’s new Battery Smelter
9Joint EC / Green Cars Initiative PPP Expert Workshop 2011 Brussels, Dec. 2011
The Unique Closed Loop Solution for batteries
2011:Hoboken Belgium
Olen, Belgium
Jiangmen, China
Cheonan, South Korea
Kansai, Western Japan
Environmental aspects: process description
Possibility to recover
F
Added value because of Li
and Possibility for closed loop
recovery of Li
Closed loop for REE’s
Recovery of Co Ni Fe Cu
Closed loop for Co Ni Cu
10Joint EC / Green Cars Initiative PPP Expert Workshop 2011 Brussels, Dec. 2011
Critical materials in rechargeable batteries
Non-critical materials in rechargeable batteriesChemicals ‘temporally’used in UBR recycling process
Environmental aspects: resource efficiency
The UBR process recycles most of the critical and economic important raw materials in the batteries and consumes only commodity chemicals (which are recycled as well)
11Joint EC / Green Cars Initiative PPP Expert Workshop 2011 Brussels, Dec. 2011
• Battery recycling increases the ‘green image’ of e-mobility• Several LCA’s, together with customers, tackle some environmental objections
against e-mobility:
• Recycling reduces global warming, acidification eutrophication and ozone depletion potential of EV’s (impact reductions from 20 to > 90 %)
• The plant has a very low CO2-footprint and nearly no external energy has to be added to the process; even if transport of batteries is included in the LCA –scope
• Resource efficiency:
• Study by University of Ghent shows more than 50 % resource efficiency credits
• Chemicals used in the process are recycled for construction; hereby reducing the CO2-footprint of construction materials as well
Environmental aspects: Resource efficiency and CO2-footprint
12Joint EC / Green Cars Initiative PPP Expert Workshop 2011 Brussels, Dec. 2011
Cu
Ni
AlLi
MnCo
REE
C
K
ClP
F
BO
H
CuNi Al LiMnCo REE
C
K
Cl
P
F
B
O
H
O Recycled as products andby-products
Recovered
Emitted
Collected
� RE: Above 50% EU target
Fe
Fe
Environmental aspects: Recycling Efficiency
Ongoing discussion on:
• use of C als reducing agent
• dry or wet basis
13Joint EC / Green Cars Initiative PPP Expert Workshop 2011 Brussels, Dec. 2011
Li: No immediate shortage, nevertheless, be prepared:
• geopolitical strategy
• sustainability considerations
UBR’s position today:
• through the UBR process, Li is recycled according to BD definition
• higher added value in special case because of Li-content (anti concrete cancer agent)
• possibility to extract Li
Environmental aspects: Li-recovery
Li (in slag) added to concrete mitigates concrete cancer
Source: R. Klein (U. Leiden)
14Joint EC / Green Cars Initiative PPP Expert Workshop 2011 Brussels, Dec. 2011
NiMH batteries contain REE’s• defined as critical raw materials for EU,
because dependency on Chinese supply
Joint project with Rhodia:• Umicore makes a REO-concentrate
• Rhodia refines the concentrate into pure REO’s
• These REO’s can be used for batteries again, or for other high end applications
REE = Rare Earth ElementREO = Rare Earth Oxide
Environmental aspects: REE-recovery
Rare earth oxides. Clockwise from top center: praseodymium , cerium, lanthanum, neodymium , samarium, and gadolinium (bold = in NiMH batteries)
15Joint EC / Green Cars Initiative PPP Expert Workshop 2011 Brussels, Dec. 2011
• Dismantling and sorting of (H)EV batteries and portable batteries
Social aspects: creating labour on several educational levels
•(H)EV dismantling at Umicore: manual job, today only in Hanau, but to be rolled out world wide
•WEEE dismantling:
•Dismantling avoids transport of parts which are ‘easy’ to recycle locally
•Creates valuable jobs for lower educated personnel on several places
16Joint EC / Green Cars Initiative PPP Expert Workshop 2011 Brussels, Dec. 2011
• smelting of batteries
• Highly specialized jobs in limited centers of competence
• Avoids ‘backyard’ recycling with high EHS risks
Social aspects: creating labour on several educational levels
17Joint EC / Green Cars Initiative PPP Expert Workshop 2011 Brussels, Dec. 2011
Economic aspects- Proven market for PRB’s, market for (H)EV still to be demonstrated, but generally accepted to grow to 10 % of new sales by 2020
- Unique position because of technology and business relations
Environmental aspects- Low carbon footprint,
- LCA-proven resource efficiency and very good results on all investigated impact categories- Closed loop for most critical elements; possibility to close the loop for other strategic elementsSocial aspects- generates quality labour on several levels of education
- possible to roll out to several area’s worldwide
Conclusions
18Joint EC / Green Cars Initiative PPP Expert Workshop 2011 Brussels, Dec. 2011
Contact: [email protected]