critical materials: rare earth & related elements
TRANSCRIPT
Critical Materials in Clean Energy
Lighting
Vehicles
Solar PVS O C
Advanced Research Projects Agency • Energy 2
Solar PV
Wind
US DOE: Critical Materials Strategy (Dec 2010)
Coordinated Critical Materials Effort
• Policy and International Affairs (PI) led Department-wide Critical MaterialsDepartment wide Critical Materials Strategy Study[David Sandalow, Assistant Secretary, PI]
• US-Japan Roundtable (LLNL) on Rare Earths (Nov 2010)
• US-EU Workshop on Rare Earths Research (Dec 2010)
• ARPA E Workshop on Critical Materials• ARPA-E Workshop on Critical Materials Technology (Dec 2010)
Advanced Research Projects Agency • Energy 3
Shifting Economics Of Rare Earth Materials
Rest of the World
Global Demand
Supply
China SupplyChina Demand
TodayWithin 5 Years: World’s Dominant Supplier of Rare Earth Materials
May Switch From a Net Exporter to a Net Importer
Advanced Research Projects Agency • Energy 4
May Switch From a Net Exporter to a Net Importer
Rare Earth Criticality by Element
Short Term (0– 5 years) Medium Term (0– 5 years)Supply
Alternatives
( y ) ( y )
ApplicationAlternativesAlternatives
Advanced Research Projects Agency • Energy 5
US DOE: Critical Materials Strategy (Dec 2010)
Batteries for Electrical Energy Storage in Transportation (BEEST) Program
g) 4
Battery System Requirements
(Wh/
kg Li-S/Li-air/Metal-air/Etc (new chems/mfg)
2
4 BEEST TARGET(EV Goal)
Storage CostCurrent Target:
$
c En
ergy
PHEV 40 Goal
Lithium Ion
8100
Next GenNickel Metal
Hydride (NiMH)
$1,000/kWh
BEEST Target:
Spec
ific (2014)
4
6y ( ) g
$250/kWh
1005 6 7 8 9 2 3 4 5 6 7 8 9
100020
Advanced Research Projects Agency • Energy
Source: David Howell, DOE Office of Vehicle Technologies, 2009.International Energy Agency, Technology Roadmaps:
Electric and Plug-in Hybrid Electric VehiclesSpecific Power (W/kg)
Possible Approach: Get Most From Available Supply
Light Rare Earth ElementsHeavy Rare Earth Elements
Advanced Research Projects Agency • Energy 8
Heavy Rare Earth Elements
Rare Earth Elements Are Not That Rare
Solar System Abundance Upper Crust Abundance
Rare Earths nearlyas ab ndant as
R E th
as abundant as Pb, Cu, Ni, Zn, Sn
Rare EarthElements
Advanced Research Projects Agency • Energy
Developing Technology AlternativesAcross Supply Chainpp y
Tb
Eu
YY
Advanced Research Projects Agency • Energy 10
Critical Materials in Clean Energyfrom DOE-Wide Study
Lighting
Vehicles
Solar PV
Advanced Research Projects Agency • Energy 11
Solar PV
Wind
Key Elements in Energy-Wide Supply Chain
Traditional Energy
Lighting
Vehiclesgy
Smart Grid
Advanced Research Projects Agency • Energy 12
Solar PV
Wind
Technology Opportunity Areas for Study
BatteriesOpportunities
F N Di ti
Lighting
Vehicles
Solar PV
Phosphors
Transparent Contacts
For New, Disruptive Approaches to
Technology Needs
Traditional Energy
Solar PV
Wind Permanent Magnets
Transparent Contacts
O S t M t i t D igy Oxygen SeparatorsSmart Grid
Catalysts
Metrics to Drive New Learning Curves and
Advanced Research Projects Agency • Energy 13
Approaches
ARPA-E Workshop: Critical Materials Technology
Electric Motors
PermanentMagnets
MaterialExtraction Processes
Geologic orRecycled
Feedstocks
Wind Generators
ProcessesFeedstocks
LightingPhosphors
Catalysts &Separators
Light EmittingSolid Oxide Fuel Cells Light Emitting Diodes (LED)
Compact Fluorescent Lights (CFL)
Solid Oxide Fuel CellsGasoline Refining
Auto Exhaust Conversion
Advanced Research Projects Agency • Energy 14
Supply Technologies Application Technologiesg ( )
45% of Global Rare-Earth ProductionBayan Obo, China
1 mile1 mile
200 ftPrimary Ore: Bastnasite: RE-(CO3)FBastnasite: RE (CO3)F
800 million metric tons; 6% REO
Secondary Ore:Monazite: RE PO
ContainmentPhotos: Google Maps
Monazite: RE-PO4
US Rare-Earth Production CapabilityUS Rare Earth Production CapabilityMountain Pass, CA (re-opened by Molycorp)
1 mile200 ft
Primary Ore: Bastnasite: RE-(CO )FBastnasite: RE-(CO3)F3.3 million metric tons:
7-9% REO
Advanced Research Projects Agency • Energy
ContainmentPhotos: Google Maps
Molycorp Rare Earth FacilityMountain Pass, CA
91%91% Gangue:
BariteCarbonates
Silicates NdLa
9%RE Oxide
Basis
Pr
Sm, Eu, Gd, Tb Dy HoBasis Tb, Dy, Ho, Er, Tm, Yb,
Lu, Y
Ce
Advanced Research Projects Agency • Energy
Different Types of Rare Earths
Heavy and Light Rare Earths are from different Ores
Light Rare Earths Neodymium – Magnets
Heavy Rare EarthsDysprosium - HighDysprosium High
Temp Magnets
Yttrium – SOFCs and PhosphorsPhosphors
Terbium – PhosphorsEuropium - Phosphors
Advanced Research Projects Agency • Energy 18
Rare Earth Oxide and Metal Extraction Processon RE Oxides
Oxi
datio
SeparationRefining
REO Product
Ore
RE-F(CO3) Reduction
Rare E th
uctio
n
Ideal
RE Product
Earths
Red
u
RE Metals
Rare-Earth Processing Cycle
RE Product
Advanced Research Projects Agency • Energy
Supply and Demand ScenariosNeodymium (Permanent Magnets)y ( g )
High Clean Energy Cases
BAU Cases
Energy Cases
BAUHigh CleanNow
BAUgEnergy Growth
Advanced Research Projects Agency • Energy 20
ARPA-E Workshop: Critical Materials Technology
Electric Motors
PermanentMagnets
MaterialExtraction Processes
Geologic orRecycled
Feedstocks
Wind Generators
ProcessesFeedstocks
LightingPhosphors
Catalysts &Separators
Light EmittingSolid Oxide Fuel Cells Light Emitting Diodes (LED)
Compact Fluorescent Lights (CFL)
Solid Oxide Fuel CellsGasoline Refining
Auto Exhaust Conversion
Advanced Research Projects Agency • Energy 21
Supply Technologies Application Technologiesg ( )
Magnetic Systems: Motors for Electric Vehicle (EV) 2020 Roadmap Goals with Low Rare Earth Contentp
30 kW / 60 kWHEV Motor
Added Goals: Low
100 kW / 200 kWEV Motors
Advanced Research Projects Agency • Energy
Added Goals: LowRare Earth
Advanced Electric Motor Concepts
High Temperature and VoltageInsulators for Windings
Non-Rare Earth Hard Magnetic Material
Complex Soft MagneticComplex Soft MagneticStructures
Reluctance Path Switching
Example: Parallel Path Magnetic Motor Technology
Advanced Research Projects Agency • Energy 23
Needed Enabling Magnetic Materials
B
Soft Magnetic NanocompositeH
Soft Magnetic NanocompositeHigh Permeability (Fe, Fe-Si, Fe-Co)
Low Eddy Current LossIsotropic Permeability (ideal)
Hard
S ft Manufacture-able / MoldableEnables Novel Structures
Soft
Hard Magnetic NanocompositeSpring Exchange CouplingSpring Exchange Coupling
Coercivity of Hard Phase (SmCo, NdFeB)Remnance of Soft Phase (Fe, Fe-Co)
High Energy Density
Advanced Research Projects Agency • Energy 24
Reduced Rare Earth ContentCurrent: U Del. & GE
Nanocomposite Permanent Magnets
Core@Shell Hard/Soft
With low rare earth
Core@Shell Hard/Soft Exchange Spring Coupled Nanocomposite Magnets
with:
• 80 MGOe(vs 59 MGOe NdFeB)
• 59 MGOe59 MGOewith 80% less rare earth
Nanocomposite exchange spring coupled permanent magnets
Advanced Research Projects Agency • Energy
p g p g p p gwith high energy product and less rare earths
ARPA-E Workshop: Critical Materials Technology
Electric Motors
PermanentMagnets
MaterialExtraction Processes
Geologic orRecycled
Feedstocks
Wind Generators
ProcessesFeedstocks
LightingPhosphors
Catalysts &Separators
Light EmittingSolid Oxide Fuel Cells Light Emitting Diodes (LED)
Compact Fluorescent Lights (CFL)
Solid Oxide Fuel CellsGasoline Refining
Auto Exhaust Conversion
Advanced Research Projects Agency • Energy 27
Supply Technologies Application Technologiesg ( )
Catalysts: Fluid Catalytic Cracking
New RE Zeolite
Spent RE Zeolite
Recycling
1-2% catalysts replaced per day.All catalyst replaced every 2 months
due to loss of aluminum.due to loss of aluminum.Old catalyst is landfilled.
Recover Rare-earth content from spent FCC t l t ld t ti ll h I t
Advanced Research Projects Agency • Energy
FCC catalyst could potentially have Impact.
ARPA-E Workshop: Critical Materials Technology
Electric Motors
PermanentMagnets
MaterialExtraction Processes
Geologic orRecycled
Feedstocks
Wind Generators
ProcessesFeedstocks
LightingPhosphors
Catalysts &Separators
Light EmittingSolid Oxide Fuel Cells Light Emitting Diodes (LED)
Compact Fluorescent Lights (CFL)
Solid Oxide Fuel CellsGasoline Refining
Auto Exhaust Conversion
Advanced Research Projects Agency • Energy 29
Supply Technologies Application Technologiesg ( )
Application: Rare Earth Phosphors for CFLs
GAPGAP
Phosphor Code ColorEmission
Wavelength Nature Rare Earth(s)BaMgAl10O19:Eu2+ BAM Blue 450 nm Broad band EuLaPO :Ce3+ Tb3+ LAP Green 545 nm Sharp line La Ce Tb
Advanced Research Projects Agency • Energy
LaPO4:Ce3 , Tb3 LAP Green 545 nm Sharp line La,Ce,TbY2O3:Eu3+ YEO Red 610 nm Sharp line Y, Eu
Cost of Lighting (CoL) vs. First Lumen Cost (Bulb)
First Purchase Cost (per bulb)Solid State Bulb$50-$120
First Purchase Cost (per bulb)Haitz Law
Innovate FasterThan
Global Competitorsrst C
ost
Compact Fluorescent$2.00
Global Competitors
Fir
Incandescent$0.30
(cost/klm)
Advanced Research Projects Agency • Energy 31
J.Tsao, et.al., Proc. IEEE (9/09)
First Purchase Price for Lightingb
Pric
eB
ulb
TechnologyDisruption
Advanced Research Projects Agency • Energy 32
Years
Technical Pathway to Low First Cost LEDs:Eliminate Droop Losses Through Innovation
ersi
on
Ideal
Ph i l O i i f D AC-D
C C
onve
Physical Origins of DroopAuger RecombinationNon-Radiative DefectsCarrier Overflow from MQWs W
all P
lug:
A
Crystal Polarity
Rare Earth Free PhosphorsLuminscent Nanoparticles
AC-DC Conversion LossADEPT Program
Advanced Research Projects Agency • Energy 33
J.Tsao, et.al., Proc. IEEE (9/09)
Luminscent Nanoparticleswithout Cadmium
Summary: Critical Materials Technology
Electric Motors
PermanentMagnets
MaterialExtraction Processes
Geologic orRecycled
Feedstocks
Wind Generators
ProcessesFeedstocks
LightingPhosphors
Catalysts &Separators
Light EmittingSolid Oxide Fuel Cells Light Emitting Diodes (LED)
Compact Fluorescent Lights (CFL)
Solid Oxide Fuel CellsGasoline Refining
Auto Exhaust Conversion
Advanced Research Projects Agency • Energy 34
Supply Technologies Application Technologiesg ( )