Industrial mineral recycling in Li-ion batteries

Transcription

1 Industrial mineral recycling in Li-ion batteries Impact on raw material supply chain? Mike O Driscoll, Director, IMFORMED Networking and knowledge for the industrial minerals business

2 Launched in January 2015 Extensive experience & reputation Market research Specialist conferences

3 Oilfield Magnesia Fluorine Graphite Logistics Recycling

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5 Industrial Mineral Recycling in Li-ion Batteries 1. Setting the scene: Industrial minerals, supply chain, & recycling 2. Li-ion battery recyling Where are we now? 3. Outlook Influencing factors, challenges, what next?

6 Industrial Mineral Recycling in Li-ion Batteries: Setting the Scene What are industrial minerals? Unglamorous Mundane Rubble The Third World of the Mining Industry!

7 Industrial Mineral Recycling in Li-ion Batteries: Setting the Scene What are industrial minerals? Minerals and rocks exploited for their non-metallurgical value. Physical/chemical properties for a wide variety of industrial and domestic uses. talc Can t live without them! paper cosmetics ceramics

8 Industrial Mineral Recycling in Li-ion Batteries: Setting the Scene What are industrial minerals? Some examples of industrial minerals and their uses: Bauxite Clay Limestone Gypsum Magnesite Potash Sand Talc Abrasives Ceramics Cement Plasterboard Chemicals Fertiliser Glass Plastics

9 Industrial Mineral Recycling in Li-ion Batteries: Setting the Scene New hi-tech market era smart devices, new energy, plastics

10 Industrial Mineral Recycling in Li-ion Batteries: Setting the Scene Industrial mineral growth markets smart devices Aluminium casing: flux mineral fluorspar; refractory minerals eg. bauxite, magnesia Plastic back cover: filler & flame retardant minerals, eg. talc, alumina trihydrate Polished hi-tech screen: glass minerals eg. alumina-silica; abrasive minerals eg. fused alumima Speaker: rare earth minerals Li-ion battery: battery minerals eg. lithium, graphite Silicon chip manufacture: fused silica crucibles; silicon carbide wiresaws Intense screen colours: rare earth minerals

11 Industrial Mineral Recycling in Li-ion Batteries: Setting the Scene Era of a new generation of batteries Source: Albermarle (2016)

12 Industrial Mineral Recycling in Li-ion Batteries: Setting the Scene Li-ion battery market growth Global sales by end use Source: Avicenne Energy (2017)

13 Industrial Mineral Recycling in Li-ion Batteries: Setting the Scene EV market growth 25 January 2017 Electric cars to rise significantly, from 1.2 million in 2015 to around 100 million by 2035 (5.5% of the global fleet). Around 25% of these electric vehicles (EVs) are plug-in hybrids (PHEVs), 75% are pure battery electric vehicles (BEVs). The global energy landscape is changing. Traditional centers of demand are being overtaken by fast-growing emerging markets. The energy mix is shifting, driven by technological improvements and environmental concerns. Bob Dudley, BP Group Chief Executive

14 Industrial Mineral Recycling in Li-ion Batteries: Setting the Scene Li-ion battery market growth Li-ion battery switch or mass market adoption is nearing % CAGR Tesla Gigafactory, NV EV sales in China growing exponentially, 56% year over year China pushing for Zero Emissions Mandates, with EVs reaching 8% of all new car sales by 2018 and 12% by January 2017: mass production of Liion cells starts at Tesla, NV Source: Avicenne Energy (2017)

15 Industrial Mineral Recycling in Li-ion Batteries: Setting the Scene Li-ion battery market growth impact on minerals Increased demand 2016 lithium supply (LCE) 175,000 tonnes 2020 additional ,000 tonnes needed 2016 anode material supply 110,000 tonnes (syn.+nat. graphite) 2020 additional ,000 tonnes needed (75% nat. flake) Source: Benchmark Mineral Intelligence (2017)

16 Industrial Mineral Recycling in Li-ion Batteries: Setting the Scene Li-ion battery market growth impact on minerals Increased prices while sources limited Source: Benchmark Mineral Intelligence (2017)

17 Industrial Mineral Recycling in Li-ion Batteries: Setting the Scene Li-ion battery market growth impact on minerals Increased investment, exploration, development of new sources Graphite Lithium Source: Benchmark Mineral Intelligence (2017)

18 Industrial Mineral Recycling in Li-ion Batteries: Setting the Scene Li-ion battery market growth impact on minerals Increased sensitivity of minerals criticality CRITICAL Report on critical raw materials for the EU May 2014 Cobalt Graphite Lithium Source: EC (2014)

19 Industrial Mineral Recycling in Li-ion Batteries: Setting the Scene Li-ion battery market growth impact on minerals Increased sensitivity of minerals criticality Source: BGS (2015)

20 Industrial Mineral Recycling in Li-ion Batteries: Setting the Scene Li-ion battery market growth impact on minerals Increased pressure on mineral supply chain

21 DEMAND Industrial Mineral Recycling in Li-ion Batteries: Setting the Scene Supply chain options for industrial minerals Trad. Captive Direct Captive route processing buy production Mineral producer Exploration, reserves, mining, processing (own mine) Mineral trader Sourcing, logistics, financing Mineral processor/distributor Sourcing, processing, storage, logistics Intermediate product manufacturer Sourcing, processing, storage, logistics, formulating, application End user market End use application

22 Industrial Mineral Recycling in Li-ion Batteries: Setting the Scene Li-ion battery market growth impact on minerals Increased interest in Li-ion battery recycling Li Source: Umicore

23 DEMAND Industrial Mineral Recycling in Li-ion Batteries: Setting the Scene Supply chain options for industrial minerals Trad. Captive Direct Captive route processing buy production Recycling Mineral producer Exploration, reserves, mining, processing (own mine) Mineral trader Sourcing, logistics, financing Mineral processor/distributor Sourcing, processing, storage, logistics Intermediate product manufacturer Sourcing, processing, storage, logistics, formulating, application End user market End use application

24 Industrial Mineral Recycling in Li-ion Batteries: Setting the Scene Secondary Raw Materials (SRM) for industrial mineral markets SRM source* SRM recovered Market Aluminium salt slag Batteries Fly ash Glass alumina graphite; lithium; manganese dioxide aluminosilicate REE; silica Gypsum wallboard gypsum wallboard cement; ceramics; geopolymers; metallurgy; mineral wool; refractories; batteries; ceramics; chemicals; glass; refractories ceramics; coatings; construction; foundry; plastics; proppants (oil & gas drilling) abrasives; chemicals; coatings; concrete; glass; plastics; sealants Refractories Steel slag alumina; andalusite; bauxite; chromite; dolomite; mag-carbon; graphite; magnesia; silicon carbide; zirconia alumina; calcia; magnesia; silica Waste water phosphorus fertiliser ceramics; metallurgy; refractories abrasives; aggregate; cement; concrete; fertiliser; filtration; metallurgy WEEE** antimony trioxide; bromine FR; fluorspar; graphite; REE batteries; ceramics; chemicals; flame retardants * ie. waste from processing, or used/discarded mineral-bearing end products to be recycled ** waste electrical and electronic equipment

25 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling Li-ion batteries in cars Li-ion battery cell Li-ion battery module: 4x cells Source: BMW Li-ion battery pack: 48x modules; 192x cells Source: Nissan

26 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling Li-ion battery recycling Why recycle? Environmentally driven legal requirements Conservation of primary mineral resources by use of recycled materials Alleviates mineral resource squeeze, their criticality, dependence on certain countries Enhances price stability for raw materials Recycling contributes to CO 2 reduction Conservation of energy Controls hazardous substances Reduces landfill cost and pressure

27 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling Li-ion battery recycling Key driver: EC & the Circular Economy the value of products, materials and resources is maintained in the economy for as long as possible waste generation is minimised

28 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling Directive 66/2006/EU included: prohibition of battery disposal or incineration obligation to recycle all kinds of portable and industrial batteries producers responsibility for battery collection with defined targets: 25% collection rate in % collection rate in 2016 quality requirements for recycling facilities in terms of: - facility management - Recycling Efficiency (RE): process efficiency to optimise the proportion of recovered materials recycling processes to achieve the minimum RE (% by weight): 65% Pb acid 75% NiCd 50% all other (eg. Li-ion, NiMH)

29 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling Directive 66/2006/EU outcome: 2015 Complexity in calculating Recycling Efficiencies (RE) Difficult to standardise recycling processes under one unique document Difficulties in uniform reporting of EU country REs Uncertainty of data Lack of transparency; figures not published Unclear on status of EU REs Revision is coming

30 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling Adopted Circular Economy Package December 2015 Key action areas: Production Consumption Waste management Secondary raw materials Priority sector: critical minerals Raw Materials Initiative 3 rd Pillar = Resource efficiency and supply of secondary raw materials through recycling. European Innovation Partnership Pilot actions for recycling; Regulatory framework for secondary raw materials (WEEE 2020) Horizon 2020 Work Programme = Climate Action, Environment, Resource Efficiency and Raw Materials

31 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling WEEE 2020 project ( ): Certification of recycling facilities for WEEE and Batteries Co-ordinator: EUROMETAUX Partners include: EBRA, Umicore, Eramet, Arcadis, Aurubis Create a new business model for the treatment of WEEE and spent batteries to incentivise investments in recycling facilities in Europe Support innovation in technological and non-technological measures supporting WEEE and batteries recycling.

32 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling CloseWEEE Project ( ): Improving the separation and recovery of SRM Consortium from 7 EU countries Efficient recovery of critical metals and minerals such as Cu, Co, Li and Graphite from Li-Ion batteries Accurec is the dedicated battery recycling partner and responsible for the improvement of the Li-Ion battery recycling technology. During 2017 and 2018 Accurec will perform a lab scale thermal treatment process, based on microwave technology

33 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling Li-ion battery anatomy LIB cells have a wider variety of materials. The active materials are in the form of powder, coated onto metal foil, each must be separated from each other during recycling. Graphite Anode materials Lithium salts Electrolyte Lithium carbonate or hydroxide Nickel, cobalt, manganese, iron Source: adapted from Liberum (2016) Source: Chris Hillseth Enterprises (2014)

34 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling Li-ion battery anatomy EV Li-ion battery materials by average weight % Li-ion battery cell materials by average value Plastic 11% Electrical 4% Steel 21% Cu cable 1% Cells 63% Source: data from Thomas Träger et al. (2015) Source: Liberum (2016)

35 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling Li-ion battery anatomy Li-ion battery cell materials by average volume Aluminium electrode foil 5% Copper electrode foil 8% Separator 4% Others 6% Casing 25% EV Li-ion battery electrode powder by average weight % O+H 24% Li 4% Al 1% Co 23% Electrolyte 10% Anode material 17% Cathode material 25% Source: data from T. Georgi-Maschler et al. (2012) C 36% Ni 11% Cu, Mn, Fe 1% Source: data from Thomas Träger et al. (2015)

36 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling Li-ion battery anatomy Average composition of components of LIB Source L. Sullivan and L. Gaines (2010)

37 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling Li-ion battery recycling process Source: EILBAMA (2014)

38 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling Li-ion battery recycling processes Dry Wet Source: Basudev Sw ain (2017) Main driver is for Co, Ni, Fe recovery rather than Li Only up to 3% of LIB are recycled with minimal focus on Li recovery There is still no closed circuit process for the recycling of LIB from the automotive sector RE of existing recycling plants challenged to meet EU target of 50%

39 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling Li-ion battery recyclers Two main strands Large scale, volume driven, often multi-process companies Pyro., smelting, refining tech. Targeting metals recovery +ve Processing range of batteries Producing range of recycled metals Existing infrastructure; process tech. Parent group resources -ve High temp., high energy, emissions Not for LIB; targets Co/Ni Li lost in slag Small scale, niche product, boutique tech. companies Hydro/Hybrid/Alt., selective chemical tech. Targeting compounds recovery +ve Aimed at specific batt. chem. ie. LIB Producing specific products Low temp., low energy, low emissions -ve Longer R&D time; chasing funding Use of chemicals Intensive sorting/separation Need to attract battery producers Lab to Pilot Plant to Commercialisation

40 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling Li-ion battery recyclers Perhaps 30 battery recycling plants in Europe <50% recycling NiMH and Li-Ion batteries Many plants in China COMPANY PROCESS PLANT LOCATION North America AERC Pyrometallurgy Allentown, PA, USA Hayward, CA, USA West Melbourne, FL, USA OnTo Technology Hydrometallurgy Bend, OR, USA Retriev Technologies Europe Accurec Recycling GmbH Hydrometallurgy Pyrometallurgy Pyrometallurgy; New hybrid process Trail, BC, Canada Lancaster, OH, USA Mulheim, Krefeld, Germany Batrec AG Pyrometallurgy Wimmis, Switzerland DK Recycling und Roheisen GmbH Pyrometallurgy Duisburg, Germany Euro Dieuze Industrie Hydrometallurgy Dieuze, France SNAM Pyrometallurgy Saint Quentin Fallavier, France Recupyl Hydrometallurgy Domène, France Umicore Valdi Asia Dowa Eco-System Co. Ltd Hunan Brunp Recycling Technology Co. Ltd Nippon Recycle Center Corp. Pyrometallurgy Hydrometallurgy Pyrometallurgy Pyrometallurgy, Hydrometallurgy Hydrometallurgy Pyrometallurgy Hoboken, Belgium Commentry, France Feurs, France Kizuno, Akita, Japan Honjo, Saitaima, Japan Nanhai, Guangdong, China Nakajima, Japan Tsukudu, Japan

41 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling Retriev Technologies Anaheim, CA Renamed in 2013, formerly Toxco Inc. New $20 million, 66,000 sq.ft., plant in Lancaster, OH, for large format EV Li-ion (4,000 tpa) and Ni-metal hydride batteries Supported by 2009 $9.5 million from US DOE to support US battery recycling Technology (cryogenic + hydrometallurgical) adaptable to different battery chemistries; segregated recycling lines Collaboration with industry: eg. with Energizer to make longer lasting alkaline batteries using 4% recycled material (aiming at 40% by 2025). Source: Mike Elicson

42 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling Onto Technology Bend, OR project to recycle Li and Co cathode materials Low energy, high efficiency liquid extraction process; 2014 pilot plant Ongoing: commercialisation; application for other chemistries; characterisation of recycled materials Source: Onto Technology (2015)

43 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling Univ. of South Florida Fungus promises to crack Li-ion battery recycling problem 22 August 2016 Engineering & Technology University of South Florida, based on previous experiments with metal extraction from slag Three strains of fungi: aspergillus niger, penicilium simplicissimum and penicillium chrysogenum Oxalic and citric acid generated by the fungi claimed to retrieve up to 85% of the lithium and 48% of the cobalt Ongoing research to remove Li and Co held in the acid

44 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling Umicore Hoboken, Belgium 7,000 tpa Li-ion & NiMH recycling plant at Hoboken, Belgium Combines unique pyrometallurgical treatment and hydro-metallurgical process ± mobile phone batteries ± E-bike batteries ± EV batteries Source: Umicore

45 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling Umicore process UHT Pyrometallurgical Process Higher metal recovery Output of directly marketable products. Direct feeding; avoids need for potentially hazardous pre-treatment Gas cleaning system Reducing energy consumption and CO 2 emissions to a minimum by using energy present inside the battery components (electrolyte, plastics and metals). Generating close to zero waste Source: Umicore Developing and pilot testing technology to recover Li (as Hydroxide or Carbonate) Working closely with industrial Li-refiners to implement a closed the loop on Li

46 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling Accurec Recycling GmbH Krefeld, Germany Developed innovative techniques for recycling of used batteries 2009 expansion to 4,000 tpa NiCd battery recycling EcoBatRec Project: Recycling of Liion automotive battery modules Patented process combining a pre-treatment with pyro- and hydrometallurgical process steps; aims at the production of a cobalt alloy and a pure lithium carbonate Source: Accurec

47 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling EcoBatRec Project 2016 commissioning of 5,000 tpa Li-ion battery recycling pilot plant at Krefeld mechanically processes battery materials following pyrolysis treatment at Currenta Environment s rotary kiln at Leverkusen. Cobalt price of 20/kg required if 1,000 tpa of Liion battery scrap is processed Source: EcoBatRec (2015)

48 Industrial Mineral Recycling in Li-ion Batteries: Li-ion battery recycling EcoBatRec Project Fe-Ni Al Electrode foil Electrode material Source: T. Georgi-Maschler et al (2012)

49 Industrial Mineral Recycling in Li-ion Batteries: Outlook Outlook: influencing factors on recycling Mineral supply Security Availability Quality Sustainable development Pricing Material Price (US$/tonne) 25 January 2017 Li-ion electrode % wt. Aluminium $1,848 1% Copper $5,867 - Cobalt $36,250 23% Graphite spherical $7-12,000 flake $ % Lithium $10-15,000 4% Manganese $1,740 <1% Nickel $9,635 11% Source: LME; InfoMine; Benchmark Mineral Intelligence

50 Industrial Mineral Recycling in Li-ion Batteries: Outlook Outlook: influencing factors on recycling Market Demand trends Technology evolution = choice of battery chemistry; eg. substitution of high cost cobalt will challenge today s recycling processes with respect to cost effectiveness as well as technology utilisation Specific volume usage Consumer preference for EV Pace of declining battery costs; by reducing amount of Co and Ni used may aid development of Li recovery processes National/Regional legislation, revisions, and incentives in battery recycling

51 Industrial Mineral Recycling in Li-ion Batteries: Outlook Outlook: influencing factors on recycling Market End of Life (EOL) Market growing, but actual EV LIB volumes recycled remains low since EV batteries still on the road; life of 7-10+yrs = delay for recycling = more demand for primary raw materials (Call2Recycle: Li-ion and Ni-Cd batteries don t reach 80% disposal rate until after eleven or even fifteen+ years, respectively ) Li-ion performance gradually declines; after 20-30% original capacity lost, their EV usefulness ceases; poss. other use..or not (according to Tesla) EOL1: autobatteries could be used in low cost grid-energy storage, since retaining ~70% of original capacity (GM and Daimler have trial projects underway). Not enough EV LIB have reached the end of their lives to support large-scale recycling plants

52 Industrial Mineral Recycling in Li-ion Batteries: Outlook Outlook: challenges on recycling Lack of recyclable LIB feedstock material at present Recycling processes: commercialise small-scale successful processes adjust to new and evolving Li-ion chemical systems improve material separation/sorting/recovery evaluate electrolyte recovery (can be %wt of cell) evaluate graphite recovery Li value <2-3% of total battery cost until recycling more economic and efficient, mineral pricing needs to be at higher level in order to justify investments in recycling processes.

53 Industrial Mineral Recycling in Li-ion Batteries: Outlook Outlook: challenges on recycling Make LIB more recyclable at manufacture standardisation of cell labelling standardisation of materials standardisation of cell design standardisation of chemistry EV LIB more complex than portable LIB, different chemistries: LCO (lithium cobalt oxide) NCM (lithium nickel manganese cobalt oxide) NCA (lithium nickel cobalt aluminum oxide) LFP (lithium iron phosphate)

54 Industrial Mineral Recycling in Li-ion Batteries: Outlook Outlook: what next? LIB recycling is coming! More than 95 GWh of used batteries will be extracted from hybrid and electric vehicles by Bloomberg New Energy Finance Global battery recycling market anticipated to expand at a CAGR 10.90% by 2024 ResearchMoz Report 2017 We are also taking the lead in developing a closed loop battery recycling system Kurt Kelty, Director of Energy Storage Systems, Tesla Motors (Tesla plans to recycle LIB at its Sparks, NV Gigafactory, and in Europe at Umicore) Renault, Nissan announced partnerships for EV LIB 2 nd lives

55 Industrial Mineral Recycling in Li-ion Batteries: Outlook Outlook: North America 1.5 million EV batteries (almost 50:50 LIB:NiMH) will reach EOL each year by Commission for Environmental Cooperation (2015) Estimated NiMH and Li-ion EV batteries at End of First Life, in Original Vehicle, in Canada, Mexico, and the USA, ( 000s units) 12 million Li-ion batteries available for recycling in USA in 2020 Call2Recycle (2016) Source: Commission for Environmental Cooperation (2015)

56 Industrial Mineral Recycling in Li-ion Batteries: Outlook Outlook: Europe Forecast of the return volumes (tonnes) of Li-ion batteries for recycling in the EU Source: Thomas Träger et al (2015)

57 Industrial Mineral Recycling in Li-ion Batteries: Outlook Outlook: Australia Forecast of EV Li-ion battery waste in tonnes and annual growth for recycling in Australia 57% 52% 47% Source: Randell Environmental Consulting (2016)

58 Industrial Mineral Recycling in Li-ion Batteries: Outlook Outlook: Reality check California Energy Commission Report July 2016 Plug-in Electric Vehicle Battery Recycling Scale-up Strategies for California ( ) California is likely to reach a sufficient battery pack disposal rate to justify a pilot-scale facility running at full capacity by approximately However, this rate may not justify a commercial-scale facility until after While hydrometallurgy recovers a greater fraction of battery materials, pyrometallurgy may prove to be preferable in the face of small battery volumes and uncertain technologies because of its ability to accept a wider range of battery types.

59 Industrial Mineral Recycling in Li-ion Batteries: Outlook Outlook LIB recycling remains in its infancy, and its impact on the primary raw material supply chain will remain negligible until at least But it will play an increasing and important role in the battery raw materials supply chain, since EV LIB in use now will reach EOL, and EV LIB consumption is set to boom Graphite recovery is not ecomonically viable, and unlikely to become so before lithium A hybrid process utilising pryo and hydrometallurgical methods able to adapt to the LIB chemistry(ies) of the day is most likely scenario; ideally in partnerships between major LIB suppliers and end users Future mineral supply overcapacity for graphite and lithium is a possibility, and would drive prices down, making recycling even less attractive Merrill Lynch Report 2017: Recycling of electric vehicle batteries could provide 50% of the lithium requirement for new batteries by 2040

60 Industrial Mineral Recycling in Li-ion Batteries: Outlook Thank you for your attention If you have any questions or comments, or would like more information, please contact me +44 (0) mobile +44 (0)