Alain Rollat

Alain Rollat - Rhodia Rare Earths System
Satisfaire la demande en terres rares :
de la mine au recyclage
Content
2
1
Rhodia Rare Earth Systems
2
World wide Rare Earths resources
3
Worldwide Rare Earths supply and demand
4
RE recycling: the urban mine
5
Medium / long term: collaboration with mining
companies
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
Content
3
1
Rhodia Rare Earth Systems
2
World wide Rare Earths resources
3
Worldwide Rare Earths supply and demand
4
RE recycling: the urban mine
5
Medium / long term: collaboration with mining
companies
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
Rhodia Eleven business units
Growth engines focused on their markets
Energy
Services
Fibras
Engineering
Plastics
Polyamide &
Intermediates
Aroma Performance
Rare Earth
Systems
Silica
4
Coatis
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
Novecare
Eco Services
Acetow
Rhodia, more than 50 years in Rare Earth
processing and refining
La Rochelle (France)
plant in 1948
HISTORY
1919: Georges Urbain founds the « SOCIETE DE PRODUITS CHIMIQUES DES TERRES RARES » in
Normandy, France
• More than 50-years in Rare Earths Processing and refining
• More than 25 years experience in customer oriented product improvement and development
• Established chemical and process expertise and proprietary know-how
In 2011, one plant in France, two plants in China, one in Japan, and one in North America
5
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
SBU Rare Earth Systems; the current footprint
North / Latin America
W. Europe
Asia / Pacific
Baotou
Anan
Cincinnati
Freeport
Paris
Cranbury
Bristol
Shanghaï
Lyon
La Rochelle
Head quarters
Production sites
6
Liyang
R&D centers
All plants are ISO 9001 certified
LRRollat
is IsoTS
iso14001
certified
Alain
– UFGand
5 Nov
2011 – Terres
Rares de la mine au recyclage
Content
7
1
Rhodia Rare Earth Systems
2
World wide Rare Earths resources
3
Worldwide Rare Earths supply and demand
4
RE recycling: the urban mine
5
Medium / long term: collaboration with mining
companies
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
What are Rare Earths ?


Group of natural elements : 14 lanthanides + Yttrium + Scandium
Present in different proportion in several naturally occuring ores
H
Li
He
Be
B
C
N
O
F
Ne
Na Mg Sc
Al
Si
P
S
Cl
Ar
Ga Ge As
Se
Br
Kr
K
Ca Y
Ti
Rb
Sr La
Zr
Tc RuSmRh Eu
Pd
Ce Nb PrMo Nd
Ag
Sn
Gd CdTb In Dy
Sb
Ho Te Er I
Xe
Tm
Cs
Ba
Hf
Au
Bi
Rn
8
V
Ta
Cr
W
Mn
Re
Fe
Os
Co
Ir
Ni
Pt
Cu
Zn
Hg
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
Ti
Pb
Po
At
Yb
Lu
Not so rare earths…
RE Relative abundance in the Earth’s crust (ppm)
100
10
Ce
Ni
Cu
La
Y
Sc
1
Pb
Sm
Sn
Eu
Mo
Lu
0,1
Ce
9
Ni
Cu
La
Y
Sc
Pb
Sm
Sn
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
Eu
Mo
Lu
Quite large and well distributed reserves,
Proven world reserves of RE (incl Y) - USGS 2007
From 2007 several deposits have been re estimated. Current estimation is more than 100 M tons
90
80
Millions tons
70
60
50
40
31%
25%
22%
30
15%
20
6%
1%
10
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
...
)
a,
an
ad
(C
er
s
O
th
10
Af
ric
a
In
d
ia
ra
lia
A
us
t
SA
U
EI
C
a
hi
n
C
W
or
ld
To
ta
l
0
Light RE (La, Ce, Pr, Nd) and heavy RE (Sm -> Lu +Y) are
included in different minerals and deposits
• Light RE bearing minerals (marker = Cerium)
• Heavy RE bearing minerals (marker = Yttrium)
LRE
Be a ring
mine ra l
Ba s tna s ite
Mona zite
Apa tite
Ionic cla y
Xe notime
Fe rgus onite
De pos it
Ba s tna e s ite
Ba ya n Obo
Mount We ld
Ce ntra l zone
Ara fura
Ionique
Middle Y
P itinga
Conce ntra te
Thor La ke
La 2O3
Ce O2
P r6O11
Nd2O3
S m2O3
Eu2O3
Gd2O3
Tb4O7
Dy2O3
Ho2O3
Er2O3
Tm2O3
Yb2O3
Lu2O3
Y2O3
11
HRE
26.90
25.6%
50.90
45.7%
5.00
5.4%
15.20
18.6%
1.15
2.4%
0.227
0.6%
0.32
1.0%
0.0300
0.1%
0.0910
0.2%
0.0095 Tra ce s
0.0110 Tra ce s
Tra ce s
0.0005 Tra ce s
Tra ce s
0.20
0.4%
20
48.2
5.9
21.5
2.4
0.41
1
0.08
0.34
Tra ce s
Tra ce s
Tra ce s
Tra ce s
Tra ce s
0.21%
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
30.00
3.00
7.00
26.40
5.10
0.650
4.20
0.7000
2.9000
0.4000
1.4000
0.3000
1.1000
0.2000
17.30
0.0
0.6
0.0
0.4
0.4
0.0
1.1
0.8
11.2
3.4
15.4
3.0
20.4
2.7
40.6
0.30
4.40
1.70
15.60
10.4
1.60
14.30
1.80
9.80
1.20
1.40
0.70
4.10
0.70
29.00
WW production has been progressively concentrated in
China
Cessation of Monazite treatment in
Rhodia La Rochelle (France) plant
Cessation of Molycorp’s Bastnasite
treatment (Mountain pass USA)
USGS 2002
In 2010 more than 97% of RE raw materials came from China
12
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
Rare Earths mines in China
Bastnasite
BayanObo
In.Mongolia
BEIJING
BaoTou
Yingkou
Qingdao
Wuxi
LiYang
Bastnasite
Mianing
Sichuan
SHANGHAI
XiChang
GuangZhou
13
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
Ionic clays
XW,XF,LN
JiangXi, FJ, GD,
Content
14
1
Rhodia Rare Earth Systems
2
World wide Rare Earths resources
3
Worldwide Rare Earths supply and demand
4
RE recycling: the urban mine
5
Medium / long term: collaboration with mining
companies
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
A sustained growth market
15
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
Supply/production balance (2014 forescat)
16
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
A lot of RE projects outside of China
… but all main advanced projects are based on LRE deposits
Main non chinese mining projects
Chinese Mines
in operation
Advanced projects
(2011-2013)
Main long term projects: > 2015
100%
80%
60%
HRE + Y
LRE
40%
20%
B
ay
an
O
M
bo
id
d
le
Y
Lo
n
M
N
o
a
u
M
nt m
o
un W
ta eld
in
P
as
S
te
s
en
O
ka ris
sa
m
p
sk
ra
al
D
ub
b
K
o
u
te
ss
a
i
A
k
Jo ta
hn u
S
tr
G
an
al
t
g
e
la
k
T
an e
b
N ree
B
o
ra z
ok
a
K
n
ar
m
r
ou
ta
in
0%
17
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
Current and past RE exploited ores are based on 4 main
minerals with high REO content after beneficiation
Main industrialy exploited RE minerals
Rare earth
Bastnaesite
Formula
CeFCO3
Type
Fluorocarbonate
Monazite
(Ce,Y)PO4
Xenotime
Ionic Clays, Laterite
•
•
REO (%)
50% - 65%
Main mines
Bayan Obo; Mountain Pass
Phosphate
65%
Allied Eneaba Australie; Orissa Inde
YPO4
Phosphate
60%
Batu Gajah Malaisie
(Al,Si)Ox,RE
Alumino Silicate
0,20%
Jiang Xi; Guandong Chine
Typical LRE ores are Bastnasite and Monazite for which beneficiation are efficient
and chemical process are well known
Chinese mines in operation
Current HRE deposits in China are very specific:
• Ionic clays
• REE are ion adsorbed
• Treatment is an easy process
(ion exchange by heap lixiviation)
18
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
Deposit
Ionic clay Xun
Wu
Lon Nam
Country
China
China
Metals
REE
REE
Bearing
mineral
Ionic clay
Ionic clay
Owner
New HRE deposits are more complex
•
New HRE deposits are much more difficult to work than the Ionic clays currently
worked in China.
• Polymetallic deposits requiring to valorize several elements (RE / Nb, Ta / Zr / U)
• Minerals requiring development of new processes (ex: Eudialyte, Noujaite…)
• Beneficiation seems very difficult to acheive (more complex mineralization). Main of the new
HRE projects are based on concentrates containing less than 5% REO
Main HRE active projects
Deposit
Kute s s ai
Aktau
John Galt
S trang e lake
Kvane fje ld
Tanbre e z
No ra Karr
Country
Kyrg yzs tan
Kazakhs tan
Que be c
S we e de n
S tans
S are c o
Rare Mine rals
Tanbre e z
Tas man
Uc o re
Metals
REE
REE
Zr,Nb,REE
Gre e nland
Gre e nland
Mine rals
U,REE
Gre e nland
Owner
Australia
Northern
Minerals
REE
Bo kan
mo utain
US A
REE
Zr, Nb, REE
Yttrosynchisite
Pho s pho rite
tailing s
Xenotime
Kaino s ite
Ge re nite
Gado linite
Kako rto kite
No ujaite
S o dalite
Eudyalite
Eudyalite
Catapleiite
REE
Te ng e rite
thale nite
Uudyalite
allanite
Bearing
mineral
19
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
How to secure RE supply
1.
2.
Light RE:
1. No risk of shortage in the coming years (thanks to Lynas, Molycorp …)
2. Processes are well known
Heavy RE is the main concern
1. Only recycling can be part of the non Chinese HRE supply in the short term. Rhodia
launched a wide recycling project with 3 pilars
•
•
•
Recycling of our historical tailings
Recycling of wastes from our customers
Recycling of RE contained in end of life products
2. Medium / Long term. Rhodia decided
•
•
20
To select the most interesting HRE projects in term of RE distribution and feasibility
To set up partnership (technical and business) with mining companies using our competency in
RE recovery and separation in order to help them in designing new processes for the very
complex new deposits.
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
Content
21
1
Rhodia Rare Earth Systems
2
World wide Rare Earths resources
3
Worldwide Rare Earths supply and demand
4
RE recycling: the urban mine
5
Medium / long term: collaboration with mining
companies
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
Can Europe play a part ?
• None of the current mining projects for RE recovery is located in
continental Europe
• Nevertheless we feel that RECYCLING is the European RE urban mine.
• Rhodia decided to launch a large program of RE containing products
recycling based on 3 pilars:
• RE recycling from our historical wastes
• RE recycling from production scraps of our customers
• RE recycling from end of life products
• Recycling of RE containing products is useful only if we can separate all
the REE recovered and Rhodia owns the only unit in Europe able to
separate all the REE.
22
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
RE recycling from our historical wastes
A Rare Earth mine in La Rochelle
24 000t of scraps containing 6000 t REO
23
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
RE recycling from production scraps of our customers
Example: Polishing powders
Purified La & Ce
La & Ce based polishing
powders
RE separation
process
Flat screens
polishing
Specific RE recovery
process
Used polishing
slurry
Rhodia Process
Landfill
24
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
RE recycling from end of life lamps to close the loop
Rhodia recycling project
Rhodia project
Rare Earth
valorization
Several thousands of
Tons of powders
are landfilled each year
Rare Earth
Concentration
Rare Earth
Separation
< 200 tons of final
Solid waste
2,000 tons of
phosphate to be recycle
Rare Earth
Finishing
Recycling Companies
Valorisation
-glass
-metals
-plastics
-mercury
De-mercurising
More than 300 tons/y
of HRE of rare earths
Lamp
treatment
Consumers
Professionals
Sorting
Eco-organisms
Lamp
collection
Collectors
80 000 tons of
Lamps ww
15~20% of used lamps
25
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
Lamp users
Recyclage complet des Terres Rares des lampes usagées
Lamp recyclers
1
New
recycling
Powder
Powder from
from used
used lamps
lamps
Phosphate to be
valorized
process
Final wastes
Rare
Rare Earth
Earth Concentrate
Concentrate
2 Separations
Pure
Pure La
La
Pure
Pure Ce
Ce
Pure
Pure Tb
Tb
Pure
Pure Gd
Gd
Pure
Pure Eu
Eu
3
Finishing
LAP
LAP
Gd2O3
Gd2O3
Lamp Manufacturers
26
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
YOx
YOx
Pure
Pure Y
Y
Luminescent powder are urban mines of Heavies
Rare Earths ready to start for exploitation
Tons powders
Rhodia
industrial unit
Start up 2013
2500
2000
1500
Marché français
Marché Européen
Rhodia
Demo plant
Start up Jan 2012
1000
500
0
2009
27
2010
2011
2012
2013
2014
2015
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
2016
2017
2018
2019
2020
Content
28
1
Rhodia Rare Earth Systems
2
World wide Rare Earths resources
3
Worldwide Rare Earths supply and demand
4
RE recycling: the urban mine
5
Medium / long term: collaboration with mining
companies
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
Du minerai aux Terres Rares séparées
Deposit
REO = 0.2% to 15%
Physical treatment
Ore Mining
crushing & grinding
Rhodia doesn’t have
wide expertise, but
can orientate the
mining companies to
get the best
concentrate for the
downstream part
RE mineral beneficiation
(flotation, magnetic separation)
REO = 20 to 70%
Concentrated ore
Chemical treatment
Ore attack
RE concentate (SX, IEx, Chemical)
Rhodia core
competency
RE concentrate
Solvent extraction
La
29
Ce
Pr
Nd Sm Eu
Gd
Tb
Dy
Ho
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
Er
Tm Yb
Lu
Y
RE Separation: One battery in Rhodia La Rochelle plant
30
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage
Merci pour votre
attention!
31
Alain Rollat – UFG 5 Nov 2011 – Terres Rares de la mine au recyclage