Rare Earth Permanent Magnets: Raw Materials, Magnets and Opportunities. S. R. Trout

Transcription

1 Rare Earth Permanent Magnets: Raw Materials, Magnets and Opportunities S. R. Trout

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3 Outline Background Raw Materials Rare Earth Magnets Applications Final Thoughts

4 Background SmCo 5

5 1976 Pittsburgh Background Previous Intermag Conferences 1986 Phoenix 1979 New York 1987 Tokyo 1980 Boston 1989 Washington D.C Grenoble 1991 Pittsburgh 1982 Montréal 1994 Albuquerque 1983 Philadelphia 1995 San Antonio 1985 St. Paul 2000 Toronto 2001 San Antonio

6 Raw Materials Sc Y La Ce Pr Nd Pm Sm Eu Gd Tb Dy Ho Er Tm Yb Lu

7 Raw Materials Ores contain all rare earths except Pm There is no shortage of ore Most rare earths are not rare Most ores are rich in Ce, La, Nd and Pr The rare earths are chemically very similar Producers try to balance supply and demand

8 Raw Materials Ores contain all rare earths except Pm There is no shortage of ore Most rare earths are not rare Most ores are rich in Ce, La, Nd and Pr The rare earths are chemically very similar Producers try to balance supply and demand And are rarely successful!

9 1 km Bayan Obo mine, near Baotou, China Photo from Google Earth

10 ~1 km Mountain Pass, CA Photo from Molycorp

11 Raw Materials Bastnasite Ce 50% Others 2% Nd 19% La 23% Pr 6%

12 Raw Materials Markets Ceramics 5% Others Phosphors 7% 7% Magnets 20% Metal Alloys 20% Catalyst 20% Polishing 12% Glass 9%

13 Production, metric tons Raw Materials Other USA China 130, , , ,000 90,000 80,000 70,000 60,000 50,000 40,000 30,000 20,000 10, Source: U.S. Geological Survey

14 Raw Materials Active mines China Baotou Ionic Ores Mines in transition USA Mountain Pass, CA Inactive mines or deposits Australia Mt. Weld Nolan s Bore Canada Hoidas Lake Thor Lake India Brazil Vietnam Russia

15 Raw Materials Source: Dudley Kingsnorth, IMCOA, 2009

16 Lack of viable ores Most rare earths are not rare Shortage of Neodymium A self-regulating market Price Design Application Raw Materials Issues Dysprosium and Terbium Constrained Abrupt changes are extremely disruptive Upsets balance Capital intensive industry Lengthy recovery

17 Rare Earth Magnets Materials Sm-Co SmCo , Sm 2 (Co,Fe,Cu,Zr/Hf) 17 Nd-Fe-B (Nd,Dy) 2 (Fe, Co) 14 B Questions When? Who? Where used? Speed of implementation?

18 Rare Earth Magnets Unfinished business The H ci of Nd-Fe-B Why do Dy and Tb Increase H ci? Updating the 1985 explanation

19 Rare Earth Magnets Source: Livingston 1985

20 Rare Earth Magnets Nd 2-x Dy x Fe 14 B Nd 2 Fe 14 B Increasing x Increasing x Source: Neomax

21 Rare Earth Magnets Unfinished business The H ci of Nd-Fe-B Why do Dy and Tb Increase H ci? Updating the 1985 explanation Controlling β, the temp. coefficient of H ci Wiser use of Dy and Tb Anisotropic bonded Nd-Fe-B Recycling, reuse Lower cost

22 Hard drive Rare Earth Magnets Voice Coil Motor (VCM) Spindle motors Applications Source: Western Digital

23 Rare Earth Magnets Automotive Current Applications Cruise Control Mirror Motors Tailgate Motor Door Lock Motor Four Wheel Steering Anti-skid Sensor and Motor Window Lift Motor Suspension System Fuel Pump Motor Seat Belt Motor Seat Adjust Motors Antenna Lift Motor Traction Control Heater-A/C Blower Throttle and Crankshaft Position Sensors Windshield Wiper Motor Starter Motor Coolant Fan Motor Ignition Systems Headlight Door Motor Economy and Pollution Control Liquid Level Indicators Windshield Washer Pump Gauges CD Player Head Rest Motor Sun Roof Motor Electric Power Steering and Sensor Lumbar Support Automatic Temperature Control Door Gasket Defogger Motor Speakers Source: Magnequench

24 Automotive Hybrids Rare Earth Magnets Applications Source: Toyota

25 Wind Turbine Magnet vs. asynchronous Rare Earth Magnets One tonne of magnet per turbine The future? Applications Source: Vestas AS

26 (BH) max (MGOe) Rare Earth Magnets The Dy Issue H ci (koe) Source: Magnequench

27 Final Thoughts Raw Materials Issues Dysprosium Sudden changes Opportunities Green technologies Magnets Ni-metal hydride batteries Lighting phosphors Rare Earth Magnets Issues Dysprosium What does it really do? How can we use less of it? Limited production outside China Opportunities Hybrid vehicles Wind turbines Recycling

28 Final Thoughts Presentation will be available on