RAW MATERIAL FLEXIBILITY ELKEM. Gro Eide 2017

Transcription

1 RAW MATERIAL FLEXIBILITY ELKEM Gro Eide 2017

2 Elkem 110 years of history as a technology provider 26 PLANTS WORLDWIDE Headquarter in Norway EMPLOYEES Worldwide 400 R&D PEOPLE Global R&D centers in Norway and Lyon Founded in 1904 by Sam Eyde Owned by China National Bluestar since ,2 B NOK Revenue in 2016* *15 BNOK incl new assets in Rana and Nagpur

3 The Elkem Group: two integrated value chains Elkem AS and the Silicones value chain: Including Xinghuo and Yongdeng Employees: 6200 Revenue: 1,900 MEUR QUARTZ SILICON, FOUNDRY ALLOYS, CARBON MATERIALS SILICONES Elkem AS and the silicones value chain The solar value chain: Elkem Solar and REC Solar SILICON BLOCK WAFER CELL MODULE Employees: 2250 Revenue: 700 MEUR Elkem Solar REC Solar Singapore 3

4 The silicon value chain our four business areas Silicon Materials Global producer and provider of silicon, microsilica and specialty materials x 5 Silicones One of the foremost fully integrated silicones manufacturers in the world x 9 Foundry Products Leading producer of specialty-alloys for the foundry and steel industries x 6 Carbon Leading producer of electrode paste and other carbon products x 6 4

5 Our products are vital for modern societies WINDMILLS INFRASTRUCTURE QUARTZ SILICON AND MICROSILICA AIRBAGS COAL SILICONES BIOCARBON FOUNDRY PRODUCTS SOLAR AUTOMOTIVE COOKING UTENSILS POWER CARBON PRODUCTS ELECTRONICS RELEASE COATING LOW COST SUSTAINABLE INPUT FACTORS HIGH TEMPERATURE / CHEMICAL PRODUCTION PROCESSES EXAMPLES OF HIGH VALUE APPLICATIONS AND MARKETS

6 6 Elkem technology R&D technical centre industrial R&D partner

7 Elkem R&D technical center: FROM IDEA THROUGH TESTS INTO RESULTS Plan Plan Design Experiment Analyse 7

8 Elkem pilot plant Facilities: Hydro-metallurgical lab Bench scale pyro-metallurgical lab Pilot skale pyro-metallurgical facility m 2 area pilot facilities Projects: Pyro-metallurgical process development and verification «Waste to resources» Raw material testing and qualification Testing and verfication of process equipment Hydro-metallurgical treatment Product testing 8

9 EU-project Spire REE4EU Elkem Technology is responsible for the pilot part in REE4EU Pilot scale set-up and operation of the integrated recycling process of Rare Earth Elements for permanent magnets and Ni-hydrid batteries The process is an integrated High Temperature Electrolysis and Ion Liquid Extraction 9

10 FutureMat Catapult centre for Future Materials Raw Materials Primary metals Powders Additive Manufacturing Aluminium 13 Al 26,982 Silicon 14 Si 28,086 By products Side streams Titanium 22 Ti 47,867 Manganese 25 Mn 54,938 Cobalt 27 Co 58,933 Nickel 28 Ni 58,693 Circular Solutions Pyrometallurgy Hydrometallurgy Size reduction Classification Separation Plasma systems Atomization Milling/classification 3D printing metals Iso-static pressing Metal Injection Moulding External markets

11 Raw material flexibility sustainable production Raw materials Finished products By products Side streams Size reduction Separation Agglomeration Pyro/Hydro metallurgy 11

12 The Elkem Group: two integrated value chains Elkem AS and the Silicones value chain: Including Xinghuo and Yongdeng Employees: 6200 Revenue: 1,900 MEUR QUARTZ SILICON, FOUNDRY ALLOYS, CARBON MATERIALS SILICONES Elkem AS and the silicones value chain The solar value chain: Elkem Solar and REC Solar SILICON BLOCK WAFER CELL MODULE Employees: 2250 Revenue: 700 MEUR Elkem Solar REC Solar Singapore 12

13 ELKEM SOLAR CIRCULAR BY DESIGN ELKEM SOLAR SILICON (ESS) ELKEM SOLAR FISKAA ELKEM SOLAR HERØYA Silicon Slag treatment Leaching Solidification Post treatment Ingot(Blokk) solidification Cut-offs Other clean Si-sources REC Solar Singapore REC Solar Singapore REC Solar Singapore Advanced materials shaping the future

14 Production of ferrosilicon-alloys tailormade for the iron foundries Norwegian quarts and biomass constitues 60% of the raw materials for production. The rest is i carbon sources transported from other parts of the world. Today both the fines from quarts and charcoal is put on landfill, the target is to make briquettes of all these resources

15 Briquetting of the fines a new raw material - Utilizing the fines: - Quarts: 6000 tons saved, 1,5 boat/year - Charcoal: 420 tons saved, 25 trucks/year - The test campaigns shows similar raw material properties of the briquettes as of the normal raw materials - More homogeneous raw material mix less fines - Briquettes consisting of 20% carbon fines og 80% quarts fines, binder is cement Product By-products Landfill

16 Tornado Controller - three prosess steps in one The Vortair is a mechanical separator with highly adjustable characteristics. Air at low pressure is accelerated and directed into the cyclone from several nozzles The innovative nozzle design delivers high air velocity with low pressure drop. The flow field with low pressure gradient forms a vortex, making the particles spin, change speeds and collide. These effects are controlable, resulting in: Effective separation of water from dry solids Selective grinding based on hardness, brittleness and elasticity Air classification based on surface area, density and specific gravity Particle surface cleaning Process temperature is C with no heat supplied 16

17 Crushing and separation in Tornado Controller Sample % Si % SiO 2, cristobalite % SiC % SiO 2, quartz % FeSi 2 % Amorph Fraction 5,5 7,1 4,3 3,4 0 79,6 Amorphous part: 20% Al2O3, 25% CaO og 55% SiO2 17 Advanced materials shaping the future

18 SolaritE - cleaning drainage water from road work landfills Biological cycle New E18 high-way causes poisoning Landfills of sulfide containing acid-producing rocks from the construction of the new E18 between Grimstad and Kristiansand kills fish and other wild life in river, lakes and sea in Lillesand 18 Advanced materials shaping the future

19 Biological cycle SOLARITE - liming agent and fertilizer from a by-product Solarite is the clean CaSi-based slag from the Elkem Solar Process Solarite has unique properties in agriculture Contains soluble calcium Perfect as a liming agent Good bioavailability of silicon (silicon mono acid) Field tests conducted on Cucumber Wheat, barley, Golf course greens Dedicated fertilizer mixtures Silicon yields thicker scale and stays fresh in the grocery stores. In addition a much better resistance towards deceases, fungal & insect attacks is obtained. 19 Advanced materials shaping the future

20 ADVANCED MATERIALS SHAPING THE FUTURE