Critical material flows and recycling of LED products

Transcription

1 Critical material flows and recycling of LED products CycLED Conference, 19th of May 2015, Berlin Dr. Otmar Deubzer, Fraunhofer IZM Dr. Max Marwede, TU Berlin subtitle

2 Definition LED die/chip LED retrofit lamps LED products Display products (LED backlighting for LCDs) LED package (LED) LED luminaires Sources: Fraunhofer IZM

3 Identification of CycLED target metals Precious PGMs metals Au Ag Pt Pd REM Al As Be Cu Ga In Mn Ni Sn Sb Ta Zn Contained in LED EU 20 criticality Avg. criticality a) Economic importance for electronics industry b) a) Average of six different criticality studies [ECN (EU), KfW (DE), NRC (USA), BERR (UK), VBW (DE), IZM (DE)] b) Economic importance for the electronics industry as yearly expense on those materials Target metals Rare earth elements (RE): highly critical, economically important Phosphors: Yttrium, Cerium, Terbium, Europium, Lutetium Indium: highly critical LED dies, Indium-Tin-Oxide in LCDs Gallium: critical & strong demand growth expected LED dies, integrated circuits Tin: highly critical and of high economic importance for the electronic industry Interconnection Gold and Silver: critical and of high economic importance for the electronic industry Interconnection 2

4 Where are the target materials? wire bond Au (1st level interconnection) submount 2 nd level interconnection SnAg solder LED package REM InGaN die/chip converter Au, ITO front contact back contact & 1st level interconnection SnAg solder board Premould Lead frame Chip on board 3

5 Market Share of Phosphors in LED Converters Eu Lu Eu, Ce Eu Y Ce Source: Phosphor manufacturer 4

6 Market-weighted concentrations Unit REM (wt.-%) Ga (wt.-%) In (wt.-%) Tablet/TV 5 x 10-4 % extremely low extremely low Retrofit LED lamp/display units 4 x 10-3 % 6 x 10-5 % 1 x 10-6 % LEDs on board (lighting) 4 x 10-2 % 7 x 10-4 % 1 x 10-5 % Package 0.2 % 7 x 10-3 % 1 x 10-4 % Converter (dispersed) ~ 1-2 % - - Phosphor ~ 30 % - -

7 6 Modelling flows in Europe until 2020 white LEDs

8 LED products put on market in Europe Shipped LED products [Mio. cm² die area] End-of-life LED products End-of-life LED products [Mio cm² die area] Delay of End-of-life flows Mio. cm² die area Mio. cm² die area 60 Cell Phones Smart Phones Tablets 50 Laptops PC Monitors TV 40(direct lit) TV (edge lit) Architectual Lighting Outdoor 30 Lighting Industrial Lighting Commercial Repl 20 Commercial New Residential Repl Residential New 10 Cell Phones Smart Phones Tablets Laptops PC Monitors TV (direct lit) TV (edge lit) Architectual Lighting Outdoor Lighting Industrial Lighting Commercial Repl Commercial New Residential Repl Residential New

9 Recycling limited to Ag, Au and Sn 100% 90% 80% 70% Material utilization LED manufacturing Recycling rate production scrap Recycling rate EoL 60% 50% 40% 30% 20% 10% 0% Ga In Au Ag Sn Ce Eu Lu Y 8

10 Net-import of materials in 2020 positive 100% 80% 60% Export (dies on wafer) Lost Import (products) Recycled 11,250 kg 246,600 kg 1,165 kg 50 kg 15 kg 590 kg 990 kg 83 kg 14 kg 40% 20% 0% -20% -40% Ga In Au Ag Sn Ce Eu Lu Y 9

11 Value in 2020 [US-$ 2010 ] Value of Au, Ag and Lu the highest 1E+8 1E+7 1E+6 Lost materials Materials in LED products PoM/ for die production 1E+5 1E+4 1E+3 1E+2 1E+1 1E+0 Ga In Au Ag Sn Ce Eu Lu Y 10

12 Summary and Conclusions Significant flows: Mass wise: Sn, Ag, Au, Y and Lu Value wise: Au, Ag, Sn and Lu Negligible flows: In and Ga (kg range) Au, Ag & Sn: High recovery rate at end-treatment EoL recycling rates (incl. collection, pre-treatment) < 20 % Ga, In and REM: Recovery rates at end-treatment = 0 Long delay of end of life flows for lighting products Improve the end-of-life chain Focus on feasibility of recycling of REMs (Lu & Y) High uncertainties for now and the future: market, products (lifetime, material composition), processes 11

13 Recycling Resource Use without Consumption 12

14 Supply Risk Critical Metal Area The cycled Target Metals Heavy REM (Yttrium, Lutetium, Europium) Light REM (Cerium) Irrelevant for products due to low total use! Indium Gallium PGM Gold Silver Critical Metal Area Tin REM: Rare Earth Metals PGM: Platinum Group Metals Economic Importance Source: European Commission, DG Enterprise (modified): 13

15 Standard End-of-Life Scenario End-processing Pre-processing Collection Recycled Materials

16 Current Situation Precious metals (PM) and platinum group metals (PGM) economic drivers of recycling activities Well established recycling paths for: Precious metals (PM) Platinum group metals (PGM) Copper (Tin) Rare earth metal recycling No recycling of REM, indium, gallium from EoL LED products REM recycling from fluorescent powders Indium and gallium recycling from LED production waste?!

17 Objectives and Core Tasks Objective: Establish recycling routes for rare earth metals (REM), indium and gallium from products with white LEDs without compromising recycling of precious (PM) and platinum group metals (PGM) Research questions Concentration of REM, indium and gallium in LED products? Can we increase these concentrations in pre-processing? Can we find recycling processes for REM, In, Ga? 16

18 REM Concentration in 1 t of EoL LED Products? 17 Source: ELPRO GmbH

19 Average REM in White LED Unit REM (wt.-%) Ga (wt.-%) In (wt.-%) Tablet/TV 5 x 10-4 % extremely low extremely low Retrofit LED lamp/display units 4 x 10-3 % 6 x 10-5 % 1 x 10-6 % Source: Philips LEDs on board (lighting) 4 x 10-2 % 7 x 10-4 % 1 x 10-5 % Package 0.2 % 7 x 10-3 % 1 x 10-4 % Converter (dispersed) ~ 1-2 % - - Phosphor ~ 30 % - -

20 Target Metals (TM) in White LED Package wire bond Au (1st level interconnection) submount 2 nd level interconnection SnAg solder LED package REM InGaN die/chip converter Au, ITO front contact back contact & 1st level interconnection AuSn solder board heat sink Source: Fraunhofer IZM

21 Ecological/Economical EoL Situation 10 MJ = 2.8 kwh 280 h (~ 12 days) light from 10 W LED

22 Source: Riva Lighting Challenges in Pre-/Endprocessing Aluminum Recycling Path Aluminum Heat Sink Al Source: Fraunhofer IZM Design for Recycling! Cu Sn LED-Chip Printed Wiring Board Au Ag Pre-processing (Manual, Mechanical) Copper Recycling Path End-processing in Smelters REM 21

23 Separation of Converters from LED Chips Source: ELPRO LED Stripes LED Packages Source: Fraunhofer IVV Precipitated Plastics: PET, PBT, PA, PC, PMMA CreaSolv Process Au Recycling in Smelter Sn LED Metallic Submount (Cu, Ga, Au, Ag, Sn, In ) Converters (Phosphors + Matrix) Cu Ag Source: Fraunhofer IVV 22

24 Approaches to REM Recycling Waste LED Phosp hors Source: Fraunhofer IVV LED Converters Phospor in Silicone Matrix Waste LED Phosp hors Phosphors from Fluorescent Lamps Recycling of Yttrium, Lutetium, (Europium, Cerium) Development of New Process (Hydro-, Pyrometallurgy) Challenge: Removal of the Silicone Matrix Recycling of Yttrium, Lutetium, (Europium, Cerium) Adaptation of Existing Process 23

25 ESTIMATED CreaSolv Cost-Benefit Source: Dr. Martin Schlummer, Fraunhofer IVV 24

26 CreaSolv Cost-Benefit Economy of scale is crucial! Potentially profitable for high value phosphors like Lu, and/or increasing prices of REM for LED Limited variety of plastics on LED-stripes improves process result (DfR) 25

27 Cost-Benefit Considerations Separate collection of LED products required Alternatively separation from other products ((compact) fluorescent lamps, CCFL-backlighted monitors/tvs, after collection Treatment of LED lamps and LED-backlighted products with consumer electronics and ICT principally possible (no Hg!) Considerable cost savings possible, in particular for lamps Challenges o Treatment cost (compact) fluorescent lamps: 1,300 /t* o Treatment cost consumer electronics, ICT: 180 /t* Consumers cannot clearly discern LED products from others Labeling of LED products? *Source: Elektroaltgeräteregister EAR, Germany 26

28 Remaining Challenges Preparation for CreaSolv process Separation of LED stripes/chips from LED products only manually possible so far Cost driver But improved recycling of PM and PGM as side effect! Collection Separate collection of LED products, or Sorting of LED products required Research on REM recycling from converters ongoing Finalize cost-benefit analysis 27

29 Efficient Use Longevity, Repair, Reuse, High Energy Efficiency 28

30 ONA: Atmospheric/Home Lighting The cycled Demonstrators Source: ONA Source: Braun Lighting Solutions Riva: Industrial Lighting Eco-innovation Framework Life Cycle Management Optimized Thermal Management: Longevity Max. Lumen/Watt: Efficiency Design for Repair, Recycling Adapted Business Models Braun: Street Lighting Source: Riva Lighting Source: ETAP ETAP: Lighting in Harsh Environments

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