Permanent Magnets for Energy Applications Part 2

1. Permanent Magnetsfor Energy ApplicationsPart 2 Stan Trout August 11, 2014

2. Permanent Magnets for Energy Applications Part 2 • Rare Earths • Basic facts • The crisis • Mines • Applications • Magnet Recycling • Permanent Magnet Selection & Specification • Case Studies • The Future

3. Rare Earths

4. Rare Earths 101 • Ores contain all rare earths except Pm • The rare earths are chemically very similar • There is no shortage of ore for light RE’s • Bastnasite & Monazite are the most common • Most ores are rich in Ce, La, Nd and Pr • Not all rare earths are rare in the Earth • Magnetic, optical, electronic and catalytic properties vary widely • The lanthanide contraction • Producers try to balance supply and demand • And are rarely successful!

6. Dilbert, February 28, 2011

7. Critical Materials Institute • DOE Program • $120 million, 5 years • National Labs • Academe • Industry • Reduce criticality • CMI opened officially on Sept. 10, 2013 Source: DOE Announcement May 2012

8. Recent RE Metal Prices

9. Source: U.S. Geological Survey

10. Two Confusing Points • Analysis and Recovery, are not the same thing • Balance • What is it? • Why it is important to the RE industry and to customers

11. Rare Earth Analysis Source: Castor, Resource Geology vol. 58, No. 4, 337-347 (2008)

12. The Castor Analysis • Original report 1986, almost 30 years old • First Mass Spec-ICP • A single sample • Widely quoted, sometimes abridged to omit heavy RE’s • Widely believed to predict recovery accurately • At best only an upper limit

13. Analysis vs. Recovery Analysis Recovery Goal: sell into marketplace Scale: 1010 gram Digestion: appropriate for scale and market Separation: appropriate for market conditions • Goal: understand composition • Scale: 10 gram • Digestion: complete as possible • Separation: no

14. Balance • The attempt by each rare earth processor to balance the available ore with the needs of the marketplace. Source: Kingsnorth

15. 1 km Bayan Obo mine , near Baotou, China Photo from Google Earth

16. ~1 km Mountain Pass, CA, Source: Molycorp

17. Rare Earth Sources • Active mines • China • Baotou • Ionic Ores • Mines coming on stream • USA • Mountain Pass, CA • Australia • Mt. Weld • Under Development • Australia • Nolan’s Bore • Canada • Hoidas Lake • Nechalacho • India • Brazil • USA • Vietnam • Russia

18. Early Lighting Options Welsbach Candoluminescence Edison Incandescence Source: Gas Light Guys Source: Wikipedia Source: Auer Licht

19. Lighting Phosphors

20. Lighting Phosphors • What we see depends on the phosphors • Red: Y2O3: Eu • Green: (La, Ce, Tb) PO4 • Blue: BaMgAl10O17:Eu Compact Fluorescent Lights (CFL) Source: GE Lighting

21. Fluorescent Lighting • Advantages • Higher output • 58 lu/W vs. 13.5 lu/W • Lower operating cost • 10 W vs. 40 W • Longer life • 12,000 hrs vs. 1,000 hrs • Disadvantages • Slightly higher price • Difficulty dimming • Unappealing light? • Cheap bulb = cheap phosphors • Hg in bulb, special disposal Data source: GE Lighting

22. Automotive Catalysts Source: BASF The metal oxide is cerium

23. Refining Catalysts • Fluid Cracking Catalyst (FCC) • A traditional use of lanthanum • Ideal for heavy crude to make gasoline • Ion-exchanged zeolite (cat litter) • Variable demand • Driving season and heating season • Available crude oil

24. Current Magnet Applications • Hard drive • Voice Coil Motor (VCM) • Spindle motors • 5 x 108 per year Source: Western Digital

25. AutomaticTemperatureControl HeadRestMotor Speakers CDPlayer WindshieldWasherPump Lumbar Support SunRoofMotor DefoggerMotor Mirror Motors Cruise Control Tailgate Motor Gauges DoorGasket LiquidLevelIndicators ElectricPowerSteering and Sensor Door LockMotor Four Wheel Steering Anti-skidSensor and Motor Economy and PollutionControl WindowLiftMotor IgnitionSystems HeadlightDoorMotor SuspensionSystem StarterMotor CoolantFanMotor WindshieldWiperMotor FuelPumpMotor Seat BeltMotor Heater-A/C Blower Seat AdjustMotors Throttle and CrankshaftPositionSensors TractionControl AntennaLiftMotor Current Magnet Applications Source: Magnequench

26. New Rare Earth Magnet Applications • Automotive • Hybrids • Electric vehicles Source: Toyota

27. Emerging Magnet Applications

28. Emerging Magnet Applications Source: Vestas AS • Wind Turbines • Reliability • The gearbox • About 500 kg of magnet per MW • Small % use magnets • 260 GW more in US by 2030* *Source: AWEA.org

29. Recycling • Historically unimportant • Value • Difficulty • Interest rises and falls with prices • Two areas of interest • Eu, Tb and Y oxides from lighting phosphors • Nd and Dy from magnets, mainly hard drives

30. Material Selection & Specification of Permanent Magnets • Motivation • Basic Considerations • Advanced Considerations • Specification • Checklist

31. Motivation • Gross oversimplification • Errors of omission • Lack of protocol

32. Basic Considerations

33. Physical Mechanical Corrosion Magnetizing Assembly Adhesives Testing Advanced Considerations

34. Writing a Specification • Two Approaches • What I happen to have • What I actually need • Avoid Contradictions • IEC or IMA (MMPA) standards • Supplier Reference, or equivalent

35. Magnetic parameters Flux variations Dimensions/Tolerances Testing Magnetizing Coating Adhesive Assembly Others Checklist

36. Case Study 1 • Direct substitution of bonded NdFeB for ferrite • Saturated return structure • Poor performance • Increase the thickness of the return path, more poles

37. Case Study 2 B = Br ln (do/di) • Bonded NdFeB ring for angle sensing application • Incorrect magnetization (axial) yields poor performance • Correct magnetization, with hairpin fixture, yields good signal and contained flux

38. Case Study 3 Window Lift Motor Toyota Prius and Toyota Harrier Source: Dr. B. Grieb Magnequench

39. 3D Model of Benchmark 2 Pole PMDC (Brush Motor) Skewing on the armature teeth

41. Torque-Speed and Torque-Current Characteristics for the Benchmarked and Redesigned Motors Torque-Efficiency Characteristics for the Benchmarked and Redesigned Motors

42. Benchmarked Motor Redesigned Motor

44. The Future • Niels Bohr, “Prediction is very difficult, especially about the future.” • Supply and Demand are dynamic • Overreacting and underreacting are normal • Supply • Demand • Government • Finding equilibrium is difficult & takes time • Energy conservation is a major driver • We need to use these materials wisely

45. Permanent Magnets for Energy Applications Part 2 • Rare Earths • Basic facts • The crisis • Mines • Applications • Magnet Recycling • Permanent Magnet Selection & Specification • Case Studies • The Future