Permanent Magnets for Energy Applications Part 2

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Permanent Magnetsfor Energy ApplicationsPart 2

• Stan Trout
• August 11, 2014

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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

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Rare Earths
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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 REs
• 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!

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Dilbert, February 28, 2011
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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
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Recent RE Metal Prices
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Source U.S. Geological Survey
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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

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

• Original report 1986, almost 30 years old
• First Mass Spec-ICP
• A single sample
• Widely quoted, sometimes abridged to omit heavy
  REs
• Widely believed to predict recovery accurately
• At best only an upper limit

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Analysis vs. Recovery

• Analysis

• Recovery

• Goal understand composition
• Scale 10 gram
• Digestion complete as possible
• Separation no

• Goal sell into marketplace
• Scale 1010 gram
• Digestion appropriate for scale and market
• Separation appropriate for market conditions

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Balance

• The attempt by each rare earth processor to
  balance the available ore with the needs of the
  marketplace.

Source Kingsnorth
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1 km
Bayan Obo mine , near Baotou, China Photo from
Google Earth
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1 km
Mountain Pass, CA, Source Molycorp
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Rare Earth Sources

• Active mines
• China
• Baotou
• Ionic Ores
• Mines coming on stream
• USA
• Mountain Pass, CA
• Australia
• Mt. Weld

• Under Development
• Australia
• Nolans Bore
• Canada
• Hoidas Lake
• Nechalacho
• India
• Brazil
• USA
• Vietnam
• Russia

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Early Lighting Options

• Welsbach
• Candoluminescence

• Edison
• Incandescence

Source Gas Light Guys
Source Wikipedia
Source Auer Licht
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Lighting Phosphors
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Lighting Phosphors

• What we see depends on the phosphors
• Red Y2O3 Eu
• Green (La, Ce, Tb) PO4
• Blue BaMgAl10O17Eu

Compact Fluorescent Lights (CFL)
Source GE Lighting
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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
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Automotive Catalysts
Source BASF
The metal oxide is cerium
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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

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Current Magnet Applications

• Hard drive
• Voice Coil Motor (VCM)
• Spindle motors
• 5 x 108 per year

Source Western Digital
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Current Magnet Applications
Source Magnequench
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New Rare Earth Magnet Applications

• Automotive
• Hybrids
• Electric vehicles

Source Toyota
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Emerging Magnet Applications
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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
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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

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Material Selection Specification of Permanent
Magnets

• Motivation
• Basic Considerations
• Advanced Considerations
• Specification
• Checklist

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Motivation

• Gross oversimplification
• Errors of omission
• Lack of protocol

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Basic Considerations
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Advanced Considerations

• Physical
• Mechanical
• Corrosion
• Magnetizing

• Assembly
• Adhesives
• Testing

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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

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Checklist

• Magnetic parameters
• Flux variations
• Dimensions/Tolerances
• Testing
• Magnetizing

• Coating
• Adhesive
• Assembly
• Others

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Case Study 1

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

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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

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Case Study 3
Window Lift Motor Toyota Prius and Toyota Harrier
Source Dr. B. Grieb Magnequench
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3D Model of Benchmark 2 Pole PMDC (Brush
Motor) Skewing on the armature teeth
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Torque-Speed and Torque-Current Characteristics
for the Benchmarked and Redesigned Motors
Torque-Efficiency Characteristics for the
Benchmarked and Redesigned Motors
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Benchmarked Motor
Redesigned Motor
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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

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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