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Molycorp Secures 78 Percent of Phase 1 Rare Earth Production in Customer Agreements and XSORBX Production
Molycorp, Inc. has announced that 78 percent of its Phase 1 rare earth production from its new Mountain Pass, Calif. manufacturing facility, which comes online in 2012, has now been secured by signed customer agreements or has been committed to production of the Company's XSORBX water treatment products.
The company said it has entered into written agreements with customers covering 58 percent of its Phase I production, and has allocated an additional 20 percent to production of XSORBX, for a total of 78 percent of the 19,050 metric tons of rare earth oxide (REO) equivalent that it intends to produce annually under Phase 1 at its flagship Mountain Pass, Calif. rare earth facility. Exact terms, prices, duration, and products covered by these agreements vary from customer to customer. Another six percent of Phase 1 production is in final stage discussions with customers, the company added.
Molycorp intends to sell its proprietary, cerium-based XSORBX water treatment products across four market segments: municipal water treatment, recreational/pool/spa water, industrial wastewater and drinking water purification. The company currently is selling XSORBX to commercial customers in the municipal wastewater treatment and recreational/pool/spa markets.
“I am very pleased that we have met the Phase 1 off-take allocation target that we set for 2011, and have found a home for more than three-quarters of our Phase 1 production prior to start-up,” said Mark A. Smith, Molycorp’s president and CEO. “In an industry that traditionally has been driven by spot sales, Molycorp continues to break ground by moving customers to stable, secure, long-term supply contracts."
"Securing long-term rare earth sales contracts requires the ability to produce and deliver actual product to customers for extensive testing, qualification, and fine tuning so that precise specifications can be met,” said Smith. “This process can take many weeks, even months, to complete. I am very pleased with our progress to date in working with our customers to ensure we can serve as a reliable, long-term supplier of these strategic materials."
Is Automotive a Promising Market for Rare Earth Elements?
Rare Earth Elements (REEs) such as neodymium are widely used in commercial electronic products and a wide range of other industries. The automotive industry, a vast consumer of raw materials, is a big potential market for REEs, not least because of the move toward hybrid and electric vehicles (EVs) which require higher volumes of REEs. However, uncertainty currently exists over the future demand for EVs and the use of REEs.
IMS Research estimates that 16 million EVs will be produced in 2021, of which nearly 60 percent will be hybrid electric vehicles. This augers well for the mining industry: after all, several kilos of expensive REEs are required per vehicle. However, Alastair Hayfield, Automotive Research Director, cautions against over-optimism, “The long term forecast for EV production is subject to uncertainty as a lot rests upon governments and private enterprises incentivizing and driving EV adoption.” Hayfield continues, “It should also be noted that vehicle manufacturers are exploring technologies that don’t rely as extensively on REEs. Not only do vehicle manufacturers want to lessen their exposure to price fluctuations, they want to reduce their reliance on materials that are hard to source. Couple this with emerging REE recycling programs that are targeting ‘urban mines’ (REEs sequestered in consumer electronic devices, for example), and the REE mining industry might not achieve the level of mid-term success it hopes for from the automotive industry.”
Despite this more pessimistic viewpoint, companies would be wise not to overlook the opportunity presented by automotive body and control motors used in internal combustion engine vehicles. IMS Research estimates that an average of 25 electrical motors were used per light vehicle in 2011, equating to annual global shipments of 2 billion units. By 2018, annual global shipments of electrical motors are forecast to rise to 3.5 billion, a 75 percent increase. This presents a healthy opportunity for motor suppliers, magnetic material suppliers and REE mining firms.
There are three main factors driving this trend: the first is rising sales of light vehicles, most notably in emerging economies. Second, more convenience and comfort systems that require motors, such as HVAC or electric windows, are being used on lower segment cars. Third, in a bid to differentiate and offer a ‘better’ driving experience, vehicle manufacturers are offering ‘premium’ features that physically manipulate the driving environment, such as multi-zone HVAC or tailgate lift, on a wider variety of vehicles.
In the long term, the automotive industry will continue to be a major consumer of REEs, particularly as the use of motors increases. However, if REEs continue to be a ‘pain point’ for automotive suppliers, either through high price or scarcity, then an attempt to reduce their consumption should be expected.
Advanced Magnet Lab Awarded US Department of Energy Grant to Develop Next Generation Wind Turbines
Magnet Lab, Inc. (AML) is among six awardees of a grant from the US Department of Energy (DOE) for the advancement of next generation wind turbine technology. AML was selected based on a proprietary innovative turbine generator which enables the development of the first fully superconducting direct-drive generator for large offshore wind turbines. These generators are up to 75 percent lighter, 50 percent smaller, more efficient and more reliable than systems in use today. This award represents an initial step in the fulfillment of AML’s Clean Energy Plan for deployment of clean, scalable and efficient generators and motors for large-scale energy systems. Successful development and deployment of this new technology will help position the US as a global leader in wind energy technologies, reduce the cost of wind energy, and support thousands of new manufacturing, construction and planning jobs in the renewable energy market.
Energy prices and environmental concerns are driving the US to develop domestic sources of clean, renewable energy. Research indicates our nation possesses abundant resources to create electricity from wind; and the DOE believes that generating up to 20 percent of the nation's electricity supply from wind power by 2030 is an achievable goal. Much of that production would come from offshore wind farms, as offshore wind is significantly steadier and nearer to where the majority of the population resides, reducing the cost and energy losses of power transmission. Over 160,000 Megawatts (MW) of offshore wind energy projects are scheduled to be installed during the next decade throughout the globe.
Vernon Prince, general manager of AML Clean Energy said, “Wind turbines generating 10-MW of electricity power will serve over 4,000 homes and will lead to more economical and efficient wind farms. Scaling up to these mega-turbines presents many challenges including high reliability and economic viability. Conventional technology simply cannot achieve that scale. AML’s solution is transformational by reducing the size and weight of the drive train using superconductors and a very robust generator architecture.”
The funding will support the design and preparation of AML’s energy analysis model for its fully superconducting 10-MW generator. Collaborators on the project include a large US industrial manufacturer and Argonne National Laboratory. "Direct-drive generators eliminate the need for a gearbox, which reduces weight, eliminates moving parts and reduces maintenance costs," said Jerry Nolen, an Argonne Distinguished Fellow. "Turbines based on superconducting technology will have a huge impact on how future electricity is generated by reducing costs and increasing reliability and efficiency."
AML’s solution is based on the principle of superconductivity, which allows the flow of electrical current with zero electric resistance and without energy losses when operating in a very low-temperature environment. “When applied to high power applications, superconductivity has the potential to provide revolutionary changes in power generation, power transmission and energy use by significantly reducing the cost of energy production and increasing energy efficiency in ways that are environmentally benign,” according to Dr. Philippe J. Masson, a Senior Scientist at AML and Principal Investigator for the DOE grant.
Ucore Rare Metals and Boulder Wind Power Latest to Join REITA
The Rare Earth Industry and Technology Association (REITA) has announced the latest companies to join the global association of industry and academic stakeholders. Joining are Ucore Rare Metals and Boulder Wind Power.
Ucore Rare Metals, Inc. is a well-funded junior exploration company focused on establishing rare earth, uranium and other rare metal resources through exploration and property acquisition. With multiple projects across North America, Ucore’s primary focus is the 100 percent owned Bokan – Dotson ridge rare earth property in Alaska. The Bokan properties are located in an area reserved for sustainable resource development with an existing road network providing access to the main target areas. The Bokan – Dotson Ridge project is located 60 km southwest of Ketchikan, Alaska and 140 km northwest of Prince Rupert, British Columbia and has direct ocean access to the western seaboard and the Pacific Rim, advantageous in expediting mine production and limiting mine construction costs. The dyke oriented structure of the deposit lends itself to innovative ore sorting technology substantially increasing the grade of mill feed. The largest NI 43-101 compliant resource of dysprosium in the US and a production target date as early as 2015 has involved Ucore in discussions with strategic organizations including the US Office of Naval Research, US Congress and major domestic manufacturers of 'green technology' products. Ucore is committed to the development of a complete mine to metal process that will maximize value for our shareholders and contribute directly to economic growth in Southeast Alaska.
Boulder Wind Power is a Colorado-based wind technology company delivering a revolutionary permanent magnet, direct drive generator for utility-scale wind turbine applications. Based around a unique printed circuit board winding technology and innovative use of low-temperature permanent magnets, the Boulder Wind Power solution offers compelling advantages in weight, reliability, maintainability and energy production, delivering energy at a cost that is 20 to 30 percent less than existing geared and direct drive technologies.
“Ucore and BWP bring the number of REITA members to 22” said Keith Delaney, the association’s executive director. “These companies also add to the breadth and balance of supply chain interests represented by REITA’s membership composition. Our current members include six rare earth resource and project companies, three original equipment manufacturers, six academic institutions, and seven companies that represent virtually all of the other intermediate links in rare earth supply chains for Clean Energy.”
Magnet Applications Expands Manufacturing and Technical Staff
Magnet Applications, Inc. (MAI), a subsidiary of Bunting Magnetics Company, has announced the promotion of Jerry DePrator to production manager and the addition of Janice Pandullo as quality engineer and Joe Benden for the Magnetic Components engineer role.
Mr. DePrator has worked for MAI as a Process Engineer since 1999. In his new role, Mr. DePrator will oversee the entire manufacturing process for our compression-molded and injection-molded magnet product lines. He will be involved in the installation of new equipment, capital improvement projects, quality initiatives and the management of all production-related personnel. Mr. DePrator holds a Bachelor of Science degree in Plastics Engineering from The Pennsylvania State University.
For over the last eight years, Ms. Pandullo has served in various Quality Control roles within metals and wind energy industries. She is a senior member of the American Society for Quality (ASQ) and is an ASQ Certified Quality Auditor. Ms. Pandullo has been trained on ISO 9001 & 14000 and has received auditor training in both categories. In her role as Quality Engineer, she will be responsible for the ISO certified quality system, be involved in operations, product development, and continuous improvement with specific responsibility for the Quality Management System program. Ms. Pandullo holds a Bachelor of Science degree in Industrial Engineering from The Pennsylvania State University.
Mr. Benden will be responsible for preparing quotes, designing magnetic circuits and working with customers on small motor assembly projects. Prior to joining MAI, he worked in several electrical engineering and magnetic components roles. Mr. Benden has a Bachelor of Science degree in Electrical Engineering from The Pennsylvania State University.
“The demand for our products has risen dramatically over the last 18 months,” stated Lipetzky. “Our magnets and related products are custom built for applications in industries ranging from defense, energy, automotive, telecommunications, and medical to basic manufacturing... more than people realize. Janice and Joe will help us meet the high standards our customers need.”
Danotek Receives Additional Orders for Permanent Magnet Generators from Tecogen
Danotek Motion Technologies has been awarded a blanket purchase order from Tecogen Inc. for the supply of 40 100 kW PM generators in 2012.
Tecogen is a manufacturer of natural gas fueled engine-driven cogeneration systems that deliver optimum cost savings from innovative technology, consistent service, product quality and adaptability. This purchase order extends a long-standing relationship between the two companies.
Danotek’s PM generators are thermally optimized high power density systems that reduce operating costs by their superior performance and reliability. High efficiencies at rated and partial loads are critical in enabling Tecogen’s CHP systems achieve overall efficiencies exceeding 90 percent, and the lightweight generator’s unique reluctance design produces negligible cogging torque making its performance ideal for cogeneration and distributed generation applications. Improved performance is supported by robust operations, especially the PM generator’s low operating temperatures, high quality class H insulation, and lack of brushes and slip-rings that combine to enhance reliability and durability.
“Tecogen is pleased to continue the successful relationship we’ve had with Danotek,” said Mr. Robert Panora, Tecogen’s president and COO. “Our InVerde Ultra 100 CHP systems deliver high efficiency and reliability that maximize our customers’ energy-related cost savings. With their excellent performance and low maintenance needs, PM generators developed by Danotek are vitally important components within our CHP systems.”
All 40 PM generators are scheduled to be delivered from Danotek’s Canton, MI, facility in 2012 with deliveries commencing mid-February. Once integrated by Tecogen, they will add value to advanced CHP systems installed in colleges, schools, hospitals, nursing homes, large residential facilities, hotels, and similar facilities that have a demand for electrical and thermal energy.
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Allegro MicroSystems, Inc. has introduced a new linear Hall-effect sensor IC with a wide ambient temperature range of 40°C to 150°C. Allegro’s A1357 device is a high precision, customer programmable, Hall-effect linear IC with a pulse width modulated (PWM), current sourced (2-wire) output. The duty cycle (DC) of the PWM output signal (freq: 1 kHz) is proportional to an applied magnetic field. The device converts an analog signal from its internal Hall sensor element to a digitally encoded PWM output signal. The coupled noise immunity of the digitally encoded PWM output is improved compared to the noise immunity of an analog output signal.
53rd ENC