Mass Flows of Selected Target Materials in LED Products

Transcription

1 Mass Flows of Selected Target Materials in LED Products Joint International Conference and Exhibition, Seminaris Dahlem Cube, Perrine Chancerel, Otmar Deubzer, Rafael Jordan, Nils F. Nissen, Klaus-Dieter Lang

2 Project Introduction Cycling Resources Embedded in Systems Containing Light-emitting Diodes (CycLED) Objective Optimise the flows of resources over all life-cycle phases of LED products Key research topics Increased recycling of scarce target metals in LED production Optimised reliability and life time of LED products Reduce resource losses in production, use and recycling Solutions for eco-innovation Step 1 Material Flow Analysis of target materials to identify hot spots of resource loss

3 Resources: LED die (Al)InGaN InGaAsP GaAs GaP GaAsP InGaAlP AlGaAs III Al Ga In V N P As

4 Resources: LED Packages Premould Lead frame Chip on board Wafer level Copper Copper, aluminium, ceramic (AlN and Al 2 O 3 ) Si Interconnection technologies Die and wire bonding gluing, soldering thermo compression (flip chip) Wire bond + die - + die - Au, Sn, Ag Au

5 Resources: Phosphor Cold white Warm white Green phosphor: Improvement of colour rendering White LED plus red LED Die level Family Garnet Compound YAG:Ce (Y 3 Al 5 O 12 :Ce) TAG:Ce (Tb 3 Al 5 O 12 :Ce) LuAG Ortho-silicate Eu-doped Silicate (Ca,Sr,Ba) 2 SiO 4 :Eu more Ca =>orange more Sr =>yellow more Ba =>green more Eu =>red less Eu =>green Package level Ce, Er, Y, Tb, Lu Lamp level x x 8000

6 Resources: LED Driver Ag 0.08% Al 3.95% Au 0.001% Cu 12.40% Fe 11.89% Others 69.35% Sn 1.98% Zn 0.35% Own calculations based on dismantling of Toshiba E-Core LED Lamp LEL-AW6L-E27-2/EU (250lm, 5.5W)

7 Criticality & economic importance of metals contained in LEDs Contained in LED Criticality Economic importance Target metals Precious metals PGMs RE Au Ag Pt Pd Al As Be Cu Ga In Mn Ni Sn Sb Ta Zn 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

8 Material Flow Analysis: Example Gallium Shipments in units of LED products LED lighting products LCDs (LED backlighting units) Die area per LED product Gallium content per square millimetre die area Gallium bound in LED products put on European market Lifetime of LED products Gallium bound in LED products at their end of life

9 Shipments of LED lighting products in Europe million units Residential Commercial Industrial Outdoor Architectural Residential Replacements Commercial Replacements Based on data from McKinsey 2011

10 Die area of LED luminaires Φ LED =Φ prod /(η opt η th d)=(e*a)/(η opt η th d) Luminous flux Φ [lm] Illuminance E [lm/m²] Visual task area A [m²] Optical efficiency η opt 60 mm² 50 mm² 40 mm² 54.9 mm² Thermal efficiency η th Degradation d of luminous flux Φ LED after hours Die Area A=Φ LED /φ*π luminous efficacy φ: 100 lm/w power density π: 1 W/mm² 30 mm² 20 mm² 10 mm² 0 mm² 9.0 mm² 14.6 mm² 18.3 mm² 14.1 mm² Residential Commercial Industrial Outdoor Architectural Replacement residential 9.0 mm² 9.0 mm² Replacement commercial Note! Residential luminaire and replacement lamps equal luminous flux of 60 W incandescent lamp (700 lm)

11 Efficacy Increase mm² Lm/W 70 mm² mm² mm² 40 mm² Residential Commercial Industrial Outdoor Architectural Replacement residential Replacement Average commercial mm² 20 mm² mm² 0 mm² DoE 2012

12 Shipments in Europe of LCDs (Backlight units) million units 700 Television (direct-lit) Television (edge-lit) 600 Computer monitor (edge-lit) Laptop monitor (edge-lit) 500 Tablets/netbooks (edge-lit) Smart phones (edge-lit) Cell phones (edge-lit) Replacement of LCDs with OLEDs Based on data from Gartner 2012; McKinsey 2011

13 Die area in back lighting units 50 mm² 45 mm² 40 mm² 35 mm² 30 mm² 25 mm² Die area depends on display size the desired brightness of the display the LED brightness transmissivity of LCD screen optical properties of the light guide and optical films 33.9 mm² 47.3 mm² 20 mm² 15 mm² 14.5 mm² 10 mm² 5 mm² 0 mm² 0.2 mm² cell phone (edge lit, 1.5", 500 cd/m²) 1.2 mm² smart phone (edge lit, 4.3", 500 cd/m²) 3.4 mm² netbook screen (edge lit, 10.1", 250 cd/m²) 5.2 mm² tablet (edge lit, 10", 350 cd/m²) 7.4 mm² source: Rambus laptop monitor (edge lit, 15", 250 cd/m²) computer monitor (edge lit, 21", 250 cd/m²) television (direct-lit,32", 300 cd/m²) television (edge lit, 32", 350 cd/m²)

14 Improvement of LED efficacy and optics Die area per screen 600 mm² 500 mm² 400 mm² 300 mm² 200 mm² 100 mm² TV direct-lit (standard) TV direct-lit (low-cost) cell phone (edge-lit) smart phones (edge-lit) Tablet/netbook (edge-lit) laptop monitor (edge-lit) computer monitor (edge-lit) television (edge-lit) television (direct-lit) 0 mm² Based on EPIC 2012

15 Gallium content Technology Elements Thickness Mass percentage Density µg per 1 mm² die GaAs (bulk) Ga 100 µm InGaN (thin-film) Ga 5 µm x40 Assumptions Architectural Lighting: RGB 2 InGaN LEDs & 1 GaAs Commercial Lighting: 10% market share RGB, 90% white Residential, Industrial, Outdoor: white LEDs (InGaN) Displays: white LEDs (InGaN) Philips

16 Gallium put on market kg 60 BLU Lighting

17 Average lifetime of LED products 20 a 18 a 16 a 14 a 12 a 10 a 8 a 6 a LED Luminaires 18.8 a Dependent on Lifetime of luminaire in hours Annual operating hours 5.9 a 8.3 a 10.0 a 10.0 a 20 a 18 a 16 a 14 a 12 a 10 a 8 a 6 a Displays 6.0 a 5.0 a 7.0 a 10.0 a 12.0 a 4 a 4 a 2 a 2 a 0 a Residential Commercial Industrial Outdoor Architectural CIE ; EN 15193: ; EN 12665; EN ; Van Tichelen, 2009 End of Life Flow: with p t probability, that a product is discarded after t years a t= o and normal distribution f(t): standard deviation equals 30% of average lifetime 0 a Cell/smart phone EoL in F ( a) = p F ( a t) t Tablet Laptop monitor Computer monitor p t = t+ 1 t f ( τ ) dτ Television Chancerel 2010

18 Gallium in end of life products kg 60 BLU Lighting

19 Gallium in stock kg BLU Lighting

20 Conclusions Long lifetime of LEDs delays end of life waste flows Low Gallium content and diffusion of products complicate collection and recycling Pre-treatment (separation of LEDs from product) probably necessary Better focus on other materials with higher specific material content during recycling Outlook Modelling material flows along the life cycle manufacturing collection, pre-treatment and recycling for all target metals Ga, Sn, Ag, rare earths Uncertainty and sensitivity analysis

21 Thank you for your attention! Project duration: January 2012 June 2015 With the support of EUROPEAN Max COMMISSION Marwede