DZP product developments and market drivers
The DZP’s set of products are all traded using bi-lateral contracts between the supplier (Alkane) and the customer, and also via a third-party marketing agent. As a result, Alkane has had to market the DZP products in advance of the mine opening and production starting. The following is a summary of Alkane’s marketing efforts and the types of agreement currently in place:
Zirconium chemicals
Alkane signed a marketing agreement in 2016 with UK chemicals firm Minchem over the marketing and sale of its zircon-based production.
DZP zircon-based products, including zirconium basic carbonate (45% ZrO2) and chemical zirconium (>99.5% ZrO2), are targeted for the growing and higher value chemical zirconia, zirconia and ceramics end-markets. Further, the success Alkane has had in removing hafnium from its zirconium-based concentrates makes DZP zircon-based output suitable for the production of refined zirconium metal, used in nuclear reactors.
Hafnium
Hafnia (hafnium oxide) samples were sent to customers for testing, a condition precedent to these customers agreeing to future DZP hafnium products. The samples were generated during the August to September 2016 pilot plant run. Alkane’s demonstration pilot plant (DPP) as it is officially known is located at the Australian Nuclear Science and Technology Organisation (ANSTO).
Industry feedback has been especially positive for DZP hafnium output as it is not tied to the vagaries of the nuclear industry. This is because growth in the extremely small (c 50tpa) hafnium market is to be largely linked to high-tech material usage, such as alloys used in the aerospace and industrial gas turbine industries. Current hafnium production is linked to production of neutron transparent zirconium metals used in nuclear fuel-rod casings (hafnium absorbs c 600x the amount of neutrons zircon does and therefore needs to be refined out of zirconium metal – a process Alkane has successfully completed). As such, with the level of depressed activity currently in the nuclear industry and uncertainty persisting on from the Fukishima disaster of 2011, plus the increasing growth in the renewable energy economy, stable hafnium output from nuclear industry sources cannot be depended upon. Further, hafnium production volumes from the nuclear industry are unlikely to meet demand from other industrial sectors.
Rare Earths: VRE due diligence underway
Alkane has a letter of intent in place with private Vietnamese firm Vietnam Rare Earths (VRE JSC). The agreement was announced April 2016. The agreement is to toll process DZP rare earth concentrates into certified quality rare earth end products. VRE has two plants in operation:
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Phu Ly can produce 4,000tpa of separated rare earth oxides for lanthanum, cerium, neodymium, praseodymium, dysprosium and terbium
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Hai Phong can produce 1,200tpa of rare earth metal and rare earth alloys
Alkane is currently completing technical due diligence on VRE plants and is looking to complete this during Q1 CY17.
Neodymium-iron-boron magnets drive REE growth
Alkane’s market commentary on rare earths is a good guide to this extremely opaque and Chinese-centric market. The long-held view of Chinese supply dominance persists (it supplies roughly 90% of global rare earths), as does the illegal mining of these metals (which is reportedly still as high as 40% of annual Chinese rare earth production). Alkane also highlights the very healthy demand for rare earth permanent magnets. The uses of these types of magnets are wide-ranging, and the increasing roll of the electric vehicle is a key driver behind this sector’s growth.
Rare earth permanent magnets, specifically neodymium-iron-boron, which will support Alkane’s neodymium (Nb) production and commercial off-take signed with German company Treibacher Industrie, are enjoying high rates of growth. Chinese annual production of sintered neodymium-iron-boron alloys in 2015 was 140kt and y-o-y growth reported at 16%, against rest-of-world growth at 12%. China produced 88% of the global supply of sintered NeFeB magnets during 2015.
A sintered magnet is manufactured from grinding a suitable composition into a powder, then compacted and heated to cause densification. Iron-neodymium-boron magnets are all made this way.
Zirconium and lanthanum could improve Li-ion battery performance
An interesting note is made in Alkane’s quarterly activities report concerning research currently being undertaken by Michigan University into the use of solid electrolytes in lithium-ion batteries. The research involves the use of a film made of lithium-lanthanum-zirconate, using proportions of lithium hydroxide (20%), lanthanum oxide (53%) and zirconia (27%). The rise of the electric vehicle, either hybrid-electric or pure-electric, would greatly benefit from this battery technology being commercialised as it allows li-ion batteries to operate at higher temperatures as well as having a greater energy density. This would allow for batteries to be made lighter with the potential positive impact on vehicle range – a key anxiety of electric vehicle customers.