Tag Archives: Tungsten

China Restricts Exports of Critical Metals to the US

Trump’s ill-tempered brinksmanship and his coarse criticism of both long-term allies and old adversaries has begun to cost the US access to strategic materials. In particular, China has announced that it has banned the export of a group of metals and non-metals to the US. Specifically, China had previously imposed export controls on Rare Earth Elements (REE), gallium (Ga), germanium (Ge), antimony (Sb) and graphite (C). More recently it has included tungsten (W), tellurium (Te), bismuth (Bi), indium (In) and molybdenum (Mo) products.

In case the reader is unfamiliar with the uses of the above elements, a list of them with a short description is given below.

Many of the elements listed above are by-products from the refining of other metals like aluminum, copper, lead and zinc. Reduced production of aluminum, copper, lead and zinc will also reduce output of their accessory metals as well.

  • Gallium– Primarily used in semiconductors; is used to produce the denser, stabilized δ allotrope of plutonium for use in nuclear weapons.
  • Germanium– Primarily used in semiconductors; a by-product found in copper-lead-zinc ores.
  • Indium– Primarily used in semiconductors or other electronic applications; it is a by-product found in sulfidic zinc (Sphalerite) and copper ores (Chalcopyrite). Indium tin oxide (ITO) forms a thin, transparent and electrically conductive layer on glass for touch-screen applications such as smart phones.
  • Tellurium– A scarce element at an average occurrence 1 ppb in the crust and never the primary ore in mining. It is mostly found combined with gold as Calaverite (AuTe), Sylvanite (AgAuTe) or Krennerite (AuTe2 Orthorhombic gold telluride.) Tellurium has use in a large variety of applications. Unfortunately for gold miners, calaverite ore is not susceptible to cyanide extraction for gold recovery. Calaverite can be roasted and tellurium volatiles removed from the gold residues. However, commercial scale roasting of minerals is problematic in the US.
  • BismuthBismuth is never the primary ore in mining. It is found with lead, copper and tungsten. Broad applications across many domains. No longer produced in US. Bismuth is the highest atomic number element that is not naturally radioactive. Well, it’s half-life has been determined to be 1.9 × 1019  years which is still “pretty stable”.
  • Antimony– The largest antimony mine in the world is the Xikuangshan mine in Lengshuijiang Hunan, China. This mine produces 50 % of the world’s antimony. The mine produces antimony from 2 different minerals, stibiconite (Sb3O6(OH)) and stibnite (Sb2S3).
  • Molybdenum– Mined as the primary metal ore. About 86 % of molybdenum is used in metallurgy with the rest used in chemical applications. An important molybdenum mineral is molybdenite, MoS2. Important US mines are the now-defunct Henderson Mine and the now operating Climax Mine, both in Colorado and both operated by Freeport-McMoRan. The Climax Mine resides at the summit of Freemont Pass at 11,360 ft altitude and to the north of Leadville, Colorado. Molybdenite deposits can be found as far away as Questa, New Mexico, with the Chevron Questa Molybdenum mine which is now closed and undergoing reclamation as a superfund site.
  • Graphite– Natural graphite arises from metamorphization of carbonaceous sediment. It can mined or produced synthetically. Graphite is the most chemically stable allotrope of carbon at standard pressure and temperature.
  • Tungsten– Also known as wolfram (W), tungsten has the highest melting point and lowest vapor pressure of the elements. As a refractory metal, tungsten us often used in high temperature applications such as welding and for its relative chemical inertness affording high resistance to corrosion. In military applications tungsten is exploited for its combination of high density, hardness and refractory properties in projectiles and other applications. In chemical form, it is often found as a polyoxometallate anion such as WO4−2, “orthotungstate”. These polyoxometallate anions can form higher order cage structures.

All of the above elements are well established in diverse products and are a part of numerous leading-edge technologies in use today. All ores are subject to the market price of their mined and milled products. All of the elements listed above are produced in various simple but purified forms that customers will plug into their own production lines. The economics of their mine operation has a high reliance on the margins offered by their raw material costs. If the raw material supplier goes a step further and captures value-added profit margins by offering an advanced intermediate or even the final product, then the customer faces having to use the more costly value-added materials. The effect can be that they must raise prices on their product or step away from the market. This is just the old familiar path of competition.

As luck would have it, early in geologic history China won the mineral lottery when many ore-forming processes valuable ores in its present territory. We have all heard of China’s supremacy in rare earth element (REE) reserves. China eventually made the choice of halting exports of rare earth minerals as the oxides in favor of offering value added finished products instead. Business-wise, this was a smart and inevitable choice for China, but users who manufactured REE products from their imported REE raw materials were suddenly facing stiff competition from abroad.

Since this policy of China metering closely the export of REE minerals, western countries have made considerable progress locating REE deposits elsewhere. Incidentally, the same holds true for lithium deposits.

From Google Maps. An aerial view (supposedly) of part of the large Xikuangshan mine in Hunan, China.

Restrictions on exports of the above elements will have a large impact on many industries in the US. My question is this: Could a better diplomatic approach to imports from China have been made?

It isn’t all bad news. Difficulties with raw material prices and availability frequently motivate users to invent a way around problematic raw materials. There is nothing like the motivation to fire up the inventive juices than to seek a work-around for a raw material supplier problem.

Thoriated Tungsten. Why?

I saw the words “thoriated tungsten” somewhere in the literature and became curious as to what brought these two metals together. Before I get to thoriated tungsten, I’ll give a little background on tungsten and filaments made from it. There is a surprising amount of art and science in tungsten filaments. Tungsten filaments split into two broad applications- illumination and thermionic emission.

I’ve been curious about the effect of surging LED lighting demand on the tungsten filament business and tungsten demand overall. Naively, I guessed that there might be a noticeable effect on tungsten demand. A Google search only turns up people who want to sell a market research document. One of these web sites claims that demand for tungsten is expected to nearly double from 2021 to 2029 from $4.41 Billion to $7.56 Billion. The major demand for this metal is from the mining and drilling industries in the form of tungsten carbide cutting tools. The major producers of tungsten are China, Russia, Portugal, Austria and Bolivia, with China producing the vast majority.

The important tungsten ores are-

  • Wolframite, (Fe2+)WO4 to (Mn2+)WO4
  • Ferberite, FeWO4
  • Hübnerite, MnWO4
  • Scheelite, Ca(WO4)

All have a +2 cation and the tungstate -2 oxyanion. The WO4-2 tungstate anion has tetrahedral geometry similar to sulfate and can also form polyoxotungstates with octahedral WO6 geometry. Polyoxotungstates can form clusters by the sharing of octahedral oxygens similar to silicates. A large number of interesting polyoxotungstates have been identified.

Tungsten filament- a coil of coils.

Tungsten turned out to be a perfect choice for light bulb filaments due to it high melting point and its mechanical integrity at high temperature. The coiled coil filament design proved to be much superior to a single coil or a straight filament. Below is a picture found at this website showing the illumination differences in the 3 configurations of the tungsten element. The difference in filament geometry is striking.

The photo above shows a 240 VAC 60 Watt bulb where a coiled coil has been uncoiled to produce a single coil section and a straight section. The whole coil is there. Light bulbs are filled with a mixture of inert nitrogen and argon at below atmospheric pressure. A coil allows a greater length of tungsten wire to be easily placed in the bulb and a coil of coils even more so. During operation the filament suffers heat losses by conduction and convection of the bulb gases. The primary coil and the coil of coils serve to reduce exposure of the filament to the cooling gas flow. The coil provides some self-heating due to the proximity of the coil to itself. It intercepts some of the radiant energy and heats further. In the coil of coils, this effect is much more pronounced as seen in the picture above. The Lamptech website containing this photo is well worth a visit.

Wikipedia: Wien’s Law plot showing how peak black-body radiation varies with temperature. Visible light is between about 380 and 750 nanometers. https://en.wikipedia.org/wiki/Wien%27s_displacement_law

As mentioned above, one advantage of using tungsten as a filament is that it has an extremely high melting temperature of 3422 oC (3695 K). This allows the filament to be heated to very high temperature with the resulting blue shifted black body curve (above), This allows the spectrum to be brighter in the shorter wavelengths and consequently less reddish to the eye than a lower temperature filament. Wiens Law is the basis of color temperature.

When you shop for LED light bulbs, you might notice that LED bulbs are rated on the basis of color temperature. The lower the color temperature, the more yellow/red the light will be. The higher the color temperature, the more whitish the light will be.

However, with high operating temperatures a filament can evaporate, removing mass and robustness. Tungsten filaments, among others, are susceptible to this mode of failure. Another mode of failure occurs when a tungsten filament is hung vertically. Convection of the hot gasses in the bulb causes the top of the filament to get hotter and fail sooner. You’ll notice that lamp filaments tend to be strung horizontally.

Why tungsten halogen? Over time a tungsten filament will evaporate enough tungsten to blacken the bulb and become fragile. The presence of a halogen vapor in a light bulb causes a reaction between the tungsten and the halogen leading to redeposition of the tungsten back to the filament. However, this process requires higher bulb envelop temperatures, i.e., >250 oC. I have to assume that the small size of halogen lamps is to assure that the bulb temperature remains high for the tungsten-halogen recycle.

Thermionic Emission

Tungsten filaments in light bulbs is an application familiar to everyone. But there is another important use of tungsten filaments. The production of electron emission from filaments has been in use for a very long time. A hot filament or other hot surface under vacuum can be made to produce electron beams that can be accelerated or deflected and focused to do useful things. The electron beams can be made to carry modulated signals that can be put to use in detecting or radiating radio signals for radio, television or a myriad of other uses. The old vacuum picture tubes in early television used a filament to generate an electron beam that could be directed to scan across a phosphor coated surface to produce moving images.

What caught my attention when sorting through the tungsten literature was the mention of thoriated tungsten filaments. This topic goes back to the 1920’s with Irving Langmuir. In 1923 he published a paper in Physical Review Langmuir found that the rate of electron emission from 1 to 2 % thoriated tungsten to be “it was discovered that by suitable treatment the filaments, containing 1 to 2 per cent of thoria, could be activated so as to give an electron emission many thousand times that of a pure tungsten filament at the same temperature.” He found that the efficiency and life of a tungsten filament could be extended by spiking the tungsten with thorium oxide. He postulated that thorium is reduced and migrates to the surface of the tungsten filament forming at most an atomic monolayer. Thermionic emission occurs when a hot object like a filament evaporates electrons.

Every substance has work function energy in eV that is required to remove an electron from a surface. Additives to tungsten like lanthanum, cerium or thorium or their oxides have a lower energy work function than does tungsten and will produce a greater flux of electrons. This even applies to TIG welding where an electric discharge must jump across a workpiece and a sharpened tungsten rod.

A 1-2 % thoriated tungsten welding rod or filament will allow thorium to migrate to the surface via grain boundaries while in operation and deposit on the surface. The work function energy of thorium is lower than that of tungsten, so the thoriated surface can release more electrons at a given temperature.

Work function energies of various compositions