from mine to speciality advanced future challenges 2013 prayon.pdf · from mine to speciality...
TRANSCRIPT
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From mine to speciality advanced materials :
Future challenges
and
potential innovations
for the phosphate industry
Fabrice RENARD, Chief Innovation Officer
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• Worldwide leader in phosphate chemistry
• Headquarters in Engis - Belgium
• More than 1400 jobs around the world
The Prayon Group
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•Engis (head office) - Belgium •Puurs - Belgium
•Les Roches de Condrieu - France •Augusta (Prayon Inc.) - USA
The Prayon Group
Four key factories around the world
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The Prayon Group
Jointly owned by :
Office Chérifien des Phosphates
Morocco
and
SRIW
(Holding held by the Walloon Region ) Belgium
The world of phosphate• One of our reference shareholders ( OCP Morocco / 50% ) owns
more than 75% of worldwide phosphate reserve• Prayon : best well-balanced and secured raw material supply in
speciality phosphate business: Morocco, Russia, Jordan, South Africa,…
Innovation & Future business
Prayon has placed innovation at the center of its economic model and has adopted a pioneering strategy.
To meet the global challenges of the 21st century, an Open Innovation Strategy is applied to the following 6 markets
Water Foodstuffs Climate Energy Health Natural resources
•Green Chemistry
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Project portofolio was only driven by…
•Nutrition
& Horti•Water•Energy
LTO
U3O8
BIOFUELS
BIOPOLYMER
FORTIPRAY
MICROEMULSION
SEL PLUS
Polyphosphoric acid
Chelating Agent
ALGAERare earth recovery
cathode 5V
LFP
Overview of Prayon Innovative Projects
Ne
w t
o W
orl
d
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� Li – ion Battery
� Polyphosphoric Acid� Aquafeed
� Flame Retardant
� Solustep
� Nutrition
Product or Technology
Existing for Prayon New for Prayon New to World
Mark
et
New
fo
r P
rayo
nE
xis
tin
g f
or
Pra
yo
n
� Uranium Recovery
� Electronic Grade
� Fosbind
�Praybrite
� Phosphagel
� Microalgae
Me Too
Short termFast Follower
Medium risk and profit
Innovative
Long termLeader
Higher risk and profit
Technology acquisition
Company Acquisition
Internal R&DJV / Partnership
University / Incubator
Market entry strategy
� Rare earth recovery
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Major Innovations
•Water Treatment
•new joint venture providing products ( macro & micro-nutriments, biopolymers…) and services to waste water treatment plants
•Nutrition ( Food & Health )
•Probiotics, Starter cultures, Innovative micro-encapsulated ingredients, Microalgae and Vegetal extracts
•Energy
•Materials for batteries, Sol gel technologies, Uranium recovery, Next generation biofuels
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Source : Johann Dreo
Future Key Driver Innovation to serve Sustainability
How to predict the future value of a company ?
Future value is related on current sustainable actions & commitment
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Major Trends for the 21st century
Food HealthWaterEnergy
Sustainability• Biodiversity conservation
• Efficiency & preservation of resources
• Social & political acceptance
• Reuse & Recycling process
• ….
Fu
ture
Ma
rke
t
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P Ecosystem
Source The Story of Phosphorus, PhD Thesis, 2010,D.Cordell,
World’s population – 7 billion in 2013
Actual Phosphorus extraction 190 million tons/y eq. 80 to 100 billion people (based on 250 g/p.y recommended intake)
&
1/3 of actual Food Production is wasted or lost + uneven repartition
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After eutrophisation…..more and more lobbies and strong communication are in progress regarding pollution and food security linked to P business
Source : Le Monde & Greenpeace,
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Long Term perspective…Huge geopolitical stresses ?
Peak and depletion :
Source The Sustainaibility Review, Cordell, White and Lindström
Unsustainaible situation
• Phosphorus : non – renewable resource
• Compared with oil, REE,…..no tech substitution for P-food
• For the time being, bad yield and lack of a global P-loop
Global ww turnover ~ 30 us$ billion/y
or 55 us$ billion/y market after transformation
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On the other hand…..Phosphate remains a key subject for high tech - development
• Patents with claims including « phosphate »
~ 250 000 worldwide since 1945
• Before 2000 => 5 000 patents / year
( i.e. 0,4% of the total )
• Since 2010 => up to 20 000 patents / year
( i.e. 1% of the total )
• 25 % for Pharma and 6 % for Electrodes/Batteries
Source : Questel ref. Jan to Apr 2010 - +phosphate+
BASF 2010 => 11 % of patent portofolio with P in claims ( 277 out of 2390 )
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Majors sustainable trends LT Opportunities
Biodiversity Preservation Rethinking mining process, phosphogpsum management, new trends : agro-ecology, local production,..
Inefficient yield from mine to plate
Reduce losses during miningand transformationImprove fertilizer technologiesIncrease crops’ uptake
Lack of P – loop Reuse of P ( urination, wastewater sludge or other P recovery,..)
Environmental topics Water, energy, management of rare and toxic elements
Non renewable resource Strict Limitation use for food ( or high value niche application )
In conclusion…
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Majors sustainable trends LT Opportunities
Biodiversity Preservation Rethinking mining process, management of phosphogpsum,..
Overview of Prayon Contribution
• Up to 90 % Valorization of phosphogypsum via CP• Working on long term viable process to recover sulfur from
phosphogypsum
Majors sustainable trends LT Opportunities
Lack of P – loop Reuse of P ( urination, wastewater sludge or other P recovery,..)
Overview of Prayon Contribution
• Recycling of 10 000 tons per year of used products• Reuse of P in our water treatment business ( Solustep )
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Majors sustainable trends LT Opportunities
Inefficient yield from mine to plate
Reduce losses during mining and transformationImprove fertilizer technologiesIncrease crops’ uptake
Overview of Prayon Contribution
• Fosusing on soluble fertilization ( horticulture, fertirrigation, ..)• Exclusive license to OCP for WS MAP• New developments to improve P intake by the crops ( P-
Booster ) and substitue organic inert chelate ( to be launched in June )
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Majors sustainable trends LT Opportunities
Environmental topics Water, energy, management of rare and toxic elements
Overview of Prayon Contribution
• Cadmium removal : working on a long term viable process• Uranium valorization : proven best available technology• Rare earths valorization : patented process• Lowest C02 emission for Purified phosphoric acid & derivatives
CO2 emission Thermal P4 vs Prayon Process
Energy Used
Conversion in
primary energy
(Mwh/T.P205)
Equivalent in CO2
emission
(kg/T.P205)
Prayon wet
process
4,46 T Steam and
0,219 MWH Electricity3,7 923 100 %
Prayon Engis with
cogeneration
4,46 T Steam and
0,219 MWH Electricity3,7 325 35 %
Thermal Process 6,5 MWH Electricity 11,8 2967 321 %
P4 route => 6,8 tons of CO2 per ton of phosphorus
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Majors sustainable trends LT Opportunities
Non renewable resource Strict Limitation use for food ( or high value niche application )
Prayon - widen the field of possibilities
Actual business LT Future business
Soluble fertilizers Engineered additives for crops
Functional specialityphosphates for food
Functional speciality for food& nutrition
Industrial applications High value Advanced speciality materials
From chemistry to Biochemistry, biotechnology and materials science
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Thank you for your attention
PRAYON s.a.Rue Joseph Wauters, 144
4480 Engis – BELGIUM
www.prayon.com
Cathode Materials – Forecast 2025
Lithium Phosphate : Market share 20 à 35 %
Upper Case
Base Case
Source : Avicenne
Reliable producer of high-quality, cost-competitive lithium iron phosphate
CREATIVE ENERGY
beLife manufacturing footprint
• LFP production in Engis, Belgium on Prayon main production site based on initial invention from CEA - Grenoble
• Lab pilot fully operational ~300kg/month
• Industrial pilot plant (100MT/y) : start-up completed in October 2012 • First shipments in November 2012• Design capacity 100MT/y• Full capacity end 2013
• First LFP production unit:• Modular unit located in the vicinity of customer • Design capacity 2500-3000MT/y• Up and running in 2015 (could start earlier
if linked to qualification schemes)
Materials roadmap overview
Licensed under LiFePO4+C AG i.e. HQ + UdM + Clariant + CNRS