Innovative technology for manufacturing 99.999% aluminum oxide Prima 107 Sarov Version 1 eng_february-2013
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Project history
• 2005: Idea generation and verification • 2007: Prototype development
• 2009: Powder manufacturing line launch • 2011: New technology’s line prototyping • 2012: Scaling of the powder production line
• 2012: Search of a partner to bring advanced version of technology to market
Applications for Aluminum Oxide Ultrapure Aluminum Oxide is
used for : Leucosapphire; Wafers for high brightness diodes Solar elements Integrated circuits Special types of ceramics Catalysts Medical instruments Drugs and cosmetics 3
Leucosapphire Applications LEDs
Smartphones and tablets
Electronics TV, PC screens
Lighting
Watches
Autos
Optics
Radio communications 4
Signals
Al2O3 Buyers: WW Leucosapphire Makers
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Technology description: Phase 1 Ultrapure product from raw materials
Aluminum Isopropyl alcohol Water
Raw material
Manufacturing
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End product
Advantages of our Alcoxide Technology Possibility of getting finished product of almost any desired purity; Relaxed requirements to the raw material’s quality where almost any
aluminum alloy or even aluminum scrap can be used Alcoxide technology requires less energy than that of the electrolysis one Alcoxide technology is flexible and makes it easy to adjust the finished
product to the market needs During the hydrolysis process almost the same amount of alcohol is returned
back into the process that was used in solvent process, thus making aluminum and water the only spare raw materials that get spent
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Production line: Key parameters Plant’s size: 1000 sq.m. Energy consumption: 500 kWt/day Staff – 27 people, including:
Process monitoring: 7 employees
Manufacturing: 16 employees
QC Lab: 4 employees
ISO 9000: certification is being
obtained The entire production process is
controlled by an IT system Fully ecology friendly process: no toxic
waste 8
Prima – the next generation alcoxide technology
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Prima: advantages & yield Provides all the benefits of
original alcoxide technology plus adds the following advantages:
Higher productivity
Lower metal consumption
Higher reliability due to replacement of vacuum environment with nitrogen one
Product
CAS
Formula
Aluminum isopropylate
555-31-7
(i-C3H7O)3Al
α – aluminum oxide
1344-28-1
Al2O3
γ – aluminum oxide
1344-28-1
Al2O3
Boehmite
1318-23-6
AlOOH
Aluminum hydroxide
21645-51-2
Al(OH)3
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Technology roadmap Density of the aluminum oxide powder 0.4-0.8gr/sm3
Ready to launch technology of powder density of 2.2 gr/sm3
Technology is under development to get to 3.0gr/sm3 density
There is a plan to expand the product line by:
Increasing density of the powder to 2.7-3.5 gr/sm3
Getting to α-phase (now, γ-only)
Increasing purity of the product from current 99.999% to 99.9999%
Achieve nano-fraction sorting capability
All these capabilities – within the single production line (6 ton/month) 11
Estimated (selected) market Scientific organizations
Leucosapphire manufacturers
Ceramic manufacturers
New areas of application
# of companies in Russia
200
20
100
over 100
Avg sales, ton/year
0,3
500
0,2
0,5
3 000 000
900 000
1 300 000
2 900 000
Addressable market, Russia, RUB mln/year
0,9
450
0,26
1,45
WW Potential, RUB mln/year
90
3 600 (4 000 ton)
20
145 (50 ton)
10%
30%
20%
30%
Quality
Price & Stability
Characteristics
TBD
By segment
Key segment
By segment
Alternate segment
Segments
Price, RUB/ton
Anticipated annual growth Main requirements to the product Classification by segments
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Key competitors Company
Country
Purity
Price per $/kg
Spolchemie White Sapphire
Slovakia
99.998
80
Crystals, manufacturing for own needs, limited offer
Emerging Material Technologies, Inc.
USA
99.999
70
Granules, High price
Sapphire Resource
China
99.999
57
Tablets, unstable supply timing
Zibo Zhengsen Chemical Co.,Ltd
China
99.995
39
Powder, low quality, unstable supply
Canada
99.99
-
Japan
99.99
50-100
Powder & Granules, severe decline in sales as of 2011 results
South Africa
99.99
50-100
Powder, Granules. 3000 ton/year expansion plan announced in the beginning of 2012
China
99.999
Orbite Aluminae Inc. Sumitomo Chemical
Sasol Limited Konne Industrial Corporation Limited
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Issues
Granules, announced plans to grab ~20% WW market by 2013
Tablets
Areas of further development Mass production of the rigs to grow very large mono crystals of leucosapphire (weight over 500 kg)
Laser quality, optically transparent complex oxide ceramic manufacturing
Innovation:
Optically transparent ceramics benefits over mono crystal technology
• Fully automated, energy efficient new generation high quality mono crystal sapphire growth machine with 500 mm diameter and up to 500 kg of crystal weight
• • • •
WW market:
• 1000 – 1500 machines to 2015 (~$750 Bln), • Machine cost