Innovative technology for manufacturing % aluminum oxide

Innovative technology for manufacturing 99.999% aluminum oxide Prima 107 Sarov Version 1 eng_february-2013  1 Project history • 2005: Idea genera...
Author: Quentin Ramsey
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Innovative technology for manufacturing 99.999% aluminum oxide Prima 107 Sarov Version 1 eng_february-2013

 1

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

5

Technology description: Phase 1 Ultrapure product from raw materials

Aluminum Isopropyl alcohol Water

Raw material

Manufacturing

6

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

7

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

9

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

10

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

12

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

13

57

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