From mine to speciality advanced Future challenges 2013 Prayon.pdf · From mine to speciality...

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From mine to speciality advanced materials :

Future challenges

potential innovations

for the phosphate industry

Fabrice RENARD, Chief Innovation Officer

• Worldwide leader in phosphate chemistry

• Headquarters in Engis - Belgium

• More than 1400 jobs around the world

The Prayon Group

•Engis (head office) - Belgium •Puurs - Belgium

•Les Roches de Condrieu - France •Augusta (Prayon Inc.) - USA

The Prayon Group

Four key factories around the world

The Prayon Group

Jointly owned by :

Office Chérifien des Phosphates

Morocco

(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

Project portofolio was only driven by…

•Nutrition

& Horti•Water•Energy

BIOFUELS

BIOPOLYMER

FORTIPRAY

MICROEMULSION

SEL PLUS

Polyphosphoric acid

Chelating Agent

ALGAERare earth recovery

cathode 5V

Overview of Prayon Innovative Projects

� Li – ion Battery

� Polyphosphoric Acid� Aquafeed

� Flame Retardant

� Solustep

� Nutrition

Product or Technology

Existing for Prayon New for Prayon New to World

� 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

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

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

Major Trends for the 21st century

Food HealthWaterEnergy

Sustainability• Biodiversity conservation

• Efficiency & preservation of resources

• Social & political acceptance

• Reuse & Recycling process

• ….

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

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,

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

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 )

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…

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

Lack of P – loop Reuse of P ( urination, wastewater sludge or other P recovery,..)

• Recycling of 10 000 tons per year of used products• Reuse of P in our water treatment business ( Solustep )

Inefficient yield from mine to plate

Reduce losses during mining and transformationImprove fertilizer technologiesIncrease crops’ uptake

• 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 )

Environmental topics Water, energy, management of rare and toxic elements

• 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

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

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

From mine to speciality advanced Future challenges 2013 Prayon.pdf · From mine to speciality...

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