pef, a 100% bio-based polyester: synthesis, properties...
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HORIZON 2020 EUROPEAN UNION FUNDING FOR RESEARCH & INNOVATION
PEF, a 100% bio-based polyester: Synthesis, Properties & Sustainability GJ Gruter, Avantium
Avantium introduction
YXY Technology (PEF, next generation polyester)
PEF properties
PEF markets
Development – Pilot Plant/ Road to commercialization
New Chemistries: Mekong Technology (MEG)
New Chemistries: Zambezi Technology (2G glucose)
Summary
2
Agenda
Avantium Business Units
3
YXY technology
development Catalysis R&D
systems & services
Profitable, cash-flow positive &
growing business
Next generation bio-based
furanic monomer and polymer
technology
New Chemistry
project portfolio
Innovative routes from biomass
to chemicals
- Lignocellulosic (2G) glucose
- Direct route to MEG from
carbohydrates
Avantium profile
Advanced Technology Foundations:
– High-throughput catalyst discovery & development
Biobased Chemicals Company:
– YXY: Cost effective catalytic process to convert plant based feedstock into chemical
building blocks: FDCA and Levulinics and materials: PEF
– Mekong: Cost effective catalytic process to convert C6 carbohydrates to MEG
– Zambezi: Cost effective high purity glucose from lignocellulosic biomass.
The Coca-Cola Company, Danone, ALPLA YXY partners for the development of 100%
bio-based PEF bottles. Wifag-Polytype for PEF thermoformed products. New
partnerships for PEF films and fibers (carpets) initiated.
Privately held: supported by Swire, TCCC, Danone, ALPLA, Sofinnova, Capricorn, ING,
Aescap, Aster (€35M financing round closed summer 2014).
150+ employees, Headquarters in Amsterdam, Pilot plant in Geleen, the Netherlands
Planned commercial production of PEF in 2018 4
PEF - The Next Generation Polyester
5
FDCA
C6-Sugars Crude oil
Confidential
PTA bioMEG MEG
Today:
BioPET
20% Plants
Yesterday:
PET
100% Fossil
Tomorrow:
PEF
100% Plants
Options overview by atom efficiency (theoretical max weight yield from C6 carbohydrates)
6
MEG
GEV
O T
PA
C2 = ethylene
O2
O2
O2
O2
O2
O2
O2
O2
O2
O2
O2
H2O
H2O
H2O
CO2
CO2
CO2
PEF has barrier !
7
PEF: the Next Generation Polyester
Superior performance over PET:
– O2 barrier: 10x improvement
– H2O barrier: 2x improvement
– CO2 barrier: 4x improvement
Improved Thermal Stability
– Tg: ~88°C 12°C higher than PET
Excellent Mechanical Properties:
– Tensile Modulus PEF : 1.6* PET
Significant reduction in carbon footprint*
– 70% lower carbon emission
– 65% lower NREU
* Patel et al. Energy Environ. Sci. 2012, 5, 6407 8
Carbon dioxide
(CO2)
4x
Water (H2O)
2x
Oxygen (O2)
10x
Improved Crystallization Behavior No co-monomer needed to
reduce crystallization rate.
PEF exhibits well behaved stress-strain curves and strain hardening
behavior.
PEF rheology comparable with typical PET grades
PEF heat distortion temperature is ~12°C higher than PET (77°C
PEF vs 65°C for PET)
Hydrolytic stability similar as PET
9
Additional properties
YXY Technology The New PEF Supply Chain
10
MMF FDCA PEF oxidation
polymerization
processing
dehydration
Existing PET assets Existing ISBM assets
PEF can be Produced in Existing PET Assets
Chemical catalytic process
Cost competitive at industrial scale
Proven at pilot plant scale
Fit with existing assets
Existing
thermoforming
assets
YXY Technology Demonstrated at Pilot Plant
11
Location: Chemelot site (‘Brightlands’) in Geleen, the Netherlands
Start operations: December 2011
Name plate capacity: 20 tpy crude MMF; 5 tpy pFDCA isolated; expansion
planned
Objective: demonstrate YXY technology scale-up and produce volumes FDCA for
application development
Organization: 24/7 operational, under full control and ownership of Avantium
From lab scale to pilot plant scale
Targeting Multi-Bn$ Markets - create market Pull
12
PET Film 5 mT
Rigid thermoformed
packaging
Flexible packaging
PET Fibers 43 mT
Carpet
Clothing
Tire cords
=
=
PET Bottles
18 mT
PET Film
5 mT
PET Fibers
43 mT
= PET Bottles 18 mT
Expected market growth
7-8% p.a.
PEF Performance Enables Penetration of Existing and New Markets
13
Current markets:
New markets:
glass aluminum carton foil
First PEF T-shirts of 100% recycled PEF bottles
Made from 100% Recycled PEF
100% Biobased
Conventional polyester dyeing
technology
Conventional polyester spinning
technology
14 Thesis Dolmans ITA, RWTH 2013
Safety
Food Contact Safety studies finalized:
– Polymer and monomer are safe
– EFSA petition filed in 2013; positive opinion
published 2014
– FDA registration under preparation
Safety studies FDCA monomer to support
REACH registration:
– Monomer is demonstrated to be safe
– REACH registration completed 2013
15
Recycling
Goal: find the optimal end-of-life solution for PEF polymer
– Close collaboration with recycling community and partners
End goal: PEF to PEF recycling:
– Mechanical recycling: demonstrated (similar to PET)
– Chemical recycling: demonstrated PEF depolymerization
– Conducting sorting trials at PET recyclers
– Conducting trials of potential effects of PEF in rPET streams
16
Why is PEF attractive for brand owners
17
‘Why is PEF, a Next Gen Polymer Interesting?’
Cost benefit
Potential to reduce need for expensive barrier technologies and
light weighting
Consumer benefit
More packaging choices; longer shelf life
Environmental benefit
Reduction in carbon footprint
Supply Chain benefit
Different sourcing options from biobased feedstock; retrofit in
non-economic assets
YXY Technology Road to Commercialization
18
Pilot Plant scale Commercial scale Industrial scale
On stream On stream 2018 On stream in >2020
Name plate capacity:
5tpa PEF
Name plate capacity:
5-50 ktpa
Name plate capacity:
>200 ktpa
Goal: prove technology Goal: commercial launch of
PEF Bottle by partners
Goal: roll-out of PEF bottles
through beverage markets
Owned & Operated by
Avantium
Own & Operate and/or Joint
Venture
Licensing model for global
deployment of technology
Avantium Business Units
19
YXY technology
development Catalysis R&D
systems & services
Profitable, cash-flow positive &
growing business
Next generation bio-based
furanic monomer and polymer
technology
New Chemistry
project portfolio
Innovative routes from biomass
to chemicals
- Lignocellulosic (2G) glucose
- Direct route to MEG from
carbohydrates
Hurdles for scale bio-based
chemicals adoption
Cost: inefficient (petro-based)
conversion routes
Sustainability: need 2G supply
for long term sustainability
Quality: no cost competitive
high-purity 2G-glucose available
Avantium New Chemistry Research – our vision
20
Avantium has found efficient routes from 2G feedstock
to bio-chemicals based on its leading chemical catalysis know-how
Theoretical yield from sugar
67% 29%
FD
CA
(P
EF
)
87%
ME
G (
via
Hyd
rog
en
oly
sis
)
100% 46%
PlantBottleTM program by Coca-Cola and its stated goal to
reach 100% use of Bio-MEG in all its PET bottles generates
a market of at least 1 million ton per year by 2020
MEKONG:
One step conversion from C6 to Bio-MEG
21
Today Bio-MEG is produced in a four-step process that was
optimized for fossil feedstock, leading to significant price
premium over petro-MEG C6
MEG Hydration
Fermentation Dehydration
Oxidation Avantium has developed a one-step, highly selective
hydrogenolysis conversion from C6 sugars (cellulose, starch and glucose) to MEG, enabling high carbon efficiency (>2 MEG per C6) leading to a potential cost lower than today’s bio- and petro-MEG price
Avantium is open for partnering for scale-up to pilot-demonstration scale and commercial scale
C6
MEG
Hydrogenolysis
Signficant 1G glucose is produced for use in Bio fuels,
supported by mandates and subsidies. Most 2G glucose
is not pure enough for Bio-Chemicals and not cost
competitive without incentives.
ZAMBEZI:
High purity 2G (non-food) glucose competitive with 1G
22
A large market demand is building for high purity 2G-
glucose for various bio-materials and chemical
intermediates
Avantium has further developed proven high-acid/low-
temperature conversion of ligno-cellulose to 2G-glucose with
unprecendented purity, cost competitive with 1G-glucose,
opening up the biochemical space for large scale 2G use
Avantium is seeking investors and partners to complete
the development and build the supply chain
Summary
PEF: The Next Generation Polyester
– Superior barrier performance, mechanical- and thermal properties
– Reduced carbon footprint
– Recyclable
– Cost competitive at industrial scale
Collaborating with The Coca-Cola Company, Danone, ALPLA, and
Wifag//Polytype to launch the first PEF packaging on the market in 2018
New partnerships to develop applications for PEF films and PEF fibers
and other FDCA applications
Preparation of first commercial FDCA plant ongoing
Open to start new collaborations on bio-MEG and 2G glucose 23
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