Biobased 1,3-Propanediol

A New Platform Chemical

For The 21st Century

Carl F. Muska and Carina Alles

BioPerspectives 2005

BREW SymposiumMay 11, 2005

5/11/05

2

Overview

• What is 1,3-Propanediol (Bio-PDO™)

• Bio-PDO™ as a New Platform Chemical

• Bio-PDO™ as a Product of DuPont Transformation

• Life Cycle Assessment as a Tool for- Process Development- Market Development

• LCA Results- Bio-PDO™ Monomer- Sorona® Polymer- Final Product - Carpet

• Summary

5/11/05

3

Joint Venture Announced - May 26, 2004

5/11/05

4

Loudon Site

5/11/05

5

5/11/05

6

The Product

Bio-PDO™ (1,3- Propanediol; 3G; Propylene glycol)

·Clear

·Colorless

·Odorless

·Low Toxicity

·Biodegradable

5/11/05

7

Apparel

Sorona®Sorona®• Softness• Stretch & Recovery• Vibrant Colors• Printability

Fiber

AutosCarpet

Sorona® Polymer

5/11/05

8

Bio-PDO™ Market Opportunities

Market Uncertainty low medium high

low

m

ediu

m

h

igh

Tech

nica

l Unc

erta

inty

Textiles/Yarn

Bi-Components

Athletic Shoes

Staple

Non-wovens

MoldedComposites

GreenSorona

PerformanceCoatings

PackagingFilm

Carpets

5/11/05

9

1802 1830 1850 1900 1925 1945 1990 2000 2050 2100

Birth

Growth

Maturity

Birth

Growth

Maturity

Birth

Growth

Explosives

Strong history of innovation, reinvention

Chemistry, Materials, Systems,Biology. . .

Chemicals,Energy

DuPont - Transforming for our Third Century

5/11/05

10

Sustainable Growth: Increasing shareholder and societal value while reducing our environmental footprint.

Our Mission

5/11/05

11

2010 Goal

25% of revenue is from non-depletable resources.

5/11/05

12

How Did We Get Here?

Bio-PDOTM…

…from corn

Biotechnology

5/11/05

13

CH2=CHCH3

Propylene

HOCH2CH2CH2OH

3G

Bio-Process

C6H12O6

Glucose Advantages:

Use of Renewable Feedstock

Smaller environmental footprint

Lower manufacturing cost

Lower capital

HOCH2CH2CH2OH

3G

CatalystBiocatalyst

Transition to Renewable Feedstock

Fossil-Based Feedstock Renewable Feedstock

5/11/05

14

A Brief History of the Program

Broad Biocatalyst Patent Allowed

Genencor-DuPont Collaboration Started

Gen I BiocatalystMilestone

Gen II BiocatalystMilestone

Tate&Lyle-DuPont Process Piloting Started

Commercial-Performance Biocatalyst in Pilot

Polymer-grade Bio-3G in Pilot

3G Genes Isolated

Process Development Team Formed

1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2006

Commercial Plant Start-Up

5/11/05

15

O

OH

OHHO

HO

OH

HO OH

(1,3-Propanediol)DextroseCorn

microorganismmicroorganism

GlucoseGlucose Bio-PDO™

Ferment glucose to PDO using patented microorganism Refine to Fiber Grade

Process to Bio-PDO™

Bio-PDO™

5/11/05

16

SoronaSorona®® Polymer Polymer& Fiber& Fiber

WaterWaterGlucoseGlucose

FERMENTERFERMENTER

CellsCells

WaterWater

ImpuritiesImpurities

FIBERFIBERGRADEGRADE

3G3G

FermentationFermentation

BiocatalystBiocatalyst

NutrientsNutrients ImpuritiesImpurities

SeparationsSeparations RefiningRefining

11 22 33

Putting it all togetherPutting it all together

The 3G Bioprocess

5/11/05

17

An important question was asked

Scientific American. August 2000Tillman U. Gerngross and Steven C. Slater

5/11/05

18

Energy as a Key Indicator

• energy production causes large environmental footprint

– depletion of fossil fuels

– greenhouse gases

– water consumption

– toxic emissions (eg, heavy metals)

• There are energy-related concerns with bio processes:

– difficult separations

– not as optimized as incumbent technologies

5/11/05

19

How Do We Answer the Question?

Life Cycle Analysis(LCA)

5/11/05

20

Life Cycle Assessment Framework

Goal & Scope Definition

Inventory Analysis

Impact Assessment

Interpretation

Direct Applications:

Product development & Improvement

Strategic Planning

Public Policy Making

Marketing

Other

Conclusions, recommendations, and reporting

ISO 14041

ISO 14042

ISO 14043

5/11/05

21

How We Use LCA

1999 2000 2001 2002 2003 2004 2005 2006

Process Development

Bench-marking

Market Development

Stakeholder Engagement

ICBR Program

Tate&Lyle-DuPont Joint Development Agreement

Process Piloting StartedCommercial Plant begins operation

Joint Ventureestablished

DuPont Tate & Lyle BioProducts

5/11/05

22

FUELS , Pharmaceuticals,

solvents, crop protection

CHEMICALS . . .

Renewable Crops Bioprocessing

Future

Present

Petroleum RefiningCHEMICALS

eg : PDO

Coatings

Fibers

Plastics

Polymers

Life Cycle Assessment of PDO

5/11/05

23

Raw Materials Intermediates Material

On-going: “gate-to-grave”

End of LifeProduct UseProduct

LCA System Boundaries

Previous work: “cradle-to-gate”

5/11/05

24

INPUTSINPUTS OUTPUTSOUTPUTS

Raw Materials Co-Products

Energy Emissions to air, water & land

PDO

Corn farming

Corn wet milling

PDO fermentation

PDO purification

Bio-PDO™ LCA System

5/11/05

25

INPUTSINPUTS OUTPUTSOUTPUTS

Raw Materials Co-Products

Energy Emissions to air, water & land

PDO

Hydrogenproduction

Propyleneproduction

Chem. PDO production

Fossil Feedstock extraction & refining

Fossil-Based PDO LCA System

5/11/05

26

PDO Comparison: LCA Total Primary Energy

0%

20%

40%

60%

80%

100%

120%

1,3 Propanediol from Bio-Route 1,3 Propanediol from ChemicalRoute

5/11/05

27

0

Fossil-Based PDO Bio-PDO™

Cu

mu

lati

ve E

ner

gy

Co

nsu

mp

tio

n

Generation 1

Generation 2

Generation 3

PDO Comparative LCA

5/11/05

28

Sorona®

INPUTSINPUTS OUTPUTSOUTPUTS

Raw Materials Co-Products

Energy

PDOproduction

TPA or DMT production

3GT polymerization

Emissions to air, water & land

Sorona® LCA System

5/11/05

29

Nylon 6 Sorona®

Cu

mu

lati

ve n

on

-ren

ewab

le e

ner

gy

con

sum

pti

on

per

kg

of

po

lym

erComparative Polymer LCA - Energy

5/11/05

30

Nylon 6 Sorona®

Gre

enh

ou

se g

ases

as

CO

2 eq

uiv

alen

ts

per

kg

of

po

lym

er

Comparative Polymer LCA - CO2

5/11/05

31

Why Carpet?

• 1.9 billion square yards produced in 1999- supplies 45% of world’s carpet- 53% is residential- 47% is industrial

• 3.5 billion pounds of fibers consumed/year- 57% nylon- 36% olefin- 7% polyester- 0.4% wool

For United States Carpet Industry

Sources: Floor Covering News, 11/19/02, The Carpet Primer, The Carpet and Rug Institute (1999)

5/11/05

32

INPUTSINPUTS OUTPUTSOUTPUTS

Raw Materials Co-Products

Energy Emissions to air, water & land

Carpet Manufacture

Installation

Residential Use

End-of-Life

Carpet LCA System

Polymer

5/11/05

33

Carpet Comparative LCA

-

50

100

150

200

250

Carpet Fiber Other CarpetMaterials

CarpetManufacture

Carpet Cleaning Total

Cu

mu

late

d E

ner

gy

Dem

and

in M

J p

er s

qu

are

ya

rd o

f ca

rpe

t

Nylon6

Sorona®

5/11/05

34

Carpet Fiber Other Carpet

Materials

Carpet

Manufacture

Carpet

Cleaning

Total

Gre

enh

ou

se g

ases

as

CO

2 eq

uiv

alen

ts

per

sq

uar

e ya

rd o

f ca

rpet

Nylon 6

Sorona®

Comparative Carpet LCA - CO2

5/11/05

35

Sustainability in Business

Sustainability: Three Legs

• In Markets: Greater Functionality• In Business: Lower Cost & Investment• In the World: Smaller Environmental Footprint

5/11/05

36

Its an exciting time to be at DuPont

5/11/05

37

Acknowledgments

Susanne Veith, Robin Jenkins, Robert Sylvester - DuPont Engineering

Steve Baere, Consultant

Konrad Saur, Consultant, Five Winds