biorefineries integrated in local areas to reindustrialise and decarbonise europe – catia bastioli
TRANSCRIPT
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CATIA BASTIOLI
TAGLIO DI PO (RO)
30.09.2016
BIOREFINERIES INTEGRATED IN LOCAL AREAS TO
REINDUSTRIALISE AND DECARBONISE EUROPE
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THE PILLARS OF OUR STRATEGY
1. THE PLANTS
Deindustrialized sites, their regeneration transforming world-first technologies into flagships (plants first in the world) intended as «bioeconomy infrastructures». Interconnected among them and connected with the local areas , starting points for new chains and new partnerships.
2. THE PRODUCTS
The products of the value chain have to contribute to solve real societal challenges and not to be one just of the million products in the market.
OUR MODEL OF BIOECONOMY AS TERRITORIAL REGENERATION
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PRODUCTION SITES
MATRÌCA 50:50 JV
NOVAMONT-VERSALIS
FLAGHIP FOR AZELAIC AND PELARGONIC ACIDS, THEIR
ESTERS, PLASTICISERS, BIOHERBICIDES, BASIS FOR
BIOLUBRICANTS
INTEGRATED AGRICULTURAL VALUE CHAIN
Porto Torres (SS) - Sardegna
HEADQUARTER
BIOECONOMY INFRASTRUCTURES IN ITALY
MATER-BIOTECH (100% NOVAMONT) FLAGSHIP FOR 1,4 BDO PRODUCTION THROUGH FERMENTATION PROCESSES Adria (RO) - Veneto
R&D CENTRES
MATER-BI PRODUCTION AND R&D ON ON INTERMEDIATES FROM RRM Terni - Umbria
BIOTECHNOLOGY RESEARCH CENTRE Piana di Monte Verna (CE) -Campania
MATER-BIOPOLYMER (78% NOVAMONT)
PRODUCTION OF
POLYESTERS FROM VEGETABLE OILS
Patrica (FR) - Lazio
HEADQUARTER AND RESEARCH CENTRE
Novara - Piemonte
NOVAMONT’S SITES
SUBSIDIARY COMPANIES
NOVAMONT’S NETWORK
JV NOVAMONT/VERSALIS
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3 R&D Centers (Novara,
Caserta, P.to Torres)
20% of people in R&D
activities
>6% of turnover in R&D
activities
About 1.000 patent
cases filed
R&D WHO WE ARE
NOVAMONT: A KNOWLEDGE-BASED INDUSTRY
4 production sites
3 technologies in place,
1 at start-up level
7 reactive extrusion lines
(95.000 t/a)
4 discontinuous
polymerization lines
(10.000 t/a)
1 continuous
polymerization line
(50.000 t/a)
INDUSTRIAL STRUCTURE
GROUP PROFILE
Pionieer and world
leader in the
development of
bioplastics and
bioproducts
Turnover (2015): 170M€
600 people
7 A WORLWIDE COMPANY
NOVAMONT S.p.A. Novara (Italy)
NOVAMONT FRANCE Paris (France)
NOVAMONT Representative office Bruxelles (Belgio)
SITES OUTSIDE ITALY
BUSINESS NETWORK
NOVAMONT NORTH AMERICA INC. Shelton, CT (USA)
NOVAMONT GMBH Eschbon (Germany)
Lebanon, Tennessee (USA)
HEADQUARTERS
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M&G
50%
VERSALIS
50%
MATRICA
NOVAMONT France
NOVAMONT GmbH
MATER BIOTECH
MATER BIOPOLYMER
22% GENOMATICA
100% 100% 100% 78% 100%
NOVAMONT North America
NOVAMONT AGRO
DIVISION
10 WHERE WE STARTED FROM TURNING A PROBLEM INTO AN OPPORTUNITY: THE EXAMPLE OF BIOWASTE
ORGANIC WASTE IN LANDFILL
The landfill gas produced by biowaste consists
mainly of methane, which is 23 times more
powerful than carbon dioxide in terms of climate
change effects in the 100-years time horizon
(source: IPCC)
If not collected properly, leachate can
contaminate groundwater and soil
Landfilling means irrecoverable loss of resources
and land
COMPOST AS DRIVER FOR SOILS FERTILITY
Quality soil conditioner to be used in agriculture
to combat desertification and soil erosion
Carbon sink effect
In some EU countries compostable bioplastics
have become an integrating element in the
biowaste management thanks to an overall
agreement with the composting network
Cases of excellence where composting and AD
transform biowaste into new resources, such as
biogas and high quality compost, thereby closing
the organic carbon cycle of the bioeconomy
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AZELAIC ACID PELARGONIC ACID
OTHER CHEMICAL INTERMEDIATES
(Matrica )
NOVAMONT’S PROPRIETARY TECHNOLOGIES UPSTREAM INTEGRATION 1989-2016
BIOBDO
4TH GENERATION MATER-BI C14 > 70%
3RD GENERATION MATER-BI C14 > 50%
2ND GENERATION MATER-BI C14 > 40%
1ST GENERATION MATER-BI C14 > 25%
SPECIALISED SEEDS
DEDICATED CROPS AND
BIOMASS TREATMENT
SEEDS CRUSHING
CHEMICAL PROCESSES
POLYESTERS FROM RRM
COMPLEXED STARCH
BIOTECH PROCESSES
12 BIO-BDO CARBON FOOTPRINT
The carbon footprint of bio-BDO is shown in this graph.
The first bar shows the cradle-to-gate CF of the current bio-BDO.
The second bar shows the expected CF in the next months.
The third and the forth bars represent the impact of fossil BDO produced with traditional processes at global or European level, respectively.
A difference of 56% is achievable when passing from the fossil-based BDO produced at global level to the bio-BDO to capacity.
Δ -56%
13 THE NEW GRADES OF MATER-BI OF 4TH GENERATION BIO-BDO (MATER-BIOTECH) AND AZELAIC ACID (MATRìCA) EFFECT
4TH GENERATION MATER-BI % OF RENEWABLE CARBON
(C14)
RELATIVE SCALE OF
CO2 EMISSIONS IN KG CO2/KG
(CRADDLE TO GRAVE)
Shopping bags grade >60 <40
Fruits & Vegetables grade >60 <40
Biodegradable products today in the market for same applications
<30 100
14 BIO-BDO MARKET
ESTIMATED ANNUAL GROWTH BDO DEMAND: 5-8%
TOTAL MARKET 2,000 MMT
BDO DERIVATIVES AND USES:
Tetrahydrofuran (THF): PTMEG (poly
THF) spandex (e.g. Lycra),
solvents
Polybutylene terephthalate (PBT ):
automotive plastics, cell phones, PCs
Gamma-butyrolactone (GBL): PVP
polymers, solvents
Polyurethanes (PU): engineering
thermoplastics, coatings
THF MERCHANT
8%
PBT 23%
PU/TPU 11%
NMP 9%
GBL (INCL. POLYMERS)
8%
OTHERS 1%
BIOPLASTICS 3%
PTMEG 37%
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INTEGRATION OF CHEMICAL PROCESSES WITH INDUSTRIAL BIOTECHNOLOGY
MATER-BIOTECH
Optimization of the production process life-cycle through the reuse of the process by-products for the plant energy demand
Integration of Novamont’s know-how and competences in the development of low-impact production processes through an innovative technology developed by Genomatica, leader in the specialization of microorganisms for fermentation processes
Regeneration of the former BioItalia/Ajinomoto site in Adria, after the shut-down of the fermentation plant in 2006
First dedicated industrial plant at world level for
the production of butanediol (1.4 BDO) directly
from sugars
INVESTMENT > 100 MILLION EURO
PRODUCTIVE CAPACITY: 30.000 TONS/Y
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12 TONS
OF LANDFILLED WASTE
350 TONS
OF ASBESTOS
150 TONS
OF SLUDGE
1,150 TONS
OF WASHING WATER 300 TONS
OF OTHER SUBSTANCES
THE REGENERATION PROCESS THE PLANT CONDITIONS
18 THE START-UP OF THE PLANT
2006 2012 2014 2016 2017 1992
ACQUISITION BY THE JAPANESE CORPORATION AJINOMOTO (LYSINE PRODUCTION)
BIRTH OF THE INDUSTRIAL SITE
IN BOTTRIGHE (MONTESI GROUP -
PRODUCTION OF GLUTAMATE)
AGREEMENT WITH GENOMATICA
START OF THE SITE
REGENERATION
FIRST BDO INDUSTRIAL
PRODUCTION
SEPT 30TH: GRAND OPENING
FROM MAY 16TH TO JUNE 10TH: WATER
BATCHING FROM JUNE 13TH TO OCT 2ND: WHITE TEST
FULL PRODUCTION OF BIO-BDO
1960
TIMELINE
SHUT-DOWN OF THE FERMENTATION
PLANT. ACQUISITION BY BIOITALIA
COMPANY
NOVAMONT ACQUIRES THE PLANT.
CREATION OF MATER-BIOTECH
JULY 18TH: START-UP
FROM JULY 18TH TO OCT 3RD: RAMP-UP
19 EMPLOYMENT
TECHNICAL HIGH-
SCHOOL DIPLOMA
65%
UNIVERSITY DEGREE
15%
NO DIPLOMA OR DEGREE
20%
QUALIFICATIONS (MATER-BIOTECH)
CHEMICAL INDUSTRY
48% PHARMACEUTICAL
INDUSTRY 26%
ENERGY INDUSTRY
7,5%
OTHER 18,5%
SECTORS OF ORIGIN (MATER-BIOTECH)
MATER-BIOTECH: 72 PEOPLE SATELLITE ACTIVITIES: 150 PEOPLE
20 STAFF GEOGRAPHICAL ORIGIN
DISTANCE OF THE STAFF GEOGRAPHICAL ORIGIN:
< 10 KM 41%
< 30 KM 26%
< 50 KM 13%
> 50 KM 20%
AREAS OF THE STAFF GEOGRAPHICAL ORIGIN:
ROVIGO
FERRARA
PADOVA
VENEZIA
Venezia
Padova
Ferrara
Rovigo
22 NEW PRODUCTS NOW AVAILABLE AT EU LEVEL THE TANGIBLE RESULT OF THE BIOECONOMY INFRASTRUCTURES NOW IN PLACE IN ITALY
AZELAIC ACID
C5-C9 ACIDS POLYMERIC PLASTICISERS
BIO-BDO
CARDOON OIL PROTEINS FOR ANIMAL FEED
ACTIVE MOLECULES
MARKET SEGMENTS
Oleochemistry
Energy industry
Packaging manufacturers
Retail market
Waste management &
multiutilities companies
Machine producers
Food brands
Feed
Farmers & sheppards
Maritime
Herbicides
PELARGONIC ACID