building a renewable economy- the bio-pdo™...

1

Building a Renewable Economy-The Bio-PDO™ Example

Pete Colombo

.

Minnesota Green Chemistry Forum/Twin Cities SCC Chapter

May 23, 2012

DuPont Tate & Lyle BioProducts Confidential2

In 2011, our global population hit 7 billion people.

By 2050, it will be 9 billion.


• Animal science solutions to improve the sustainability and efficiency

• Enzymes that reduce food production costs and extend freshness

• Technology for first generation ethanol and advanced biofuel production

• Materials and chemicals made from renewable resources

• Solutions that improve performance while reducing energy or water use

• Sustainable alternatives to less desirable chemical solutions

REDUCING DEPENDENCE ON FOSSIL FUELS

PROTECTING PEOPLE AND THE ENVIRONMENT

FEEDING THE WORLD


Who We Are and Where We Work

� Industrial Biosciences is comprised of more than 2500 dedicated colleagues globally. � We discover and develop market-based biotechnology solutions at 8 R&D sites worldwide. � We produce a broad portfolio of products and manage 19 operations sites.

DuPont Industrial BiosciencesResearch & Development Centers

Production, Operations and Pilot Sites

DuPont Tate & Lyle BioProducts Confidential

What does “green”mean??


Many terms used in the market to communicate “green”


United States Environmental Protection Agency (US EPA) Green Chemistry Program

“Green chemistry, also known as sustainable chemistry, is the design of chemical products and processes that reduce or eliminate the use or generation of hazardous substances. Green chemistry applies across the life cycle of a chemical product, including its design, manufacture, and use.”

“Green chemistry consists of environmentally friendly, sustainable chemicals and processes whose use results in reduced waste, safer outputs, and reduced or eliminated pollution and environmental damage. Green chemistry encourages innovation and promotes the creation of products that are both environmentally and economically sustainable.”

Source:US EPA Green Chemistry Program http://www.epa.gov/gcc/pubs/basic_info.html


U.N. World Commission on Environment and Development

"Development that meets the needs of the present without compromising the ability of future generations to meet their own needs."

— from the World Commission on Environment and Development’s(the Brundtland Commission) report Our Common Future (Oxford: Oxford University Press, 1987).


The Sustainability Trinity


The creation of shareholder and societal

value while we reduce the

environmental footprint* along the

value chains in which we operate.

The creation of shareholder and societal

value while we reduce the

environmental footprint* along the

value chains in which we operate.

* DuPont defines “footprint” as all injuries, illnesses, incidents, waste,

emissions, use of water and depletable forms of raw materials and energy.

The Mission of DuPont

10

SUSTAINABLE GROWTH


Value

Business Integration

SustainableGrowth

DuPont’s Journey Toward Sustainable Growth

The Goal Is ‘0’

1972 1989 1994 2000 2006

Sustainable Growth --Market Facing Approach

CorporateEnvironmentalism

SHECommitment

Compliance


2015 Market-Facing GoalsEnvironmentally Smart Market Opportunities from R&D Efforts: Double our investment in R&D programs with direct, quantifiable environmental benefits for our customers and consumers along our value chains.

Products that Reduce Greenhouse Gas Emissions: Increase our annual revenues by at least $2 billion from products that create energy efficiency and/or significant greenhouse gas emissions reductions.

Revenues from Non-Depletable Resources: Nearly double revenues from non-depletable resources to at least $8 billion.

Products that Protect People: Introduce at least 1,000 new products or services that help make people safer globally.

DuPont Tate & Lyle BioProducts Confidential 13

The source The source isis renewablerenewable

Building a Renewable Economy...

Oil Refining Chemistry

Crops Biomass Feedstock Metabolic Engineering

The source is not renewable

From:

To:

Solvents

Molded Parts

Fibers


DuPont is a world leader in science andinnovation across a range of disciplines,

including agriculture and industrial biotechnology, chemistry, biology,

materials science and manufacturing. 2011 revenues were $38.7 billion.

Tate and Lyle is a global provider of renewable ingredients, solutions and

services to the food, beverage and industrial customers. 2011 revenues

were $4.3 billion.

Joint venture (50/50) formed in 2004 between DuPont and Tate & Lyle to produce propanediol from corn sugar, a renewable resource

DuPont Tate & Lyle Bio Products


Bio-PDO TM – 1,3 Propanediol

What is it?• A highly-pure, petroleum-free derived diol

• 100% renewably sourced

• Used as a monomer in the production of polymers

• Used in cosmetics, personal care and home care as an emollient, humectant, carrier or solvent.

• Currently being used in a range of industrial applications including polymers, fluids and coatings

How is it made?• Made by a fermentation process derived from corn sugar

• Made in the USA


Renewably Sourced Propanediol Applications

Antifreeze & Deicing

Paints & CoatingsFabric & Home Care

Polymers & Fibers

Cosmetics & Personal Care


World Headquarters and Production located in Loudon, Tennessee

• 12 year R&D effort

• Production started Nov. 2006

• 140 million pound annual capacity

• Award winning…

� 2003 EPA Presidential Green Chemistry Award

� 2007 ACS Heroes of Chemistry Award

� 2009 ACS-BIOT Industrial Biotechnology Award

� 2010 State of Tennessee Governor’s Award


1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 20052004 2006 2007

BioBio--PDOPDO™™ Program Program –– A Highly Collaborative EndeavorA Highly Collaborative Endeavor

Broad Biocatalyst

Patent Allowed

Genencor-DuPont

collaboration started

Gen II

biocatalyst

milestone

Commercial

biocatalyst

deliveredGen I biocatalyst

milestone

PDO Genes Isolated

Tate & Lyle-DuPont

Joint Venture started

Process

development

team formed

Polymer-grade

Bio-PDO

Ground breaking

Loudon, TN

100MM ppy

Loudon plant

start up

Detailed engineering

design started


O

OH

OHHO

HO

OH

HO OH

(1,3-Propanediol)GlucoseCorn

microorganismmicroorganism

GlucoseGlucose Bio-PDO™

Ferment glucose to PDOusing a patented bio catalyst. Processed to 99.7% Purity

Process to Bio-PDO™

Bio-PDO™

CO2


Nature - then Metabolic Engineering

Two microorganisms convert sugar to PDO stepwise.

A single microorganism is desired for an industrial process.

Nature Provided Blueprint…

……Metabolic Engineering Made it Practical.Metabolic Engineering Made it Practical.

YeastYeast((Saccharomyces cerevisiaeSaccharomyces cerevisiae ))

BacteriumBacterium((Klebsiella pneumoniaeKlebsiella pneumoniae ))

Glucose Glycerol PDODAR1 GPP2 dhadha B1B1 B2B2 B3B3 dhadha TT

((yqhyqh D)D)

orf YdhaB1

dhaB2dhaB3

orf X dhaX DAR1 GPP2

Glucoseyqh D

HO OH


1,3 Propanediol Process Flow Chart

Fermentation

SeparationsDistillation Product Storage Tanks

Quality ChecksPDO Purity (GC)

Color (Hazen)Water (Karl Fischer)Appearance (Visual)

Meet Specification

1,3 - PropanediolNot MeetSpecification

QC

Corn Sugar

Air

Water

Biocatalyst

Nutrients

Air

Water Biocatalyst Nutrients

Trace ImpuritiesOur Vision to Our Customers

“DuPont Tate & Lyle Bio Products provides renewably sourced, high quality

ingredients that deliver superior functionality and enable our customers to

offer better products.”


LCA is the only standardized method to evaluate the environmental footprint of a whole supply chain. Energy consumption and GreenHouse Gas (CO 2) emissions are key factors in determining environmental footprint.

Life Cycle Assesment Approach

Cradle-to-gate

Cradle-to-graveCO2

Biodegradation of

product results in no net

CO2 increase

Manufacturing

Transportation TransportationUse/Reuse/

Maintenance

Recycle

Waste Management

AirEmissions

WaterborneWastes

Solid WastesCo-products

EnergyRaw Materials

Raw MaterialAcquisition


Bio-PDO™ Life Cycle Assessment* Comparisons

*Bio-PDO™ LCA data based on Loudon process design data; peer reviewed by Five Winds International

2.18

5.00

3.75

111.00

103.60

63.90

0

1

2

3

4

5

6

Bio-PDO™ Propanediol(PO route)

PropyleneGlycol

Bio-PDO™ Propanediol(PO route)

PropyleneGlycol

GH

G E

mis

sion

s (k

g C

O2

equi

v / k

g)

0

20

40

60

80

100

120N

on Renew

able Energy (M

J/kg)GHG EmissionNon Renewable Energy

Green House Gas Emissions- 56% less than Propanediol- 42% less than Propylene glycol

Non Renewable Energy Use- 42% less than Propanediol- 38% less than Propylene glcyol


The source The source isis renewablerenewable

Building a Renewable Economy...

Oil Refining Chemistry

Crops Biomass Feedstock Metabolic Engineering

The source is not renewable

From:

To:

Solvents

Molded Parts

Fibers


Propanediol (PDO) - A range of potential uses

Common Name Formal Name CAS # Formula Structure Mol. Wt. Bp, oC Mp, oCDensity,

g/mlEthylene Glycol

(EG)1,2-Ethanediol 107-21-1 C2H6O2 62.1 197.6 -12.7 1.116

Propylene Glycol (PG)

1,2-Propanediol 57-55-6 C3H8O2 76.1 187.3 -60 1.038

PDO 1,3-Propanediol 504-63-2 C3H8O2 76.1 214 -24 1.053

Butylene Glycol (BG)

1,3-Butanediol 107-88-0 C4H10O2 90.1 207.5 -50 1.006

BDO 1,4-Butanediol 110-63-4 C4H10O2 90.1 230 16 1.017

MPDiol 2-Methyl-1,3-Propanediol 2163-42-0 C4H10O2 90.1 221 -91 1.015

DPG Dipropylene Glycol (several isomers are possible)

25265-71-8 C6H14O3 134.17 231 1.023

HO

OH

OH

HO

HO OH

OH

OH

HO

OH

OHHO


Cosmetics and Personal Care: Clear Value

Zemea® Market Value- Reduced Skin Sensitization vs. PG- Improved Hydration/ Humectancy- Excellent sensorial characteristics- Can boost preservative efficacy

Skin Hydration Averages

0

3

6

9

12

15

0 1 2 3 4

Time, hrs

Ave

rage

s(n

orm

aliz

ed to

bas

elin

e)

Zemea™ Propanediol

Butylene Glycol

Propylene GlycolControl


Fabric & Home Care

0

20

40

60

80

100

120

6.39 8.52 10.65 12.78

Enzyme Concentration (mg/ml)

Rel

ativ

e A

ctiv

ity (

%)

Zemea t = 0 Zemea t = 1mo. PG t = 0 PG t = 1 mo.

Bio PDO™ fit with HI&I:

• Trends to “green” products with Skin irritation and

sensitization benefits

• Potential as enzyme stabilizer in liquid detergents

• Used in hand dish soaps, hand sanitizers, hand

soaps, hard surface cleaners/degreasers, liquid

laundry, etc.

Protease Enzyme Stability over time

Indu

stria

l Cle

anin

g

Liquid Laundry

Personal Care

Institutional Cleaning

Household Cleaning

Liquid Dishwashing

Indu

stria

l Cle

anin

g

Liquid Laundry

Personal Care


Household Cleaning

Liquid Dishwashing

Indu

stria

l Cle

anin

g

Liquid Laundry

Personal Care


Household Cleaning

Liquid Dishwashing


Bio PDO™ Contributes to Biobased Content

28

Polyester Polyol Diisocyanate Chain Extender

Bio-PDO™- basedPolyurethane

Biobased Content

Material Final PU

Susterra® chain extender 100 wt% 3 - 10 wt%

Susterra® based polyester polyol up to 40 wt% 20 - 30 wt%

Susterra® based polyurethane --- up to 33 wt%

Biobased Content


Polyurethane Applications

Transportation Mechanical Sports & RecreationIndustrial

forktruck wheels and tires

casters

pipeline cleaning pigspipeline cleaning pigs

squeegees

seals

gaskets

engine mounts

suspension bushings

rolls and rollers

skate wheels

footwear

Bio PDO™ adds up to 33 wt% renewably sourced content.

TPU’s and Cast Elastomers

exercise equipment


Deicing fluidsSusterra® propanediol offers manufacturers and formulators of fluids (such as

heat transfer and deicing fluids) a highly functional glycol that is easy to handle at low temperatures , has good stability at higher temperatures and enables the

incorporation of a low toxicity product with renewable content to expand their

offerings to end users.

Lowest Operational Use Temperature Bio-Content

DF Sustain -41 90%Type I PG Fluid -32 0%Type I EG Fluid -33 0%

Freeze Points of Glycol Solutions

-140.0

-120.0

-100.0

-80.0

-60.0

-40.0

-20.0

0.0

20.0

40.0

60.0

0.0 20.0 40.0 60.0 80.0 100.0 120.0

Percent Glycol

Deg

rees

F

EG

PG

PDO

ASTM D1177 method is limited below-60 oF. Products become slushy.


Engine Coolants Cars, Light and Heavy Duty Trucks

ASTM International D15 Committee on Engine Coolants

Formed D15.07 Subcommittee to investigate PDO as an engine coolant

Industry Standard for PDO in coolants approved

0

200

400

600

800

1000

1200

1400

1600

0 25 50 75 100 125 150 175 200

HOURS

PP

M

EG

PG

PDO


Unsaturated Polyester Resins

Susterra® propanediol offers an alternative short chain diol that enables formulations that are less stiff and more

flexible without sacrificing strength and hardness. Due to

its higher boiling point, Susterra® can provide less glycol

loss during the polyester cook step. For resin manufacturers and their customers, use of Susterra®

enables the incorporation of renewable content.

Higher boiling point provides more efficient glycol use

400 rpm

Nitrogen

Cooling water

Mechanical stirrer

Dean Stark

(water)

Heating mantle (205 °C)

1L Glass vessel (2 parts)

Isolation (heating ribbon)To prevent sublimation of Phthalic anhydride

Diol+MA+PAHydroquinone, toluene

PG: 187 °CPDO: 214 °C

Marine: Susterra® in the hull resin system

DuPont Tate & Lyle Bio Products and Ashland Inc.expand renewable resource resin capabilities

ENVIREZ® resin line to use Susterra® renewably-sourced propanediol

ENVIREZ resins, developed by Ashland using patented technology and renewable ingredients,

such as Susterra®, provide composite fabricators with the first step to sustainable composites.


Sorona ® for Residential Carpet (DuPont uses Bio-PDO™ to make polymer)

Sorona® (also called PTT or 3GT) is poly(trimethylene terephthalate), a co-polymer of Bio-PDO™ (fermentation-

derived 1,3-propanediol), and petroleum derived terephthalic acid (TPA) or dimethyl terephthalate (DMT).


Zemea® Certifications

• EcoCert™

• Natural Products Association (NPA)

• DfE – EPA’s Design for the Environment

• USDA 100% Bio based


Bringing together Green Drivers

Company & IndustryFocus

Certification(NGOs or Government)

ProductAttributes

Market Opportunity• Market size• Competitive Advantage• Buyer preferences• Legal regulations• How does company define “green”

Product Differentiation• Performance• Attributes • Verifiable data

Market Influencer•Industry recognized• Sustainable or green definition • Third party validation

“Sweet Spot”


Loudon Bio-PDO™ Production is “The Leading Edge of Industrial Biotech”

building a renewable economy- the bio-pdo™...

Documents