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Squaretable Chemical Industry 26th January 2012 - New Customer Realities: Capturing Added Value from Sustainability
 

Squaretable Chemical Industry 26th January 2012 - New Customer Realities: Capturing Added Value from Sustainability

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On the 26th of Jnuary 2012, Squareiwse hosted the Squaretable event with the subject of Chemical Industry - New Customer Realities: Capturing Added Value from Sustainability

On the 26th of Jnuary 2012, Squareiwse hosted the Squaretable event with the subject of Chemical Industry - New Customer Realities: Capturing Added Value from Sustainability

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    Squaretable Chemical Industry 26th January 2012 - New Customer Realities: Capturing Added Value from Sustainability Squaretable Chemical Industry 26th January 2012 - New Customer Realities: Capturing Added Value from Sustainability Presentation Transcript

    • New Customer Realities:Capturing Added Value from Sustainability Squaretable 26-01-2012 1
    • Agenda Time Programme 13:45 – 14:15 Welcome 14:15 – 14.30 Introduction Squarewise 14:30 – 15:00 Opening Squaretable 15:00 – 15:45 Key note - Gert Jan Gruter, CTO, Avantium “Platform for the Future: sustainable bio-based solutions for the future in plastics” 15:45 – 16:00 Break 16:00 – 16:30 Dr. Ir. Mirjam Kibbeling, New Business Development, Van Gansewinkel “Of Material Importance: from waste management to material and energy supply” 16:30 – 18:00 Plenary discussion 18:00 – 18:15 Closing remarks and round-up 18:15 – 19:15 Walking dinner 19:15 – open Networking drinks 2
    • Introduction Squarewise 3
    • Squarewise is driven by the understanding that organizations need newcapabilities to capture opportunities and maintain market leadership Internal target setting Internal and External target setting (3P’s) Structurally envision your future and capture current opportunities Real-time, practical Reposition the Redesign strategy development organization asExcel in core processes and a network ofactivities focus on Structurally develop supportive and bottom line organizational capabilities competitive to communicate and players mobilize in networks Controlled experimenting Market leader e.g in cutting Operational Innovative organization edge excellence technology 4
    • Opening Squaretable 5
    • Subject for discussion “Capturing added value from new sustainability driven customer requirements: Reassessing value chain position and business dynamics” 6
    • Value chain Raw Materials Production Re-use & recycling Packaging & Transportation Customer use 7
    • Changing consumer behavior towards sustainability centered demand:dynamics in the food packaging industry Ingredients: What the product contains Barcode: Could also be a QRcode for extra info Nutritional value: e.g. sugar, fat, carbs etc Recipes: Possible uses of the product Expiration date: Could change color depending on date Leading to... Source: DSM Specialty Packaging 8
    • Consumer driven value chain – traditional value chain dynamics change:biological banana packaging The plastic banana package features “Controlled ripening technology” which extends the shelf life of the fruit. This technology could reduce the carbon footprint by cutting back the frequency of deliveries. It’s recyclable. 9
    • Motivation Call for action to generate solutions in times of great complexity How to take advantage of sustainability and innovate further Global chain alignment for longer-term look at sustainability value creation World Creating valuable solutions amid changing world/value chain dynamics Finding the New Vibrant Ecosystem – from megatrends to business impact Collective intelligence and collaborative spirit required to advance the entire Outside- industry in The shift in Value Distribution through Co-Creation ( new Value Chain Dynamics) Reprioritize in the face of complexity Opportunities beyond the Core and Business Model Adjacencies Inside- Aligning Sustainability and Business Objectives out From complexity to clarity – way forward Material Passport Act Accordingly Solution Value chain alignment
    • Discussion 1. Creating and capturing value from sustainability throughout the value chain What is your vision? What is your role? 2. Drivers of sustainable development.. What? Performance? Price – green premium? Marketing? Who? Market pull versus technology push 3. How to create synergy between the bio-based developments and recycling initiatives? 4. How will this impact… Your value chain position and business partners? The value chain dynamics? 11
    • Avantium 12
    • Platform for the Future: sustainable bio-based solutions for the future of plastics and other applicationsGert-Jan Gruter, AvantiumSquaretable sustainability, Amsterdam, January 26 2012. 13
    • Agenda1. Introduction to biomass conversion bulk chemicals2. Introduction to Avantium & YXY 3. Feedstock strategy 4. Carbon efficiency 5. Land required 6. Life Cycle Assessment 7. Economics 8. Way forward 14
    • Bio-based chemicals playing field Resources –availability & marketprice * • Ethylene 100 Mio. t/a 1000 €/t • Propylene 64 Mio. t/a 1000 €/t • Benzene 23 Mio. t/a 900 €/t • Terephthalic acid 55 Mio. t/a 1500 €/t (2012) • Cellulose 320 Mio. t/a 500 €/t • Starch 55 Mio. t/a 250 €/t (for current non food applications) • Sugar 140 Mio. t/a 250 €/t • Ethanol 32 Mio. t /a 650 €/t * Source: Nexant, 2007
    • Main (non fuel) conversions – Carbohydrates (sugars)Glucose fermentation followed by Chemical conversion Ethanol ethylene PE (commercial; Braskem) (PE = 70 Mt/y) EO EG (Coke, Danone: greening PET; plantbottle) butylene/butanediol (Genomatica) Butanol (BP/Dupont) x2 p-xylene PTA (Gevo) (PET = 50 Mt/y) PTA + PG/BD (PPT/PBT = 3 Mt/y; Dupont) Succinic Acid (DSM, Bioamber, Roquette, Mits.C.) butane diol (BD) THF 1,4-butanediamine (BDA) Lactic acid/3-HPA (Cargill/Codexis) Acrylic Acid (AA; Ceres, Rohm&Haas) 1,3-PD (Braskem, Dupont, Tate&Lyle) 1,2-PD cost targets: same or less than oil-based analogs (green premium??). Typically 750-2000 €/ton PE =Polyethylene; EO = ethylene oxide; EG = ethylene glycol; PET = Polyethylene Terephthalate; PTA = purified Terephalic Acid; PG = propylene Glycol; BD = 1,4-Butane diol; PPT = polypropylene terephthalate; PBT = polybutylene Terephthalate; THF = tetrahydrofuran; 3-HPA = 3-hydroxypropionic acid; 1,3-PD = 1,3-propane diol
    • Main (non fuel) conversions - SugarsOnly Chemical catalytic conversion• Acid catalyzed dehydration of carbohydrates • Levulinic Acid/ester (Shell (fuel additives)/ Segetis (chemicals)) • MMF FDCA (Avantium) PEF (Avantium + Coke ++) PA (Avantium + Teijin/Solvay/Rhodia); coatings/resins; plasticizers) • Aqueous Phase reforming to hydrogen, alkanes or aromatics (BTX) Dehydration, aldol condensation & hydrogenation (Virent; fuels & BTX) • Hydrogenation sorbitol/mannitol (Cerestar/Cargill; Roquette, Tate&Lyle) (400kt/y) 1,2-PG isosorbide (Roquette, Cargill) • Retro Diels alder 2x C3 fragments (glycerol)
    • Main challenge: catalysis Elemental composition of feedstocks Crude oil Lignocellulose (wood) C 85-90% 50% H 10-14% 6% O 0-1.5% 43% CATALYST CATALYST Oil (CxHy) chemicals biomass (CxH2xOx) PROCESS PROCESSe.g. C10H22 (alkane) e.g. C6H12O6 (glucose)“under functionalized” “over functionalized” (Hydro)cracking (Depolymerization & Functionalization defunctionalization (O-removal) O-introduction - decarboxylation (fermentation) N-introduction - dehydration (water removal) - oxidation, etc. - reduction (hydrogenation) - C-C coupling - water present !!
    • INTRODUCTION TO AVANTIUM & YXY 19
    • Avantium Chemicals Profile• Spin-off from Royal Dutch Shell in 2000• 120 employees; 5,200 m2 of high-tech laboratories and offices • From 1 reactor in the • …to 64 parallel reactors in the conventional way… Avantium way• Created to develop new products and processes faster, more cost effective and with a superior rate of success• Petrochemical service business• Own R&D program on biomass conversion
    • A Proven ApproachAvantium’s 10 year track record in catalyst and process R&D contractresearch services demonstrates the value of its technology and expertise • Over 25 oil, refinery and chemicals customers from all over the world • High level of repeat business and customer loyalty • Addressing industry’s need for improved, accelerated product & process development
    • Company strategy • Advance the product development programs to commercial viability • Attract value-adding partners for final development and Product commercialization development programs • Backed by strong financial Biofuels program partners (€18M + €30M Biobased polymers program rounds in 2008-11) • Continue to expand the Services & Systems profitable Services & Tools businessAdvanced high-throughput R&D • Continue to invest in further strengthening the high- throughput R&D technology
    • FDCA as substitute for terephthalic acid (50 Mt/y)
    • Moving to 100% biobased• PET is the most widely used polyester made of PTA and EG• Plantbottle launch in 2009 - PET with biobased EG and oil-based PTA• PEF by Avantium: biobased FDCA + biobased EG = 100% green 100% FDCA PTA PTA Renewable Oil-based EG EG EG 0% PET
    • Biopolymers andBiodegradability • Renewable (bio) and Biodegradable – From renewable source (Starch, Protein, cellulose) – 100% biodegradable and compostable (PLA) • Renewable (bio) and NOT Biodegradable our – From renewable source (PEF can be recycled) focus • Non renewable (oil) and Biodegradable – From petrochemical resource – 100% biodegradable and compostable – Polycaprolactone (PCL), Polybutylene Succinic Adipate (PBSA) and other polyesters • Non renewable (oil) and degradable – From petrochemical resource – Depolymerization (nylon) • Non renewable (oil) and non-degradable – From petrochemical resource – not depolymerizable (PE, PP, etc)
    • YXY Technology Conversion Dehydration Oxidation Polymerization Polyesters GreenCarbohydrates RMF FDCA Polyamides Materials/fuels Polyurethanes O O O O O RO HO OH 26
    • Lead application: PEF bottles 27
    • “We’ve got barrier!”Superior barrier & thermal properties PEF:• O2 barrier > 6 times better than PET• CO2 barrier > 3 times better than PET• H2O barrier > 2 times better than PET• Tg of PEF is 11°C higher than PET• Tm of PEF is 40°C lower than PET 28
    • Closing the loopRecycling of PEF:• Reprocessing: proven• De-polymerization to monomers: proven• PEF in PET recycle streams (1,2 and 5%) doesn’t affect recycled PET performance 29
    • PEF The next generation bioplasticBy using FDCA as a biobased replacement for TPA it ispossible to produce PEFPEF: the next generation polyester:• 100% Biosourced (when using green MEG)• Excellent properties (barrier, thermal)• Very competitive process economics (to oil based TPA)• 100% Recyclable• Can be processed in existing supply chains• Highly attractive carbon footprint 30
    • Building a PEF bottle Consortium Objective - PEF to become the new world standard for polyester bottles - Accelerate road to mass scale production - Ensure rapid adoption of PEF in recycling industry Structure - Partner with iconic brands to develop and commercialize of PEF bottles Soft Water drinks Alcoholic Non- beverages food Sauce 31
    • Avantium partnership with Coca-Cola 32
    • 33
    • FEEDSTOCK STRATEGY
    • Feedstock strategyFeedstock flexibility: • Today: YXY technology can process currently available carbohydrate feedstock from sugarcane, corn, sugar beet, wheat • Tomorrow: When available, YXY technology can process future carbohydrate feedstock from waste streams, agricultural waste, energy crops, waste paper, etc Avantium 2nd gen collaborations: • ECN (hemi-cellulose, organosolv) • Cosun (beet pulp) • APC (Dutch Agro-Paper-Chemicals joint initiative) • Avantium is working on samples from many 2ng gen BM tech developers.Avantium continuously monitors new technologiesto get access to low cost carbohydratesRelevant parameters for carbohydrate sourcing: • availability and reliability of supply (quality !) • price and price stability • sustainability“Don’t fall in love with one feedstock” 35
    • 2nd GEN. (APC - Dutch Agro-Paper-Chem)
    • Waste use (APC - Dutch Agro-Paper-Chem)
    • CARBON EFFICIENCY
    • Economics exampleEconomics can easily be estimated via mass balanceExample: bio-based p-xylene (for terephthalic acid (50 Mt/y) (“GEVO route”)Step 1: Fermentation:Glucose i-butanol + 2 CO2 (1 kg glucose yields max 420 g i-butanol at 100% yield !!)Step 2-5: Chemical conversions2 x i-butanol p-xylene (1 kg butanol yieldsmax 700 g p-xylene (at 100% yield)Overall: max obtainable:3.4 kg glucose 1 kg p-xylene.Assume:• Yield overall 65% (optimistic) 5.2 kg glucose required per kg pX• Processing cost 50% & feedstock cost 50% (see analysis DOW) Overall production cost PX = 10.4 x feedstock cost
    • Carbon efficiency of feedstock input at 100% conversion % Biopolymer carbohydrates % CO2 % Water This graph represents the “destination” of the carbon and oxygen of the carbohydrate feedstock at 100% conversion. It doesn’t reflect the CO2 emitted during the whole process.1. bPE: Polyethylene produced from bioethanol derived fro sugarcane (Braskem)2. bPET: Poly-ethylene-terephthalate: produced from biobased PTA derived from iso-butanol (Gevo) and biobased MEG3. bPEF: Poly-ethylene-furanoate: produced from biobased FDCA (Avantium) and biobased MEG. NB: CO2 emission for bPEF is from MEG production only 40
    • Background on feedstock carbon efficiency (at 100% conversion)bioPE – C6H12O6 2 H2O + 2 CO2 + 2 C2H4 (ethylene) PE – 180 g CH (per mol) 56 g PE + 88 g CO2 + 36 g H2O – 3.2 tons of carbohydrate required to produce 1 ton of PEFDCA – 1 C6H12O6 C6H2O5 ending up in polymer (+4H2O) (2O is introduced during oxidation (and 4H leave as H2O)) – 180 g CH (per mol) 154 g “FDCA” in PEF – 1.17 tons of carbohydrate contributes to 1 ton in PEF 41
    • Broad range of applications 42
    • Avantium and Rhodia (Jan 24 2012) 43
    • LAND REQUIRED
    • Example 1: Brazilian sugarBrazil produces 570 million State of São Paulotons sugarcane per year (250.000 km2) is the most important sugar producing region: 350 million ton/yr Full-scale FDCA plant: 300 kton/yr Requires 600 kton of carbohydrates per year = 4.3 million ton of sugarcane ~1.2 % of São Paulo state production ~0.76 % of Brazilian sugar production 45
    • Example 2: US corn State of Iowa producesUSA produces >12 billion >2 billion bushels cornbushels corn per year per year Sioux county in Iowa (2.000 Full-scale FDCA plant: 300 km2) produces >45 million kton/year bushels of corn per year Requires 600 kton of carbohydrates = 44 million bushels per year ~2.1% of Iowa production ~0.4% of USA corn production 46
    • LIFE CYCLE ASSESSMENT 47
    • Life Cycle AnalysisCopernicus Institute (Utrecht University; Patel & Faaij)Comparison of PEF versus PET (revised 2010 PET data set) 100 80 -40-50% -50-60% 60 PET 40 PEF 20 0 NREU CO2 Significant reduction in NREU and CO2 More reductions expected: feedstock and process improvements 48
    • ECONOMICS 49
    • Compete on price TPA FDCA • Oil-based • Bio-based • Price drivers: • Price drivers: Oil price Carbohydrate price Supply/demand Economy of scale• At scale (350 kt/a), the cost price of FDCA will be competitive with the cost price of pTA• Drivers: – An efficient catalytic conversion process – Significantly lower feedstock cost – 100% carbon efficiency in the sugar dehydration – Economic at moderate yield (65%, higher now) – More economic oxidation (under milder conditions) – Use of existing PTA/PET assets 50
    • WAY FORWARD 51
    • Scale-up Full scale industrial plant: On stream in 2017-2018 Name plate capacity: 300-500 kta First commercial plant: On stream in 2015 Name plate capacity: 30-50 ktaPilot plant:Name plate capacity: 20-40 tpa
    • Pilot Plant opening (8 Dec 2011) 53
    • Go to marketScale-upAvantium’s pilot plant to: – Demonstrate YXY technology – Process development – Produce FDCA and PEF for application developmentPartneringAvantium is in partnering discussions with: – Leading brand owners to develop PEF bottles, fibers and film – Industrial companies to develop FDCA based materials (polyamides, coatings, plasticizers, etc) – Feedstock suppliers – Chemical companies that are interested in producing FDCA monomers and polymers 54
    • Our Furanics Program in a Nut Shell2009 - 2012 Time Frame with partner logo’sFeedstock Process Testing Application Development Crops Conversion Properties Plastics Lab Material properties Fuels C5 / C6 Pilot Engine test sugars
    • Contact Information gert-jan.gruter@avantium.com www.yxy.com Zekeringstraat 29 – 1014 BV – Amsterdam, The Netherlands 56
    • Break 57
    • Van Gansewinkel 58
    • from waste management to material supply
    • “Survival of the fittest”
    • Landfill map
    • Golfclub “Gulbergen”> 300 landfill areas> 40 golf courses…
    • Second skin approach Second life approach Renewable energy Biological Technical nutrients nutrients
    • Indepth product and market knowledge are essential for a cycle approach in the material clusters Transport Transport Transport Transh. Pretreatm. Treatment (End)Customer Collection Raw Material Customer (sorting and Recycling Treatment preconditioning) Waste No More Waste No More
    • Raw Materials€ Down Stream Production Product Parts €€ Production Sales – Financing - Distribution €€€ Consumer / (End)user €€€€ Waste
    • Raw Materials €€ €Energy from Waste Recycling Collection Waste €€
    • Recycle Re-Use / Refurbish
    • Without Planet & People… No Profit
    • 86
    • Discussion 1. Creating and capturing value from sustainability throughout the value chain What is your vision? What is your role? 2. Drivers of sustainable development.. What? Performance? Price – green premium? Marketing? Who? Market pull versus technology push 3. How to create synergy between the bio-based developments and recycling initiatives? 4. How will this impact… Your value chain position and business partners? The value chain dynamics? 87
    • Sustainability Stewardship through Entire Value Chain Create value from waste Minimize waste and Raw Materials consumables Production Use renewable and reclaimed external feed stocks Increase energy efficiency and reduce greenhouse gas Re-use & emissions recycling Design less toxic and environmentally safer products Packaging & Transportation and processes Customer use Enable use of renewable Optimize packaging and energy and raw materials transportation logistics to Enable resource conservation minimize energy and materials by customers and end-use requirements and reduce consumers potential for accidents 88
    • Sustainable environmental system management and integral value chainapproach Governments NGO’s Raw Materials Raw Production Materials ProductionRe-use & Re-use & Investorsrecycling recycling Packaging & Transportation Packaging & Partners Transportation Customer use Customer use Communities Employees 89
    • Drinks and Dinner“Club zaal” at 1st floor 90
    • SQUAREWISEClaude Debussylaan 48, 1082 MD AmsterdamT +31 (0) 20 4473925 F +31 (0) 20 6110419E-mail: info@squarewise.comInternet: www.squarewise.comKvK te Amsterdam 341.38.272 91