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Presentation squaretable chemical industry 20110126


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Presentation used as background info to the Squarewise Squaretable event January 26th 2012.

Presentation used as background info to the Squarewise Squaretable event January 26th 2012.

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  • 1. New Customer Realities: Capturing Added Value from Sustainability Squaretable 26-01-2012 1
  • 2. Agenda 2 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
  • 3. Introduction Squarewise 3
  • 4. Squarewise is driven by the understanding that organizations need new capabilities to capture opportunities and maintain market leadership Innovative organization Market leader technology Market leader e.g in cutting edge technology Operational excellence Excel in core activities Redesign processes and focus on bottom line Structurally develop organizational capabilities to communicate and mobilize in networks Controlled experimenting Structurally envision your future and capture current opportunities Real-time, practical strategy development Internal target setting Internal and External target setting (3P’s) Reposition the organization as a network of supportive and competitive players 4
  • 5. Opening Squaretable 5
  • 6. Subject for discussion 6 “Capturing added value from new sustainability driven customer requirements: Reassessing value chain position and business dynamics”
  • 7. Value chain 7 Raw Materials Production Re-use & recycling Packaging & Transportation Customer use
  • 8. Changing consumer behavior towards sustainability centered demand: dynamics in the food packaging industry 8 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
  • 9. Consumer driven value chain – traditional value chain dynamics change: biological banana packaging 9 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.
  • 10. How to take advantage of sustainability and innovate further Global chain alignment for longer-term look at sustainability value creation Call for action to generate solutions in times of great complexity Opportunities beyond the Core and Business Model Adjacencies Aligning Sustainability and Business Objectives Reprioritize in the face of complexity Finding the New Vibrant Ecosystem – from megatrends to business impact Collective intelligence and collaborative spirit required to advance the entire industry The shift in Value Distribution through Co-Creation ( new Value Chain Dynamics) Creating valuable solutions amid changing world/value chain dynamics Material Passport Act Accordingly Value chain alignment From complexity to clarity – way forward Motivation World Inside- out Outside- in Solution
  • 11. 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
  • 12. Avantium 12
  • 13. 13 Platform for the Future: sustainable bio-based solutions for the future of plastics and other applications Gert-Jan Gruter, Avantium Squaretable sustainability, Amsterdam, January 26 2012.
  • 14. Agenda 1. Introduction to biomass conversion bulk chemicals 2. Introduction to Avantium & YXY 3. Feedstock strategy 4. Carbon efficiency 5. Land required 6. Life Cycle Assessment 7. Economics 8. Way forward 14
  • 15. 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
  • 16. 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
  • 17. Main (non fuel) conversions - Sugars Only 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)
  • 18. Main challenge: catalysis Elemental composition of feedstocks Crude oil Lignocellulose (wood) C 85-90% 50% H 10-14% 6% O 0-1.5% 43% (Hydro)cracking Functionalization O-introduction N-introduction - oxidation, etc. (Depolymerization & defunctionalization (O-removal) - decarboxylation (fermentation) - dehydration (water removal) - reduction (hydrogenation) - C-C coupling - water present !! Oil (CxHy) chemicals biomass (CxH2xOx) e.g. C10H22 (alkane) e.g. C6H12O6 (glucose) “under functionalized” “over functionalized” CATALYST PROCESS CATALYST PROCESS
  • 20. 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 conventional way… • …to 64 parallel reactors in the 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
  • 21. A Proven Approach Avantium’s 10 year track record in catalyst and process R&D contract research 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
  • 22. Company strategy Advanced high-throughput R&D Services & Systems Product development programs Biofuels program Biobased polymers program • Advance the product development programs to commercial viability • Attract value-adding partners for final development and commercialization • Backed by strong financial partners (€18M + €30M rounds in 2008-11) • Continue to invest in further strengthening the high- throughput R&D technology • Continue to expand the profitable Services & Tools business
  • 23. FDCA as substitute for terephthalic acid (50 Mt/y)
  • 24. 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 EGPTA EGFDCA PTAEG PET Oil-based Renewable 0% 100%
  • 25. Biopolymers and Biodegradability • Renewable (bio) and Biodegradable – From renewable source (Starch, Protein, cellulose) – 100% biodegradable and compostable (PLA) • Renewable (bio) and NOT Biodegradable – From renewable source (PEF can be recycled) • 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) our focus
  • 26. YXY Technology Conversion Carbohydrates RMF Dehydration Green Materials/fuels Oxidation FDCA Polyesters Polyamides Polyurethanes Polymerization O RO O O HO O OH O 26
  • 27. Lead application: PEF bottles 27
  • 28. “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
  • 29. Closing the loop Recycling 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
  • 30. PEF The next generation bioplastic By using FDCA as a biobased replacement for TPA it is possible to produce PEF PEF: 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
  • 31. Building a PEF bottle Consortium 31 Water Sauce Alcoholic beverages Non- food 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 drinks
  • 32. Avantium partnership with Coca-Cola 32
  • 33. 33
  • 35. Feedstock strategy Feedstock 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 technologies to get access to low cost carbohydrates Relevant parameters for carbohydrate sourcing: • availability and reliability of supply (quality !) • price and price stability • sustainability “Don’t fall in love with one feedstock” 35
  • 36. 2nd GEN. (APC - Dutch Agro-Paper-Chem)
  • 37. Waste use (APC - Dutch Agro-Paper-Chem)
  • 39. Economics example Economics can easily be estimated via mass balance Example: 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 conversions 2 x i-butanol p-xylene (1 kg butanol yields max 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
  • 40. Carbon efficiency of feedstock input at 100% conversion 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 MEG 3. bPEF: Poly-ethylene-furanoate: produced from biobased FDCA (Avantium) and biobased MEG. NB: CO2 emission for bPEF is from MEG production only % Biopolymer % CO2 % Water carbohydrates 40 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.
  • 41. 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 PE FDCA – 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
  • 42. Broad range of applications 42
  • 43. 43 Avantium and Rhodia (Jan 24 2012)
  • 45. Example 1: Brazilian sugar State of São Paulo (250.000 km2) is the most important sugar producing region: 350 million ton/yr Brazil produces 570 million tons sugarcane per year 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
  • 46. State of Iowa produces >2 billion bushels corn per year Sioux county in Iowa (2.000 km2) produces >45 million bushels of corn per year Full-scale FDCA plant: 300 kton/year Requires 600 kton of carbohydrates = 44 million bushels per year ~2.1% of Iowa production ~0.4% of USA corn production USA produces >12 billion bushels corn per year Example 2: US corn 46
  • 48. Life Cycle Analysis 48 Copernicus Institute (Utrecht University; Patel & Faaij) Comparison of PEF versus PET (revised 2010 PET data set) Significant reduction in NREU and CO2 More reductions expected: feedstock and process improvements 0 20 40 60 80 100 NREU CO2 PET PEF -40-50% -50-60%
  • 49. ECONOMICS 49
  • 50. Compete on price 50 TPA • Oil-based • Price drivers: Oil price Supply/demand FDCA • Bio-based • Price drivers: Carbohydrate price 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
  • 51. WAY FORWARD 51
  • 52. Pilot plant: Name plate capacity: 20-40 tpa 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 kta Scale-up
  • 53. Pilot Plant opening (8 Dec 2011) 53
  • 54. Go to market Scale-up Avantium’s pilot plant to: – Demonstrate YXY technology – Process development – Produce FDCA and PEF for application development Partnering Avantium 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
  • 55. Our Furanics Program in a Nut Shell PlasticsPropertiesCrops Process Fuels Conversion Lab Pilot C5 / C6 sugars Engine test Material properties Feedstock Testing Application Development 2009 - 2012 Time Frame with partner logo’s
  • 56. 56 Contact Information Zekeringstraat 29 – 1014 BV – Amsterdam, The Netherlands
  • 57. Break 57
  • 58. Van Gansewinkel 58
  • 59. from waste management to material supply
  • 60. “Survival of the fittest”
  • 61. Landfill map
  • 62. Golfclub “Gulbergen” > 300 landfill areas > 40 golf courses…
  • 63. Biological nutrients Technical nutrients Second skin approach Second life approach Renewable energy
  • 64. Waste No MoreWaste No More Indepth product and market knowledge are essential for a cycle approach in the material clusters Customer Collection Transh. Pretreatm. (sorting and preconditioning) Treatment Recycling Transport Transport (End) Treatment Raw Material Transport Customer
  • 65. Product Parts Production Waste Consumer / (End)user Raw Materials Down Stream Production Sales – Financing - Distribution €€€€ €€€ € €€
  • 66. Waste Collection Recycling Energy from Waste Raw Materials €€ € €€
  • 67. Re-Use / Refurbish Recycle
  • 68. Without Planet & People… No Profit
  • 69. 86
  • 70. 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
  • 71. Create value from waste Sustainability Stewardship through Entire Value Chain 88 Raw Materials Production Re-use & recycling Packaging & Transportation Customer use Enable use of renewable energy and raw materials Enable resource conservation by customers and end-use consumers Optimize packaging and transportation logistics to minimize energy and materials requirements and reduce potential for accidents Minimize waste and consumables Use renewable and reclaimed external feed stocks Increase energy efficiency and reduce greenhouse gas emissions Design less toxic and environmentally safer products and processes
  • 72. Sustainable environmental system management and integral value chain approach 89 Raw Materials Production Re-use & recycling Packaging & Transportation Customer use NGO’s Governments Communities Partners Employees Investors Raw Materials Production Re-use & recycling Packaging & Transportation Customer use
  • 73. Drinks and Dinner “Club zaal” at 1st floor 90
  • 74. 91 S Q U A R E W I S E Claude Debussylaan 48, 1082 MD Amsterdam T +31 (0) 20 4473925 F +31 (0) 20 6110419 E-mail: Internet: KvK te Amsterdam 341.38.272