OPXBIO & Dow: Renewable Route to Acrylic Acid


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OPXBIO & Dow: Renewable Route to Acrylic Acid

  1. 1. Renewable Route to Acrylic AcidBioAcrylic Acid Commercialization Progress andChallenges 1
  2. 2. Renewable BioAcrylic Acid Joint Development Objective – Develop an Industrial-Scale Process to Cost- Effectively Produce Acrylic Acid from Sugar 3-Hydroxypropionic Acrylic Sugar (3-HP) Acid Slide 2 2
  3. 3. Dow Chemical-OPXBIO Strategic Partnership Faster, Lower-Risk, Shared-Cost Development and Commercialization  Dow – Largest US producer of petro-acrylic and derivatives – Demonstrated capability to develop recovery technology and applications – Committed bio-based strategy and investments  OPXBIO – Unique biocatalyst development capability – Multiple products in development  BioAcrylic joint development agreement – Joint funding and work to demonstrate BioAcrylic process – Intent to jointly commercialize Microbe & BioAA Commercial Sugar Channel to 3-HP Conversion Plant Feedstock Market Bioprocess Process Dow OPXBIO Dow Joint Dow 3
  4. 4. The Dow Chemical CompanyCorporate Overview Dow provides a diversified, industry-leading portfolio of technology-based products and solutions to customers in approximately 160 countries worldwide More than 5,000 products manufactured at 188 sites in 35 countries with 2011 sales of $60B 50,000 employees worldwide 4
  5. 5. Dow Performance MonomersPortfolio Acrylic Acid & Acrylates – GAA, BA, EA, 2 EHA, MA – Acrylic coatings, water treatment, detergent additives, adhesives, super absorbent polymers Methacrylates – MMA, GMAA – Acrylic sheet and resins, petroleum additives, plastic additives, electronic displays Specialty Monomers – Hydroxies, GMA, BMA – Automotive and industrial coatings, printing inks, and powder coatings Vinyl Acetate Monomers – VAM – Acrylic coatings, fibers, adhesives 5
  6. 6. Why Is This Project Important to Dow? Acrylic monomers are key strategic building blocks for several of Dow’s market-facing businesses - coatings, personal care, packaging, building and construction Creating differentiated, sustainable product offerings for our customers is a top Dow priority Dow is interested in cost-effective, renewable alternatives to conventional petroleum-based feedstocks This project is an opportunity to commercialize a differentiated, bio-based acrylic acid product based on a fermentable sugar feedstock 6
  7. 7. Acrylates/Acrylic Acid Market Existing $8+ Billion Growing Global Market Customers interested in renewable alternative 7
  8. 8. Acrylates/Acrylic Acid Market Global Acrylic Acid Consumption U.S. End Uses for Global Glacial Acrylic Acrylate Esters Glacial Acid End Use Acrylic Acid Paper Products Acrylic 40% Other 5% Esters 9% 60% Polyacrylic Plastics Acid Additives Surface Coatings Polymers 9% 44% 30% Super Textiles Absorbent 15% Polymers 70% Adhesives and Sealants 18%  Customers are asking for renewable options • Improved sustainability / carbon footprint • Increased consumer interest in “green” products • Feedstock flexibility Source: SRI Feb 2011 8
  9. 9. BioAcrylic Acid Process Technology • Dextrose (corn) or sucrose (cane) • Genetically engineered E-Coli1/2 Fermentation organism optimized via OPXBIO EDGE™ Technology Platform HO O 3-HP • Biomass Kill & Removal OH Recovery • Water Removal and Recycle - H2O H2C O Conversion to • 3-HP Dehydration to Acrylic Acid HO Acrylic Acid • Acrylic Acid Purification J. Repman 11/2/11 9
  10. 10. OPXBIO Strategy Grow a Large, Global, Profitable & Highly Valued Renewable Chemicals Company 10
  11. 11. OPXBIO EDGE™ Technology Platform Efficiency Directed Genome Engineering Massively Parallel Quantitative Genetic Experimental Manipulations Design Comprehensive & High Resolution Parallel Processing 11
  12. 12. OPXBIO EDGE Technology Platform Conventional Microbial Pathway Engineering Create random Test population Repeat to and unknown and select better directionally genetic variants in performing evolve optimized microbe microbes microbe population EDGE Microbe Engineering Create specific Design Test each and known comprehensive, genetic variant genetic variants rational strategy and analyze across entire and construct performance microbial optimized genome microbe 12
  13. 13. OPXBIO EDGE™ Technology for BioAcrylic 13
  14. 14. Fermentation Development Comml Plant Current TBD at Lbs/Yr MBI Demo Plant-2 30k L 600K Lbs/Yr Demo Plant-1 3000L 60K Lbs/Yr Pilot 250L 5K Lbs/Yr Lg Bench 10L 250 Lbs/Yr Sm Bench 1L 25 Lbs/Yr Shake Flask 100 ml 2008 2009 2009-10 2010 2011-12 2012-13 2014-16 14
  15. 15. BioAcrylic Acid Downstream Process Fermentation Development Highlights • Screening tests completed on >10 different 3-HP processing schemes • Scale-up validation in progress (batch and Recovery continuous lab-scale units) • Developmental samples available 4Q 2012 Conversion to Acrylic Acid 15
  16. 16. Key Challenges - Sugar Price Volatility Sugar prices will strongly influence bio acrylic acid market penetration Historical Commodity Sugar Prices 35 Challenges 30Sugar Price ¢/lb 25 • Potential linkage to fuel 20 prices 15 • Weather/seasonal 10 impacts 5 • Feasibility of cellulosic 0 sugar alternatives Dec-08 Aug-06 Oct-07 Apr-04 Apr-11 Nov-04 Nov-11 Jan-06 Feb-03 Sep-03 Feb-10 Sep-10 May-08 Jun-05 Jun-12 Jul-02 Jul-09 Mar-07 16
  17. 17. Key Challenges - Impact of Shale Gas Shale gas availability in U.S. will strongly influence long term conventional feedstock prices Historical U.S. Natural Gas Prices 16.0 Natural Gas Price ($/MMBtu) 14.0Challenges 12.0 10.0• Impact on conventional 8.0 6.0 acrylic acid economics 4.0• Regional differences 2.0 0.0 Dec-08 Aug-06 Oct-07 Apr-11 Apr-04 Nov-04 Nov-11 Jan-06 Sep-03 Feb-10 Sep-10 Feb-03 May-08 Jun-05 Jun-12 Jul-02 Jul-09 Mar-07 17
  18. 18. Key Challenges – Right Sizing of Plant InvestmentsChallenges• Capacity planning to meet customer demands• Achieving economy of scale vs. overbuilding• Feedstock selection• Location / Integration options 18
  19. 19. Summary – Dow and OPX are jointly developing a new industrial- scale process for production of acrylic acid from sugar – Excellent progress made on organism development, fermentation and downstream process scale-up – Anticipate commercialization in 2014-2016 timeframe Sugar Microbe & BioAA Commercial Channel to Feedstock 3-HP Conversion Plant Market Bioprocess Process Dow OPXBIO Dow Joint Dow 19