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green chemistry by design

  Biobased Adipic Acid and Feedstock Freedom
Presented to the 2010 World Congress on Industrial Biotechnology
                 Washington DC, 30 June 2010
Green Chemistry by Design

                       Reduce our dependency on petroleum and minimize our
 MOTIVATION environmental footprint


                       Exploit chemistry and biology to achieve breakthroughs in
  CHALLENGE            how we manufacture everyday products from renewable
                       resources

                       Develop economical fermentation processes for producing
     GOAL              renewable fuels and chemicals




     INTRODUCTION   OPPORTUNITY   COMPETITIVE   ECONOMICAL   SUSTAINABLE   DIFFERENTIATED   2
Technology & Business Snapshot

•   Deep expertise in synthetic biology
     – In-silico pathway modeling & protein
       design algorithms
     – Metabolic engineering, strain and
       fermentation process development
•   IP Estate that protects our innovative
    technology
                                                  •   Three Organisms in development:
                                                        – Improving ethanol productivity with
                                                          “Yield Booster”
                                                        – Fermenting pentose sugars from
                                                          lignocellulosic biomass to ethanol
                                                        – Producing adipic acid from
                                                          multiple feedstocks
                                                  •   Business strategy involves
                                                        – Development partnerships to
                                                          accelerate time to market

       INTRODUCTION   OPPORTUNITY   COMPETITIVE   ECONOMICAL    SUSTAINABLE   DIFFERENTIATED   3
Adipic Acid: Compelling Biobased Chemical
                                                                           Others, 13%
                                                                                                          Invista, 21%
                                                               Asahi Kasei, 
    Large Growing                                                  4%
        Market
                                                           Hongye, 5%
   4.8 billion lb (2009)
       4.3% CAGR                                           Bohui, 5%

   Strong growth for light
  weight, temperature stable                                Radici, 5%
                                                                                                                  Rhodia, 18%
            plastics                                        Liaoyang 
                                                         Petrochemical, 
                                                               6%

                                                                         BASF, 11%
                                                                                                  Ascend, 13%

                                              Economic
  Strong Market Pull                         Opportunity
                                                                                     “Without investment in
 Green pull in automotive,                   U.S. $2,375/te                          innovation, branding and
   textiles, carpets and                       ($1.08/lb)                            downstream pull it is
          coatings                                                                   unlikely that adipic polymer
                                       Gross Margin = 30-40%
  High market awareness of                                                           can sustain the premium it
   biobased developments               Biobased offers alternative to                has historically enjoyed” (PCI,
                                          Benzene price swings                       2010)



        INTRODUCTION     OPPORTUNITY   COMPETITIVE     ECONOMICAL              SUSTAINABLE      DIFFERENTIATED      4
Future Need for Adipic Acid
              Global Adipic Acid Supply / Demand Balance
4000

                 Speculative Capacity (ktes)                                                                         New production
3500                                                                                                                facilities needed in
                 Speculative
                Existing / Planned Capacity (ktes)
                 Capacity (ktes)                                                                                            2016
                Demand (ktes)
3000              Existing / Planned
                  Capacity (ktes)
2500              Demand (ktes)


2000                                                                                                                Opportunity to
                                                                                                                   demonstrate and
1500                                                                                                              entrench biobased
                                                                                                                 production processes
1000                                                                                                                while demand
                                                                                                                       recovers
 500


   0
                                                                2008


                                                                        2011




                                                                                            2017


                                                                                                     2020
                                                       2005




                                                                                  2014
                  1993


                             1996


                                       1999


                                               2002
       1990




 Source: PCI
                                                      Adipic lost 5 yrs demand

              INTRODUCTION             OPPORTUNITY        COMPETITIVE          ECONOMICAL          SUSTAINABLE       DIFFERENTIATED   5
Competitive Yeast Production Platform
    Feedstock
     Flexibility                                                           Robust Yeast Platform
• Engineering a                                                        • Robust strain with performance
  proprietary metabolic                                                  attributes highly suited to industrial
  pathway with sugars                                                    scale fermentation
  and oils as feed                                                     • Combinatorial Pathway Engineering
  stocks                                                                 for rapid strain development




           Starch



                                                 Platform
 Biomass                                        Improvements
                                        C6 Engineering a novel
                                           glycolytic pathway for higher
                                           yield from hexose sugars

       Sucrose            Oils          C5 Engineering a novel xylose
                                           isomerase enzyme for                           Adipic Acid
                                           utilization of pentose sugars
                                           from biomass
       INTRODUCTION       OPPORTUNITY      COMPETITIVE    ECONOMICAL        SUSTAINABLE      DIFFERENTIATED       6
Platform Improvement Demo for Ethanol

                          C6                                Dry Mill – Base
                                                     Capacity      100 MM gal/yr
               Novel Glycolytic                                                             EtOH            Increased
Starch         Pathway in Yeast                       Capital        $1.05/gal                               Margin
                                                                                        2.915 gal/bu
           Higher Yields and                           Corn          $3.68/bu                               $10.6 MM
                                                                                           Capacity
Cane    Specific Productivity from
                                                    EtOH Yield      2.75 gal/bu            107 MM
            Hexose Sugars                                                                                  $0.098/gal
Sucrose                                                                                     gal/yr
                                                      Ethanol        $2.03/gal



       Ethanol Development
    Partnership with Lallemand
        Ethanol Technology

                                                                                   Laboratory results have
                                                                                  Laboratory results have
CARLSBAD, CA. and MILWAUKEE, WI. — April
 7, 2010 – Verdezyne, Inc., an industrial biotechnology                           shown a 10% increase in
                                                                                 shown a 10% increase in
company, and Lallemand Ethanol Technology, a global provider                        ethanol yield and 30%
                                                                                   ethanol yield and 30%
of yeast to the fuel ethanol industry, today announced they have                   increase in productivity
                                                                                  increase in productivity
     signed an agreement to develop and commercialize a
    genetically enhanced high-yield ethanol producing yeast.


           INTRODUCTION         OPPORTUNITY       COMPETITIVE      ECONOMICAL       SUSTAINABLE       DIFFERENTIATED   7
Demonstration of Adipic from Renewable Oils
 •    Engineered a yeast that selectively produces adipic acid
      from mixed plant-based oil feedstocks

                                                           Acid/Diacid Profile Produced from Coconut Oil

                                                                  100
  Fatty Acid Profile of Coconut Oil                                90



                                            Percent Composition
Formula     Name          Percent                                  80
C6:0        Caproic               0.5
C8:0        Caprylic              7.8                              70
C10:0       Capric                6.7                              60
C12:0       Lauric               47.5                              50
C14:0       Myristic             18.1
C16:0       Palmitic              8.8                              40
C18:0       Stearic               2.6                              30
C20:0       Arachidic             0.1                              20
C18:1       Oleic                 6.2
C18:2       Linoleic              1.6
                                                                   10
                                                                    0
                                                                        d

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                                                                                                                                               IP
                                                                                                                                              D
                                                                                                                                             A
          INTRODUCTION        OPPORTUNITY                          COMPETITIVE          ECONOMICAL              SUSTAINABLE            DIFFERENTIATED       8
Diversifying the Raw Material Base

                                                      •     Oil / Naptha / Benzene
                                                            relationship squeezes
                                                            adipic acid margins
                                                      •     Adipic acid producers
                                                            carry the feedstock risk
                                                             – product demand does
                                                               not move raw material
                                                               prices
                                                      •     Raw material prices are
                                                            rising again …


                                                            A biobased process
                                                            utilizing renewable sugars
                                                            and oils is free from this
                                                            volatility

    INTRODUCTION   OPPORTUNITY   COMPETITIVE   ECONOMICAL      SUSTAINABLE   DIFFERENTIATED   9
Fermentation Process has less Capital Risk

                                                                         • A new large scale
                                                                           chemical plant built
                                                                           today would not
                                                                           reach capacity for
                                                                           another 8 years.

                                                                         • Fermentation facility
                                                                           provides a larger
                                                                           economic advantage
                                                                           at smaller scale

                                                                         • A smaller scale
                                                                           fermentation plant
                                                                           could be built for a
                                                                           fraction of the volume
                                                                           risk



            Smaller scale fermentation plants can be distributed
            regionally based on different feedstocks

     INTRODUCTION    OPPORTUNITY   COMPETITIVE   ECONOMICAL    SUSTAINABLE     DIFFERENTIATED   10
Cost Advantaged Adipic Acid
                                                                                             Comparative Economics
                                                                                              Cash Cost of Manufacturing
                                                            0.7


“There is a huge growth potential                                         current proces s
                                                            0.6
for bio-based adipic acid and
other products, as long as it is                                                                                               Operating
cost competitive.” ~ Adell Plastics                         0.5                                                                Utilities




                                         $/lb adipic acid
                                                                                                                               Raw Materials
                                                            0.4


                                                            0.3
 Petrochemical ADA cost
 will range between                                         0.2
 $0.71-0.93/lb if
 petroleum exceeds                                          0.1

 $100/bbl
                                                             0

                                                                    Chemical Oxidation of            Fermentation w/        Fermentation w/
                                                                       Cyclohexane                     Soapstock               Sucrose

                                                                            Cost
                                                                         Advantage
                                                                                                         19%                      32%


 Shut down economics apply if
 cash cost advantage > 15%

         INTRODUCTION      OPPORTUNITY                            COMPETITIVE           ECONOMICAL        SUSTAINABLE      DIFFERENTIATED      11
A Sustainability Advantage
Automotive
Industry is looking to light-weight
plastics to improve fuel efficiency
“The industry wants biobased
adipic to increase sustainable
plastic use in cars.” ~ DuPont
Engineering Polymers                                              Footwear
                                                    Industry is listening to consumer
                                                    aspiration for renewable products
 Biobased Adipic Acid
                                                              “TPU materials are not
 (ADA) offers significant                                    currently green, we are
 GHG reduction compared                                      interested in renewable
 to traditional petrochemical                                    alternatives.” ~ Nike
 production



     GHG                                            Sugar                                     Carbon credits could
                               Corn                                      Paraffin
   Reduction                                        Cane                                      further reduce the cost of
                                                                                              biobased adipic acid by
   t CO2eq/t
                                2.2                    4.2                   0.56             14% (at $30/t CO2)
      ADA

            Based on Cradle-to-gate analysis in The Brew Project, adjusted for
            Verdezyne fermentation assumptions

          INTRODUCTION             OPPORTUNITY           COMPETITIVE             ECONOMICAL   SUSTAINABLE   DIFFERENTIATED   12
Green Differentiation Creates Market Pull
              Applications                                       Consumers
   10%
                                                                      Demand for sustainable
                                     Carpet                           carpet is increasing, because
                                                                      sustainability is now regarded as
                                                                      important – In Out Space
                           Industrial
   11%

                                                                      When consumers have the choice,

             26%
                            Polyurethane                              they tend to want to make the
                                                                      greener choice - Timberland
Adipic
                                                                      Retailers in particular are pushing
 Acid        10%
                                                                      sustainability requirements
                       Textile                                        back down their global
                                                                      supply chains - Sustainable Clothing
                                                                      Roadmap Initiative


   25%                           Engineered                           A quarter of US adults prefer
                                   Plastics                           eco-friendly products & are more
                                                                      loyal towards socially responsible
                                                                      companies – 2009 Ward’s Auto
                                                                      Interior Conference
                                 Plasticizers
    7%

    INTRODUCTION   OPPORTUNITY     COMPETITIVE   ECONOMICAL   SUSTAINABLE        DIFFERENTIATED   13

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2010 industrial biotechnology world congress verdezyne

  • 1. green chemistry by design Biobased Adipic Acid and Feedstock Freedom Presented to the 2010 World Congress on Industrial Biotechnology Washington DC, 30 June 2010
  • 2. Green Chemistry by Design Reduce our dependency on petroleum and minimize our MOTIVATION environmental footprint Exploit chemistry and biology to achieve breakthroughs in CHALLENGE how we manufacture everyday products from renewable resources Develop economical fermentation processes for producing GOAL renewable fuels and chemicals INTRODUCTION OPPORTUNITY COMPETITIVE ECONOMICAL SUSTAINABLE DIFFERENTIATED 2
  • 3. Technology & Business Snapshot • Deep expertise in synthetic biology – In-silico pathway modeling & protein design algorithms – Metabolic engineering, strain and fermentation process development • IP Estate that protects our innovative technology • Three Organisms in development: – Improving ethanol productivity with “Yield Booster” – Fermenting pentose sugars from lignocellulosic biomass to ethanol – Producing adipic acid from multiple feedstocks • Business strategy involves – Development partnerships to accelerate time to market INTRODUCTION OPPORTUNITY COMPETITIVE ECONOMICAL SUSTAINABLE DIFFERENTIATED 3
  • 4. Adipic Acid: Compelling Biobased Chemical Others, 13% Invista, 21% Asahi Kasei,  Large Growing 4% Market Hongye, 5% 4.8 billion lb (2009) 4.3% CAGR Bohui, 5% Strong growth for light weight, temperature stable Radici, 5% Rhodia, 18% plastics Liaoyang  Petrochemical,  6% BASF, 11% Ascend, 13% Economic Strong Market Pull Opportunity “Without investment in Green pull in automotive, U.S. $2,375/te innovation, branding and textiles, carpets and ($1.08/lb) downstream pull it is coatings unlikely that adipic polymer Gross Margin = 30-40% High market awareness of can sustain the premium it biobased developments Biobased offers alternative to has historically enjoyed” (PCI, Benzene price swings 2010) INTRODUCTION OPPORTUNITY COMPETITIVE ECONOMICAL SUSTAINABLE DIFFERENTIATED 4
  • 5. Future Need for Adipic Acid Global Adipic Acid Supply / Demand Balance 4000 Speculative Capacity (ktes) New production 3500 facilities needed in Speculative Existing / Planned Capacity (ktes) Capacity (ktes) 2016 Demand (ktes) 3000 Existing / Planned Capacity (ktes) 2500 Demand (ktes) 2000 Opportunity to demonstrate and 1500 entrench biobased production processes 1000 while demand recovers 500 0 2008 2011 2017 2020 2005 2014 1993 1996 1999 2002 1990 Source: PCI Adipic lost 5 yrs demand INTRODUCTION OPPORTUNITY COMPETITIVE ECONOMICAL SUSTAINABLE DIFFERENTIATED 5
  • 6. Competitive Yeast Production Platform Feedstock Flexibility Robust Yeast Platform • Engineering a • Robust strain with performance proprietary metabolic attributes highly suited to industrial pathway with sugars scale fermentation and oils as feed • Combinatorial Pathway Engineering stocks for rapid strain development Starch Platform Biomass Improvements C6 Engineering a novel glycolytic pathway for higher yield from hexose sugars Sucrose Oils C5 Engineering a novel xylose isomerase enzyme for Adipic Acid utilization of pentose sugars from biomass INTRODUCTION OPPORTUNITY COMPETITIVE ECONOMICAL SUSTAINABLE DIFFERENTIATED 6
  • 7. Platform Improvement Demo for Ethanol C6 Dry Mill – Base Capacity 100 MM gal/yr Novel Glycolytic EtOH Increased Starch Pathway in Yeast Capital $1.05/gal Margin 2.915 gal/bu Higher Yields and Corn $3.68/bu $10.6 MM Capacity Cane Specific Productivity from EtOH Yield 2.75 gal/bu 107 MM Hexose Sugars $0.098/gal Sucrose gal/yr Ethanol $2.03/gal Ethanol Development Partnership with Lallemand Ethanol Technology Laboratory results have Laboratory results have CARLSBAD, CA. and MILWAUKEE, WI. — April 7, 2010 – Verdezyne, Inc., an industrial biotechnology shown a 10% increase in shown a 10% increase in company, and Lallemand Ethanol Technology, a global provider ethanol yield and 30% ethanol yield and 30% of yeast to the fuel ethanol industry, today announced they have increase in productivity increase in productivity signed an agreement to develop and commercialize a genetically enhanced high-yield ethanol producing yeast. INTRODUCTION OPPORTUNITY COMPETITIVE ECONOMICAL SUSTAINABLE DIFFERENTIATED 7
  • 8. Demonstration of Adipic from Renewable Oils • Engineered a yeast that selectively produces adipic acid from mixed plant-based oil feedstocks Acid/Diacid Profile Produced from Coconut Oil 100 Fatty Acid Profile of Coconut Oil 90 Percent Composition Formula Name Percent 80 C6:0 Caproic 0.5 C8:0 Caprylic 7.8 70 C10:0 Capric 6.7 60 C12:0 Lauric 47.5 50 C14:0 Myristic 18.1 C16:0 Palmitic 8.8 40 C18:0 Stearic 2.6 30 C20:0 Arachidic 0.1 20 C18:1 Oleic 6.2 C18:2 Linoleic 1.6 10 0 d d ci d ci d ci A d ci A d ci A d 14 ci A d 12 ci A d 10 ci ia ID C 8 ci ia C 6 C ia D C C C ia D D A 14 D 12 10 IC C 8 C C C IP D A INTRODUCTION OPPORTUNITY COMPETITIVE ECONOMICAL SUSTAINABLE DIFFERENTIATED 8
  • 9. Diversifying the Raw Material Base • Oil / Naptha / Benzene relationship squeezes adipic acid margins • Adipic acid producers carry the feedstock risk – product demand does not move raw material prices • Raw material prices are rising again … A biobased process utilizing renewable sugars and oils is free from this volatility INTRODUCTION OPPORTUNITY COMPETITIVE ECONOMICAL SUSTAINABLE DIFFERENTIATED 9
  • 10. Fermentation Process has less Capital Risk • A new large scale chemical plant built today would not reach capacity for another 8 years. • Fermentation facility provides a larger economic advantage at smaller scale • A smaller scale fermentation plant could be built for a fraction of the volume risk Smaller scale fermentation plants can be distributed regionally based on different feedstocks INTRODUCTION OPPORTUNITY COMPETITIVE ECONOMICAL SUSTAINABLE DIFFERENTIATED 10
  • 11. Cost Advantaged Adipic Acid Comparative Economics Cash Cost of Manufacturing 0.7 “There is a huge growth potential current proces s 0.6 for bio-based adipic acid and other products, as long as it is Operating cost competitive.” ~ Adell Plastics 0.5 Utilities $/lb adipic acid Raw Materials 0.4 0.3 Petrochemical ADA cost will range between 0.2 $0.71-0.93/lb if petroleum exceeds 0.1 $100/bbl 0 Chemical Oxidation of Fermentation w/ Fermentation w/ Cyclohexane Soapstock Sucrose Cost Advantage 19% 32% Shut down economics apply if cash cost advantage > 15% INTRODUCTION OPPORTUNITY COMPETITIVE ECONOMICAL SUSTAINABLE DIFFERENTIATED 11
  • 12. A Sustainability Advantage Automotive Industry is looking to light-weight plastics to improve fuel efficiency “The industry wants biobased adipic to increase sustainable plastic use in cars.” ~ DuPont Engineering Polymers Footwear Industry is listening to consumer aspiration for renewable products Biobased Adipic Acid “TPU materials are not (ADA) offers significant currently green, we are GHG reduction compared interested in renewable to traditional petrochemical alternatives.” ~ Nike production GHG Sugar Carbon credits could Corn Paraffin Reduction Cane further reduce the cost of biobased adipic acid by t CO2eq/t 2.2 4.2 0.56 14% (at $30/t CO2) ADA Based on Cradle-to-gate analysis in The Brew Project, adjusted for Verdezyne fermentation assumptions INTRODUCTION OPPORTUNITY COMPETITIVE ECONOMICAL SUSTAINABLE DIFFERENTIATED 12
  • 13. Green Differentiation Creates Market Pull Applications Consumers 10% Demand for sustainable Carpet carpet is increasing, because sustainability is now regarded as important – In Out Space Industrial 11% When consumers have the choice, 26% Polyurethane they tend to want to make the greener choice - Timberland Adipic Retailers in particular are pushing Acid 10% sustainability requirements Textile back down their global supply chains - Sustainable Clothing Roadmap Initiative 25% Engineered A quarter of US adults prefer Plastics eco-friendly products & are more loyal towards socially responsible companies – 2009 Ward’s Auto Interior Conference Plasticizers 7% INTRODUCTION OPPORTUNITY COMPETITIVE ECONOMICAL SUSTAINABLE DIFFERENTIATED 13