Polyflow

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A powerpoint presentation about Polyflow Corporation and the Polyflow Process. The respobsible solution to our world's polymer waste.

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  • Aromatic compounds are important in industry. Key aromatic hydrocarbons of commercial interest are benzene, toluene, ortho -xylene and para -xylene. About 35 million tonnes are produced worldwide every year. They are extracted from complex mixtures obtained by the refining of oil or by distillation of coal tar, and are used to produce a range of important chemicals and polymers, including styrene, phenol, aniline, polyester and nylon.
  • Because of their utility, plastics, over the last 40 years, have been a boon to the growth of our economy. Today the hydrocarbon to make these plastics comes from crude oil and natural gas. Polyflow is commercializing a technology to derive that hydrocarbon from the waste plastics themselves. US statistics 2007 (US Energy Information Administration June 16, 2008) Oil and gas liquids production 8,487,400 barrels/day Consumption 20,697,530 barrels/day Imports 12,210,130 barrels/day Refinery Capacity 17,397,000 barrels/day Proved Reserves 21,757,000,000,000 barrels *http://www.epa.gov/epaoswer/non-hw/muncpl/pubs/06data.pdf Tables 2 and 3, respectively US EPA 2006 study of Municipal Solid Waste indicates: Only 6.9 wt% of plastics are recycled*. 16.2 wt% of material going to landfills is plastic*. Plastic occupies over 30 % of landfill volume. $52,880,835,000/yr at $100/barrel used in polymer production (This equates to $39,660MM at $75/barrel At 93% landfilled $49,179,176,550 opportunity
  • A low cost feedstock available in excess and a high value product in strong demand make a compelling business model. Polyflow’s production costs are about 10% higher than the major petrochemical companies making the same products but enjoys a $800/ton raw material advantage at $117 per barrel crude oil pricing from November 2008. ($510/ton at $75 per barrel) Additionally, these raw materials are available locally and at stable costs. Polyflow’s products are commodities. A $6BB market for styrene exists today in the US alone. One major petrochemical company has a stated serious interest in investing in Polyflow and buying the first 5 plants. Their stated goal is the stably priced, local supply of raw materials for their plastics manufacturing plants.
  • The Polyflow patents have been filed in the US and through the PCT, around the world. The first patent on the Polyflow processor issued in the US in March 2008. Process patents are pending and most are now in examination. The patents applications are a basic chemistry patent and broadly cover the conversion of mixed polymer waste into aromatic chemicals, the equipment necessary for the process and the operating conditions for success.
  • Polyflow Process is a high temperature anaerobic de-polymerization and chemical reaction. Self contained and environmentally sound. Polyflow Plant #1 concept: 3 plant sections 1. transfer station feed end 2. 8 Polyflow processors 3. Petrochemical refinery Capacity of an eight processor plant: 150,000 tons/yr feed 102,000 tons/yr product 35% of product is styrene and its precursors. Build plant #1 with a single processor and expand to eight processors over the next two years. Char and light off-gas is used as fuel. Plant requires about 10% supplemental fuel for startup. Distillations and extractions are off the shelf technologies but will require equipment sized to Polyflow.
  • Polyflow

    1. 1.
    2. 2. Polyflow – What We Do <ul><li>The Polyflow process utilizes mixed dirty polymer waste as a replacement for crude oil in the manufacturing of valuable petrochemicals and fuels. </li></ul><ul><li>This provides a unique difference compared to other processes in the ability to convert a low cost raw material into a high value end product without significant sorting or cleaning costs. </li></ul>
    3. 3. The Technology: <ul><li>The base technology is pyrolysis </li></ul><ul><li>Polyflow has developed the algorithms of dependent process factors in a production environment including: </li></ul><ul><ul><li>Anaerobic environment </li></ul></ul><ul><ul><li>Vertical and longitudinal thermal profile </li></ul></ul><ul><ul><li>Volumetric heat input </li></ul></ul><ul><ul><li>Specific reaction space requirements </li></ul></ul><ul><ul><li>Surface chemistry conditions </li></ul></ul><ul><ul><li>Critical moving bed conditions </li></ul></ul><ul><ul><li>Mixed polymer waste </li></ul></ul>
    4. 4. The Technology: <ul><li>The Polyflow technology operates with : </li></ul><ul><ul><li>No catalysts </li></ul></ul><ul><ul><li>Low temperature, low oxygen and low pressure </li></ul></ul><ul><ul><li>A high conversion rate for dirty polymer input </li></ul></ul><ul><ul><li>(69% to 83% conversion depending upon inert content) </li></ul></ul><ul><ul><li>Produces valuable aromatics and other petrochemicals </li></ul></ul><ul><ul><li>(Styrene, Ethyl benzene, Toluene and Cumene.) </li></ul></ul><ul><li>The benefits of that environment include: </li></ul><ul><ul><li>Low temperature (we don’t melt aluminum so we can recover most entrained metals in the polymer waste) </li></ul></ul><ul><ul><li>Low oxygen (we don’t burn the plastic which creates dioxins and released CO2 to the atmosphere) </li></ul></ul><ul><ul><li>Low pressure (reduces complexity and increases life of equipment) </li></ul></ul><ul><ul><li>- Real world tolerance for variability (reduces operating costs) </li></ul></ul>
    5. 5. Input to the Polyflow Process PyGas Char Off Gas
    6. 6. Output of the Polyflow Process Mixed Polymer Waste Stream 35% Valuable Aromatics 65% Gas & Diesel These are burned to continue fueling the process 69% PyGas 13% Char 18% Off Gas
    7. 7. The Market: <ul><li>7% of oil and gas consumed in the US is used in the manufacturing of plastic and rubber. </li></ul><ul><ul><li>$39,660,000,000/yr ($75.00 per barrel pricing) </li></ul></ul><ul><li>93% of all plastic and rubber ends up in landfills. **** 2007 EPA report on waste </li></ul><ul><li>$36.9 billion untapped opportunity to harvest the polymer waste stream as a feedstock that replaces oil. </li></ul>A ton of plastic waste is worth more than a ton of crude oil. Polyflow has the technology to capitalize on this opportunity.
    8. 8. <ul><li>External Influences </li></ul><ul><ul><li>Increased environmental focus </li></ul></ul><ul><ul><li>Alternative energy/dependency on foreign oil </li></ul></ul><ul><ul><li>Oil price volatility/future reserve </li></ul></ul><ul><ul><li>Constraints on opening new landfills </li></ul></ul><ul><ul><li>Recycling technology improvements in waste streams. </li></ul></ul><ul><ul><li>Negative public view on polymers. (bag bans, water bottle bans, etc) </li></ul></ul>An ideal technology for today’s business environment. A convergence of external and internal factors to make Polyflow the right technology at the right time
    9. 9. An ideal technology for today’s business environment. <ul><li>Inside Influences: </li></ul><ul><li>Designed and assembled pilot facility </li></ul><ul><li>Proof of Chemistry - Independent lab results from over 50 runs to prove the chemistry of the process: </li></ul><ul><ul><li>Critical process design parameters </li></ul></ul><ul><ul><li>Repeatability of the process </li></ul></ul><ul><ul><li>Ability to vary the input feedstock and maintain results </li></ul></ul><ul><li>Proof of Production - processing over 6 tons of polymer waste we have proven the production: </li></ul><ul><ul><li>Availability of feedstock </li></ul></ul><ul><ul><li>Yields of the process </li></ul></ul><ul><ul><li>Energy requirements </li></ul></ul><ul><ul><li>Value of the end product </li></ul></ul><ul><li>Assembled mgmt team and supply partners to develop a shovel ready project. </li></ul><ul><li>Resolved IP rights and have furthered the patent process. </li></ul><ul><li>Enlisted support from OEC, Sierra Club, ACC, Solid Waste Districts, municipalities, etc. </li></ul>
    10. 10. Why have other technologies struggled? Cost of Raw Material Delivered Value of End Product Create Electricity Waste Disposal Low Yield High Conv Cost Expensive Catalysts Emissions Cleaning Excess Sorting Need For Clean Material LimitedLocal Supply Only Handles A Few Plastics High Labor Cost Profit Losses $
    11. 11. Why is Polyflow Different? Cost of Raw Material Delivered Value of End Product Dirty Plastics Ample Local Supply Mixed Plastics Low Energy Needs No Hazard. Waste Petro Chem. Prod. Profit Losses High Yield No Catalysts $
    12. 12. Quality of Polyflow Product
    13. 13. Business Model – Basic Premise Polyflow Starts with a Compelling Cost Advantage Fuel Market Economics Polyflow produces high value commodity materials from low cost raw materials available in excess, locally
    14. 14. Patented & Patent Pending Technology <ul><li>United States </li></ul><ul><li>Australia </li></ul><ul><li>Brazil </li></ul><ul><li>Canada </li></ul><ul><li>China </li></ul><ul><li>Taiwan </li></ul><ul><li>European Union </li></ul><ul><li>India </li></ul><ul><li>Indonesia </li></ul><ul><li>Korea </li></ul><ul><li>Mexico </li></ul><ul><li>Philippines </li></ul>Issued 3/18/2008 A basic chemistry patent on the conversion of mixed polymer waste to aromatic chemicals.
    15. 15. Steps To Commercialization: <ul><li>Demonstrate proof of chemistry (completed) </li></ul><ul><li>Operate production processor to prove out throughput, yield and energy requirements for business model (complete) </li></ul><ul><li>Design high volume production processor (A-level is complete) </li></ul><ul><li>Build high volume production plant (part of funding requested) </li></ul><ul><li>Design scaleable high volume production plant for sale to others (part of funding requested) </li></ul><ul><li>Implement concurrent plants around the world. (future funding on a case by case basis) </li></ul>
    16. 16. Polyflow Technology <ul><li>8 Polyflow processors running in parallel provide redundancy. </li></ul><ul><li>Energy efficient </li></ul><ul><li>High conversion rate </li></ul><ul><li>Very high profitability </li></ul><ul><li>Reduces dependency on outside refining. </li></ul>Scalable: 16,000 to 150,000 tons/yr feed 11,000 to 102,000 tons/yr product 1/3 of product is chemical feedstock. 2/3 gasoline and diesel fuel Large Plant Only S O L I D S Polymer Receiving and Processing Polyflow Black-Box Technology Char/Coke/Metals R E F I N E R Y Diesel Fuel High Octane Gasoline Blendstock Chemical Feedstock Liquids
    17. 17. Cost for first single processor plant? <ul><li>$10.0 MM for a single unit production plant </li></ul><ul><ul><li>Design, permitting, constr. $1.1MM </li></ul></ul><ul><ul><li>Plant and equipment $5.3MM </li></ul></ul><ul><ul><li>Design of full plant $0.5MM </li></ul></ul><ul><ul><li>Corp. overhead (1.5 yrs) $0.5MM </li></ul></ul><ul><ul><li>Operating cost of plant $1.4MM </li></ul></ul><ul><ul><li>Contingency $1.2MM </li></ul></ul><ul><ul><li>Includes required corporate costs to further the intellectual property, design for future plants and market the growth strategy. </li></ul></ul>
    18. 18. Polyflow Single Processor Facility 2.5 Ton per hour
    19. 19. What resources do you have to implement this? <ul><li>Strong team of experienced chemical engineers, project managers and business managers. </li></ul><ul><li>Strong advisory board. </li></ul><ul><li>Experienced partners capable of supporting an aggressive growth strategy </li></ul>
    20. 20. Management Team <ul><li>Jay Schabel (CEO) – </li></ul><ul><ul><li>Prior technology startups (mim, alum. Mini-mill, cont. copper plating) </li></ul></ul><ul><ul><li>Acquired and integrated over 20 businesses to create an $350MM entrepreneurial organization </li></ul></ul><ul><li>Joe Hensel (Chairman and Business Development) </li></ul><ul><ul><li>Norton St. Gobain ceramics and polymer development </li></ul></ul><ul><ul><li>Ohio Polymer Enterprise Development lead business development for new technology commercialization. </li></ul></ul><ul><li>Dick Schwartz (Technology Backup/Advisor) </li></ul><ul><ul><li>Phd Chemist working along side inventor since 2002. </li></ul></ul><ul><ul><li>Polymer development experience at PPG and Firestone. </li></ul></ul><ul><li>Charlie Grispin (Technology Inventor/Developer) </li></ul><ul><ul><li>Over twenty years experience with the technology. </li></ul></ul><ul><ul><li>Akron University degree in quantum chemistry. </li></ul></ul><ul><li>Mehmet Gencer (Technical Advisor) </li></ul><ul><ul><li>Built and operated Pyrolysis reactor for competitive technology in Poland, Turkey and Taiwan. </li></ul></ul><ul><li>Vinny Gupta (JumpStart Tech Lift Advisor) </li></ul><ul><ul><li>Mentor for the development of the company to achieve a viable business. </li></ul></ul>
    21. 21. Board of Advisors <ul><li>Dr.Frank Kelley – Retired Dean of College of Polymer Science and Engineering at the University of Akron. </li></ul><ul><li>John Ong – Previous Chairman and CEO of B.F. Goodrich Co. Appointed Ambassador to Norway. </li></ul><ul><li>Phill Ashkettle – Ex CEO of MA Hanna. Facilitated the merger of MA Hanna with Geon Co. to form PolyOne. </li></ul><ul><li>Rick Jordan – Waste industry strategist. Past director of the Solid Waste Association of North America. </li></ul><ul><li>Calvin Cobb – Petroleum Industry strategist with Invensys and Cap Gemini. </li></ul><ul><li>Ira Kaplan – Managing Partner Benesch Friedlander Coplan & Aronoff LLP </li></ul><ul><li>Jim Sacher – Partner at Skoda Minotti </li></ul>
    22. 22. Growth Partners ?
    23. 23. Summary of Benefits <ul><li>A very profitable solution to polymer waste. </li></ul><ul><li>Produce stably priced, high value, virgin chemical feedstocks. </li></ul><ul><li>Help provide an extension of life for products made from oil. </li></ul><ul><li>Create revenue for municipalities. </li></ul><ul><li>Make plastic more recyclable than glass. </li></ul><ul><li>Reduce the cost of disposal of industrial and commercial polymer wastes. </li></ul><ul><li>Produce 70% less CO 2 than incineration. </li></ul><ul><li>Extend the life of landfills. </li></ul><ul><li>Will increase recycling rates and recovery of other materials for the recycling industry. </li></ul>
    24. 24. For Additional Information <ul><li>Polyflow LLC </li></ul><ul><li>Jay Schabel, Director, Business Development </li></ul><ul><li>440-773-3517 (Cell) </li></ul><ul><li>526 S. Main St., Ste 230, </li></ul><ul><li>Akron, OH 44311 </li></ul><ul><li>[email_address] </li></ul>

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