Bioplastics Advances and Sustainability

December 14, 2012

The 9th SPSJ International Polymer Conference (IPC2012)

Basic Definitions for Bioplastics.

Growth Factors For Bioplastics.

Feedstocks and Sustainability.

First and Second Generation Bioplastics.

Bioplastics Growth Projections and Market Trends.

Applications in Use Today for Bioplastics.

Presentation Outline

Basic Definitions for Bioplastics

Biodegradable or Compostable Bioplastics Meet all scientifically recognized standards for biodegradability and compostability of plastics and plastic products.

Independent of carbon origin-(i.e. Ecoflex, PBS, PLA ). Focus is on end-of-life or disposability.

Biobased Bioplastics Must be organic and contain some percentage of recently fixed (new) carbon found in biological resources or crops.

Focus on renewable resource based origin. Uses C14 content measurement.

Renewable resource versus oil based.

Reduced environmental impact.

Concerns about human health.

End-of-Life disposal issues – Landfill.

Legislative initiatives.

Growth Factors for Bioplastics

Bioplastics

Opportunity

Growth Factors for Bioplastics

Today's Bioplastic Feedstocks

Corn

Cassava

Sugarcane

Sugar beet

Sorghum

All refined sugars - dextrose, glucose, sucrose.

Sorghum

Food versus Fuel Debate:

• Food Crops Diversion to Fuels/Plastics

• Land Use

• Fertilizer Use

• Pesticide Use

• The “Ripple Effect “

Use of GMO's

Bioplastics Feedstock Issues

More “Sustainable” Biomass Feedstocks

Lignocellulose (wood, corn stover, other agricultural residues)

Oil seeds (soy, rape/canola, palm, coconut, Jatropha)

Microalgae

Macroalgae (kelp)

Waste:

MSW, food processing (cellulosic) Used fats and oils Animal processing wastes (rendering, feathers, hair, manure)

Leading Biomass Source – Lignocellulosics

Corn stover

Sugar cane bagasse

Tall grasses

Rice straw

Wood chips Wheat straw

Source: Virent –”The Future For Bioplastics Feedstocks”

Extracting Sugars From Cellulosics

Dilute acid and enzyme hydrolysis

Wet oxidation and enzyme hydrolysis

Concentrated acid extraction

Catalytic biomass deconstruction

Most Common Industrial Approaches

Commercially Proven Technology

Virdia Process (c1938)

Loblolly Pine

Preparation Sizing

Tall Oil Removal

Tall Oil

Concentrated HCL Deconstruction

Lignin Deacidification

Lignin

Sugar Recovery HCL Recycle

Final Purification

Soluble C5/C6 Sugars

HCL

HCL

Compounded, Biobased

& Compostable

O O

OH OH HO HO

H H

CH3 CH3

L-Lactic Acid L-Lactic Acid

O

OH HO

H

CH3

L-Lactic Acid

O O

OH OH HO HO

H3C H3C H H

D-Lactic Acid

(0.5%)

O

OH HO

H3C H

D-Lactic Acid

(0.5%)

Polylactic Acid (PLA)

100% Renewable & Compostable

First Generation BioplasticsFirst Generation Bioplastics

Starch/PLA/ECOFLEX

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First Generation PHA’s

PHA picture courtesy of Telles

Compostable, biodegradable and renewable

Bioplastics are still less than 1% of the approximate 230 million tons

of plastics in use today.

Projected Biomaterials TrendsProjected Biomaterials Trends

Projected 20-30%AGR

Increasing demand for biobased, durable products in electronics and automotive applications.

By 2011 durables were expected to account for almost 40% of bioplastics –

compared with 12% in 2010. (European Bioplastics)

Projected Durables Growth Projected Durables Growth

Sales Trends in Bioplastics Sales Trends in Bioplastics

Jim Lunt & Associates LLC. Projections

205KT 500KT 1.2MT

Continuing lack of infrastructure for use and disposal of compostable plastics. “Compostables” performance v durables. Increasing demand for biobased, semi-durable and durable products for household goods, electronics and automotive applications. Increasing interest and developments in existing and new monomers from renewable resources.

Why The Change?Why The Change?

Braskem “Green Polyethylene” from Sugar Cane

ethanol

ethylene

sugar cane molasses

HDPE polyethylene

Bio Ethylene Glycol

ethanol

ethylene

sugar cane molasses

ethylene oxide Ethylene glycol

India Glycols, GTC, FENC, JBF

-H2O

fermentation

oxidation +H2O

Biobased TPA for PET from Sugars Gevo Global Bioenergies

Amyris Genomatica

Toray/UOP

SABIC

t,t muconic acid

d limonene p cymene BP

dimethyl furan

fdca

biobutanol isobutylene isooctene

p-xylene

TPA

Anellotech/Virent Processes for Biobased Aromatics

BTX=benzene, toluene, xylenes mixture.

Anellotech Process

Virent Process

Other Bio “Building BlocksOther Bio “Building Blocks””

Succinic acid

Adipic acid

Butane diol

PTT, DSM, BASF, Bioamber, Roquette, Mitsubishi Chem., Myriant, Purac

Rennovia, Verdezyne, Genomatica

Genomatica

FDCA

Avantium

Ketals Segetis, XLTerra/Reluceo

Caprolactam

Acrylic acid

Isosorbide

Propylene

Propane 1,3 diol

Amyris

Ceres, Dow/OPX

ADM, Roquette

Braskem

DuPont / Tate & Lyle

Biobased Succinic Acid and Derivatives

Biobased Succinic Acid

Courtesy Myriant

Succinic acid/PBS • BioAmber • PTT • MCC • DSM/Roquette • BASF/Purac

Butane diol • Genomatica

Adipic acid • Rennovia • Verdezyne

Examples of Emerging Technologies

bottles

films

fibers

Plant based carbohydrates

FDCA

PEF

EG

Avantium’s PEF is a 100% biobased polyester, with glass transition 10 C higher than PET ,oxygen barrier 6-10 times better than PET, CO2 barrier 2-4 times better than PET, and water 2 times better than PET.

Courtesy of Avantium

Avantium PEF ‘yxy’

L-Ketals HO

OH

O

O

succinic acid

HO OH

O

3-hydroxypropionic acid

OH

O

NH2

HO

O

glutamic acid

aspartic acid

OHHO

O

O NH2

HO OH

OH

glycerol

O

OHO

4-hydroxybutyrolactone

itaconic acid

HOOH

O

O

O

O

OH

levulinic acid

O

O

OH

O

HO

2,5-furandicacboxylic acid

OH OHOH

OH OH

xylitol

OH

OHOH

OH

OH

OH

sorbitol

HOOH

OH

OH

OH

OH

O

O

glucaric acid

OO

HO

O

OR

Ketal Plasticizers/Poly XLK

OO

O

O

O

O

n

XLTerra

PXLK

Bioplastic Products In The Marketplace

PLA

Cellulose Acetate

Compounded PLA/Starch Blends

Green Polyethylene

Bio PET

The Future For Bioplastics The Future For Bioplastics Will Depend OnWill Depend On

Oil pricing continuing to increase.

Improved performance.

Composting/recycling infrastructure developments.

Expanding from single-use compostable to durable applications.

Moving to non-food source feedstocks.

Competition from carbon dioxide based plastics.

Thank YouThank YouThank YouThank You