Novamont s Model of 3 Generation Biorefineries: opportunities and new developments in biolubricants

Transcription

1 Novamont s Model of 3 Generation Biorefineries: opportunities and new developments in biolubricants 9-10 Oct : WORKSHOP ON BIOLUBRICANTS MARKETING, USES AND CHEMISTRY Luigi Capuzzi Angela Sagliano

2 The opportunities for biobased products A significant and demonstrative case of sustainable development and cultural growth

3 From naturalto petroleumbasedproductsand reverse 3

4 Our roots(1989) Montecatini Chemical Technologies Eridania-Beghin Say Agricultural Raw Materials FERTEC- Ferruzzi Research and Technologies Research&Development Projects with focus on: materials, cobuilders for cleaning, biofuels, pulp additives, chemical intermediates from hydrocracking, etc. Integration of Chemistry, Agricolture and Environment

5 Novamont as a Research Centre R&D asthe drivingforce of industrial development: 5%of turnover, 20%of the employees, around patents Awardedby EPO and by the European Commissionthe prize EuropeanInventor of the Year2007 for a seriesof patents registered between 1992 and 2001 that allowed the realization of the first bioplastic family from renewable resources that permanently entered the market

6 Novamontasan industrial company Research Centre Turnover of 135 mln/ Pioneer and market leader in the fieldof bioplastics from renewable sources Production capacity: Complexed Starch: tons/y Polyesters: tons/y Availability of a wide range of materialsfor tailor-made industrial applications: 438 people employed

7 Network of production and research sites Headquarters and research centre Novara - Piemonte Mater-Biotech (100% Novamont) biobdo production Adria (RO) - Veneto Mater-Bi production and researchon intermediates from RRM Terni - Umbria Matrìca Porto Torres (SS) Sardegna Biotechnological research centre Piana di Monte Verna (CE) Campania Mater-Biopolymer (78% Novamont) Polyesters production Patrica (FR)

8 Novamont technologies and development scheme Upstream Integration Biomass Treatments Biotechnological process Monomer 2 Biolubricants Monomer 1 Biolubricants Additives for rubbers Other chemical intermediates IV generation of Mater-Bi C14 > 70% III generation of Mater-Bi C14 > 50% II generation of Mater-Bi C14 > 40% I generation of Mater-Bi C14 > 25%

9 Third-generation biorefineries What is a third-generation biorefinery integrated in the local area? Primarly dedicated to the production of chemicals Different local raw materials(low-input crops, scraps, etc.) respect for local biodiversity Use of marginal lands and redevelopment of deindustrialized sites Integration of a wide and rising range of low-impact technologies and plants Production of energy from waste Investments in: Research Plants Multidisciplinarity and creation of partnerships Training of Human Resources

10 MAP OF RESEARCH ON DRY CROPS Novamont Novamont Novara Novara Matrica Matrica Novara Novara AgriNewTech- AgriNewTech- Grugliasco Grugliasco Matrica Matrica Porto Matrica Porto Torres Porto Torres CNR Torres CNR Sassari CNR Sassari Università Sassari Sassari Filarete Filarete Servizi Servizi - - Milano Milano CRA CRA ING ING - - Treviglio Treviglio CRA CRA ING ING - - Monterotondo Monterotondo CNR CNR - - Catania Catania CRA CRA CIN CIN -Bologna -Bologna Novamont Novamont Terni Terni Università Università di di Perugia Perugia - - Perugia Perugia Novamont Novamont - - Caserta Caserta ENEA ENEA Trisaia Trisaia Agronomic aspects Soil preparation Weed control Fertilization Entomology Mechanization and logistic aspects Agricultural evaluations Genetic improvements Active molecules extraction Crushing/Oilproduction and modification Proteic Meal Sugars from biomass Fermentation Energy from biomass

11 Novamont Biotechnology Platform Innovative processes of industrial biotechnology, in synergy with the traditional chemical processes, for the further development of the Biorefinery and of Novamont s products portfolio. Creation of a national Biotechnology Platform For the production of chemicals from renewable resources. Tecnologie a basso impatto Chemicals Reindustrializzazione Acquisitionin 2012 of a biotechnological research centre of excellence, with the integrationof knowledge capital and know-how in the development of fermentation processes with Novamont R&D programs for the development of new supply chains. Creation of the start-up Mater-Biotech: reconversion of the BioItalia site in Adria(Italy), decommissioned from 2006, into a plant dedicated to the industrial production of bio- BDO from renewable resources and through fermentation processes.

12 Novamont technologies and development scheme Upstream Integration Biomass Treatments Biotechnological process Monomer 2 Biolubricants Sincro 50/50 JV with Coldiretti Monomer 1 Biolubricants Additives for rubbers Other chemical intermediates Matrìca 50/50 JV with Versalis Mater-Biopolymer 78% Novamont/22% M&G Mater-Biotech 100% Novamont

13 Novamont and biolubricants: why? Currently, over 95% of these materials are mineral-oil based or nonrenewable and non biodegradable synthetic oils. Approximately 50% (may be 70-80% for hydraulic fluids) of all lubricants used worldwide ends up in the environment via total-loss applications, evaporation, spillage and accidents a serious threat for aquatic and terrestial environment! The global volume consumption of Biolubricants is relatively small. Global : About 1.3 million pounds in 2013, valued at about US$2 billion) Europe: About 160 ktons sinthetic esters, 60 ktons natural oils but thanks to the increasing environmental awareness growth rates are higher than for the overall lubricant market forecast at 1.4 million pounds (US$2.1 billion) in 2014 estimated CAGR of 5.5% between 2010 and 2020 to reach a projected 1.9 million pounds, of value US$3 billion, by 2020.

14 Novamont and biolubricants: why? Major constraint limiting the biolubricant market penetration are perceived cost and general lack of awareness of technical potential....but as technically over 90% of all lubricants could be replaced by biolubricants this gives a present potential European biolubricant market of at most 5 Mt/yr.

15 Biolubricantmarket in Europe 12% 7% Market share (%) Hydraulic fluids chainsaw oils 14% 67% gear oils/2t engine oils and cutting oils concrete release agents Long-term European market expectations for biodegradable biolubricants Product group Biolubricant market volume (kt/yr) Market share (%) Automotive oils Industrial gear oils 10 5 Hydraulic oils Compressor oils Turbine oils Metalworking Fluids 10 2 Demoulding oils Chainsaw oils Lubricating greases Process oils biolubricants: science and technology, woodhead publishing, 2013 autori: J.C. Bart, Emanuele Gucciardi e Stefano Cavallaro

16 SINCRO SINCRO S.R.L. Sincro is a 50:50 joint venture between Novamont and Oroverde (a farmer cooperative under the auspices of Coldiretti ) to develop an agricultural supply chain for the production of chemical intermediates from renewable resources. Work in progress on.. Hydraulic Fluids (ISO 32, 46, 68) U.T.T.O. Li Greases In case of incidental spilling, no long termdamage for cultivated lands Production of High Oleic Sunflower Oil Formulation of vegetable oilto give lubricants for agricoltural applications The lubricants return and are employed by famers who produce the raw material.

17 Sincro biolubricants Environmentally friendly, renewable and biodegradable Low toxicity and ecotoxicity, non-water polluting Excellent lubricating properties Good viscosity index Low friction coefficients High flash point and low potential fire hazard Good Compatibility with existing oil seal and gasket materials

18 Matrìca- Porto Torres (SS) - Sardegna Joint Venture 50/50 betweennovamontand for the reconversionof the Porto Torres petrolchemical site into a third-generation biorefinery with an integrated production chain. Integrated agricultural supply chain: use of agricultural raw materials and vegetable scraps, identification of multi-year low-impact crops. Production of a wide range of products from renewable resources(biochemicals, biointermediates, bases for biolubricants and bioadditives for rubbers) through innovative low-impact processes. From 2014: dicarboxylic and monocarboxylic acids usable both as a base for the production of bioplastics and for applicationsin the pharmaceutical, phytosanitaryand cosmeticsectors, aswellasfor the production of biolubricants(for application in the agricultural and marine sectors and in the car industry). Research centre in support of the innovative processes of the site.

19 Matrìca: production scheme phase 1 (now starting-up) Potential upstream integration Azelaic Acid Novamont bioplastics Lignocellulosic Biomass Proteic Meal Biomonomers plant Polymers additives plant Mix Palmitic Stearic Acids Pelargonic acid; Light acids Glycerine New plasticizers Rubber additives Esterification plant Other applications Versalis rubbers

20 Market sectors BUILDING BLOCKS FOR POLYMERS BASES FOR BIOLUBRICANTS ADDITIVES FOR SBR RUBBERS ADDITIVES FOR POLYMERS AND NON SBR RUBBERS PERSONAL CARE/COSMETICS AGRICULTURE OIL DRILLING

21 Bio-lubricants base stock Base stock bio-lubricants A wholerangeof syntheticestersobtainedfrom renewableand sustainableresources: NPG, TMP, PE, dipeesterswith pelargonicand C5 C9 acids High oxidative stability; Low Pour Point; high lubricity, high Viscosity Index, anti wear properties Low toxicity, biodegradable products with excellent performances for environmentally sensitive applications APPLICATIONS Metalworking Automotive Agricolture Eolic Bio-lube Matrìca Aviation Industrial Marine Forestry 21

22 Conclusions Novamont, in the phase of implementation of its project of Third Generation Biorefinery integrated in the local area identified biolubricants as an area of development Biolubricants, as bioplastics, can become for Novamont a case study of relevant dimensions of sustainable growth to redesign entire application sectors to modify product s use and disposal to define reliable standards

23 Thanks for your attention!