NatureWorks Ingeo Polylactide: Past, Present and Future

Transcription

1 NatureWorks Ingeo Polylactide: Past, Present and Future RC Bopp NatureWorks LLC Minnetonka, MN IOWA STATE UNIVERSITY BIOPOLYMERS & BIOCOMPOSITES WORKSHOP August 14,

2 Agenda NatureWorks: Who we are and what we do Early History Bioplastics Value Proposition Ingeo EOL Value Proposition Further Look into the Future 2

3 Who We Are... 1 st world-scale biopolymer producer Economies of scale to compete in traditional plastics markets (140,000 MT capacity) Peer reviewed eco-profile (LCA) Global plastics & fibers customer base Ingeo applications breadth across many markets, geographies, and retail applications Privately owned by Cargill Inc and PTT Global Chemical 3

4 What We Do... Where it comes from.natural plastic from plants, not oil Our Customers Carbon dioxide and water Plants sugar (dextrose) 4 manufacturing

5 5 Polylactide Synthesis HO CH 2 HO CH 2 OH O Hydrolysis OH O O O HO OH OH Starch n OH Dextrose (Glucose) O O 2 HO OH H CH 3 Lactic Acid Chemical Processing O H CH 3 PLA O n 5

6 6 Creating a Family of Polymers 180 o C 220 o C D-Lactic Unit 6 L-Lactic Unit

7 Early History of Polylactide Polymers Lactide monomer production described in 1912 Polylactide production described in 1932 (W.H. Carothers et al.) Technology developed further by DuPont, with high molecular weight polymers in 1955, but technology appears to have been shelved First commercial application c.1972, with Ethicon Inc. development of resorbable sutures (poly-lactide-co-glycolide) Resurgence of interest in 1980 s E.S. Lipinsky, Chemicals from Biomass: Petrochemical Substitution Options, Science, 212, (1981) (Battelle Columbus Laboratories) E.S. Lipinsky and R.G. Sinclair, Is Lactic Acid a Commodity Chemical?, Chem. Eng. Progress (Aug. 1986) Cargill project started in 1989 Commercial production in Blair, Nebraska Dec

8 By 1996 the field was heating up. Company PLA capacity (MM lb/yr) Patent activity PLA approach Purity/ mol wt control Cargill (U.S.) 10 (100 MM lb/yr in preliminary design phase, not announced) 10 Ring opening polymerization Lactide distillation Chronopol (US) 2 planned (1996) 56 Ring opening polymerization Crystallization/ melt crystallization Shimadzu (Japan) Mitsui Toatsu (Japan) Neste OY (Finland) Ring opening polymerization 2-20 planned 97 Direct condensation Not available 1 Direct condensation Lactide crystallization, solid state polymerization Solvent with water removal Reactive coupling Capacity based on published news reports. Patent activity is worldwide published applications. Chronopol patents assumed to include Battelle, EcoChem, Ecopol, and DuPont. Adapted from D. R. Witzke Ph. D. thesis, 1997, Michigan State University 8

9 It has been a complex journey.. Project begins at Cargill JDA Dow Chemical NatureWorks LLC (Stand Alone JV) NatureWorks jointly owned by Cargill and Teijin Polysar JDA Cargill Dow Polymers, LLC (JV) Cargill acquires Dow s interest in NatureWorks Wholly owned by Cargill Pilot plant (5 lb/hr) Semi-works plant (1,000 lb/hr) Blair, NE (20,000 lb/hr) Blair, NE (40,000lb/hr).AmberWorks JV w/ BioAmber 9

10 A Cycle of Innovation Innovation: People implementing new ideas to create value. Requires: People using new knowledge and understanding to experiment with new possibilities in order to implement new concepts that create new value. Adapted from Joyce Wycoff, Innovation Network, Thinksmart.com Implement concepts Produce new value/ products Develop New concepts New knowledge Experiment/ New possibilities New understanding 10

11 Cycle 1. Project begins in Cargill Semiworks plant (1,000 lb/hr) JDA Dow Chemical Blair, NE (20,000 lb/hr) Blair, NE (40,000 lb/hr) Pilot plant (5 lb/hr) Chart Cycle 1. ( ) Development of basic monomer properties, polymer properties, technology to purify lactide and to control polymer molecular weight, melt point, and stability. Process technology developed. Culminates in products available for market development. N(Process) Development of processes has initial peak in , NatureWorks is actively filing at same time Priority year 11

12 Cycle 2. Project begins in Cargill Semiworks plant (1,000 lb/hr) JDA Dow Chemical Blair, NE (20,000 lb/hr) Blair, NE (40,000 lb/hr) Pilot plant (5 lb/hr) Chart Cycle 2. ( ) Market development quantities of Ingeo TM are available. Polymer is processed on commercial scale lines. Process control and manufacturing strategy are refined. Culminates in design and construction of full scale manufacturing plant at Blair, Nebraska. N(End-Use) Development of end use applications expands explosively, peaking in Priority year 12

13 Cycle 3. Project begins in Cargill Semiworks plant (1,000 lb/hr) JDA Dow Chemical Blair, NE (20,000 lb/hr) Blair, NE (40,000 lb/hr) Pilot plant (5 lb/hr) Chart Cycle 3. ( ) Ingeo TM available in standard grades. End products are developed and moved into retail. New compositions, copolymers, flow additives, color packages, nucleants, inhibitors, etc. being developed worldwide. New investments in processing equipment opens bigger markets* and achieves economy of scale. N(Product) Development of new products such as copolymers, compositions, modifiers of all types continues to expand Priority year *Historically, new polymers have averaged 11 yrs to reach 300 MMlb/yr sales from when commercial plant was operational. C. Musso, Ph.D. (McKinsey) 13

14 Cycle 4. A Quick Look at What s New & What s Next Our collective journey to a sustainable future New players enter PLA field Implement concepts Produce new value/ products Production becomes global Develop New concepts New knowledge Full complement of biobased additives/ modifiers Stereocomplex available in market development quantities Pilot development of 2 nd generation biopolymers and biobased chemicals Experiment/ New possibilities New understanding Recycle infrastructure developed and organics collection/ composting becomes widespread Implement concepts Produce new value/ products Develop New concepts 15 New knowledge Cellulosic feedstock in use at commercial scale Experiment/ New possibilities New understanding Biorefinery campus, with multiple ventures. On-site cogeneration, minimal waste. Implement concepts Produce new New knowledge value/ products Children today are in college and in the workforce, innovating even better ways to a sustainable future. Develop Experiment/ New concepts New possibilities New understanding

15 Value Drivers for the Industry Even in these extraordinarily difficult economic times, the STRATEGIC and ENVIRONMENTAL value drivers remain strong A SIGN OF THE TIMES Oil vs. plants feedstock cost (stability) Carbon or waste taxation Target: create viable alternate product portfolio (plastics) Environmental (consumer, retail, brand owners) Lower carbon footprint, less energy usage Better end-of-life options (litter, landfill, incineration) Target: lower environmental footprint of plastics Economic (plastics value chain) Strategic (governments) Renewable feedstock vs. oil Reduce dependence on foreign oil Target: cellulosic bio-refinery concept (gas + plastics) 16

16 Ingeo Technology Credentials Review process for new Eco-Profile 1. Publication in the Industrial Biotechnology Journal, August Manuscript reviewed by several reviewers - Update of our 2007 publication 2. Peer review by Dr. Ian Boustead of Boustead Consulting. - Final report now available 3. Review by Dr. Alberta Carpenter of NREL followed by uploading the eco-profile as well as a process description into the US LCI database Download: - Spreadsheets with the data files - Report giving description of Ingeo production process 17

17 Value drivers: Environmental Greenhouse Gases Ingeo Target -60% Ingeo 2009 CIT Ingeo (current 2009 tech) CIT Ingeo Target 0.8 Ingeo 2009 CIT Ingeo 2005 PVC (suspension) Polypropylene LD Polyethylene PET (amorphous) PET (SSP) Polystyrene (HIPS/GPPS Avg) Polycarbonate PVC 2.0 (suspension) PET (amorphous) PET (SSP) Polystyrene PS (HIPS/GPPS Avg) Nylon 6 Nylon Polycarbonate Nylon 6 Nylon Ingeo Polypropylene LD Polyethylene From cradle to polymer factory gate [kg CO 2 eq. / kg polymer] %-50% Non-renewable energy use -50% Continuous improvement process Ingeo 2005 Ingeo Current Ingeo Target From cradle to polymer factory gate [kg [MJ CO 2 / eq. kg polymer] / kg polymer] Economic Strategic

18 Strategic (governments) April 26, OBAMA ADMINISTRATION UNVEILS BIOECONOMY BLUEPRINT ANNOUNCES NEW R&D INVESTMENTS The world is shifting to an innovation economy and nobody does innovation better than America. President Obama, December 6, 2011 Decades of life-sciences research and the development of increasingly powerful tools for obtaining and using biological data have brought us closer to the threshold of a previously unimaginable future: ready to burn liquid fuels produced directly from CO2, plastics made not from oil but from renewable biomass... 19

19 20 Strategic (governments)

20 2012 & Beyond: NatureWorks Looking Forward Globalizing the Manufacturing Platform Broadening Products & Applications Monetizing the EOL Value Proposition Cellulosic Feedstocks 21

21 Blair, NE Rayong Province, Thailand In 2015 NatureWorks will have 2 Ingeo plants operational Supported by 3 feedstock sources (corn, sugar cane, cassava) Stronger global commercial organization 2015 target: Ingeo bioresin structurally less expensive than PS (and PET) 22

22 Broadening Products & Applications Broadening from A comprehensive platform of polymer grades with world scale economies 8000 Series - foam 7000 Series ISBM Bottles 6000 Series fibers/nonwovens 4000 Series - films 3000 Series Injection Molding Ingeo Polylactides 2000 Series - Thermoforming To... NatureWorks Ingeo Lactides Now offering polymer grade Ingeo lactides to support further global growth of the industry Cost effective Ingeo production is via the Ingeo lactide intermediate Lactic Acid Lactide Ingeo Polylactide 23

23 Where we are in the Market Rigids Food Serviceware Films Nonwovens / Fibers Durables Lactides Bus. Dev. 24

24 Ingeo High-Heat Technologies - Food Service-Ware High-Heat Ingeo Hot Cup Lids High-Heat Ingeo Cutlery StalkMarket International Paper StalkMarket US Biopolymers 25

25 Biaxially Oriented Films Growth Taghleef Industries successfully starts production of NATIVIA NATIVIA is based on Ingeo, and is 100% made from renewable resources NATIVIA is a compostable film that complies with EN

26 Ingeo Based Card Technology DaiNippon, Mitsubishi Plastics and Sony itunes Sony Bank, Inc. REI 27

27 Injection Stretch Blow Molded Technology Bormioli Vedat Extrusion Blow Molded Technology Shiseido Shampoo Bottle Polenghi Lemon Juice Bottle 28

28 Fibers / Nonwovens GroVia Ahlstrom Huggies Elements Naturals 29

29 Apparel Hernandez Cornet Max Jenny Dave Andersen 30

30 31 Ingeo in Japan

31 Ingeo in Korea LG Hausys zea Wall Paper Structure 0.2(T) x 1,060(W) 15M(L) Print Ingeo Backing Paper Roll type Application -. Residential -. Commercial 32

32 Ingeo in Korea LG Hausys, zea Flooring, Prestige line Structure 9.0(T) x75(w) 900(L) Ingeo Laminate -. Residential Application Water Resistant Plywood Yellow Soil Adhesive Eco-friendly Dent, scratch resistant No color change by environmental 33

33 Agenda NatureWorks: Who we are and what we do Early History Bioplastics Value Proposition Ingeo EOL Value Proposition Further Look into the Future 34

34 Wood 6.6% Rubber, leather & textiles 7.6% 31.8 MM tons/year Methane (x23 CO 2 ) release in landfill Total US MSW Generation (by material), Million tons (before recycling) Plastics 12.0% Yard trimmings 13.2% Metals 8.4% Glass 4.9% Food Scraps 12.7% Paper 31.0% Other 3.5% Source: Municipal Solid Waste in the US: 2008 Facts & Figures End of Life Options Incumbent Plastics Ingeo Landfill X X Recycle X X Incineration X X Compost Anaerobic Digestion Feedstock Recovery Progressing New After-Use Options X Food waste diversion: From landfill to composting facility X X 35

35 End-of-Life Options And Opportunities RENEWABLE SUSTAINABLE END-OF-LIFE COMPOST Total US MSW Generation (by material), Million tons (before recycling) Wood 6.6% Rubber, leather & textiles 7.6% Yard trimmings 13.2% Food Scraps 12.7% Other 3.5% Plants A Credible Closed Loop Solution Exists Today In Seattle Plastics 12.0% Paper 31.0% Metals 8.4% Glass 4.9% Source: Municipal Solid Waste in the US: 2008 Facts & Figures 36

36 Progressing New After-Use Options Total US MSW Generation (by material), Million tons (before recycling) Wood 6.6% Rubber, leather & textiles 7.6% Plastics 12.0% Yard trimmings 13.2% Metals 8.4% Glass 4.9% Food Scraps 12.7% Paper 31.0% Other 3.5% Source: Municipal Solid Waste in the US: 2008 Facts & Figures 30 MM tons/year < 10% recycled (some PET bottles only) End of Life Options Incumbent Plastics Ingeo Landfill X X Recycle X X Incineration X X Compost Anaerobic Digestion Feedstock Recovery X X X Closed loop recycling vs. today s bottle package landfill 37

37 A new paradigm for Cradle-to-Cradle materials recycle... Feedstock Recovery Ingeo is a bio-polymer made from lactic acid Lactic Acid Ingeo Polylactide Polymerization H O O O H Hydrolysis O O O O O 38

38 Monetizing the EOL Value Proposition COP 15 main conference area: Ingeo used in main hall carpeting and Food Serviceware New Company, BIOCOR LLC, launched with a business model founded on trading post consumer PLA in any format... 39

39 Agenda Who we are and what we do Early History Bioplastics Value Proposition Ingeo in the Market Today Ingeo 3801X Ingeo EOL Value Proposition Further Look into the Future 40

40 Latest Ingeo Business & Product Developments Extending the Ingeo Product / Applications Range 1. Ingeo Lactides 2. New High % L (> 0.3%D) Performance Grades 3. NatureWorks - BioAmber Joint Venture 4. Arkema s Rnew Partnering to produce bio-based (& improved) Plexiglas 41

41 Ingeo Platform Extension Family of Monomers M-3000 Lactide L-800 Lactide L-300 Lactide L-100 Lactide Lactide monomer platform Ingeo Platform: Performance materials from renewable resources 42

42 Ingeo Platform Extension Family of Monomers M-3000 Lactide L-800 Lactide L-300 Lactide L-100 Lactide Family of Polymers 8 series Foam 7 series ISBM bottles, BM 6 series Fibers, Nonwovens 4 series Films, cpla 3 series Injection Molding 2 series Thermoforming Family of High % L Polymers 6100 D 6260 D 3100 HP 3260 HP Lactide monomer platform 1st Gen (Lactic) polymer platform Ingeo Platform: Performance materials from renewable resources 43

43 High % L Performance Polymers Improved Nonwovens Reduced shrinkage and improved dimensional stability Increased hydrolysis resistance Capable of higher heat set temperatures Higher T m creates advantages in bicomponent systems Larger processing windows Improved Durables Faster cycle times & higher production rates for lower molded part cost 3-4x increase in bulk crystallization rate 15 C improvement in heat deformation temperature vs traditional Ingeo grades ~30% higher modulus above Tg Increased hydrolysis resistance 44

44 Stiffness Broadening the Addressable Ingeo Property Window Performance Properties Lactic Acid based polymers PS Starch PET New compounded Ingeo grades combining properties of succinic and lactic acid polymer platforms PP PE Bio-based Conventional Plastics Succinic Acid based polymers Elongation 45

45 Basis of the JV Partnership & Synergy Novel resin compounding intellectual property Award-winning biotechnology Renewable chemicals delivering high performance, low carbon footprint, cost competitive, building blocks Global commercial presence Established Ingeo customer relationships Applications development experience Breadth of markets Experience in commercializing new-to-the-world polymers The Joint Venture combines the best of both companies into an entity tasked with developing a new family of bio-based compounded Ingeo polymers Slide 46 ITR, February

46 New Developmental Grades Resulting from the JV Thermoforming Grade Ingeo AW 240D Injection Molding Grade Ingeo AW 300D 47

47 Arkema s Ingeo-based Plexiglas Rnew resins Compounded alloys of Arkema / Altuglas International s PMMA and NatureWorks Ingeo (durable product focus) Provide step change in impact performance ( PETG, PC) Significant increase in chemical resistance ( > PC) Drastic increase in processability Reduced carbon footprint & cost - All whilst incorporating bio-sourced materials without compromising optics, scratch resistance, color acceptance or surface aesthetics 48 48

48 Impact strength (J)- Arkema s Ingeo based Plexiglas Rnew resins Multi-axial impact Synergistic Impact Modification Effect 60 Acrylic / Ingeo Alloys PETG PC Acrylic 0 High impact PMMA Impact PMMA 10%PLA Impact PMMA 20%PLA Impact PMMA 40%PLA Impact PMMA 60%PLA PETG PC Formulation design allows for tailored solutions Extraordinary improvements in impact strength while maintaining modulus and strength Impact performance comparable to PETG and PC 49 Source: Altuglas International a subsidiary of Arkema International

49 Cellulosic Feedstocks Where we re going Where we are Our footprint is small: At full capacity, Ingeo represents: < 0.2 % of 2007 US corn production (< 0.05 % of global corn production) Ingeo technology is feedstock Agnostic. 2 nd plant will use most abundant local industrial sugar or starch source 2 nd Generation is becoming an industrial reality 50

50 Cellulosic Feedstocks Abengoa - Spain Myriant - Louisiana Switching from 1 st to 2 nd generation feedstock will be as much an economic as an environmental decision Verenium - Louisiana 51 US government strongly supports cellulosic bio-refinery concept Various feedstocks being evaluated Questions: Timing of first bio-refineries? Economics of bio-refineries?

51 Globalizing the Manufacturing Platform Summarizing Comments: Biopolymers are here to stay... Meet a strategic need to shed our oil addiction Meet a strategic need to lower our carbon footprint Meet global consumer expectation for sustainability without sacrifice Broadening Products & Applications Monetizing the EOL Value Proposition Cellulosic Feedstocks Biopolymers are no longer embryonic (Translation: hard to get, hard to use, very expensive) Let the journey continue... New entries into the market place (partially Bio PET, Bio PE, PHA) Feedstock diversification Economies of scale (resin, converters) Recycling infrastructure 52 Keeping innovation going

52 53 Acknowledgements: -Dr. Jeff Kolstad -Steve Davies -Andrea Ziadi -Lisa Moore -Julie Sobon 53

53 54 54

54 Thank you! 55