Plastics and Renewable Resources -a Life Cycle Perspective-

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1 Plastics and Renewable Resources -a Life Cycle Perspective- CEES Brussels, February 2008 &

2 The agenda driving the debate Sustainable development life cycle thinking GHG emissions/carbon footprint Energy efficiency & resource debate Waste management Litter issues plastics bags & foodservice packaging marine litter Agricultural & biomass issues Common Agricultural Policy (EU) bio-energy biomass action plan 2

3 Life cycle thinking in sustainable decision making Key aspects: Considers the complete life cycle to avoid shifting-of-burdens Considers all relevant aspects jointly To avoid over-estimation of 1 indicator, i.e. carbon footprint Compares on the basis of functional unit To avoid misleading comparisons Quantifies the overall impact along the life cycle To avoid over-estimation of one single step Consider the work of Dr. Jan Kooijman, a supply chain expert from The Netherlands 3

Proper system definition is crucial The environmental impact of packaging is inextricably linked to the product it contains and the actual needs of the consumer E.g. a 2 litre milk container has less environmental impact than four 0.

4 Proper system definition is crucial The environmental impact of packaging is inextricably linked to the product it contains and the actual needs of the consumer E.g. a 2 litre milk container has less environmental impact than four 0.5 litre containers However, if a small amount (5%) of the milk goes off and has to be thrown away, this wastes more energy than the total energy in making any size or type of container Relative to its job, the environmental impact of packaging is small consider the energy used by the average UK household from: Towards Greener Households, Products, Packaging and Energy; Incpen: 4

5 Strength of the Use-phase: PLASTICS SAVE ENERGY! Resource debate opens opportunities for plastics: plastics materials are resource efficient Do more with less plastics-in-use save energy Light-weighting and insulation capacities plastics-in-use reduce emissions Less energy = less emissions 5

Plastics packaging: Resource efficient In less developed world up to 50% of all food is wasted between farm and fork ; in a packaging-oriented society wastage is reduced to around 3% Without plastics

6 Plastics packaging: Resource efficient In less developed world up to 50% of all food is wasted between farm and fork ; in a packaging-oriented society wastage is reduced to around 3% Without plastics in the UK: Weight will be up to 391% Energy +150% Waste +160% CO2 +200% Costs +190% METAL CAN 23.7g PLASTIC 3.1g GLASS 100.8g CARTONBOARD 24.8g In a world without plastics packaging¹: Energy consumption would increase from Mtoe/year CO2 emissions would increase from 7 51 Mio tonnes/year ¹ Gua, Vienna

7 What is the learning? Performance in application is highest priority more than 200 plastics families custom tailored properties Total cost of material and conversion process determines the material choice Plastics performance in the use phase contributes much more to resource and energy savings than substitution of their raw materials 7

8 Does plastics consumption influence oil availability? Total fuel demand EU25 (2004).: 1747 Mtoe Final energy consumption EU25 (2004)... : 1141 Oil demand..: 651 Plastics consumption EU25 + N/CH (2005) 47.5 Mt; gross energy expressed in Mtoe...: 70 (*) recoverable as fuel...: 42.5 Oil demand is driven by energy demand! (*) Source: PlasticsEurope Eco-profiles 8

9 The meaning of bio-plastics For public opinion, bio-plastics degrade completely and instantly in nature are produced from renewable raw material resources are more environmentally friendly than man-made plastics However, biomass based plastics are not always biodegradable in a short term and biodegradable plastics are not always biomass-based. Biodegradability is not synonym with being environmentally friendly*. * (IFEU 2003) 9

10 Snapshot Europe 2005 Total plastics demand 47.5 Mio.t 1 Bioplastics demand 0.05 Mio.t (30% p.a. Growth) 2 Current production of energy from biomass 69 Mtoe 3 Total Oil & gas consumption Mtoe 4 1) PlasticsEurope 2)European Bioplastics 3) EEA 4) Eurostat

Bio-based plastics production capacity world* Total

600 000tpa 1 Potential long term 1 World 20 Mio.

Tpa Based on comparison of physical properties Up to 10%

11 Bio-based plastics production capacity world* Total capacity 2007 unclear tpa 2 vs tpa 1 Potential long term 1 World 20 Mio. tpa Europe 5 Mio. Tpa Based on comparison of physical properties Up to 10% of total plastics demand Volume projections are still uncertain! 1) European Bioplastics 2) Novamont *Polymerisation and compounding 11

12 Packaging is main market driver High moisture transition Crackling noise symbolising crispiness Transparancy for display Combined waste disposal 12

13 Sources of bio based pastics Oil / Fats use as is lactic acid; citric acid; fatty acids; triglycerides;.. Biocomposite Biocomposite Starch / Sugar Chemistry or Metal-catalysis Biomass Catalyst; Δ T; Δ p.. Chemicals PLA Levulinic acid Levulinic Acid Lignocellulose Renewable Resources Enzymatic Catalysis Cellulose Polyester Polyols Polyols Natural fibres Ferm entation 1,3 Propandiol 1,3 Propandiol Succinic acid Lactic PHB; Proteins acid (PLA) Proteins In-planta Production Organic Acids acids Proteins, PHB Only a few polymers naturally available Most require modification to become plastics 13

14 A word of caution not all chemicals for plastics can be provided by biomass-based resources economically 14

15 Development of sustainable plastics Both resources should be considered! biomass based and fossil resources Look for eco-efficiency! 15

16 Two approaches biomass based plastics Synthesis of new monomers for production of new plastics with different property balances (e.g. PLA) Initially small markets, growth rate depends on market development needs Synthesis of known monomers from RRM, complementing fossil resources, to produce existing plastics (e.g. PE) Well established markets, introduction mainly cost driven 16

17 Starch based compounds Application: shopping bags Elastomeric fossil based polyesters filled with starch Compostable under defined conditions Side track: Will not resolve litter issue 17

18 Polyurethane foam for insulation Sugar as basis for polyol synthesis Polyol and isocyanates react to form Polyurethane foam Quelle: Bayer MaterialScience 18

19 Rilsan (PA11) Production Chain Castor oil Methyl Ricinoleate Amino 11 Undecanoic Acid Polymerization & Compounding Rilsan PA11 19

20 Sorona - poly propylene terephtalate (PPT) Stretch - recovery Soft hand Stain resistance Easy care & dye Resilience Crush resistance Glucose price - performance naturally derived Yeast Glycerol Bacterium Softness PDO Vibrant colors Stretch & Recovery Textiles Flooring Coatings Nonwovens Film Staple Engineering Polymers 20

Ethanol to PE or PVC the technology exists Production of ethylene from bio-based ethanol (1981-1991)

21 Ethanol to PE or PVC the technology exists Production of ethylene from bio-based ethanol ( ) Plant Capacity: 100,000 ton/year (PVC) 3 ton / ha PE 100% renewable according to Standard ASTM D

22 Bioplastics no perpetuum mobile 1t bioplastic Consumed energy: ~0.89 toe recovered lost Matter: ~0.46 toe* *based on lower heat value 22

23 Land use aspects Comparing agricultural systems, land use is an important aspect, with regard to: - the environmental performance, - the economic impacts, - the social impacts, based on the increasing competition for space 23

24 Competition for bio-based plastics Bioplastics are competing against Food Biofuels Other chemicals for the same resource arable land Keep in mind: demand fuels vs. demand materials is >10:1 24

25 Land use aspects What would happen, if 10 Mio t of ethylene (approx. ¼ of the European demand) would be substituted by ethylene from bio routes? Renewable resource Land use [ha] Corn (US) Wheat grains (EU) Sugar cane (BR) (79% of EU fallow land) Sugar beet (EU) (44% of EU fallow land) Source: PE Europe, personal communication 25

26 Bio-based plastics environmental footprint typical example Learning: Do not focus on carbon footprint only! 26

Are additional emissions caused by bio-based plastics relevant? What would happen, if 10 Mio t of ethylene (approx. ¼ of the European demand) would be substituted by ethylene from bio routes?

27 Are additional emissions caused by bio-based plastics relevant? What would happen, if 10 Mio t of ethylene (approx. ¼ of the European demand) would be substituted by ethylene from bio routes? Acidification emissions would increase by t t SO2 equvalents. Equals ~ ¼ of annual SO2 emissions saved due to the phase out of East German lignite power plants ( ). Increase of phosphate equivalents in Eutrophication emissions would equal ~ ¼ of the annual German phosphate use for commercial fertilization. Source: PE Europe, personal communication 27

28 Bio-based plastics Environmental impact learning s from LCA Main benefit linked to feedstock (biomass = solar energy). Benefit offset by higher process energy requirements (PLA today) or by poorer performance (starch based plastics). Total energy savings due to biomass-based plastics will remain insignificant during, at least, the next two decades. RRM based plastics are not truly CO2-neutral. Agricultural issues like eutrophication, ozone depletion are generally worse for RRM-based plastics than for oil based plastics. Uncertainty remains about land requirements, water consumption, impact on biodiversity and soil modification due to extensive monoculture lack quantitative data. 28

29 Conclusions and recommendations Life cycle thinking is a must for sustainable decision making All life cycle stages must be taken into consideration To avoid shifting of burden and misleading conclusions Reliable life cycle data (LCI, eco-profiles) are crucial for good decision making Plastics contribute to energy efficiency mainly in the use phase. Plastics enable eco-efficient use of natural resources and save energy. 29

30 Conclusions and recommendations Bioplastics are an integrated part of the plastics family Bioplastics will not replace fossil based plastic significantly Use most eco-efficient ways make plastics from carbon sources Plastics industry will use biomass based materials where they are economically / technically advantageous More research needed to efficiently exploit biomass resources Food, fuel and materials compete for same resoucre, i.e. arable land, conflicting with biodiversity, eutrophication etc. Society needs to address the priorities 30

31 31

32 PlasticsEurope life cycle database history Was the first industry based organization in the world to assemble a detailed environmental footprint of the production processes of their members Its LCI methodology was developed with the input from academia, consultancy, industry, government and NGOs Publishes its eco-profiles free of charge via the internet Eco-profiles are used by LCA practitioners and have been the basis for numerous LCAs Is partner in the EU Platform for Life Cycle Assessment managed by the Joint Research Centre. 32

33 Over 75 eco-profile data-sets & reports INDEX OF ECO-PROFILES: Click on green circle to go to relevant flow chart ABS Ethylene dichloride PET (Bottle grade) Polypropylene PVC pipes Acetone Hydrogen (cracker) PET bottles Polypropylene inj. moulding PVC calendered sheet Acetone cyanohydrin Hydrogen (electrolytic) PET film Polypropylene oriented film Pyrolysis gasoline Acrylonitrile Hydrogen (reformer) PET film (packed) Polystyrene (expandable) Styrene-acrylonitrile (SAN) Ammonia Hydrogen chloride Phenol Polystyrene (gen purpose) Sodium hydroxide Benzene Hydrogen cyanide PMMA beads Polystyrene (high impact) Steam Brine MDI PMMA sheet Polystyrene thermoform Styrene Butadiene Methodology Polybutadiene Polyurethane flexible foam TDI Butenes Methylmethacrylate (MMA) Polycarbonate Polyurethane rigid foam Terephthalic acid Chlorine Naphtha HDPE resin Polyvinylidene chloride Toluene Crude oil Natural gas LDPE resin Propylene Vinyl chloride (VCM) Electricity Nylon 6 LLDPE resin Propylene (pipeline) Xylenes Epoxy liquid resins Nylon 6 (glass filled) HDPE bottles PVC resin (bulk) Ethylbenzene Ethylene Nylon 66 Nylon 66 (glass filled) HDPE pipe LDPE bottles PVC resin (emulsion) PVC resin (suspension) OTHER POLYMERS Ethylene (pipeline) Pentane LDPE film PVC film previous page PET (amorphous) Polyols PVC injection moulding next page 33

34 Manufacturing capacity of biodegradable plastics (tpa, world) Manufacturer Natureworks Novamont BASF Eastman Rodenburg ? PHB/PHV ? Biotec Biop 1000 Others (based on petrochemicals) Others (based on RRM) TOTAL TOTAL FROM PETROL TOTAL FROM RRM Source: Novamont

35 Cost analysis for bio-based aromatics 35

36 Yields from agricultural crops Energy/fuel 9 toe/ha from energy plants (EEA for 2030) 1 t/ha biodiesel from rapseede oil (FNR)** Plastics* 4.6 t/ha PLA (polylactic acid) 6.4 t/ha corn starch (Europe) 2.9 t/ha PLA 4 t/ha wheat starch (FNR) 1.1 t/ha PE (polyethylene) 4 t/ha wheat starch (FNR) 1.4 t/ha PE 4,6 t/ha cane sugar (ave. world) 2.8 t/ha PE 9 t/ha sugar from sugar beeds (Europe) World market price ratio ~ 1 : 4.5 cane versus bead sugar * Not accounting for conversion losses ** Fachagentur Nachwachsende Rohstoffe e.v. 36

37 Biomass-based material for use in plastics Plastics industry uses already renewable raw materials where they are economically viable and technically advantageous cellulose plastics, polylactic acid or polyamide 11. polyurethane foams and coatings partly based on sugars and natural oils bio-based additives such as fatty acid esters composite systems containing natural fibers such as flax, wood fibers, etc. within the German chemical industry, for instance, 10% of the overall chemical feedstock is bio-based 37

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