IEA Bioenergy. Novamont biorefinery: a new model of sustainable development integrated with the territory

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1 IEA Bioenergy Novamont biorefinery: a new model of sustainable development integrated with the territory Sassari, 5th May 2015 Luigi Capuzzi, Novamont S.p.A.

2 Novamont Today: A knowledge-based industry MORE THAN 250 TRAINING PROGRAMMES SINCE 2000 HUMAN CAPITAL 25-YEAR R&D EXPERIENCE 6.2% OF TURNOVER 20% OF EMPLOYEES PATENTS R&D RESEARCH CENTRE TURNOVER OF 135 MIO/ 253 PEOPLE DIRECTLY EMPLOYED BY NOVAMONT(2013) 500PEOPLE EMPLOYED INCLUDING JVs AND START-UPs) INDUSTRY

3 Novamont key facts THE ORIGINS (1989) A strategic Research Centre withinmontedisongroupwith the aim of integrating chemicals and agriculture Combining Eridania-BeghinSay s agricultural raw materialsand Montecatini s chemical technologies PRODUCTS Innovative bioplasticsbasedon renewable resources,which are biodegradable and compostable according to the most important international standards. Solutions economically and environmentally sustainable in specific application sectors with a view to rethinking the overall system. DEVELOPMENT MODEL To promote transition from a product-based economy to a system-based economy To build up a Biorefinery integrated in the local area:

4 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)

5 Addressing Societal Challenges with Bioplastics TOPSOIL ORGANIC CARBON CONTENT (SOURCE: JRC) ORGANIC WASTE IN LANDFILL DEVELOPMENT OF ORGANIC WASTE SEPARATE COLLECTION SYSTEMS THROUGH BIOPLASTICS COMPOST AS DRIVER FOR SOILS FERTILITY Addressing the Build-up of a Third Generation Biorefinery for Bioplastics and Chemicals UPSTREAM INTEGRATION

6 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

7 Integratedtechnologiesand developmentschemeof the biorefinery UPSTREAM INTEGRATION 50/50 JV INVESTMENT: 180 MIO/ DIRECT EMPLOYMENT: 120 PEOPLE (145 FINAL) INDIRECT EMPLOYMENT: AVERAGE 400 (PEAK>700) Azelaic Acid (monomerfor Mater-Bi) Pelargonic acid Components for Biolubricants Additives for rubbers, etc. RECONVERSION OF A DEINDUSTRIALIZED PETROLCHEMICAL SITE INTO AN INTEGRATED BIOREFINERY WITH A LOCAL PRODUCTION CHAIN IDENTIFICATION OF LOCAL SUSTAINABLE PLURIENNAL OLEAGINOUS CROPS AND VEGETABLE SCRAPS CREATION OF A LOCAL REASEARCH CENTRE TO SUSTAIN LOCAL DEVELOPMENT WITH PILOTS

8 Matrìca production cycle From oil to chemicals Vegetable oil Chemicals and reagents Bio monomers Plant Intermediates for extendied oils Azelaic acid Glycerin Fatty acids blend C5-C9 acid blend Polymers and rubber additives plant Esters plant Extended oils Plasticizers C5-C9 esters Pelargonic acid esters Pelargonic Acid Complex esters market Esterification reagents Note: simplified scheme BIOMONOMERS PLANT: VEGETABLE OIL FEEDSTOCK. PRODUCTION CAPACITY: TON/Y ESTERS PLANT: PRODUCTS FOR SPECIALTY APPLICATIONS: 2 INDIPENDENT AND FLEXIBLE PRODUCTION LINES ADDIVES PLANT: ADDITIVES FOR RUBBERS AND POLYMERIC PLASTICIZERS

9 SectorswhereMatricaProducts will Contributeto the Quality of Environment PLASTICIZERS FOR PVC AND OTHER POLYMERS AS REPLACEMENT OF PHTALATES BIOLUBRICANTS FOR AGRICULTURE, MARINE AND INDUSTRIAL APPLICATIONS: high lubricity, biodegradability, low flammability WORLDWIDE PRODUCTION OF PHTALATES: 5,5 MIO TON EU PRODUCTION OF LUBRICANTS: 5,2 MIO TON HYDRAULICFLUIDS: 0,7 MIO TON PALM OIL FREE COMPONENTS FOR COSMETICS OIL EXTENDERS FOR RUBBER EUROPEAN PRODUCTION: > 0,5MIO TON BIO-HERBICIDES FOR INTEGRATED AGRICULTURE

10 Integratedtechnologiesand developmentschemeof the biorefinery UPSTREAM INTEGRATION 50/50 JV INVESTMENT: 180 MIO/ DIRECT EMPLOYMENT: 120 PEOPLE (145 FINAL) INDIRECT EMPLOYMENT: AVERAGE 400 (PEAK>700) Azelaic Acid (monomerfor Mater-Bi) Pelargonic acid Components for Biolubricants Additives for rubbers, etc. RECONVERSION OF A DEINDUSTRIALIZED PETROLCHEMICAL SITE INTO AN INTEGRATED BIOREFINERY WITH A LOCAL PRODUCTION CHAIN IDENTIFICATION OF LOCAL SUSTAINABLE PLURIENNAL OLEAGINOUS CROPS AND VEGETABLE SCRAPS CREATION OF A LOCAL REASEARCH CENTRE TO SUSTAIN LOCAL DEVELOPMENT WITH PILOTS

11 Map of research on dry crops Filarete Servizi - Milano CRA ING - Treviglio CRA CIN -Bologna Novamont - Novara Matrìca - Novara AgriNewTech- Grugliasco Matrìca - Porto Torres CNR - Sassari Università Sassari CRA ING Monterotondo CNR - Catania Novamont - Terni Università di Perugia Novamont -Piana di Monte Verna ENEA - Trisaia Agronomic aspects Soil preparation Weed control Fertilization Entomology Mechanization and logistic aspects Agricultural valuations Genetic improvements Active molecules extraction Crushing/Oil production and modification Proteic Meal Sugars from biomass Fermentation Energy from biomass

12 What crops for Sardinia? : An example : Thistle (Cynara Cardunculus) It is a spontaneous polyennial plant Itneedsamountof water compatiblewith winter rain regime (400 mm) Itcan be grownin marginalareasbecomea source of extra incomefor farmersand sheperds Itproducesoilusableasfeedstockfor the monomers plant Proteicmealscan be usedin feed It produces big amount of biomass usable immediately to produce all the energy neededby the plantand in the midtermfor the manufacturing of strategic monomers

13 Some images from thistle harvesting in Matrìca experimental fields(august 2014) AFTER 3 CONSECUTIVE YEARS OF EXPERIMENTATION: BIOMASS PRODUCTION > 15 TON/HA (17 TON/HA IN 2014) SEEDS PRODUCTION 1,5 TON/HA (1,74 TON/HA IN 2014) ENGINEERING OF SPECIFIC FARMING MACHINES SUITABLE FOR SARDINIAN STONY GROUNDS

14 Potential areas for thistle production HARABLE LAND IN SARDINIA: JUST IN SASSARI PROVINCE 70,000 HA OF HARABLE LAND LOST FROM 1982 TO 2010 (SOURCE: ISTAT)

15 Spilloversin termsof territorialregenerationand new growth along the whole value chain PRIVATE INDUSTRIAL INVESTMENTS IN WORLD PREMIER PLANTS (3 FLAGSHIPS) (MORE THAN 500 MIO ALREADY INVESTED ). PLANTS TO BE STARTED IN 2015; PRIVATE INVESTMENTS IN R&D (AROUND 200 MIO EURO) TRIGGERING MULTIDISCIPLINARY PROJECTS WITH UNIVERSITIES AND PRIMARY RESEARCH CENTRES; START-UP OF SPECIFIC AND LOW IMPACT AGRICULTURAL VALUE CHAINS, NOT COMPETING WITH FOOD PRODUCTION; REVITALIZATION OF DOWNSTREAM VALUE CHAINS; REINDUSTRIALIZATIONOF 6 DEINDUSTRIALIZES SITES, FOR A TOTAL OF MORE THAN EMPLOYEES: TERNI, PIANA DI MONTE VERNA (CE), PATRICA (FR), PORTO TORRES (SS), NOVARA, ADRIA (RO); NEW PROCESSES AND BIOPRODUCTS AT EU LEVEL: AZELAIC ACID PELARGONIC ACID THEIR DERIVATIVES NEW OIL EXTENDERS FOR RUBBER AND PLASTICIZERS BIOBUTANEDIOL A VIRTUOUS CHAIN OF HIGH QUALITY COMPOST WITH EXTRAORDINARY CASES OF EXCELLENCE (MILAN CHAMPION IN QUANTITY AND QUALITY OF ORGANIC WASTE )

16 Thanks for your attention! «The challenge of our millennium is in the balance between the technical means that humanity possesses and the wisdom in how we will make use of them» Umberto Colombo Luigi Capuzzi