An update on polyethylene furanoate: Projects and aims PET Value Chain: Transitioning from Linear to Circular Amsterdam, March 13 th 2018 Francesco

Transcription

1 An update on polyethylene furanoate: Projects and aims PET Value Chain: Transitioning from Linear to Circular Amsterdam, March 13 th 2018 Francesco Acquasanta Project Leader Application Development

2 Table of content About Synvina From Sugars to PEF PEF properties, Applications and markets Circular Economy: PEF and Recycling 2

3 ABOUT SYNVINA 3

4 SYNVINA: Joint Venture of Avantium & BASF HQ in Amsterdam, NL R&D in Amsterdam, NL Pilot Plant in Geleen, NL BASF Verbund site in Antwerp, BE Established September 23 rd 2016 ~70 employees Naming origin SYN = Synergies, VI(a) = The Road, NA = Nature Global Company Satellites also in Canada, Japan, USA PET Value Chain: Transitioning from Linear to Circular - March 13th

5 Maintaining Leadership Turning YXY technology into world scale LAB- SCALE PILOT PLANT SCALE COMMERCIAL SCALE INDUSTRIAL SCALE / > 2024 Amsterdam Geleen Antwerp Licensee Site Kg s Tons 50kta Industrial Scale Innovative research Technology development Commercial launch of FDCA & PEF Roll-out of FDCA & PEF at larger scale Licensing 1 Commercial plant for proof of concept & market development 2 Licensing to rapidly expand market PET Value Chain: Transitioning from Linear to Circular - March 13th

6 FROM SUGARS TO PEF 6

7 A New Value Chain: From Sugars to PEF Naphtha p-xylene PTA PET resin (Terephthalic acid) (Polyethylene-terephthalate) Feedsto ck preparat C6 Sugars ion Catalytic reforming Sugar DeHydration Oxidation & Purification Oxidation & Purification Polymerization RMF pfdca PEF resin (Fructose) (5-methoxyMethylFurfural) (FuranDiCarboxylicAcid ) - H 2 O +O 2 Polymerization Building on existing PET know-how Fitting with existing PET assets (Polyethylene-Furanoate) + bio MEG Plastic processing Plastic Processing Scalable Catalytic processes PET Value Chain: Transitioning from Linear to Circular - March 13th

8 8 PEF PROPERTIES, APPLICATIONS AND MARKETS

9 PEF properties, applications 100% Biobased Renewable material Shelf Life Improvement Factor vs PET O 2 10x CO x H 2 O 3x BIOBASED GAS BARRIER PEF MECHANICS HEAT RESISTANCE RECYCLA- BILITY Light-weighting 60% higher modulus and strength than PET 100% Recyclable Using same steps as PET Hot Fill / Hot Serve 12 o C higher T g than PET APPLICATIONS OF PEF PEF Bottle Thin Film Thermoform Fibre Fulfilling packaging market needs & trends PET Value Chain: Transitioning from Linear to Circular - March 13th

10 Application Example 1 Flexible Film Packaging - BOPEF 1 - High-barrier substrate film 11x higher O 2 & 3x higher moisture barrier Avoids need for barrier layers such as PVDC and EVOH Does not vary with humidity Consistent & reliable barrier 2 - Processability No new equipment required Equal thermo-mechanical & surface properties to BOPET Conventional coating, printing and lamination 3 - Opportunities: 100% Bio-based layer Brand differentiation + reduced complexity Recyclable with suitable other layers or compatible with clean energy recovery at reduced GHG emissions PET Value Chain: Transitioning from Linear to Circular - March 13th

11 Application Example 2 100% Bio- based Bottle 1- Shelf Life extension & Waste reduction vs PET 6x higher CO 2 Barrier for Carbonated Beverages 10x higher O 2 Barrier 2 Same Safety & Design Freedom as PET Equal pressure & break resistance Full transparency & shape freedom No additional equipment required Standard investments in preform and blow molds 3-100% Bio-Based No fossil based Feedstock Fully recyclable PET PEF Volume (ml) / preform weight 237 /9g 237 /13g 237 /10g 237 /14g 4.2 Vol. CO 2 Shelf life to -17.5% (wks) Oxygen ingress - time to 5 ppm (wks) (est.) 26 (est.) PET Value Chain: Transitioning from Linear to Circular - March 13th

12 Fulfilling packaging market needs & trends Trends in packaging Sustainability Healthier drinks Smaller servings Cost reduction PEF as enabler for the growing demand of sustainable barrier solutions Small bottles and pouches +Simplification +Recyclability PET Value Chain: Transitioning from Linear to Circular - March 13th

13 13 CIRCULAR ECONOMY: PEF AND RECYCLING

14 PEF recycling Synvina recycling targets PEF to rpef recycling Conducting sorting trials Mechanical recycling Chemical recycling PEF and the rpet stream Assessing PEF effect on rpet processes/quality Discussing industrial acceptance EPBP in Europe APR in NA JCPRA in Japan Main target (Long Term) Initial focus PET Value Chain: Transitioning from Linear to Circular - March 13th

15 PEF to rpef Sorting via NIR Detection test performed by TOMRA and Pellenc in 2017 PET and PEF bottles + other material PET Opaque HDPE LHDPE PEF PP PET PET + Label PEF easily distinguished from other materials With current settings, PEF will be ejected as an unknown Recognition as PEF possible with a simple software update PET Value Chain: Transitioning from Linear to Circular - March 13th

16 PEF to rpef - Example 100% Biobased Conventional polyester spinning technology Made from Recycled PEF Conventional polyester dyeing technology PET Value Chain: Transitioning from Linear to Circular - March 13th

17 PEF and the rpet stream Adapted from EPBP protocol Down-scaled simulation of most common PET recycling pathway Reference PET Bottles Flakes Washed flakes 100- X % Route 1 Plaques with 50% vpet Bottle innovation Bottles Flakes Washed flakes Dried flakes X % Extruded pellets SSP-ed pellets Route 2 Bottles with 50% vpet Synvina assessed adapted route 1 and route 2 at PTI Europe, with X= 2 % and 5 % Route 3 Fibers & Films PET Value Chain: Transitioning from Linear to Circular - March 13th

18 PEF and the rpet stream EPBP adapted Route 1 - Key learnings Pellettized washed flakes IV [dl/g] SSPed pellets IV increase rate [dl/g*h] Ref. 0% PEF 2% PEF 5% PEF Limited effect on IV drop and build during the process PET Value Chain: Transitioning from Linear to Circular - March 13th

19 PEF and the rpet stream EPBP adapted Route 1 - Key learnings Plaques with 50% virgin PET + 50 % r-pet (+ X% rpef) L* = 93.4 b* = 3.2 L* = 93.4 b* = 4.2 Db* = 1 L* = 92.9 b* = 5.3 Db* = 2.1 Reference X= 2% (1% PEF) X= 5% (2.5% PEF) No haze good compatibility and hindered unwanted crystallization Color is marginally affected, improvement expected with PEF color 2% rpef in rpet Db* < 1.5 limit 5% rpef in rpet Db* > 1.5 limit PET Value Chain: Transitioning from Linear to Circular - March 13th

20 PEF and the rpet stream EPBP adapted Route 2 - Key learnings 1.5 L CSD bottle Control* 2% Route 2 5% Route 2 Typical PET PTI data PET+1% PEF PET+2.5% PEF Burst Pressure Linear increase bar Thermal stability Drop test (4 C and 22 C) Top Load Base push-up, 4.25 vol CO2, 24h 38 C, 1.8 m, bottom down, 72h after SBM At 1 mm deflection, Empty mm PASS rate 100 % 100 % 100 % N Bottle properties are within acceptable range of control bottle PET Value Chain: Transitioning from Linear to Circular - March 13th

21 PEF and the rpet stream Assessment in fibers - Key learnings Fiber trials up to 20% virgin IV 0.6 dl/g PEF in PET <10% PEF no significant changes in process conditions and properties > 10 % PEF process adjustment would be required to obtain sufficient properties PET Value Chain: Transitioning from Linear to Circular - March 13th

22 EPBP interim approval Interim approval of 50 kton/year market launch by European PET Bottle Platform PET Value Chain: Transitioning from Linear to Circular - March 13th

23 Synvina s Continuous commitment to Circular Economy PEF end-product developments Development of end-of-life options Involvement of recycling industry Recycling assessment depends on end-products developments (volumes and values) PET Value Chain: Transitioning from Linear to Circular - March 13th

24 24

25 BACKUP SLIDES 25

26 Why PEF? Trends in packaging: Sustainability Smaller servings Healthier drinks Cost reduction O 2 10x CO x H 2 O 3x 100% Biobased Renewable material Shelf Life Improvement Factor vs PET BIOBASED GAS BARRIER PEF MECHANICS HEAT RESISTANCE RECYCLA- BILITY Light-weighting 60% higher modulus and strength than PET 100% Recyclable Using same steps as PET Hot Fill / Hot Serve 12 o C higher T g than PET < 300mL PEF bottles APEF APET PLA PET Value Chain: Transitioning from Linear to Circular - March 13th

27 PEF bottles Obtained bottle properties (vs PET) CO 2 Shelf life (6-10x) O 2 Shelf life (10x) PEF bottles as enabler for higher shelf life Growing market for rigid plastics in beverage packaging PET Value Chain: Transitioning from Linear to Circular - March 13th

28 PEF and the rpet stream EPBP Route 2 - Key learnings 1.5 L CSD bottle Control* 2% Route 2 5% Route 2 Typical PET PTI data PET+1% PEF PET+2.5% PEF Burst Pressure Linear increase bar Vol incr. at burst Linear increase ml Thermal stability Base push-up, 4.25 vol CO2, 24h 38 C, mm Drop test vertical 4 C 1.8 m, bottom down, 72h after SBM PASS rate 12/12 10/10 8/8 Drop test vertical 22 C Top Load 1.8 m, bottom down, 72h after SBM At 1 mm deflection, Empty PASS rate 12/12 10/10 8/8 N Bottle properties are within acceptable range of control bottle PET Value Chain: Transitioning from Linear to Circular - March 13th