DuPont Sorona Polymer: A New Bio Based Material for the 21st Century

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1 Environmentally Friendly Materials for Automotive Markets DuPont Bio Based Materials DuPont Sorona Polymer: A New Bio Based Material for the 21st Century Joseph V. Kurian for the Team DuPont CR&D/BBM/EP, Wilmington, DE, USA Presented at the Korea Technology Fair

2 Outline Introduction on Renewable Polymers Bio Based Materials Platform Sorona Polymer and applications A Family of Bio Based Offerings Grow the Future! 2

3 210 Sites in over 70 Countries Over 25,000 Customers 2,500 Trademarks & Brands One of the safest company in the world Sustainable Growth Goals Ranked #1 of "The Top Green Companies. (Business Week, 2005) BY % of revenues from businesses not requiring depletable raw materials 10% of energy needs derived from renewable resources 3

Business Impact Commercially Important Polymers 5000000 B.C. Animal Skin 24000 B.C. Plant Fiber 10000 B.C. Flax, Ramie, Jute 9000 B.C. Wool 5000 B.C. Silk 3000 B.C. Cotton 1850 A.D. Carbon 1884 A.D. Rayon 1902 A.

4 Business Impact Commercially Important Polymers B.C. Animal Skin B.C. Plant Fiber B.C. Flax, Ramie, Jute 9000 B.C. Wool 5000 B.C. Silk 3000 B.C. Cotton 1850 A.D. Carbon 1884 A.D. Rayon 1902 A.D. Acetate Polyureas Polypropylene Adiprene Polyurethane Vinylon Triacetate Modacrylic Boron Dinitrile PBI & PBO Novaloid Polyimide Delrin Polyacetal Alpha-Alumina Kevlar Aramid Kapton Polyimide Lycra Polyurethane Nomex Aramid Polylactic Acid Sorona Vinylidene Chloride Polyurethane Dacron Polyester Teflon Fluoropolymer Bakelite st Synthetic Polymer PET Nylon 6,6 PVC Polystyrene Neoprene Year 4

Renewable Polymers - Background Polymers will continue to play an important role in our life Renewable raw materials played an important role in the 19th century.

5 Renewable Polymers - Background Polymers will continue to play an important role in our life Renewable raw materials played an important role in the 19th century... then came coal, and then petroleum Preparation of polymers from renewable resources is an attractive option because of new technologies, diminishing petroleum reserves and increasing prices The social prices of using renewable raw materials are attractive as this provides increased value for traditional agricultural products. Economic, environmental and social benefits! 5

6 Biomass Bio-Based Materials to Products Bio Based Materials: A new DuPont technology platform 6

7 Bio- Based Materials Concept CO 2 Chem-processing Bioprocessing Building Blocks Lower Environmental Footprint Renewable resources Lower energy consumption Lower toxicity Safer manufacturing process Unique Properties Plastics, Fibers, Coatings Markets 7

DuPont and Tate & Lyle Form Bio-Products Joint Venture New Company Will Replace Petrochemicals with Renewable Resources Photo taken in Sept 2005 March 2006 WILMINGTON, Del.

8 DuPont and Tate & Lyle Form Bio-Products Joint Venture New Company Will Replace Petrochemicals with Renewable Resources Photo taken in Sept 2005 March 2006 WILMINGTON, Del., May 26, 2004 DuPont and Tate & Lyle PLC today announced a joint venture to create products from renewable resources such as corn for numerous applications including clothing, carpets, auto interiors, engineered polymers, films and other markets. Design Capacity of this bio-pdo plant is 45 K Tons. Start up in Loudon, TN. 8

CH 2 CH 2 O)- n Tg ~ 50 0 C Tm ~ 228 0 C Unique

9 Sorona Polymer 1,3-propanediol (PDO) + DMT / TPA Catalyst Unique polymer with attractive properties O -(-C O C-OCH 2 CH 2 CH 2 O)- n Tg ~ 50 0 C Tm ~ C Unique Functionality Lower cost & Investment Smaller environmental footprint 9

10 Sorona 3GT Properties Derive From Its Unique Molecular Structure Sorona Polymer is Unique Polyester Sorona PBT Softness Stretch & recovery Elasticity & Resilience Improved toughness Durability and stability Printability 2GT 3GT 4GT Better LCA 3GT 10

11 1930 s Carother s Initial work on polyesters 1940 s Polyester (PET) patent filed with broad coverage s Sorona Polymer History Investigated various routes for PDO 1990 s - Acquired Degussa technology and developed polymer-grade PDO (Wesseling 1998) - Developed 3GT Polymer Technology - Developed technology to make Bio-PDO 2000 Sorona Polymer CP production began (Kinston, NC) New SBU - Bio-Based Materials Business 2004 Formation of DuPont/T&L Bio-products and the construction of Bio-PDO TM plant at Loudon, TN Commercial production of Bio-PDO TM 11

12 POLYMER PROPERTIES COMPARISON Sorona* 2GT 4GT Nylon 6 Nylon 6,6 PP PLA Melt Temperature, Tm ( 0 C) Glass Transition, Tg ( 0 C) Density Sorona polymer is a good thermoplastic material well suited for fibers and engineering resins. 12

13 Sorona Polymer Production Successfully demonstrated process technology and achieved over 95% yields. 6 years of safe operation. Commercially demonstrated both DMT and TPA based polymer; Capacity expansion in progress 13

14 Sorona Polymer Strands and Pellets No toxic metals; PDO is directly recycled to make high quality polymer. CP Polymer provides good quality, consistency and an environmentally friendly process 14

15 Benefits of Sorona Polymer in Carpets Permanent stain resistance Exceptional durability Softness Beautiful styles and colors Excellent color clarity Easy cleanability 15

16 Sorona Polymer in Textiles Stretch and recovery Soft hand Stain resistance Easy care Easy dye Improved resilience Textile Market is Growing. Sorona received China Central Television s "Most Visionary Innovation" award in

Sorona Polymer in Engineering Thermoplastics Properties Strength, stiffness, toughness, heat

electrical insulation, chemical resistance and laser weldability Processing characteristics

components and parts Coil forms, plugs, sockets, receptacles, switches Sensors, motor housings,

17 Sorona Polymer in Engineering Thermoplastics Properties Strength, stiffness, toughness, heat resistance, impact resistance and excellent surface finish Outstanding dimensional stability, electrical insulation, chemical resistance and laser weldability Processing characteristics similar to PBT Applications and markets Electrical and electronic connectors Automotive interior components and parts Coil forms, plugs, sockets, receptacles, switches Sensors, motor housings, wiper blades & racks Appliance and power tools components Filaments for various types of brushes GR Resins 17

18 Sorona based Bio-Fabric for Use in Automobile Interiors Natural fiber based fabrics have not been used commercially for automobile interiors due to concerns about functionality, durability and aesthetics. Courtsey: Honda Motor Corporation Sorona based fabric offers: Softness Stain Resistance Luxurious appearance High durability, stability and style Better LCA 18

19 Industrial Biotechnology An example of successful application of Industrial Biotechnology... Bio PDO from corn Take advantage of new knowledge in biotechnology to make useful materials and products 19

20 Nature - then Metabolic Engineering Glucose to 1,3-Propanediol In Nature: Two microorganisms convert sugar to PDO stepwise. Glucose Glycerol PDO Yeast Bacterium For an Industrial Process: A single microorganism is required. OH OH 20

21 A Highly Collaborative Endeavor Biocatalyst & Intellectual Property Fermentation Integrated & Process Separations Development Raw Materials Refining 3GT Polymer Production & Market Access Bio-3G Bio-PDO TM Strategic partnerships Unique competencies 21

22 Quality Requirements Sorona Polymer made from Bio-PDO TM meets all and exceeds several of the quality characteristics of the chemical route PDO. PDO Purity Trace Impurities ph Stability Color Consistency Polymerization Rate Attainable DP T m,t c, T g End Groups Color Di-PDO Content Consistency Polymer Processing Spinnability Fiber Properties Processibility (dyeability, etc. ) Performance Consistency 22

23 Cradle-to-Grave Life Cycle Assessment LCA System Raw Materials Energy Recycle MS clip art style 592 Transport Transport Transport Raw Material Extraction Product Manufacturing Product Use Waste Management Co-products Air Emissions Waterborne Wastes Solid Wastes => track all inputs and outputs to the system => assess environmental impacts (energy consumption & greenhouse gases) 23

24 PDO Benchmarking: Energy Fossil-based PDO Bio-PDO TM 24 Cumulative non-renewable energy consumption per kg of PDO

25 Bioprocessing for the Future Present Pharmaceuticals, solvents, crop protection chemicals... Plastics Polymers Petroleum Refining Chemicals& Intermediates Films Future Fibers Engineered Crops Bio-processing Coatings 25

26 PO3G Polyol A New Polymer Intermediate from Renewable Resources C C [ ] O C 100% Bio n Coatings Polyether esters Polyurethanes Cast elastomers Bio PO3G copolymers Polymer blends PDO Resins, Dispersions, Films, Coatings 26

27 Attributes of Renewable PO3G Polyol Unique properties Reactive hydroxyls Lower viscosity & melting point Easy processing Slower crystallization Easy to store & transport Lower toxicity & bio-degradable Renewable resourced 27

28 Hytrel is a polyetherester Renewable Hytrel SOFT SEGMENT HARD SEGMENT O O O O O polyether O O C 4 H 8 O x 1,4-BDO y Polyether: PO3G is a polyether made from bio-pdo TM DuPont has a very strong patent position. Applications include: Airbag doors, air ducts, CVJ boots, Chassis & interiors, and other non-automotive markets 28

Excellent balance of properties Excellent flex fatigue and cut growth life across a broad temperature range airducts Low

29 Renewable Hytrel Benefits High performance thermoplastic elastomer based on 30-70% environmentally friendly monomers derived from farm crops. Properties mostly similar to commercial Hytrel products. Excellent balance of properties Excellent flex fatigue and cut growth life across a broad temperature range airducts Low temperature flexibility Continuous use range of C to C CVJ boot Good chemical and oil resistance High tear strength, toughness, resilience, and impact resistance airbrake tube airbag door 29

30 Growing the Future 30

31 For more information visit

Sustainable Growth: Biobased Fuels and Materials at DuPont. Mark A. Harmer DuPont, Wilmington, DE

Sustainable Growth: Biobased Fuels and Materials at DuPont Mark A. Harmer DuPont, Wilmington, DE verview 2 DuPont: ur Businesses Sustainability The trend to a biobased economy Biofuels Biobased materials