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 Areas of future growth Discussion
Business Platforms 3 DuPont Safety & Protection DuPont Electronic & Communication Technologies DuPont Coatings & Color Technologies $30B In Annual Sales DuPont Performance Materials DuPont Agriculture & Nutrition Applied BioScience
ur 2015 Sustainability Goals 4 Reducing Environmental Footprint Greenhouse Gas Emissions Water Conservation Fleet Fuel Efficiency Air carcinogens Independent Verification of Site Programs Serving the Marketplace Revenues from Non-Depletable Resources Products that Reduce Greenhouse Gas Emissions Products that Protect People
Examples of Sustainable Products 5
Rynaxypyr TM Insecticide 6
A Shifting Trend: Bio-Based Economy 7 Current Feedstocks Fuels il Refining Chemistry Solvents New Feedstocks Molded parts Crops Biomass Metabolic Engineering Fibers
DuPont Danisco Cellulosic Ethanol 8 8 200 2002 Refiners cost per gallon 1 100 Fixed cost incl deprec. ther Input costs * Net feedstock cost Cellulose from Cob ($50/ton) Corn Grain Ethanol ($5/bu) Regular Gasoline ($80/bbl) Regular Gasoline ($120/bbl) Target Source: DuPont Danisco estimates, on a volume basis. For illustration purposes only. Grain Ethanol indexed to 100 DuPont BP Biobutanol
Biobased Materials a New Platform 9 Chem-processing C 2 Building Blocks Bioprocessing Lower Environmental Footprint Renewable resources Lower energy consumption Lower toxicity Safer manufacturing process Unique Properties Plastics, Fibers, Coatings Markets
Propane Diol Bio vs. Chemical Transition to a bio-based process 10 DuPont Chemical Process CH 2 =CHCH 3 Propylene DuPont Biological Process C 6 H 12 6 Glucose Catalyst HCH 2 CH 2 CH 2 H PD Advantages over chemical process: Lower manufacturing cost Lower capital Smaller environmental footprint (LCA) Biocatalyst HCH 2 CH 2 CH 2 H PD
A new building block for next generation of polymers H-CH 2 -CH 2 -CH 2 -H 11 Corn Starch Glucose Glycerol PD Yeast Bacterium Combined in a Single Biocatalyst Breakthrough in Industrial Biotechnology 100 MM PPY, Loudon, TN
The DuPont Bio-PD Value Chain 12 Biomass Textile Fibers Brand Glucose Sorona Polymer Carpet Fibers Auto Interiors Resins, Packaging, etc. etc. Sorona Cosmetics & Personal Care Bio-PD PD Direct Applications 100 Million ppy Cerenol Polymers Specialty Applications Elastomers Cerenol Stretch Fibers Zemea & Susterra TM are registered trademarks of the DuPont Tate & Lyle Bio Products LLC
DuPont Sorona Polymer 13 H C H C C 1,3-Propanediol (PD) + H C C H Terephthalic Acid PD component is Bio- PD, derived from corn. 37% of Sorona content from renewable corn resource. Requires 40% less energy than petrochemical based PD C C C C C C C C C Polytrimethylene terephthalate
Sorona Polymer is Manufactured at Kinston, NC, USA & at Uentrop, Germany from Bio-PD 14 Starch Fermentation -(-C C-CH 2 CH 2 CH 2 )- n
DuPont Sorona 15 DuPont Sorona for Fibers Textiles - Commercial Carpets - Commercial Automotive Interior In development DuPont Sorona polymer EP Resins - Commercial this year Packaging - Commercial this year Sorona carpets offer superior built-in stain resistance, resilience, and softness Sorona will not retain odors like current carpet materials Sorona moisture regain is very low and therefore resistant to mold and mildew growth Lower environmental footprint
Cerenol is a family of high performance renewably sourced polyols 16 Biomass Feed Stock Bio-PD Cerenol Products Structure Bio Content Homopolymer (H-Series) H C C [ C ] H n 100% Industrial Coatings - Product launches in 2008 Imron Industrial Strength Polyurethane Enamel Imron High Gloss Direct-to-Metal (DTM) Urethane
Cerenol in Performance Coatings 17 (US Patents: 6,875,514; 7,169,475; 7,268,182) Control Cerenol formulation 120% Durability of Clear coats 100% 80% 60% 40% 20% 0% Lab V7500S 3.50% 7% 10.50% V7500S Improvement in chip resistance Improvement in flexibility Hardness retention % 20 Gloss ret. 1 year % 20 Gloss ret. 3 yr %20Gloss ret. 48.7 months %DI ret. 1 year % DI ret. 3 year %DI ret. 48.7 months 4+ years of Florida exposure Comparable or better retention of gloss and DI
Hytrel RS 18 Hytrel is a copolyetherester elastomer Better elasticity & lower temperature flexibility SFT SEGMENT PBT HARD SEGMENT Excellent flex fatigue and cut growth life polyether C 4 H 8 Good chemical & oil resistance x y High tear strength, toughness, resilience, impact resistance In Hytrel RS, renewably sourced replaces petroleum sourced polyethers in the soft segments. % renewable content 70 60 50 40 30 20 10 0 30 40 50 60 70 shore D hardness
Zytel RS 19 Developing specialty polyamides from renewable feed stocks. Sebacic acid is derived from a renewable resource and is used in preparing PA 6,10 & PA10,10. Sebacic acid Good mechanical properties & Impact Resistance to polar fluids Low moisture absorption Good paintability, extrudability Up to 100% bio-sourced Non-food crop sourced PA10,10 PA 6,10 Fuel lines Pneumatic tubes Air brake tubes Handheld device
Lightweighting Cars: Support Electrification and manifolds 20 Mass, space & packaging Getting weight, cost out of batteries, power modules Helping boost power, performance Delivering electrical Insulation for motors Materials for thermal management systems in batteries, electronics
Renewably sourced materials 21 Sorona, Sorona EP, Hytrel RS, Zytel RS for Interiors Seating, headliners, carpets, floor mats, airbag doors. Powertrain, Fuel, Chassis Hoses, tubing, air ducts, CVJ boots Electrical & Electronics Connectors, wire & Cable harnesses Lighting Bezels, connectors. Ingredient opportunities Fluids, coolants, paints SEED THE FUTURE
Marketplace Needs Properties: 22 Windmill applications Solar panels Fuel Cells, energy storge Renewably sourced Strong, tough Building Envelopes for energy efficiency Protection from severe weather conditions, tornadoes, storms Building & Construction Energy Biofuels Transportation, lighter, fuel effecient Light Stable and yet biodegradable Range of microstructures (Dense or porous) Air & Water filtration products Food & Agriculture Renewable Sourced Materials and Composites Clear and colorless Different morphologies Hydrophilic-Hydrophobic Low global warming refrigerants Food production and supplies: connecting seeds to end-use Crosslinked New Materials Cost effective
The Trend is Clear 23 The use of renewably sourced and the concept of Green is here to stay and will grow Cellulose and biomass are central to the success of all these areas A fully integrated solution is needed Cellulose and Nanocellulose can play a strong role Light weight Strong Cheap Renewable Tailorable Lets make it happen!