PEF Recycling June 2017
SYNVINA: Joint Venture of Avantium & BASF BASF s Verbund site in Antwerp, Belgium perates pilot plant production in Geleen, with HQ and R&D in Amsterdam, NL Intention to build first commercial scale production plant Intended reference plant of 50,000 tons FDCA capacity Building licensing package for Synvina s technology and enabling industrial scale roll-out 2
The Synvina value chain: from sugars to PEF Feedstock preparation Sugar DeHydration xidation Green & Purification Materials/fuels Polymerization Processing New assets Retrofit assets Retrofit assets Existing assets R H H Sugars RMF pfdca PEF resin Bioplastic products (Fructose) (5-methoxyMethylFurfural) (FuranDiCarboxylicAcid ) (Polyethylene-Furanoate) - H2 +2 +MEG Catalytic processes developed using high throughput screening at Avantium, who continues to work on a.o. 2 nd generation feedstock sugar processes Targeting a good fit with the existing chemical industry: Chemistry of RMF to PEF is comparable to paraxylene to PET 3
PEF bottles Realized in final bottle properties (vs PET) C 2 Shelf life (4-6x) 2 Shelf life (8-10x) Top load (2x) Initially we expect PEF bottles where monolayer PET is currently not used, thus growing the market for rigid plastics in beverage packaging 4
PEF recycling Synvina aims to promote re-use and recycling of PEF Main target: PEF to PEF recycling : Mechanical recycling: demonstrated using same steps as PET Chemical recycling: demonstrated PEF depolymerization to monomers Timing depends on volume and value PEF and the rpet stream Conducting sorting trials with sorting equipment manufacturers Assessing PEF effect on rpet processes and rpet quality for various end-products Discussing industrial acceptance with industry associations e.g. EPBP in Europe and APR in North America 5
PEF recycling Synvina aims to promote re-use and recycling of PEF Main target: PEF to PEF recycling : Mechanical recycling: demonstrated using same steps as PET Chemical recycling: demonstrated PEF depolymerization to monomers Timing depends on volume and value initial launch 50000 t/year PEF and the rpet stream Initial focus Conducting sorting trials with sorting equipment manufacturers Assessing PEF effect on rpet processes and rpet quality for various end-products Discussing industrial acceptance with industry associations e.g. EPBP in Europe and APR in North America 6
PEF Sorting NIR detection by TMRA and Pellenc (example below) Initial test 2013 Updated test 2017 237mL, 10g vs 13g PET paque HDPE LDPE PEF PP PET PET+Label PEF can easily be distinguished as a non-pet material: Without software updates it will be ejected as an unknown 7
PEF in rpet Testing according to EPBP protocol (adapted schematic) Relative effects of a contaminant compared to bottle flakes from reference PET grades Down-scaled simulation of most common PET recycling pathway Reference Bottles Flakes Bottle innovation Bottles Flakes Washed flakes Washed flakes 100 / 98 / 95% Dried flakes 0 / 2 / 5% Extruded pellets SSP-ed pellets Route 1 Plaques with 50% vpet Route 2 Bottles with 50% vpet Route 3 Fibers & Films Synvina has conducted the following trials with PEF as the bottle innovation Bottle to Plaque according to EPBP Route 1 at PTI Europe Bottle to Bottle according to EPBP Route 2 at PTI Europe (without flake washing) Fiber trials using virgin IV 0.6 dl/g resins of up to 20% PEF in PET at Centexbel 8
PEF in rpet - Key learnings End products are haze-free Rare result for high levels of another polymer, typically haze at >0.2% Tendency of haze formation via crystallization is further reduced (melt point stays within acceptable range) L* = 93.4, b* = 3.2 L* = 93.4, b* = 4.2 L* = 92.9, b* = 5.3 Control 2% PEF 5% PEF Picture: EPBP route 1 final plaques w 50% vpet Color is marginally affected; within target Δb* = 1.5 at 2% and close to target at 5% Improvements are expected with improved PEF resin color 9
PEF in rpet - Key learnings IV drop and build during washing, extrusion and SSP is barely affected by the presence of 2 and 5% PEF in rpet Control (IV 0.754) 2% PEF (IV 0.752) 5% PEF (IV 0.750) Extruded fakes (after washing) Control (0.017 dl/g.h) 2% PEF (0.018 dl/g.h) 5% PEF (0.018 dl/g.h) SSP-ed pellets Confidential 10
PEF in rpet - Key learnings Bottle properties are within acceptable range of control bottle Control* 2% Route 2 5% Route 2 Large CSD Bottle volume 1.5L 1.5L 1.5L Material PET PET+1% PEF PET+2.5% PEF Burst Pressure Linear increase 11.0 bar 11.8 bar 11.5 bar Vol incr. at burst Linear increase 565 ml 594 ml 565 ml Thermal stability 4.25 vol C2, 24h 38 C, Base push-up -4.0 mm -4.19 mm -4.11 mm Drop test vertical 4 C 1.8 m, bottom down, 72h 12/12 K 10/10 K 8/8 K Drop test vertical 22 C 1.8 m, bottom down, 72h 12/12 K 10/10 K 8/8 K Top Load @1.0 mm deflection Empty 225.0 N 239.8 N 224.7 N Fibers show need for changes in spinning conditions above 10% PEF in that case, higher draw ratios are required to obtain sufficient properties *Typical PTI data 11
EPBP interim approval Interim approval of 50,000 ton/year market launch by European PET Bottle Platform Please find the full press release here. 12
Next steps Continuation as key aspect of PEF end-product development programs: Continued development of end-of-life options: Sorting efficiency trials Pilot trials through common PET recycling technologies, and rpet quality validation in common rpet applications Development of target rpef applications Continued involvement of recycling industry 13
PEF to rpef - Example 100% bio-based Conventional polyester spinning technology Made from Recycled PEF Conventional polyester dyeing technology 14