Bio-Based Polymers - IHS Markit

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Bio-Based PolymersPEP Report 265BDecember 2018Susan BellSr. Principal AnalystAuthor NameIHS Job TitleAuthor NameIHS Job TitleSusan BellSr. Principal AnalystProcess Economics Program

IHS Markit PEP Report 265B Bio-Based PolymersPEP Report 265BBio-Based PolymersSusan Bell, Sr. Principal AnalystAbstractBio-based polymers are defined as material where at least a portion of the polymer consists of materialproduced from renewable raw materials. For example, bio-based polymers may be produced from cornor sugar cane. The remaining portion of the polymers may be from fossil fuel–based carbon. Bio-basedpolymers have generally lower CO2 footprint and are associated with the concept of sustainability. Thetotal bio-based polymer market represents a tiny portion—about 1%—of the global polymer market.However, the market for bio-based polymers is expected to grow faster with growing usage in thebeverage packaging industry, cost reduction, increasing government support for adopting bio-basedmaterials, and rising consumer acceptance.The largest potential market for bio-based biodegradable polymer is in the packaging industry.Consumption of biodegradable polymer is expected to grow globally at an average annual rate of 9%between 2017 and 2022. Polylactic acid (PLA) and polyhydroxyalkanoates (PHAs) are both major biobased biodegradable plastics. Most of the PLA produced is used for packaging. PHAs are versatilebiodegradable bio-based polymers that can be used in a wide range of applications. Poor productioneconomics have limited commercialization of PHAs.Conventional bottle-grade polyethylene terephthalate (PET) resin is used to produce beverage bottles.The plastic bottle beverage industry has been under intense pressure over the amount of PET producedand the solid waste generated from discarded conventional PET-based bottles. Responsible andsustainable PET consumption has been a major goal. Feedstocks for PET are petroleum-based. Toachieve sustainability, bio-based feedstocks for PET production are being commercialized.This report examines production technologies for PLA and its monomer lactic acid, PHA, and biobased PET, and evaluates the process economics for producing the polymers and lactic acid. This reportwill be of value to those companies engaging in the production of bio-based polymers and conventionalpetroleum-derived feedstock-based polymers.Confidential. 2018 IHS Markit. All rights reserved.1December 2018

IHS Markit PEP Report 265B Bio-Based nIndustrial aspectsTechnical aspectsLactic acid productionPolylactic acid (PLA) productionPolyhydroxyalkanoates (PHAs) productionBio-based polyethylene terephthalate (PET) productionEconomic aspectsLactic acidBio-based polymersPolylactic acid and polyhydroxyalkanoateBio-based polyethylene terephthalate (PET)Summary of production costsIndustry statusIntroductionPolylactic acid (PLA)CargillBASF SECorbion (Purac)GalacticNatureWorksPlaxicaSynbra Technology bvTotal Corbion PLAUhde Inventa-FischerPolyhydroxyalkanoates (PHAs)Bio-based polyethylene terephthalate (PET)TechnologyPolylactic acid (PLA)Lactic acid productionLactic acidLactic acid production by chemical synthesisLactic acid production by fermentationPLA productionTypes of PLALactide synthesisLactide polymerizationSustainabilityPolyhydroxyalkanoates (PHAs)IntroductionChemistryPHA productionMetabolic pathwaysMicroorganismsCarbon sourcesFermentationPHA recoveryConfidential. 2018 IHS Markit. All rights 58606262December 2018

IHS Markit PEP Report 265B Bio-Based Polymers56Bio-based polyethylene terephthalate (PET)IntroductionBio-based ethylene glycolBio-based purified terephthalic acid (PTA)Bio-based para-xylene productionPurified terephthalic acid production from para-xylenePolyethylene terephthalate (PET) productionPolylactic acidIntroductionLactic acid productionProcess descriptionSection 100—FermentationSection 200—Biomass separation and lactic acid recoverySection 300—Lactic acid purificationProcess discussionPlant design capacityPlant locationYeast fermentationSimple defined mediaLactic acid recoveryMaterial of constructionWaste treatmentCost estimateCapital costsL-lactic acid production costsComparison of L-lactic acid production costsPolylactic acid productionProcess descriptionSection 100—Lactide production and purificationSection 200—Lactide polymerizationProcess discussionPlant design capacityStorageLactide productionLactide ion and crystallizationMaterial of constructionWaste treatmentCost estimateCapital costsPLA production costsPolyhydroxyalkanoateIntroductionPHA productionProcess descriptionSection 100—FermentationSection 200—PHA recoveryProcess discussionPlant design capacityCarbon substrateBacterial fermentationMCL-PHA recoveryConfidential. 2018 IHS Markit. All rights er 2018

IHS Markit PEP Report 265B Bio-Based PolymersMaterial of constructionWaste treatmentCost estimateCapital costsMCL-PHA production costs7Bio-based polyethylene terephthalate (PET)IntroductionBio-based PET productionProcess descriptionSection 100—Ethanol productionSection 200—Ethylene productionSection 300—Ethylene glycol productionSection 400—p-Xylene productionSection 500—Purified terephthalic acid (PTA) productionSection 600—Bottle-grade polyethylene terephthalate (PET) productionProcess discussionPlant design capacityProcess selectionOnstream factorUtilities consumptionOffsites storageWaste treatmentCost estimateAppendix A—Cited referencesAppendix B—PatentsAppendix C—Patent references by companyAppendix D—Design and cost basisDesign conditionsSite locationFacility site basisCost basesCapital InvestmentProject construction timingAvailable utilitiesProduction costsEffect of operating level on production costsAppendix E—Process flow 2172174174175175177TablesTable 2.1 L-Lactic acid production costsTable 2.2 Polylactic acid and polyhydroxyalkanoate production costsTable 2.3 Commodity polymer pricesTable 2.4 Bio-based PET and conventional PET production costsTable 3.1 PLA production capacityTable 4.1 Select properties of lactic acidTable 4.2 Typical properties of commercial polylactic acidTable 4.3 Polylactic acid propertiesTable 4.3 Physical properties of polylactic acidTable 4.4 Commercial PHAsTable 4.5 Physical properties of PHAsConfidential. 2018 IHS Markit. All rights reserved.41920202126334246525555December 2018

IHS Markit PEP Report 265B Bio-Based PolymersTable 4.6 PHA production by fed-batch mode fermentationTable 4.7 Carbon substrates used for commercial PHATable 4.8 Comparison of methods for PHA recoveryTable 5.1 L-Lactic acid by a process similar to Cargill’s low-pH technology—Design basesTable 5.2 L-Lactic acid by a process similar to Cargill’s yeast fermentation—Major stream flowsTable 5.3 L-Lactic acid by a process similar to Cargill’s yeast fermentation—Major equipmentTable 5.4 L-Lactic acid by a process similar to Cargill’s yeast fermentation—Utilities summaryTable 5.5 Summary of major waste streamsTable 5.6 L-Lactic acid by a process similar to Cargill’s yeast fermentation—Total capitalinvestmentTable 5.7 L-Lactic acid by a process similar to Cargill’s yeast fermentation—Capital investment bysectionTable 5.8 L-Lactic acid by a process similar to Cargill’s yeast fermentation—Production costsTable 5.9 L-Lactic acid by a conventional bacterial fermentation process—Production costsTable 5.10 PLA by a process similar to Uhde Inventa-Fischer PLAneo process—Design basesTable 5.11 PLA by a process similar to Uhde Inventa-Fischer PLAneo process—Major streamflowsTable 5.12 PLA by a process similar to Uhde Inventa-Fischer PLAneo process—MajorequipmentTable 5.13 PLA by a process similar to Uhde Inventa-Fischer PLAneo process—UtilitiessummaryTable 5.14 Summary of major waste streamsTable 5.15 PLA by a process similar to Uhde Inventa-Fischer PLAneo process—Total capitalinvestmentTable 5.16 PLA by a process similar to Uhde Inventa-Fischer PLAneo process—Capitalinvestment by sectionTable 5.17 PLA by a process similar to Uhde Inventa-Fischer PLAneo process—ProductioncostsTable 6.1 MCL-PHA production by bacterial fermentation with canola oil as the carbon source—Design basesTable 6.2 MCL-PHA production by bacterial fermentation with canola oil as the carbon source—Major stream flowsTable 6.3 MCL-PHA production by bacterial fermentation with canola oil as the carbon source—Major equipmentTable 6.4 MCL-PHA production by bacterial fermentation with canola oil as the carbon source—Utilities summaryTable 6.5 Typical canola oil compositionTable 6.6 Summary of major waste streamsTable 6.7 MCL-PHA production by bacterial fermentation with canola oil as the carbon source—Total capital investmentTable 6.8 MCL-PHA production by bacterial fermentation with canola oil as the carbon source—Capital investment by sectionTable 6.9 MCL-PHA production by bacterial fermentation with canola oil as the carbon source—Production costsTable 7.1 Bio-based PET production from corn—Utilities summaryTable 7.2 Summary of major waste streamsTable 7.3 Bio-based PET production from corn by an integrated process (IV 0.82 dL/g)—CapitalinvestmentTable 7.4 Bio-based PET production from corn by an integrated process (IV 0.82 dL/g)—VariablecostsTable 7.5 Bio-based PET production from corn by an integrated process (IV 0.82 dL/g)—Production costsTable 7.6 PET by a process similar to INVISTA CP process and Polymetrix EcoSphere SSPprocess (IV 0.82 dL/g) ¾ Variable costsTable 7.7 PET by a process similar to INVISTA CP process and Polymetrix EcoSphere SSPprocess (IV 0.82 dL/g)—Production costsConfidential. 2018 IHS Markit. All rights 3144December 2018

IHS Markit PEP Report 265B Bio-Based PolymersFiguresFigure 2.1 World production capacity of bio-based polymersaFigure 2.2 Lactic acid production process by Cargill’s lactic acid process with yeast fermentationFigure 2.3 Uhde Inventa-Fischer PLAneo process block diagramFigure 2.4 MCL-PHA production process block diagramFigure 2.5 Corn to bio-based PET value chainFigure 2.6 Bottle-grade bio-based PET from corn input and outputFigure 2.7 Process economics summaryFigure 3.1 World production capacity of bio-based polymersaFigure 4.1 Lactic acid enantiomersFigure 4.2 Lactic acid production from cornFigure 4.3 Lactate production by Embden-Meyerhof-Parnas (EMP) pathwayFigure 4.4 Lactic acid production process by bacterial fermentationFigure 4.5 Lactic acid production process by Corbion’s gypsum-free lactic acid processFigure 4.6 Lactic acid production pathway by modified yeastFigure 4.7 Lactic acid production process by Cargill’s lactic acid process with yeast fermentationFigure 4.8 First-generation PLA production processFigure 4.9 Routes to polylactic acidFigure 4.10 Lactide enantiomersFigure 4.11 Depolymerization reactor from Hitachi’s patent US 20100249362Figure 4.12 Depolymerization reactor from Companhia Refinadora Da Amazonia’s patent US20130267675Figure 4.13 Uhde Inventa-Fischer PLAneo process block diagramFigure 4.14 PLA process with Optipure Figure 4.15 Plaxica’s D-lactate production process based on US 20150152449Figure 4.16 Tubular lactide polymerization reactor from Companhia Refinadora Da Amazonia’spatent US 20130267675Figure 4.17 Polymerization system from Uhde’s patent US 8399602Figure 4.18 PLA tacticitiesFigure 4.19 Basic structure of PHAFigure 4.20 Metabolic pathways to PHB and PHBVFigure 4.21 Metabolic pathways to MCL-PHAFigure 4.22 Biomass conversion to VFA by anaerobic digestionFigure 4.23 Structure of polyethylene terephthalate (PET)Figure 4.24 Bio-based ethylene glycol via bio-based ethanolFigure 4.25 Ethylene production from ethanol by adiabatic fixed-bed catalytic dehydrationFigure 4.26 Ethylene glycol production from ethylene and oxygen by Shell OMEGA processFigure 4.27 Bio-based ethylene glycol via Haldor Topsoe’s Monosaccharide Industrial Cracker(MOSAIK ) processFigure 4.28 Bio-based purified terephthalic acid (PTA) via bio-based para-xyleneFigure 4.29 Bio-based para-xylene by Gevo processFigure 4.30 Bio-based para-xylene by Virent processFigure 4.31 Bio-based para-xylene by Anellotech processFigure 4.32 Purified terephthalic acid production from para-xylene by INVISTA processFigure 4.33 Bottle-grade PET production using the Integrated INVISTA continuous polymerizationPET/Polymetrix (Buhler) EcoSphere SSP processFigure 7.1 Corn-to-PET value chainFigure 7.2 Corn-to-ethanol input and outputFigure 7.3 Ethylene input and outputFigure 7.4 Ethylene glycol input and outputFigure 7.5 Corn-to-p-xylene input and outputFigure 7.6 p-Xylene-to-PTA input and outputFigure 7.7 Bottle-grade PET from PTA and EG input and outputFigure 7.8 Bottle-grade bio-based PET from corn input and outputFigure 5.1 Polymer-grade lactic acid—Fermentation sectionConfidential. 2018 IHS Markit. All rights 1132133134134135178December 2018

IHS Markit PEP Report 265B Bio-Based PolymersFigure 5.1 Polymer-grade lactic acid—Biomass separation and lactic acid recovery sectionFigure 5.1 Polymer-grade lactic acid—Purification sectionFigure 6.1 Polymer-grade lactic acid—Purification sectionFigure 5.2 PLA by a process similar to Uhde Inventa-Fischer PLAneo process—Lactideproduction and purification sectionFigure 5.2 PLA by a process similar to Uhde Inventa-Fischer PLAneo process—Lactidepolymerization sectionFigure 6.1 MCL-PHA by bacterial fermentation with canola oil as the carbon source—Fermentation sectionFigure 6.1 MCL-PHA by bacterial fermentation with canola oil as the carbon source—PHArecovery sectionConfidential. 2018 IHS Markit. All rights reserved.7179180181182183184185December 2018

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Bio-based polymers are defined as material where at least a portion of the polymer consists of material produced from renewable raw materials. For example, bio-based polymers may be produced from corn or sugar cane. The remaining portion of the polymers may be from fossil fuel–based carbon. Bio-based polymers have generally lower CO 2

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