Process Economics Program - IHS Markit

IHS ChemicalProcess EconomicsProgramReport 265ABio-Based PolymersBy Susan L. Bell

IHS Chemical Process Economics Program Report 265AIHS Chemical agrees to assign professionally qualified personnel to the preparation of the ProcessEconomics Program’s reports and will perform the work in conformance with generally acceptedprofessional standards. No other warranties expressed or implied are made. Because the reports areof an advisory nature, neither IHS Chemical nor its employees will assume any liability for thespecial or consequential damages arising from the Client’s use of the results contained in the reports.The Client agrees to indemnify, defend, and hold IHS Chemical, its officers, and employees harmlessfrom any liability to any third party resulting directly or indirectly from the Client’s use of the reportsor other deliverables produced by IHS Chemical pursuant to this agreement.For detailed marketing data and information, the reader is referred to one of the IHS Chemicalprograms specializing in marketing research. THE IHS CHEMICAL ECONOMICS HANDBOOKProgram covers most major chemicals and chemical products produced throughout the world. Inaddition the IHS DIRECTORY OF CHEMICAL PRODUCERS services provide detailed lists ofchemical producers by company, product, and plant for the United States, Europe, East Asia, China,India, South & Central America, the Middle East & Africa, Canada, and Mexico.August 2013 2013 IHS

IHS Chemical Process Economics Program Report 265APEP Report 265ABio-Based PolymersBy Susan L. BellAugust 2013AbstractBio-based polymers are defined as materials for which at least a portion of the polymer consists of materialproduced from renewable raw materials. For example, bio-based polymers may be produced from corn orsugarcane. The remaining portion of the polymers may be from fossil fuel-based carbon. Bio-basedpolymers generally have a lower CO2 footprint and are associated with the concept of sustainability.Because of concerns about the depletion of fossil resources and the global warming associated with the useof petrochemicals, new bio-based polymers continue to be developed.Several new bio-based polymers have been commercialized. A bio-based polycarbonate, isosorbidepolycarbonate, can potentially be used as an alternative to petroleum-based polycarbonate. Corn-basedisosorbide is used as a replacement for bisphenol A (BPA) monomer. Bio-based polybutylene succinate(PBS) resin prepared from bio-based succinic acid and bio-based 1,4-butanediol (BDO) can replacebiodegradable petrochemical-based PBS. Green polyethylene has been commercialized with bio-basedethylene.In this report, recent developments in bio-based polymers since our last report published in 2008 arediscussed. This report reviews the production of the bio-based monomers required to produce isosorbidepolycarbonate, polybutylene succinate, and polyethylene. The process economics for producing themonomers and polymers are evaluated. Comparative process economics for the conventional petroleumderived polymers are included. This report will be of value to those companies engaged in the productionof bio-based polymers and the conventional petroleum-derived-feedstock-based polymers.August 2013 2013 IHS

IHS Chemical Process Economics Program Report 265AContentsGlossary . xiii1. Introduction . 1-12. Summary . 2-1Introduction . 2-1Industrial aspects . 2-1Overview . 2-1Bio-based polycarbonate . 2-1Bio-based polybutylene succinate . 2-2Bio-based polyethylene . 2-2Renewable feedstocks . 2-2Technical aspects. 2-4Monomer production . 2-4Isosorbide production from glucose feedstock. 2-4Succinic acid production from glucose feedstock . 2-41,4-Butanediol production from glucose feedstock . 2-4Ethylene production from corn or sugarcane feedstock . 2-4Polymer production . 2-5Isosorbide polycarbonate production . 2-5Polybutylene succinate production . 2-5Polyethylene production . 2-5Economic aspects . 2-6Bio-based isosorbide. 2-6Bio-based succinic acid . 2-6Bio-based 1,4-butanediol . 2-7Bio-based ethylene. 2-8Bio-based polycarbonate . 2-10Bio-based polybutylene succinate . 2-11Bio-based polyethylene . 2-123. Industry status . 3-1Introduction . 3-1Overview . 3-1Bio-based polymers . 3-3Polycarbonate . 3-3Conventional polycarbonate. 3-3Bio-based polycarbonate . 3-5Mitsubishi Chemical . 3-5Roquette. 3-6Polybutylene succinate . 3-6Petroleum-based polybutylene succinate . 3-6Bio-based polybutylene succinate . 3-7August 2013iii 2013 IHS

IHS Chemical Process Economics Program Report 265AContents (continued)Mitsubishi Chemical . 3-8Showa Denko . 3-8Uhde Inventa-Fischer . 3-8Bio-Based Succinic Acid. 3-8BioAmber . 3-9Myriant Technologies . 3-9Reverdia . 3-9Succinity GmbH . 3-10Bio-based 1,4-butanediol (BDO) . 3-10Genomatica . 3-10BioAmber . 3-10Myriant and Davy Process Technology . 3-10Metabolix . 3-11Polyethylene . 3-11Petroleum-based polyethylene . 3-11Bio-based polyethylene . 3-14Other bio-based polymers . 3-15Polyamide. 3-15Castor oil-based polyamide . 3-15PA56 . 3-15PA66 . 3-15Polylactic acid . 3-15Starch-based polymers . 3-16Novamont . 3-16Ingredion . 3-16BIOP Biopolymer Technologies AG. 3-17Rodenburg Biopolymers . 3-17Polyhydroxyalkanoates (PHA). 3-17Bio-based polyols. 3-174. Bio-based polymer production chemistry and technology . 4-1Introduction . 4-1Isosorbide polycarbonate. 4-1Sorbitol production . 4-1Isosorbide production . 4-4Isosorbide polycarbonate production . 4-7Polybutylene succinate (PBS) . 4-11Polybutylene succinate production . 4-11Bio-based succinic acid . 4-17Bio-based 1,4-butanediol (BDO) . 4-211,4-Butanediol by fermentation of sugar (direct route). 4-21August 2013iv 2013 IHS

IHS Chemical Process Economics Program Report 265AContents (continued)1,4-Butanediol by hydrogenation of bio-based succinic acid (indirect route) . 4-23Polyethylene . 4-24Polyethylene production . 4-24Bio-based ethanol production . 4-25Corn to ethanol . 4-25Sugarcane to ethanol . 4-27Ethylene from ethanol. 4-295. Economic evaluation of bio-based monomer production . 5-1Introduction . 5-1Isosorbide production from glucose feedstock . 5-1Process description . 5-1Section 100—sorbitol production . 5-7Section 200—isosorbide production . 5-7Process discussion . 5-8Materials of construction . 5-8Production of highly purified sorbitol . 5-8Production of isosorbide . 5-9Cost estimates . 5-10Cost sensitivity . 5-19Succinic acid production from glucose feedstock . 5-20Process description . 5-20Section 100—fermentation . 5-22Section 200—recovery and purification . 5-22Cost estimates . 5-23Cost sensitivity . 5-281,4-Butanediol production from glucose feedstock. 5-28Process description . 5-28Section 100—fermentation . 5-31Section 200—recovery and purification . 5-31Cost estimates—recovery and purification . 5-32Cost sensitivity . 5-38Bio-based ethylene production . 5-38Bio-based ethanol . 5-38Sugarcane feedstock . 5-38Description . 5-38Cost estimates .

Bio-based polymers are defined as materials for which 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 sugarcane. The remaining portion of the polymers may be from fossil fuel-based carbon. Bio-based polymers generally have a lower CO