An update on polyethylene furanoate: Projects and aims€¦ · 2008 2011/2016 2024 > 2024 Amsterdam...

An update on polyethylene furanoate: Projects and aimsPET Value Chain: Transitioning from Linear to Circular

Amsterdam, March 13th 2018

Francesco Acquasanta – Project Leader Application Development

Table of content

2

About Synvina

From Sugars to PEF

PEF properties, Applications and markets

Circular Economy: PEF and Recycling

3

ABOUT SYNVINA

SYNVINA: Joint Venture of Avantium & BASF

PET Value Chain: Transitioning from Linear to Circular - March 13th 2018 4

Established

September 23rd

2016

~70 employees

Naming origin

SYN = Synergies,

VI(a) = The Road,

NA = Nature

Global Company

Satellites also in

Canada, Japan, USA

BASF Verbund site in Antwerp, BE

Pilot Plant in Geleen, NL

R&D in Amsterdam, NLHQ in Amsterdam, NL

Maintaining LeadershipTurning YXY technology into world scale


LAB-

SCALE

PILOT PLANT

SCALE

COMMERCIAL

SCALE

INDUSTRIAL

SCALE

2008 2011/2016 2024 > 2024

Amsterdam Geleen Antwerp Licensee Site

Kg’s Tons ≤50kta Industrial Scale

Innovative researchTechnology

development

Commercial

launch of FDCA & PEF

Roll-out of FDCA &

PEF at larger scale

Licensing

1 | Commercial plant for proof of concept & market development

2 | Licensing to rapidly expand market

6

FROM SUGARS TO PEF

A New Value Chain: From Sugars to PEF


Feedstock

preparation

Sugar DeHydration

C6 Sugars

Oxidation &

PurificationPolymerization

RMF pFDCA PEF resin

Plastic

Processing

(Polyethylene-Furanoate)(5-methoxyMethylFurfural)(Fructose) (FuranDiCarboxylicAcid )

+ bio MEG

Catalytic reforming

Oxidation &

PurificationPolymerization

Plastic

processing

Naphtha p-xylene PTA PET resin(Polyethylene-terephthalate)(Terephthalic acid)

Building on existing PET know-how

Fitting with existing PET assets

- H2O +O2

Scalable Catalytic processes

8

PEF PROPERTIES,

APPLICATIONS AND

MARKETS

APPLICATIONS OF

PEF

PEF properties, applications


PEF

Bottle

Thin Film

Thermoform

Fibre

100%

Recyclable

Using same

steps as PET

Shelf LifeImprovement

Factor vs PET

Hot Fill / Hot Serve12oC higher Tg

than PET

GAS

BARRIER

BIOBASEDRECYCLA-

BILITY

HEAT

RESISTANCE

MECHANICS

PEF

100%

Biobased

Renewable

material

Light-weighting60% higher modulus and strength than PET

O2 10xCO2 6-10x

H2O 3x

Fulfilling packaging market needs & trends

1 - High-barrier substrate film

• 11x higher O2 & 3x higher moisture barrier

Avoids need for barrier layers such as PVDC and EVOH

• Does not vary with humidity Consistent & reliable barrier

2 - Processability

• No new equipment required

• Equal thermo-mechanical & surface properties to BOPET

Conventional coating, printing and lamination

3 - Opportunities:

• 100% Bio-based layer

Brand differentiation + reduced complexity

• Recyclable with suitable other layers or compatible with clean energy

recovery at reduced GHG emissions

Application Example 1

Flexible Film Packaging - BOPEF

10PET Value Chain: Transitioning from Linear to Circular - March 13th 2018

Application Example 2

100% Bio- based Bottle

11

1- Shelf Life extension & Waste reduction vs PET

• 6x higher CO2 Barrier for Carbonated Beverages

• 10x higher O2 Barrier

2 – Same Safety & Design Freedom as PET

• Equal pressure & break resistance

• Full transparency & shape freedom

• No additional equipment required

Standard investments in preform and blow molds

3- 100% Bio-Based

• No fossil based Feedstock

• Fully recyclable

PET PEFVolume (mL) / preform weight 237 /9g 237 /13g 237 /10g 237 /14g

4.2 Vol. CO2 Shelf life to -17.5%

(wks)4 6 12 20

Oxygen ingress - time to 5 ppm

(wks) 3 (est.) 26 (est.)

PET Value Chain: Transitioning from Linear to Circular - March 13th 2018

Fulfilling packaging market needs & trends


Small bottles

and pouches

Trends in packaging

Sustainability

Smaller servings

Healthier drinks

Cost reduction

+Simplification

+Recyclability

PEF as enabler for the

growing demand of

sustainable barrier

solutions

13

CIRCULAR ECONOMY:

PEF AND RECYCLING

PEF recycling


PEF and the rPET stream

Assessing PEF effect on rPET processes/quality

Discussing industrial acceptance

EPBP in Europe APR in NA JCPRA in Japan

Synvina recycling

targets

PEF to rPEF recycling

Conducting sorting trials

Mechanical recycling

Chemical recycling

Main target

(Long Term)

Initial focus

PEF to rPEFSorting via NIR


Detection test performed by TOMRA and Pellenc in 2017

PET and PEF bottles + other material

PET

Opaque

HDPE

LHDPE

PEF

PP

PET +

Label

PET

PEF easily distinguished from other materials

With current settings, PEF will be ejected as an unknown

Recognition as PEF possible with a simple software update

PEF to rPEF - Example


Made from

Recycled PEF

100% Biobased

Conventional polyester

dyeing technology

Conventional polyester

spinning technology

PEF and the rPET streamAdapted from EPBP protocol


Dried flakesExtruded

pelletsSSP-ed pellets

Bottles FlakesWashed

flakes

Bottles FlakesWashed

flakesPlaques

with 50% vPET

Bottleswith 50% vPET

Fibers &

Films

Reference PET

Bottle innovation

X %

100- X %

“Route 1”

“Route 2”

“Route 3”

Down-scaled simulation of most common PET recycling pathway

Synvina assessed adapted route 1 and route 2 at PTI

Europe, with X= 2 % and 5 %

Ref. 0%

PEF2% PEF 5% PEF

Pellettized washed

flakes

IV [dL/g]0.754 0.752 0.750

SSPed pellets

IV increase rate

[dL/g*h]0.017 0.018 0.018

PEF and the rPET stream EPBP adapted Route 1 - Key learnings


Limited effect on IV drop and build during the process



Reference X= 2% (1% PEF) X= 5% (2.5% PEF)

Plaques with 50% virgin PET + 50 % r-PET (+ X% rPEF)

L* = 93.4

b* = 3.2

L* = 93.4

b* = 4.2

Db* = 1

L* = 92.9

b* = 5.3

Db* = 2.1

No haze good compatibility and hindered unwanted crystallization

Color is marginally affected, improvement expected with PEF color

2% rPEF in rPET Db* < 1.5 limit

5% rPEF in rPET Db* > 1.5 limit



Control* 2% Route 2 5% Route 2

Typical PET PTI data

PET+1% PEF PET+2.5% PEF

Burst Pressure Linear increase bar 11.0 11.8 11.5

Thermal stabilityBase push-up, 4.25 volCO2, 24h 38°C,

mm -4.0 -4.2 -4.1

Drop test(4°C and 22°C)

1.8 m, bottom down, 72hafter SBM

PASS rate 100 % 100 % 100 %

Top LoadAt 1 mm deflection,Empty

N 225 240 225

Bottle properties are within acceptable range of control bottle

1.5 L CSD

bottle

Fiber trialsup to 20% virgin IV 0.6 dL/g PEF in PET

<10% PEF no significant changes in process conditions and properties

> 10 % PEF process adjustment would be required to obtain sufficient properties

PEF and the rPET stream Assessment in fibers - Key learnings


EPBP interim approval


Interim approval of 50 kton/year market launch by European PET Bottle Platform

http://www.epbp.org/download/319/interim-approval-

synvinas-polyethylene-25-furandicarboxylate-or-pef

http://www.epbp.org/download/319/interim-approval-synvinas-polyethylene-25-furandicarboxylate-or-pef

Synvina’s Continuous commitment to Circular Economy


Development of end-of-life options

Involvement of recycling industryPEF end-product developments

Recycling assessment depends on end-products

developments (volumes and values)

25

BACKUP SLIDES

Why PEF?


Trends in packaging:

• Sustainability

• Smaller servings

• Healthier drinks

• Cost reduction

APEF

APET

PLA

< 300mL PEF bottles

100%

Recyclable

Using same

steps as PET

Shelf LifeImprovement

Factor vs PET

Hot Fill / Hot Serve12oC higher Tg

than PET

GAS

BARRIER

BIOBASEDRECYCLA-

BILITY

HEAT

RESISTANCE

MECHANICS

PEF

100%

Biobased

Renewable

material

Light-weighting60% higher modulus and strength than PET

O2 10xCO2 6-10x

H2O 3x

PEF bottles


Obtained bottle properties (vs PET)

CO2 Shelf life (6-10x)

O2 Shelf life (10x)

PEF bottles as enabler for higher shelf life

Growing market for rigid plastics in beverage packaging

1.5 L CSD

bottle

PEF and the rPET stream EPBP Route 2 - Key learnings


Control* 2% Route 2 5% Route 2

Typical PET PTI data

PET+1% PEF PET+2.5% PEF

Burst Pressure Linear increase bar 11.0 11.8 11.5

Vol incr. at burst Linear increase ml 565 594 565

Thermal stabilityBase push-up, 4.25 volCO2, 24h 38°C,

mm -4.0 -4.2 -4.1

Drop test vertical 4°C1.8 m, bottom down,72h after SBM

PASS rate 12/12 10/10 8/8

Drop test vertical 22°C1.8 m, bottom down,72h after SBM

PASS rate 12/12 10/10 8/8

Top LoadAt 1 mm deflection,Empty

N 225 240 225

Bottle properties are within acceptable range of control bottle

An update on polyethylene furanoate: Projects and aims€¦ · 2008 2011/2016 2024 > 2024 Amsterdam...

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Transcript of An update on polyethylene furanoate: Projects and aims€¦ · 2008 2011/2016 2024 > 2024 Amsterdam...