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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
PET Value Chain: Transitioning from Linear to Circular - March 13th 2018 5
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
PET Value Chain: Transitioning from Linear to Circular - March 13th 2018 7
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
PET Value Chain: Transitioning from Linear to Circular - March 13th 2018 9
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
PET Value Chain: Transitioning from Linear to Circular - March 13th 2018 12
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
PET Value Chain: Transitioning from Linear to Circular - March 13th 2018 14
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
PET Value Chain: Transitioning from Linear to Circular - March 13th 2018 15
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
PET Value Chain: Transitioning from Linear to Circular - March 13th 2018 16
Made from
Recycled PEF
100% Biobased
Conventional polyester
dyeing technology
Conventional polyester
spinning technology
PEF and the rPET streamAdapted from EPBP protocol
PET Value Chain: Transitioning from Linear to Circular - March 13th 2018 17
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
PET Value Chain: Transitioning from Linear to Circular - March 13th 2018 18
Limited effect on IV drop and build during the process
PEF and the rPET stream EPBP adapted Route 1 - Key learnings
PET Value Chain: Transitioning from Linear to Circular - March 13th 2018 19
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
PEF and the rPET stream EPBP adapted Route 2 - Key learnings
PET Value Chain: Transitioning from Linear to Circular - March 13th 2018 20
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
PET Value Chain: Transitioning from Linear to Circular - March 13th 2018 21
EPBP interim approval
PET Value Chain: Transitioning from Linear to Circular - March 13th 2018 22
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
Synvina’s Continuous commitment to Circular Economy
PET Value Chain: Transitioning from Linear to Circular - March 13th 2018 23
Development of end-of-life options
Involvement of recycling industryPEF end-product developments
Recycling assessment depends on end-products
developments (volumes and values)
24
25
BACKUP SLIDES
Why PEF?
PET Value Chain: Transitioning from Linear to Circular - March 13th 2018 26
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
PET Value Chain: Transitioning from Linear to Circular - March 13th 2018 27
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
PET Value Chain: Transitioning from Linear to Circular - March 13th 2018 28
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