Coating%20Resins%20on%20Bio-based%20Raw%20Materials

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Coating Resins on Bio-based Raw Materials
Reality or Distant Future? Tosko Misev, Dirk
Stanssens DSM Resins bv, DSM Innovation Center
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Introduction

• Since existence of human beings, people have
  always used paints to express themselves
• Early paints based on natural products were of
  inferior quality

• Non-natural products were introduced to improve
  properties
• alkyds, acrylics, polyurethanes, polyesters,
  epoxies, amino resins

• Now we see a reverse movement
• Oil reserves are limited and have a long cycle
  time (100 mln years)
• Natural renewable resources are abundantly
  available with cycle time of 1 year
• White biotechnology is developing with increasing
  speed

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What is white (industrial) biotechnology?
Industrial applications
Market penetration
Biofeedstock
Replacement of fossil feedstock by sugar and
biomass
Pharma (red) biotech
Bioprocesses
Use of natures toolbox for industrial
processes (e.g., enzymes,bacteria)
WhiteBiotech
Ag (green) biotech
Bioproducts
Current and new bio based products (e.g., fuel,
materials)
Bioremediation
Use of biological processes for environ mental
cleanup (e.g., waste water, oil pests)
Time
Today
Source McKinsey
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White (industrial) biotechnology
Biotechnology The use of natures toolbox for
industrial processes
Feedstock
Bioprocess (cells / enzymes)
Products
Fermentable sugars
Specialties Materials Base chemicals Fuel
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Basic feedstock price developments
Over the last 10 years oil and sugar prices have
followed quite opposite trends
Feedstock prices are expected to decrease further
on with the conversion of wood and agricultural
waste into fermentable sugar
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Resin Raw Materials
Existing raw materials of petrochemical origin
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Polycondensation Resins
Mineral oil - Natural gas
Methanol
Reformate
Propylene
Ethanol
Propylene
Iso-or n-butyraldehyde
Formaldehyde
Acetaldehyde
Allyl Chloride
o,m,p-xylene
Epichlorohydrine
Pentaerytritol
Glycerol
Phthalic acids
Neopentyl Glycol
Trimethylol Propane
500 kT
200 kT
150 kT
Polyesters
Alkyds
1800 kT
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Polymerization Resins
Mineral oil - Natural gas
Propylene
Acetone
Alcohols
Methanol
Benzene
Ethylene
Acetone cyanhydrine
Acetic acid
Ethylbenzene
Acrolein
HCN
H2SO4
Acrylic acid
Methacrylic esters
Styrene
Acrylic esters
Vinyl acetate
Acrylics, Styrene/Acrylics and Vinyl Acetate
Copolymers
3200 kT
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Upcoming bio-based building blocks
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Building Blocks Through White Biotechnology
Sugar crops Oil crops Biomass (straw, switchgrass)
20 billion Pharma intermediates Amino acids,
Vitamins Citric acid, Oleochemicals Flavors,
fragrances Enzymes
Fermentation Bio-catalysis
1 billion Polylactic acid Glycols Ethylene Acryl
ic acid
Bio-fuel Biomaterials Nutritional
Ingredients Specialty Chemicals Commodity
Chemicals
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What can we count on ?
Biological Feedstock
Sugar crops
Oil crops
Sugars
Vegetable oils
Basic raw materials
Biotechnological and/or Conventional Processes
Polyols Polyacids Monomers
Polyols Fatty Acids
Polyesters Alkyd Resins Polyurethanes Epoxy
Resins Acrylic resins
Polyurethanes Alkyd Resins Polyamides Epoxy Esters
Coating Resins
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What we already use
Vegetable oils Renewable Non
toxic Biodegradable Full environmental
acceptance Use Alkyd resins
Glycerol Renewable Non toxic Biodegradable Full
environmental acceptance Use Alkyd resins,
Polyesters
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What is already available in the market

• Soyol biobased polyols
• OH functionality 2 3
• Molecular weight 1000-2000
• Uses
• Seating foam furniture
• Foam insulation
• Carpet backing
• Shoe soles
• Roof coatings.
• Effects
• Cost less than the petroleum polyols they
  replace.
• Plant based, annually renewable resources.
• Reduce demand and dependence on limited
  petroleum reserves.

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What we can expect to come ?
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What we expect to come
Succinic Acid C4H6O4 One of the top 12 chemicals
from biomass

• Potential use
• Diacid for polyesters
• Diacid for alkyds
• Intermediate for manufacturing of
• Maleic acid (polyesters)
• Butanediol (polyesters)
• Diaminobutane (polyamides)
• Adipic acid (polyesters, polyamides)

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Interrelation between the most relevant
1,4-bifunctional C4 building blocks. The
reactions from left to right require reduction
(so the reverse require oxidation), whereas the
ring-closures are dehydratation reactions.
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What we expect to come
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Summary of existing and potential opportunities
Acids Fatty acids Succinic acid Maleic
acid Fumaric acid Adipic acid
Polyols Glycerol Sorbitol Isosorbide Butane diol
Monomers Itaconic acid esters Acrylic acid
esters Acrylonitrile Acrylamide
Polycondensation resins Alkyd resins Polyesters Po
lyurethanes
Polymerization resins Acrylic resins Alternatives
to acrylic resins
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Can the prices go even further down?
Energy crops Miscanthus -1 years growth without
replanting!
20 tons/acre? (www.bical.net) 10-30 tons/acre
(www.aces.uiuc.edu/DSI/MASGC.pdf)
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Biomass Will Make a Difference
Turning South Dakota into
a member of OPEC?!
Thousand barrels/day
Today
Tomorrow
44 Million
Farm acres
44 Million
Saudi Arabia
9,400
Iran
3,900
Tons/acre
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15
3,429
South Dakota
80
Gallons/ton
25
2,600
Kuwait
Thousand barrels/day
857
3,429
Venezuela
2,500
UAE
2,500
2,200
Nigeria
Iraq
1,700
Libya
1,650
1,380
Algeria
925
Indonesia
Qatar
800
Source Ceres Company Presentation
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Biomass Will Make a Difference

• The chemical industry is working hard to use
  ligno-cellulose as a feedstock
• Ligno cellulose is much more available than e.g.
  crops.
• A whole plant can be used.
• Use of land not suitable for food or feed (
  prairies-USA, pampas-Argentina)
• No competition between making chemicals and
  supplying food.
• Selection and\or genetically modified plants
  that grow very fast.
• Environmentally friendly cultivation plants
  that do not need fertilizers

The next step bio-refinery
The biomass as a feedstock will further reduce
the prices of the chemicals
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Conclusion

• Oil reserves are limited, not renewable. Oil
  price still volatile and has tripled in the past
  five years
• Sugars/vegetable oils Costs decreased with a
  tendency to stabilize.
• Further progress in white biotechnology offers
  solutions based on even cheaper biomass feedstock

Coating Resins on Bio-based Raw Materials
Reality or Distant Future?
Not yet but will be soon