asking more from chemistryexpertise in polymers and formulations advanced materials developing...

04/03/2013

Asking more from chemistry

“More than a pledge, our signature is a vision and a challenge to which we are fully committed”

Jean-Pierre Clamadieu, CEO

2 Présentation CNRS Paris 2015-11-09 Confidentiel ©

Building a strong leader, a player in the reshaping of the global chemical industry. Asserting ourselves as a model of sustainable chemistry, capable of attracting and developing talented people who conceive, design and produce solutions to meet the major challenges facing society today.

Building a model of sustainable chemistry

10,213 million net sales

26,000 employees

119 sites

52 countries

15 major R&I centers

2014 figures


26%

18% Automotive

& aeronautics

10% Energy & environment

11% Agro, feed

& food

12% Building & construction

7% Electrical & electronics

16% Industrial applications

Distribution of 2014 net sales

A diversified offering

Consumer goods

& healthcare

Solvay by market


6 R&I areas to meet the challenges of the future

Expertise in polymers and formulations

Advanced materials

Developing alternatives to fossil fuel consumption: new generation batteries, photovoltaics, bio-energy

Sustainable energy

Materials to improve the sustainability of lighting devices and screens

Organic electronics

New processes offering diminished raw materials and energy consumption, and reduced emissions

Eco-designed processes

Innovation in renewable or recycled raw materials

Renewable chemistry Creating responsible products that provide solutions to global issues

Advanced formulations


Our business activities…

Soda Ash & Derivatives

Aroma Performance

Coatis

Novecare

Silica

Rare Earth Systems

Specialty Polymers

Acetow

Peroxide P&I

Engineering Plastics

Polyamide

Corporate Functions

Energy Services

Special Chemicals Emerging

Biochemicals

Fibras Adva

nced

Mate

rials

Perfo

rman

ce C

hemi

cals

Func

tiona

l Poly

mers

Corp

orate

& B

usine

ss S

ervic

es

Adva

nced

For

mulat

ions

Function Competitiveness Bio-attribute


eucalyptus spruce pine coconut palm soybean rapeseed peanut

corn rice

castor bean

guar sugarcane

Plants: a source of natural molecules and polymers

fatty acids

sugars

glucose polymers polysaccharides

wheat

alcohols glycerin

… rely on diversified biosourced materials…

b-pinene


… from different geographical origins

eucalyptus

eucalyptus

spruce rapeseed

corn/wheat

guar

coconut palm

castor bean

rice pine

pine pine

pine

Sugarcane (sugar, bagasse)

sugarcane


- Use of glycerol instead of propylen: Epicerol® - Development of N-butanol production on bagasse in Brazil

Some needs of clarification ? Same challenges ? Same answers ?

Renewable based chemistry

Sustainable chemistry

Biotech-based chemistry

Green Chemistry



Some needs of clarification ? Same challenges ? Same answers ?




Green Chemistry

10 Présentation CNRS Paris 2015-11-09 Confidentiel © Confidentiel ©

The bio-based chemistry is a new production paradigm driven by the latest developments in both classical chemistry and biotechnologies

• A bio-based chemical or polymer is defined as a material that contains carbon derived from renewable feedstocks - Not to be confused with bio-

degradable or bio-processed/biotechnology

- It can be bio-sourced identical replacement (“drop in”), new types (polymers such as PLA, PHA) or functional replacement (esters for plasticizers or hydrocarbon solvents, isobutanol for gasoline, FDCA for TPA)

- No global standard defining the bio-sourced products, but multiple certifications and labels with important variations (bio-sourced content limited to carbon or extended to other atoms, level of minimum bio-sourced content…)

Our definitions

Prod

uct o

rigin

Non

Fos

sil

~ bi

o so

urce

d

Foss

il

Biotechnologies Classic chemistry

Transformation routes

Limited range of opportunities. Indeed, most of the biotransformation raw materials are oxidized products, whereas fossil products are mainly reduced

Scope of the bio-based strategy

E.g: Epicerol, Biobutanol, FDCA,

Bio-sourced ethylene...

E.g: Cobalt/Biobutanol, Succinic acid , 1,3PDO,

production from glucose

fermentation,…

E.g: Acrylamide synthesis from acrylonitrile via

enzymatic hydrolyze, DDDA from paraffins..

NB: the « bio » terms used in every day life corresponds to a defined specifications , without any systematic link with bio sourced or bio transformed


Propylene glycol

2,3 Butanediol

Lactic acid

Ethane/ Ethylene

Propylene

Butanes Butadiene

Isobutylene

Maleic anhydride Succinic acid

PE, PVC

PP

Ethylene oxide

Propylene oxide

Acrylic acid

Acrylic fibers ABS Adiponitrile Acrylamide

Methane Methanol

Epichlorhydrin

C4

C3

C2

C1

MTBE

PUR

Ehylene glycol

Butanol

Polybutadiene, neoprene, Styrene butadiene rubber

Epoxy resins

Acrylic esters, polymers

Syn gas

Antifreeze, polyester, resins, surfactants

Formaldehyde

1,3 propane diol PTT

O OO

N

Glycolic acid

O

OHO

OHOH PGA

Acetic acid

CO

Furfural (C5) H2O2

CO2

Glycerol (C3)

Glucose C6

Biomass Acrylonitrile

OH

O

3-HP

Ethanol


Agro/food/feed Chemical Renewable Chemistry

Petroleum

BP Shell

Tate&Lile

Cargill

Roquette

ADM

Dupont

DSM

Teijin Dow

Arkema BASF Evonik

Cognis Ajinomoto Kyowa Hakko

Kureha

General motors

Toyota Car

Planes Boeing

Many changes appearing in the value chain (1)


Starch

Sugar

Oils

Wood ligno-cellulose

Sugar

Oils

Many changes appearing in the value chain (2)

Bio-based value chain

Feedstock/Agro Chemicals

Recycling Seed Farming Biomass producer

Biomass transformer

Chemical intermediates and building

blocks

Derivatives Finished Products

End Consumers

Consumer

Natureworks Galactic

2nd generation biomass

transformer

Enzyme majors

NOT EXHAUSTIVE

Potential new entrants

Partnership and joint

development

Secure competitive feedstock

Premium

Downstream integration

Sell licences for making competitive feedstock

Sell licenses of breakthrough processes and new building blocks

Sell Enzymes

Bioprocessing Chemocatalytic

http://www.thecoca-colacompany.com/index.html

http://www.danone.com/

http://www.thecoca-colacompany.com/index.html

http://www.google.com/url?sa=i&source=images&cd=&cad=rja&docid=3bGOwmgUtoOM5M&tbnid=KmBDuJ7jTfm7wM:&ved=0CAgQjRwwAA&url=http://www.tereos.com/en-gb/groupe/actualites.html?actu=46&ei=wpotUtOgJYae0wXVsYC4DA&psig=AFQjCNHAv8HrK_4IxvGDnGO2H0Jv79dUwA&ust=1378806850717075

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=MXyv9xCj639kVM&tbnid=_tjHrmHd2o-DJM:&ved=0CAUQjRw&url=http://www.groupe-glon.com/le-groupe-glon/presentation&ei=-5otUtayCKuK1AX2xYHgCw&bvm=bv.51773540,d.d2k&psig=AFQjCNG2xRMvokQpC5n_DGLVPXq3DVWZEg&ust=1378806887996637

http://www.novozymes.com/


Bio-conversions have an intrinsic disadvantage for large scale bulk production

Chemical

Fermentation

Plant size

Prod

uctio

n co

st /

t Scale up savings are limited


Reading

Writing

Technology – synthetic biology


An ever faster pace of innovation


An increasing number of alternative for the same market needs

Illustration: Polyamide production routes

Bio feedstock (sugar /

cellulose, glycerin,

castor oil)

Petro chemical feedstock

PA12

PA11

PA 6-10

Propylene / ACN

Benzene / Toluene

HMDA

Laurolactam Butadiene

PA 6-6 Adipic acid

Gas, coal, others

Sebacic acid (C10)

Undecylenic acid (C11)

Future GMO: algae and oil

Other

Polyvinyl Butyral

Other Resins

Polycarbonates

Polyethylenes

Acrylonitr-Butadi-Styrene 6%

8%

12%

15%

Polyvinyl Chloride

Polyamides

Polyurethanes

Polypropylene

Plastics in cars [2011]

170 kg/car

9% 2%

13%

5% 5%

24%

Function to material arbitrage Chemical to raw material arbitrage

New feedstock

(algae, GMO crops,..)

New fossil feedstock


.. leading to an ever increasing complexity ! Addressing renewable chemistry means answering to questions like:

• The competitiveness of biobased raw materials versus present and new C-

sources

• The ability to define new competitive chemical schemes more specific to biobased molecules

• The breakthrough economic potential of biorefineries, which would integrate several businesses

• The suitability of biobased raw materials for designing final products with differentiated properties and market traction

• The potential of biotechnologies to revolutionise or not the commodity/specialty chemical production, from raw materials to end products



- Natural vanillin: Rhovanil Natural® - Augeo® solvent, based on glycerol for paints

- Polyamides using sebacic acid: Stabamid® 6.10, Kalix® HPPA - JAGUAR®, a guar based rheological agent for cosmetic - Rhodoclean, surfactant based on pine derivatives

The 3 levers of Renewable Based Chemistry

Improve competitiveness

New functions and properties

Valorisation of Bio-Attribute(s)






Green Chemistry


The central problem with the present times,

is that the future

isn’t what it used to be….

Paul Valéry


The main drivers for competitive biotech-based production

Sugar unit. price Yield Capital

Process definition

Strain/ Chemistry

Process definition

Integration within existing sites Tuning

Lockers :

Levers :

* Chemical or enzymatic hydrolyisis

Biomass cost Capital


Cellulosic transport solved?

Technological


Feedstocks costs:volatility for all ?

0%

100%

200%

300%

400%

500%

600%

700%

1981

1982

1983

1985

1986

1987

1989

1990

1991

1993

1994

1995

1997

1998

1999

2001

2002

2003

2005

2006

2007

2009

2010

Maize (USD/ton)Wheat (USD/ton)Palm oil (USD/ton)Soybean oil (USD/ton)Sugar (USD/lb)Crude oil (USD/barrel)

Jan 2001 = 100%


Feedstock: correlation ?


Feedstock: dispersion ?

35 Présentation CNRS Paris 2015-11-09

Confidentiel ©

Return on investment - Constraints Develop Process Build Factory Operate

Timeline

Time

Spen

ding

Pathway eng. Optimization

Pilot Demo

~100 mUSD Or more…

5-10 yrs 2 yrs

2000-4000 USD/T

Fine Specialty Bulk

Margin

Market

Price

• Equation will not work for many molecules… Upfront analysis! - Market size - Margin - Scaling factor - Drop-in vs new molecule - Etc.

• One factory will not cover R&D investment… Business Model!


Confidentiel ©

Challenges to reduce constraints • Total cost should decrease – Don’t forget: Time is money too!

• Increase range of potential molecules

Development stage

• Faster and cheaper optimization

• Eliminate demo stage

• Novel enzymes/Micro-organisms

Operations

• Low-cost, available feedstock with low price volatility

• Trinity - Titer, Yield and Productivity (Impact on building cost, operating cost and scaling)

• Novel industrial downstream processes


Confidentiel ©

Other challenges, questions, trends • Societal challenges

• Competition with food / feed chains • ILUC (indirect land use change) • Engineered crops and GMO • GMM and corresponding processes • Synthetic biology: understanding ? acceptability ? • Circular economy, waste valorisation • Management of emerging technologies

• CO2 challenge: helping or not ? - LCA and footpint improvement of processes and products ?

• Scientific and technological challenges


Confidentiel ©

• Economical challenges • Regional ? Which advantages for each region ? • Switch to biomass: when ? • Raw materials: a new one per decade ?

– Methane / shale gas/ methanol – Coal

• Speed of evolution of fossil energies / raw materials ? • Price variability of biobased raw materials, especially if exposed to food/feed chains • Time and cost of process developments

• Regulatory questions : • Increasing number of labels, triggering even more debates: eg biosourced contents • Biology: one of identified KET • Support to R&D : • Subsidies and biaised competition :

– Subsidies to biofuels ? – Subsidies to biosourced products ?

• Some trends:

• Convergence nano/bio/info

Other challenges, questions, trends


Confidentiel ©

Some signals for the future • BOB = Berkeley open biofoundry

• In silico development: - The robo-chemist + IBM’s robo-chef - Interconnected databases - Targeted evolution of enzymes

• Consortia of strains

• Outsourcing of chemistry to upstream part: - Tailored crops

• Impact of circular economy ?

• Discoupling biotech and biosourcing: - Biotech on paraffins, on gases (CH4,..)

• Artificial enzymes with non-natural amino-acids

• Synthetic biology - Increasing knowledge on the system level - Increasing speed of the integration/optimization process

• Intracellular isolation of toxic intermediates

• Metagenomics as a way to tap into new enzymes, MOs


Confidentiel ©

Some questions the Twelve Principles of Green Chemistry: a need for redefinition ?

• What does « green » mean ? an old fashioned, imprecise concept ?

• The 12 principles: interesting but too narrow scope - Too closely linked to the manufacturing process - Process not seen as a possible loop - Missing a more systemic view - Not a complete set able to capture the many dimensions we now have to take into

accounts - …

• Balance between the benefit and the cost (environmental, societal, ..etc)

• From a « clean production » to a « beneficial product » to a « sustainable solution »


Confidentiel ©

(Green) Chemistry facing breakthroughs ? • Increasingly powerful materials

• Increasing ability to design chemicals

• But also increasing ability to analyse, detect, monitor - Improvement of detection systems - Dramatically increased number of sensing / monitoring devices - Ability to detect / predict harmfull effect - Ability to track more systematically « cocktail effects »

• Nevertheless, gaps could become wider between: - Fast product innovation pace - Longer time needed to evaluate the products or even build new assessment /

evaluation methods - Even longer time to generate a (detrimental) impact and detect it

• Sharper expectations from “non chemical stakeholders”


Confidentiel ©


Confidentiel ©

How to mainstream « green chemistry » ? Sustainability, a more inclusive concept

• Some possibilities external to the company, pushed by a growing public sensitivity - Regulation, as long as it doesn’t introduce a competitive biais and is

scientifically sound - Norms, referentials, environmental notation agencies - Pressure from external stakeholders: Markets, NGOs, Communities

• Internal possibilities, from the industry as a whole or for a company

• Solvay’s answers - Formalised approach (Solvay Way) embedding Corporate Social

Responsibility - Responsible Research & Innovation (Nanos, GMO,..) - SPM methodology and tool to assess each product (or each R&D project)

along 2 dimensions (production vulnerability, market sustainability)



SPM materializes the business sustainability risks and opportunities

Forces us to consider key elements that are usually

overlooked

Operations Vulnerability

What and where are the risks and opportunities on our P&L if consumers or actors in the downstream value chain prefer solutions with lower environmental footprint? • Ecoprofile (cradle-to-gate) • Monetization of the impacts • Compare to sales price

Market Alignment

From a sustainability standpoint and a consumer perspective, is our product used in selling propositions that are part of the solutions or part of the problems? • Questionnaire (cradle-to-grave) • Authoritative external evidences to support

claims


Confidentiel ©

Responsible Research & Innovation what happens if you don‘t keep an eye out!

“In the age of information, ignorance is a choice.” Anne Goldberg, New Innovation Platform Director, Solvay,

EIRMA Consultation meeting Towards a set of responsible innovation guidelines for members;


Confidentiel ©

Solar Impulse needs our Chemistry for energy management and weight reduction

Solar Impulse Pioneering sustainable chemistry

www.solvay.com

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