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1 Renewable Route to Acrylic Acid Platts 2 nd Annual Renewable Chemicals BioAcrylic Acid Scaling Up Current Experience

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Page 1: Renewable Route to Acrylic Acid - · PDF fileRenewable Route to Acrylic Acid Platts 2nd Annual Renewable Chemicals BioAcrylic Acid Scaling Up ... scale process for production of acrylic

1

Renewable Route to Acrylic Acid

Platts 2nd Annual Renewable Chemicals BioAcrylic Acid Scaling Up – Current Experience

Page 2: Renewable Route to Acrylic Acid - · PDF fileRenewable Route to Acrylic Acid Platts 2nd Annual Renewable Chemicals BioAcrylic Acid Scaling Up ... scale process for production of acrylic

2

Slide 2

Renewable BioAcrylic Acid Joint Development

Objective – Develop an Industrial-Scale Process to Cost-

Effectively Produce Acrylic Acid from Sugar

Sugar 3-Hydroxypropionic

(3-HP)

Acrylic

Acid

Page 3: Renewable Route to Acrylic Acid - · PDF fileRenewable Route to Acrylic Acid Platts 2nd Annual Renewable Chemicals BioAcrylic Acid Scaling Up ... scale process for production of acrylic

3

Dow Chemical-OPXBIO Strategic Partnership

Dow

– Largest US producer of petro-acrylic and derivatives

– Demonstrated capability to develop recovery technology and applications

– Committed bio-based strategy and investments

OPXBIO

– Unique biocatalyst development capability

– Multiple products in development

BioAcrylic joint development agreement

– Joint funding and work to demonstrate BioAcrylic process

– Intent to jointly commercialize

Faster, Lower-Risk, Shared-Cost Development and Commercialization

Sugar Feedstock

Microbe & 3-HP

Bioprocess

BioAA Conversion

Process

Commercial Plant

Channel to Market

Joint OPXBIO Dow Dow Dow

Page 4: Renewable Route to Acrylic Acid - · PDF fileRenewable Route to Acrylic Acid Platts 2nd Annual Renewable Chemicals BioAcrylic Acid Scaling Up ... scale process for production of acrylic

4

Dow provides a diversified, industry-leading portfolio of

technology-based products and solutions to customers in

approximately 160 countries worldwide

More than 5,000 products manufactured at 188 sites in 35

countries with 2011 sales of $60B

50,000 employees worldwide

The Dow Chemical Company

Corporate Overview

Page 5: Renewable Route to Acrylic Acid - · PDF fileRenewable Route to Acrylic Acid Platts 2nd Annual Renewable Chemicals BioAcrylic Acid Scaling Up ... scale process for production of acrylic

5

Acrylic Acid & Acrylates

– GAA, BA, EA, 2 EHA, MA

– Acrylic coatings, water treatment, detergent

additives, adhesives, super absorbent

polymers

Methacrylates

– MMA, GMAA

– Acrylic sheet and resins, petroleum

additives, plastic additives, electronic

displays

Specialty Monomers

– Hydroxies, GMA, BMA

– Automotive and industrial coatings, printing

inks, and powder coatings

Vinyl Acetate Monomers

– VAM

– Acrylic coatings, fibers, adhesives

Dow Performance Monomers Portfolio

Page 6: Renewable Route to Acrylic Acid - · PDF fileRenewable Route to Acrylic Acid Platts 2nd Annual Renewable Chemicals BioAcrylic Acid Scaling Up ... scale process for production of acrylic

6

Why Is This Project Important to Dow?

Acrylic monomers are key strategic building blocks for several of

Dow’s market-facing businesses

- coatings, personal care, packaging, building and construction

Creating differentiated, sustainable product offerings for our

customers is a top Dow priority

Dow is interested in cost-effective, renewable alternatives to

conventional petroleum-based feedstocks

This project is an opportunity to commercialize a differentiated,

bio-based acrylic acid product based on a fermentable sugar

feedstock

Page 7: Renewable Route to Acrylic Acid - · PDF fileRenewable Route to Acrylic Acid Platts 2nd Annual Renewable Chemicals BioAcrylic Acid Scaling Up ... scale process for production of acrylic

7

Existing $8+ Billion Growing Global Market Customers interested in renewable alternative

Acrylates/Acrylic Acid Market

Page 8: Renewable Route to Acrylic Acid - · PDF fileRenewable Route to Acrylic Acid Platts 2nd Annual Renewable Chemicals BioAcrylic Acid Scaling Up ... scale process for production of acrylic

8

Acrylates/Acrylic Acid Market

Customers are asking for renewable options • Improved sustainability / carbon footprint

• Increased consumer interest in “green” products

• Feedstock flexibility

Acrylic

Esters

60%

Glacial

Acrylic Acid

40% Paper Products

5% Other

9%

Surface Coatings

44%

Adhesives and

Sealants

18%

Textiles

15%

Plastics

Additives

9%

Super Absorbent Polymers

70%

Polyacrylic Acid

Polymers 30%

Global Acrylic Acid Consumption

Acrylic

Esters

60%

Glacial

Acrylic Acid

40%

U.S. End Uses for

Acrylate Esters

Paper Products

5% Other

9%

Surface Coatings

44%

Adhesives and

Sealants

18%

Textiles

15%

Plastics

Additives

9%

Global Glacial Acrylic

Acid End Use

Super Absorbent Polymers

70%

Polyacrylic Acid

Polymers 30%

Source: SRI Feb 2011

Page 9: Renewable Route to Acrylic Acid - · PDF fileRenewable Route to Acrylic Acid Platts 2nd Annual Renewable Chemicals BioAcrylic Acid Scaling Up ... scale process for production of acrylic

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BioAcrylic Acid Process Technology

Fermentation

3-HP Recovery

Conversion to Acrylic Acid

•3-HP Dehydration to Acrylic Acid

•Acrylic Acid Purification

•Biomass Kill & Removal

•Water Removal and Recycle

•Dextrose (corn) or sucrose (cane)

•Genetically engineered E-Coli

organism optimized via OPXBIO

EDGE™ Technology Platform

O

OH

OH

CH2

O

OH

1/2

- H2O

J. Repman 11/2/11

Page 10: Renewable Route to Acrylic Acid - · PDF fileRenewable Route to Acrylic Acid Platts 2nd Annual Renewable Chemicals BioAcrylic Acid Scaling Up ... scale process for production of acrylic

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OPXBIO Strategy

Grow a Large, Global, Profitable & Highly Valued

Renewable Chemicals Company

Page 11: Renewable Route to Acrylic Acid - · PDF fileRenewable Route to Acrylic Acid Platts 2nd Annual Renewable Chemicals BioAcrylic Acid Scaling Up ... scale process for production of acrylic

11

OPXBIO EDGE™ Technology Platform

Quantitative

Experimental

Design

Massively

Parallel

Genetic

Manipulations

Comprehensive &

High Resolution

Parallel

Processing

Efficiency Directed Genome Engineering

Page 12: Renewable Route to Acrylic Acid - · PDF fileRenewable Route to Acrylic Acid Platts 2nd Annual Renewable Chemicals BioAcrylic Acid Scaling Up ... scale process for production of acrylic

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OPXBIO EDGE Technology Platform

Create random

and unknown

genetic variants in

microbe

population

Test population

and select better

performing

microbes

Repeat to

directionally

evolve optimized

microbe

Conventional Microbial Pathway Engineering

Create specific

and known

genetic variants

across entire

microbial

genome

Test each

genetic variant

and analyze

performance

Design

comprehensive,

rational strategy

and construct

optimized

microbe

EDGE Microbe Engineering

Page 13: Renewable Route to Acrylic Acid - · PDF fileRenewable Route to Acrylic Acid Platts 2nd Annual Renewable Chemicals BioAcrylic Acid Scaling Up ... scale process for production of acrylic

13

OPXBIO EDGE™ Technology for BioAcrylic

Page 14: Renewable Route to Acrylic Acid - · PDF fileRenewable Route to Acrylic Acid Platts 2nd Annual Renewable Chemicals BioAcrylic Acid Scaling Up ... scale process for production of acrylic

14

Fermentation Development

2008 2009 2009-10 2010 2011-12 2012-13 2014-16

Comml Plant

TBD

Lbs/Yr

Demo Plant-2

30k L

600K Lbs/Yr

Demo Plant-1

3000L

60K Lbs/Yr

Lg Bench

10L

250 Lbs/Yr

Sm Bench

1L

25 Lbs/Yr

Shake Flask

100 ml

Pilot

250L

5K Lbs/Yr

Current

at

MBI

Page 15: Renewable Route to Acrylic Acid - · PDF fileRenewable Route to Acrylic Acid Platts 2nd Annual Renewable Chemicals BioAcrylic Acid Scaling Up ... scale process for production of acrylic

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BioAcrylic Acid Downstream Process

Fermentation

3-HP Recovery

Conversion to Acrylic Acid

Development Highlights

• Screening tests completed on >10 different

processing schemes

• Scale-up validation in progress (batch and

continuous lab-scale units)

• Developmental samples available 4Q 2012

Page 16: Renewable Route to Acrylic Acid - · PDF fileRenewable Route to Acrylic Acid Platts 2nd Annual Renewable Chemicals BioAcrylic Acid Scaling Up ... scale process for production of acrylic

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Key Challenges - Sugar Price Volatility

Challenges

• Potential linkage to fuel

prices

• Weather/seasonal

impacts

• Feasibility of cellulosic

sugar alternatives

Sugar prices will strongly influence bio

acrylic acid market penetration

0

5

10

15

20

25

30

35

Jul-

02

Feb

-03

Sep

-03

Ap

r-0

4

No

v-0

4

Jun

-05

Jan

-06

Au

g-0

6

Mar

-07

Oct

-07

May

-08

De

c-0

8

Jul-

09

Feb

-10

Sep

-10

Ap

r-1

1

No

v-1

1

Jun

-12

Suga

r P

rice

¢/l

b

Historical Commodity Sugar Prices

Page 17: Renewable Route to Acrylic Acid - · PDF fileRenewable Route to Acrylic Acid Platts 2nd Annual Renewable Chemicals BioAcrylic Acid Scaling Up ... scale process for production of acrylic

17

Key Challenges - Impact of Shale Gas

Shale gas availability in U.S. will strongly

influence long term conventional feedstock prices

Challenges

• Impact on conventional

acrylic acid economics

• Regional differences

0.0

2.0

4.0

6.0

8.0

10.0

12.0

14.0

16.0

Jul-

02

Feb

-03

Sep

-03

Ap

r-0

4

No

v-0

4

Jun

-05

Jan

-06

Au

g-0

6

Mar

-07

Oct

-07

May

-08

De

c-0

8

Jul-

09

Feb

-10

Sep

-10

Ap

r-1

1

No

v-1

1

Jun

-12

Nat

ura

l Gas

Pri

ce (

$/M

MB

tu)

Historical U.S. Natural Gas Prices

Page 18: Renewable Route to Acrylic Acid - · PDF fileRenewable Route to Acrylic Acid Platts 2nd Annual Renewable Chemicals BioAcrylic Acid Scaling Up ... scale process for production of acrylic

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Key Challenges – Right Sizing of Plant Investments

Challenges

• Capacity planning to meet

customer demands

• Achieving economy of scale vs.

overbuilding

• Feedstock selection

• Location / Integration options

Page 19: Renewable Route to Acrylic Acid - · PDF fileRenewable Route to Acrylic Acid Platts 2nd Annual Renewable Chemicals BioAcrylic Acid Scaling Up ... scale process for production of acrylic

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Summary

– Dow and OPX are jointly developing a new industrial-

scale process for production of acrylic acid from sugar

– Excellent progress made on organism development,

fermentation and downstream process scale-up

– Anticipate commercialization in 2014-2016 timeframe

Sugar Feedstock

Microbe & 3-HP

Bioprocess

BioAA Conversion

Process

Commercial Plant

Channel to Market

Joint OPXBIO Dow Dow Dow