Issue 04/2016
bioplasticsMAGAZINE_1604
bioplasticsMAGAZINE_1604
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Blow Moulding<br />
A new, cost-effective route<br />
to PEF<br />
Since the US Department of Energy named<br />
2,5-Furandicarboxylic acid (FDCA) as one of the<br />
top 12 platform chemicals, it has been considered<br />
a holy grail for bioplastics, alongside its downstream<br />
polymer polyethylenefuranoate (PEF). However,<br />
the road has been bumpy and the main challenge is to<br />
find a process which allows price competitiveness with<br />
petro-based alternatives. Brand owners also need to<br />
get on board – Coca-Cola’s PlantBottle may replace all<br />
its petro-based bottles by 2020 as promised, but more<br />
brands need to make similar commitments.<br />
However, we are one step closer to bringing FDCA<br />
and PEF to market. A hydrothermal processing (HTP)<br />
technology developed by Swiss biotechnology company<br />
AVA-CO2 yields substantial advantages over other<br />
technologies.<br />
Other processes use highly-toxic methanol as<br />
a solvent in dehydrating fructose which must be<br />
eliminated by an extra, costly distillation and purification<br />
step. Methanol-based processes also immediately<br />
transform most of the 5-Hydroxymethylfurfural (5-<br />
HMF) into 5-MMF (Methoxymethylfurfural), which is<br />
inefficient and impacts negatively on yields. AVA-CO2’s<br />
process uses water as a solvent,<br />
meaning a less costly,<br />
more environmentallyfriendly<br />
process,<br />
which leads to<br />
better LCA results<br />
and significantly<br />
higher yields.<br />
AVA-CO2 also<br />
recently announced<br />
a simple<br />
interface<br />
which allows a<br />
tailored use of<br />
different solvents,<br />
e.g. acetic<br />
acid, in existing<br />
FDCA oxidation<br />
processes. This<br />
solvent switch<br />
allows 5-HMF<br />
to be used as a<br />
drop-in for purified<br />
terephthalic<br />
acid (PTA) pro-<br />
Generic bottle picture (not PEF) (Shutterstock, HSNphotography)<br />
duction plants. The HTP technology now supports the<br />
main FDCA oxidation routes – biological, enzymatic,<br />
chemical and electro-chemical oxidation of 5-HMF to<br />
FDCA. This flexibility, in combination with AVA-CO2’s<br />
innovative process, will make a difference in the race<br />
to PEF.<br />
Compared to PET, PEF is a more sustainable option,<br />
with a 50 % less carbon footprint and better recyclability.<br />
It also has many superior product characteristics –<br />
with higher tensile strength and improved gas barriers<br />
in oxygen, CO 2<br />
and moisture, PEF allows for energy<br />
savings and reductions in material use compared to<br />
PET. This leads to a longer shelf life, thereby reducing<br />
food waste.<br />
Recent joint development announcements across the<br />
value chain show that PEF is regarded as an important<br />
strategic development. For AVA-CO2, a large-scale<br />
sugar-based production plant (LSPP) is already in the<br />
pipeline. Set to produce 30,000 tonnes/year of FDCA in<br />
a first phase, the LSPP will ramp up to 120,000 tonnes/<br />
year of FDCA at full capacity. Set to come online in<br />
2019/2020, a first round of financing for the plant has<br />
already been completed by AVA-<br />
CO2.<br />
AVA-CO2 is in talks<br />
with industry leaders<br />
to develop<br />
new downstream<br />
chemistry pathways<br />
and exploit<br />
the potential of<br />
5-HMF, FDCA<br />
and PEF. The<br />
LSPP will accelerate<br />
market<br />
development<br />
of 100 %<br />
sugar-based<br />
beverage and<br />
food packaging.<br />
Through<br />
PEF, sugarbased<br />
chemicals<br />
and polymers<br />
for the<br />
mass market<br />
are just around<br />
the corner. MT<br />
www.ava-co2.com<br />
bioplastics MAGAZINE [<strong>04</strong>/16] Vol. 11 17