Periodic Reporting for period 3 - PEFerence (From bio-based feedstocks via di-acids to multiple advanced bio-based materials with a preference for polyethylene furanoate)
Période du rapport: 2022-03-01 au 2023-08-31
The PEFerence project will establish a globally first-of-a-kind, industrial scale (5 kton/year), cost-effective 2,5-Furandicarboxylic acid (FDCA) biorefinery flagship plant producing bio-based chemicals for materials (such as bottles, films, cosmetic packaging, polyurethanes) using existing facilities in industrial symbiosis. The consortium aims to replace a significant part of fossil based polyesters such as Polyethylene terephthalate (PET), but also technologically superior packaging materials like glass and aluminum with 100 % bio-based polyesters such as Polyethylene Furanoate (PEF). The unique and excellent barrier and strength properties of PEF make it a material that can be applied in areas where PET is less suitable. The initial market focus will be on applications where it can optimally leverage the superior properties of PEF. On the longer term, when FDCA is produced at large scale and technology is further matured, FDCA based polyesters are expected to penetrate further into markets which allow smaller or no price premium.
The potential significant reductions in non-renewable energy usage and greenhouse gas (GHG) emissions compared to fossil based PET or aluminum based cans for PEF based packaging solutions will be assessed. Furthermore, PEF bottles can be recycled and used again as raw material for bottles, as well as in a cascading approach for packaging and textiles. During the project also 2nd generation feedstock will be assessed. The full value chain will be optimized ensuring cost-effective and environmentally sustainable raw material sourcing and production of FDCA, PEF and polyurethane products. Finally, together with customers and brand owners (Carlsberg, Nestle, Henkel, Lego, Kebony, LVMH), 100% bio-based end-products will be demonstrated and validated to ensure fast market deployment.
The potential significant reductions in non-renewable energy usage and greenhouse gas (GHG) emissions compared to fossil based PET or aluminum based cans for PEF based packaging solutions will be assessed. Furthermore, PEF bottles can be recycled and used again as raw material for bottles, as well as in a cascading approach for packaging and textiles. During the project also 2nd generation feedstock will be assessed. The full value chain will be optimized ensuring cost-effective and environmentally sustainable raw material sourcing and production of FDCA, PEF and polyurethane products. Finally, together with customers and brand owners (Carlsberg, Nestle, Henkel, Lego, Kebony, LVMH), 100% bio-based end-products will be demonstrated and validated to ensure fast market deployment.
The initial period has focused on design of Flagship plant, first draft of Life cycle assessment (LCA), formulating PEF compounds for different end use applications, and the business & commercialization plan of YXY(R) Technology. In plant design, the progress made by BASF, Worley and Synvina during the first reporting period was in line with the overall schedule for the FEED phase. During the first Reporting Period, the goal and scope of the LCA of FDCA and PEF polymers were set. Further, the PEF end products and their fossil-based counterparts were selected for benchmark. The first LCA results showed remarkable savings in greenhouse gas (GHG) emissions and reduced usage of fossil resources. Synvina has investigated a wide range of PEF formulations, both in-house and with partners. Multiple prototypes have been developed together with converters, including small carbonated soft drink (CSD) bottles, tubes and pouches with ALPLA. FDCA and humins are being investigated for commercial uses by Henkel and Kebony respectively.
The second Reporting Period, has seen continued work on the plant engineering, ISO-certification of the PEF Life Cycle Assessment, continued research into the formulation of PEF compounds, and extensive testing of possible FDCA and PEF-based products. TEREOS has signed an agreement with ARNP to supply fructose feedstock to the FDCA flagship plant, and have performed the FEED for the engineering work to expand their fructose production capacity. Worley worked intensively with ARNP to finalise the FEED assessment of the FDCA flagship plant, to draft the EPC phase plan and commence the EPC phase. PEFerence partners ALPLA, Nestle, LEGO, Henkel, OMV, Kebony and new partner Carlsberg performed extensive work on the development and testing of prototype bio-based products. A summary of the ISO-certified LCA of PEF has been published, sharing with the public GHG emissions savings that are possible with the use of PEF in place of fossil-based materials. Significant progress has been made on the regulatory registration of both FDCA and PEF, as well as on recycling testing an European recycling approval of PEF together with the European PET Bottle Platform (EPBP).
During the third Reporting Period and after the permit to build and operate the flagship plant has become irrevocable on March 9th, 2022, Worley and ARNP have been working together through the EPC phase. The contracts have been signed with key subcontractors and construction of the FDCA Flagship Plant is progressing well, with commercial production set to start in 2024. PEFerence partners are progressing in developing and testing their bio-based prototypes. Henkel, LVMH and Carlsberg and an undisclosed partner have signed offtake agreements. Significant progress has been made towards validation of the formulations and recycling assessment as well as food contact approval. Avantium has received from EPBP, a 3-year interim endorsement to allow multilayer PET/PEF packaging in PET bottle recycling stream in the European bottle recycling market and the Critical Guidance Recognition for PEF from the US-Based Association of Plastic recyclers. An ISO-certified LCA has been performed for FDCA and PEF. Evaluating the potential environmental impacts of the technology for FDCA and PEF production using 2G feedstocks confirmed that a shift to 2G feedstocks can reduce the overall environmental footprint of the technology significantly.
The second Reporting Period, has seen continued work on the plant engineering, ISO-certification of the PEF Life Cycle Assessment, continued research into the formulation of PEF compounds, and extensive testing of possible FDCA and PEF-based products. TEREOS has signed an agreement with ARNP to supply fructose feedstock to the FDCA flagship plant, and have performed the FEED for the engineering work to expand their fructose production capacity. Worley worked intensively with ARNP to finalise the FEED assessment of the FDCA flagship plant, to draft the EPC phase plan and commence the EPC phase. PEFerence partners ALPLA, Nestle, LEGO, Henkel, OMV, Kebony and new partner Carlsberg performed extensive work on the development and testing of prototype bio-based products. A summary of the ISO-certified LCA of PEF has been published, sharing with the public GHG emissions savings that are possible with the use of PEF in place of fossil-based materials. Significant progress has been made on the regulatory registration of both FDCA and PEF, as well as on recycling testing an European recycling approval of PEF together with the European PET Bottle Platform (EPBP).
During the third Reporting Period and after the permit to build and operate the flagship plant has become irrevocable on March 9th, 2022, Worley and ARNP have been working together through the EPC phase. The contracts have been signed with key subcontractors and construction of the FDCA Flagship Plant is progressing well, with commercial production set to start in 2024. PEFerence partners are progressing in developing and testing their bio-based prototypes. Henkel, LVMH and Carlsberg and an undisclosed partner have signed offtake agreements. Significant progress has been made towards validation of the formulations and recycling assessment as well as food contact approval. Avantium has received from EPBP, a 3-year interim endorsement to allow multilayer PET/PEF packaging in PET bottle recycling stream in the European bottle recycling market and the Critical Guidance Recognition for PEF from the US-Based Association of Plastic recyclers. An ISO-certified LCA has been performed for FDCA and PEF. Evaluating the potential environmental impacts of the technology for FDCA and PEF production using 2G feedstocks confirmed that a shift to 2G feedstocks can reduce the overall environmental footprint of the technology significantly.
The PEFerence project will demonstrate the production of PEF and FDCA materials at 5 kton/year scale. The flagship plant has been financed by investments from multiple parties, including new shareholders, EU and national grants, and debt financing by Dutch banks. This is a key step not just for PEFerence and Avantium Renewable Polymers, but for all aspiring sustainable industry projects that require funding, since such projects do not fall within the typical risk profile for bank financing packages.
There is very strong market interest in both PEF and FDCA as materials from not only project partners but also other companies. Multiple parties have signed Conditional Offtake Agreements to secure material from the FDCA flagship plant.
The most impactful achievement for society is in bringing a new, bio-based plastic to market that has superior properties to the incumbent fossil-based alternative, and is also readily recyclable in existing facilities. In bringing PEF to the market, Avantium is contributing to re-balancing the carbon cycle, which is critical for packaging industries as climate change becomes worse. Making use of nature-based feedstocks, recycling and designing products for re-use wherever possible will help to support the environment, as well as contributing to the shift to circular economy.
The PEFerence project contributes directly to the EU Bioeconomy strategy by supporting the shift from dependency on fossil-fuels towards a post-petroleum society. Avantium is encouraging brand owners to step forward and join the transition to bio-based materials by introducing PEF into the market.
The project is contributing to the EU's Circular Economy Package through the work on product light-weighting (reduce), re-use, and recycling. By building end-of-life research into the product development phase, the PEFerence consortium is supporting the EU Plastics Strategy objectives to transform the way that products are designed, and transition to more sustainable products. Innovation in recycling is being encouraged, through looking at used material collection systems for co-recycling of PEF into rPET streams whilst the level of PEF in the market is low.
There is very strong market interest in both PEF and FDCA as materials from not only project partners but also other companies. Multiple parties have signed Conditional Offtake Agreements to secure material from the FDCA flagship plant.
The most impactful achievement for society is in bringing a new, bio-based plastic to market that has superior properties to the incumbent fossil-based alternative, and is also readily recyclable in existing facilities. In bringing PEF to the market, Avantium is contributing to re-balancing the carbon cycle, which is critical for packaging industries as climate change becomes worse. Making use of nature-based feedstocks, recycling and designing products for re-use wherever possible will help to support the environment, as well as contributing to the shift to circular economy.
The PEFerence project contributes directly to the EU Bioeconomy strategy by supporting the shift from dependency on fossil-fuels towards a post-petroleum society. Avantium is encouraging brand owners to step forward and join the transition to bio-based materials by introducing PEF into the market.
The project is contributing to the EU's Circular Economy Package through the work on product light-weighting (reduce), re-use, and recycling. By building end-of-life research into the product development phase, the PEFerence consortium is supporting the EU Plastics Strategy objectives to transform the way that products are designed, and transition to more sustainable products. Innovation in recycling is being encouraged, through looking at used material collection systems for co-recycling of PEF into rPET streams whilst the level of PEF in the market is low.