Dow and Crystalsev to make polyethylene from sugar cane in Brazil
The Dow Chemical Company, the world's largest producer of polyethylene, and Crystalsev, one of Brazil's largest ethanol players have announced plans for a world-scale facility to manufacture polyethylene from sugar cane. The news comes after Braskem, a leading Brazilian chemical company, recently succeeded in making the ubiquitous product from cane based ethanol (earlier post).
Polyethylene is the most widely used of all plastics and can be found in all kinds of everyday products, from food packaging, milk jugs and plastic containers to pipes and liners. The bioeconomy is based on making plant based alternatives to the pertochemical plastics and polymers, in efficient biorefineries. This new, green economy is making steady progress: we now have a bio-based alternative most of the commonly used plastics (more here). By using renewable resources for the production of biomaterials, both the carbon footprint and the environmental impact of the products are significantly reduced. With record oil prices, finding a crop-based substitute becomes even more attractive.
Under the terms of a memorandum of understanding agreed by Dow and Crystalsev, the two companies will form a joint venture in Brazil to design and build the first integrated facility of its scale in the world. It is expected to start production in 2011 and will have a capacity of 350,000 metric tons. The venture will combine Dow's leading position in polyethylene with Crystalsev's know-how and experience in ethanol to meet the needs of Dow's customers in Brazil and what will likely be international interest.
The new facility will use ethanol derived from sugar cane, an annually renewable resource, to produce ethylene - the raw material required to make polyethylene, the world's most widely-used plastic. Ethylene is traditionally produced using either naphtha or natural gas liquids, both of which are petroleum products. It is estimated that the new process will produce significantly less CO2 compared to the traditional polyethylene manufacturing process.
The companies have already begun conducting a feasibility study to assess various aspects of the project, including engineering design, location, infrastructure needs, supply chain logistics, energy and economics. The study, which is expected to take one year, will also look at the possibility of receiving approval for the project and the process as a Clean Development Mechanism (CDM). The CDM was developed by the United Nations to help companies manage their carbon credits from emerging market projects:
energy :: sustainability :: biomass :: ethanol :: bioplastics :: biopolymers :: polyethylene :: renewable :: Clean Development Mechanism :: Brazil ::
The areas being considered as potential sites for the new facility are currently being used for low-density cattle grazing and are not near any rain forests. Both companies have underscored their commitment to ensuring that the plant is located in a sustainable environment.
The new facility will use Dow's proprietary Solution technology to manufacture DOWLEXT polyethylene resins - the world's leading linear low density polyethylene, which combines toughness and puncture resistance with high performance and processability. The material offers significant advantages in a range of different applications, including pipes, films, membranes, and food and specialty packaging.
At a molecular level, the joint venture's product will be identical to the DOWLEXT polyethylene resins manufactured at other Dow facilities. The advantage of this material versus most renewable resource-based plastics is that customers will be using a drop-in replacement made with a renewable resource not a different polymer altogether. Also, like the traditional PE product, the sugar cane-based polyethylene would be fully recyclable using existing infrastructure.
Dow has operated in Brazil since 1956 when it established a Latin America headquarters in São Paulo. As Dow has expanded, so has its presence in Brazil with 21 locations, including manufacturing plants, business centers and research and development facilities. Dow has 2,100 employees in Brazil.
Crystalsev is a 100% Brazilian group that commercializes products made from sugar cane through three areas: providing of services to mills; commercialization of sugar and alcohol; and trading - purchase, resale and management of assets. The Group produces 1.8 million tons of sugar, which corresponds to 8% of all sugar manufactured in Brazil, and employs 30,000 people. Crystalsev operates in several regions in the country through 13 companies that, together, form the second major producer of sugar cane in Brazil. Its management system is used as a model in the sugar & alcohol industry.
Sugarcane remains key and is only gradually beginning to reveal its potential to yield products other than liquid biofuels. The humble crop is a goldmine of potential green chemistry products, ranging from bioplastics, detergents, tinctures, drugs, glues, gels, biopolymers and a whole range of molecules and platform chemicals. Major science organisations and companies are now investing in the production of bioplastics from sugarcane (amongst them the University of Queensland, the Korea Advanced Institute of Science and Technology and Metabolix.)
The good thing is that the crop thrives in developing countries, who know they now have a resource in hand that allows them to leapfrog beyond the petroleum era. In the future, they will rely on highly integrated biorefineries that convert biomass into a wealth of fuels, green chemicals and energy. A glimpse of this future in developing countries already comes from the tiny island state of Réunion, where scarce research resources are being invested in sugarcane based green chemistry and biorefineries (earlier post).
References:
Dow Chemical: Dow and Crystalsev Announce Plans to Make Polyethylene from Sugar Cane in Brazil - July 19, 2007.
Biopact: The bioeconomy at work: Braskem develops polyethylene from sugarcane ethanol - June 25, 2007.
Biopact: Notes on biopolymers in the Global South - March 11, 2007
Polyethylene is the most widely used of all plastics and can be found in all kinds of everyday products, from food packaging, milk jugs and plastic containers to pipes and liners. The bioeconomy is based on making plant based alternatives to the pertochemical plastics and polymers, in efficient biorefineries. This new, green economy is making steady progress: we now have a bio-based alternative most of the commonly used plastics (more here). By using renewable resources for the production of biomaterials, both the carbon footprint and the environmental impact of the products are significantly reduced. With record oil prices, finding a crop-based substitute becomes even more attractive.
Under the terms of a memorandum of understanding agreed by Dow and Crystalsev, the two companies will form a joint venture in Brazil to design and build the first integrated facility of its scale in the world. It is expected to start production in 2011 and will have a capacity of 350,000 metric tons. The venture will combine Dow's leading position in polyethylene with Crystalsev's know-how and experience in ethanol to meet the needs of Dow's customers in Brazil and what will likely be international interest.
The new facility will use ethanol derived from sugar cane, an annually renewable resource, to produce ethylene - the raw material required to make polyethylene, the world's most widely-used plastic. Ethylene is traditionally produced using either naphtha or natural gas liquids, both of which are petroleum products. It is estimated that the new process will produce significantly less CO2 compared to the traditional polyethylene manufacturing process.
The companies have already begun conducting a feasibility study to assess various aspects of the project, including engineering design, location, infrastructure needs, supply chain logistics, energy and economics. The study, which is expected to take one year, will also look at the possibility of receiving approval for the project and the process as a Clean Development Mechanism (CDM). The CDM was developed by the United Nations to help companies manage their carbon credits from emerging market projects:
energy :: sustainability :: biomass :: ethanol :: bioplastics :: biopolymers :: polyethylene :: renewable :: Clean Development Mechanism :: Brazil ::
The areas being considered as potential sites for the new facility are currently being used for low-density cattle grazing and are not near any rain forests. Both companies have underscored their commitment to ensuring that the plant is located in a sustainable environment.
The new facility will use Dow's proprietary Solution technology to manufacture DOWLEXT polyethylene resins - the world's leading linear low density polyethylene, which combines toughness and puncture resistance with high performance and processability. The material offers significant advantages in a range of different applications, including pipes, films, membranes, and food and specialty packaging.
At a molecular level, the joint venture's product will be identical to the DOWLEXT polyethylene resins manufactured at other Dow facilities. The advantage of this material versus most renewable resource-based plastics is that customers will be using a drop-in replacement made with a renewable resource not a different polymer altogether. Also, like the traditional PE product, the sugar cane-based polyethylene would be fully recyclable using existing infrastructure.
Dow has operated in Brazil since 1956 when it established a Latin America headquarters in São Paulo. As Dow has expanded, so has its presence in Brazil with 21 locations, including manufacturing plants, business centers and research and development facilities. Dow has 2,100 employees in Brazil.
Crystalsev is a 100% Brazilian group that commercializes products made from sugar cane through three areas: providing of services to mills; commercialization of sugar and alcohol; and trading - purchase, resale and management of assets. The Group produces 1.8 million tons of sugar, which corresponds to 8% of all sugar manufactured in Brazil, and employs 30,000 people. Crystalsev operates in several regions in the country through 13 companies that, together, form the second major producer of sugar cane in Brazil. Its management system is used as a model in the sugar & alcohol industry.
Sugarcane remains key and is only gradually beginning to reveal its potential to yield products other than liquid biofuels. The humble crop is a goldmine of potential green chemistry products, ranging from bioplastics, detergents, tinctures, drugs, glues, gels, biopolymers and a whole range of molecules and platform chemicals. Major science organisations and companies are now investing in the production of bioplastics from sugarcane (amongst them the University of Queensland, the Korea Advanced Institute of Science and Technology and Metabolix.)
The good thing is that the crop thrives in developing countries, who know they now have a resource in hand that allows them to leapfrog beyond the petroleum era. In the future, they will rely on highly integrated biorefineries that convert biomass into a wealth of fuels, green chemicals and energy. A glimpse of this future in developing countries already comes from the tiny island state of Réunion, where scarce research resources are being invested in sugarcane based green chemistry and biorefineries (earlier post).
References:
Dow Chemical: Dow and Crystalsev Announce Plans to Make Polyethylene from Sugar Cane in Brazil - July 19, 2007.
Biopact: The bioeconomy at work: Braskem develops polyethylene from sugarcane ethanol - June 25, 2007.
Biopact: Notes on biopolymers in the Global South - March 11, 2007
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