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2012
- BIOCYCLE -
Sustainable polymer from sugar cane
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The Concept
PHB Production
Bagasse
Energy
Polymer
Ethanol
CO2
Compost CO2
Dispose
Energy
M
l
Solvent
Sugar
Sugar mill
BoilerCane fields
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Company Overview
The development of PHB in Brazil
1991
Research grant establishes the
Production of BiodegradablePlastics from Sugar via Bio
technological Route
COPERSUCAR - IPT
1994
Implementation of the Pilot Plant to
produce PHB / PHB-HV at Usina da
Pedra, Serrana -SP
2004
PHB production process proves to be
economically viable
Focus on Material EngineeringMarket
Applications1stgeneration
2000
PHB Industrial S/A was created along
with the BIOCYCLE brand.
2008
Consolidation of productive process
Applications, New Solvent, New
Patents2ndgeneration
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ORGANIZATIONAL STRUCTURE
Pedra Agroindustiral S.A. / The Balbo Group
More than 80 years of experience in the sugarand alcohol industry
Industrial assets comprised of six mills in the stateof So Paulo and one in the state of Minas Gerais
Total annual production (1):
20 Million tons of crushed Sugar Cane
650 Million kilograms of sugar
900 million liters of alcohol
More than 10,000 employees
Culture area of more than 180,000 hectares ofsugarcane (1)
Energy generation capacity of approximately800,000 MWh (1)
Commercialization of CERs through KyotoProtocol
Major worldwide organic sugar producer
PHB Industrial S.A.
Leverages the collective experience andrelationships of Pedra Agroindustrial S.A. and theBalbo Group
PedraAgroindustrial
S.A.
Balbo Group
PHB Industrial S.A.
50% 50%
(1) 2010 / 2011 crop
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SouthAmerica
Brazil So Paulo
SerranaRibeiro Preto
Santos Port
Company Overview
PHBISAs technology has been developing and refining over 16 years of research
Usina da Pedra
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PHB INDUSTRIAL S.A.Overview
PHBISA utilizes a completely renewable conceptto produce PHB, its blends and composites (brand -
Biocycle)
100% Brazilian Technology to produce biopolymer based in vegetable glucose supported by know-how
and patents(17), embodying from the bacteria selection to the applications;
Production process filled without GMO.
Biopolymer completely biodegradable, compostable and sustainablePP contra type.
Product with high performanceand functionality
Newtechnology frontier
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Sugar CaneCompetitive advantage over other biomass
Beet
Fonte: Unica
1,01,4 2,0
9,3Fossil-fuel energy used to make the fuel(input) compared with the energy in the
fuel (output)
Sugar CaneCornFossil-fuel
INPUT OUTPUT
Sugar Cane presents the highest energetic productivity
compared to other biomass.
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32
23
45
2,20
3,09
4,39
Biopolymers - Productivity comparison & Demanded Area
Necessary area to produce100.000 tpy of PHB
(thousand hectares)
PE from
Ethanol***
PHB Sugar
Cane
PHB from
Corn
Source: PHBISAs Analysis /
* Braskems Green Polymers: A Partnership Beyond Renewable Raw Materials European Bioplastics ConferenceNov09
PE from
Ethanol**
PHB Sugar
Cane
PHB from
Corn
Biopolymer Production(ton/hectare)
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Biocycle is a net CO2consumer / cleaner, when considered theentire lifecycle
1 kg of PHB rescue around~4,4 kg CO2
Source: Rescue CO2
1. PHBISA: EstudoLCACETEA/ITAL & Estudos CTC / Unicamp
2. PE Braskem: BraskemsGreen Polymers: A Partnership Beyond Renewable Raw Materials4 European Bioplastics Conference
3. PHB Milho:Metabolix
4. PE / PET / PLA: Cargill Dow LLC
Lifecycle CO2- Rescue Comparison
Product CO2(kg) / Ton of Product
PHBBiocycle
(Sugar Cane)4.400
PE Green 2.500
PHB (corn) 2.200
PLA (corn) 1.700
PP (1.900)
PET (3.200)
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Chemical FormulaLinear chain of poly (3-hydroxybutyric) acid (PHB)
CH3
CH CH2 C
O
O
Laboratory Propagation Prefermentation
Fermentation
Microorganism Settling
PHB Extraction
Cristallization
Drying
Solvent Recovery
Effluent Treatment
Sugar Nutrients Water
Sterilization
Purification
Nutrient Broth
Syrup
Water
Land Field
Solvent
Solvent
Water
Solvent
PHB
Production Technology
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PHB Extraction
The solvent, a non-toxic ethanol productionby-product, is mixed
The cells react to the solvent by bursting,leaving the PHB absorbed in the solvent
The rest of the cell particles remainundissolved, suspended in the solvent
The bulk of the solvent plus dissolved PHBis then filtered from the cell debris
At this point, the mixture of solvent anddissolved PHB moves on to thecrystallization / purification steps while thedebris by-product is removed from thebatch
Laboratory Propagation Prefermentation
Fermentation
Microorganism Settling
PHB Extraction
Cristallization
Drying
Solvent Recovery
Effluent Treatment
Sugar Nutrients Water
Sterilization
Purification
Nutrient Broth
Syrup
Water
Land Field
Solvent
Solvent
Water
Solvent
PHB
Production Technology
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Production Technology
Crystallization / Purification
After the filter stage, the PHB andseparated it from the remaining solvent
In the purification stage, the separatedsolvent is removed and recycled
Once the PHB is at this high purity level,it is steam dried and packaged for
delivery to converters and other endcustomers
Laboratory Propagation Prefermentation
Fermentation
Microorganism Settling
PHB Extraction
Cristallization
Drying
Solvent Recovery
Effluent Treatment
Sugar Nutrients Water
Sterilization
Purification
Nutrient Broth
Syrup
Water
Land Field
Solvent
Solvent
Water
Solvent
PHB
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ProductionNew Technology Frontier
Copolyester
PCL
PLA
Wood Powder
Starch
Bagasse
Sisal Fiber
Other
PHB Production Compoundwith
Laboratory Propagation
PHB Extraction
Drying
Pre-fermentation
MicroorganismSettling
Crystallization
Effluents Treatment
Sugar Nutrients Water
Fermentation
Solvent Recovery
Sterilization
Purification
Nutrients
Syrup
Water
Organic
FertilizerSolvent
Solvent
Solvent
PHB
Water
Material
Engineer
ing
Fermentation Process
PI 9103116-8
Process Extraction
PI 9302312-0 /PI 0405622-1 / PI 0501844-7 COMPOSTABILITY
BIODEGRADABILITY
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Technical characteristics of the base polymer that can be improvedthrough polymer blends and alloys with PHB
Processing Technologyviscosity, crystallization and reactive extrusion
Mechanical Propertiestensile strength and impact resistance
Thermal Propertiesheat deflection, melting point, glass transition and
decomposition
Biodegradabilityvelocity and rate
Cost
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Such products have been obtained through joint efforts with potential
clients and partners
Applications developed by PHBISA
Traditional Polymer Replaced Process Products
Polypropylene Extrusion
Thermoforming
Injection
Recipients for nursering crops
Automotive parts
Parts to crop monitored growth
Toys
Packaging partscaps
Polystyrene Thermoforming Trays for plantsDisposable cutlery
Polyurethane Injection
Extrusion
Elastomers and foams
Isolation (construction)
Shoes
Automotive parts
ABS Extrusion
Thermoforming
Banking cards
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Ecoflex (AAC)74,000 ton
DuPontUSA
Biomax (PGA)up to 200,000 ton
Cargill DowUSA
Natureworks (PLA)140,000 ton
BASFGermany
Dow
/Mitsui
Green PE*240,000 ton
MitsubishiJapan
/PTT
Thailand
Green Pla(PBS)*
30,000 ton
Green PE200,000 ton
Braskem(Brazil)
Major Players from Europe, America and Asia are investing indifferent biobased technology streams, showing the markettrends
ADMUSA
PHA**
50,000 ton
http://www.adm.com/en-US/Pages/default.aspxhttp://www.corporate.basf.com/en/http://www.mitsui.co.jp/tkabz/english/body.htmlhttp://images.google.com.br/imgres?imgurl=http://www.dow.com/about/aboutdow/joint/images/CDLLC_LO.jpg&imgrefurl=http://www.dow.com/about/aboutdow/joint/cargill.html&h=79&w=367&sz=15&tbnid=oqEqh8i31rUJ:&tbnh=25&tbnw=116&start=4&prev=/images?q=cargill+dow+llc&hl=pt-BR&lr=&ie=UTF-88/10/2019 Phb Brasil
19/19
Tel: 55 16 3987-9130
Fax: 55 16 3987-9019
www.biocycle.com.br
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