 "Versalis' bio-butadiene rubber")
Versalis (Eni), a European producer in the polymers and elastomers industry, and Genomatica, a leader in bioengineering solutions, have successfully advanced to pilot-scale production of bio-butadiene (bio-BDE) from fully renewable feedstock. Versalis used this bio-BDE to make bio-rubber, specifically, bio-polybutadiene (bio-BR). These accomplishments represent a remarkable milestone for the rubber industry, by enabling an improved technological and sustainability footprint; and to the broader industry for butadiene, one of the most widely-used chemicals in the world, with over ten million tonnes produced per year.
The success of this innovative undertaking results from a newly-developed process for the on-purpose production of butadiene which uses various types of sugars as feedstock, rather than the traditional use of hydrocarbon feedstocks. The project started with the establishment of a technology joint venture between Versalis and Genomatica in early 2013. The joint venture - with Versalis having the majority stake - has developed a complete process to make bio-BDE and plans to license the resulting technology.
The joint venture uses the proven and complementary strengths of both companies. Versalis and Genomatica together determined that 1,3-butanediol (1,3-BDO) was the most suitable intermediate to produce bio-BDE. Genomatica applied its ‘whole-process’ systems approach to bioengineering to develop a microorganism that produces 1,3-BDO in a way that enables cost-efficient, scalable fermentation, recovery and subsequent process operations.
Versalis leverages its industrial process engineering and catalysis capabilities, plus expertise in overall polymer production, to purify the 1,3-BDO, dehydrate it and then purify the resulting butadiene. Versalis has produced several kilograms of butadiene from 1,3-BDO made in 200 litre fermenters at its two research centres at Novara and Mantova in Italy, and then made bio-polybutadiene, at the Ravenna R&D centre, using both anionic and Ziegler-Natta catalysis.
Initial testing of the bio-BDE and bio-BR demonstrates good compatibility with industry standards. Versalis is continuing to test the bio-BDE within its other proprietary rubber and plastics downstream technologies such as styrene butadiene rubber (SBR), styrene butadiene styrene rubber (SBS) and acrylonitrile butadiene styrene (ABS).
The latest development will ensure a strategic raw material from alternative feedstock, contributing at the same time to drive a greater sustainability profile for downstream applications in the plastics and rubber businesses.
