IEA T 42 : BIOREFINERY

Meeting March 3rd 2010 - Lestrem

Christophe Rupp-Dahlem Programs Director Vegetal-Based Chemistry / ROQUETTE President of the French Association for the Vegetal-Based Chemistry (www.chimieduvegetal.com) [email protected]

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 1 AGENDA

14h - 14h30 : Roquette Introduction : general, innovation strategy

14h30 - 16h30 : Tour plant ( , glucose, )

16h30 - 17h00 : Conclusion

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 2 THE ROQUETTE GROUP TODAY

One of the leading global producers of starch products : ¾ Number 2 in ; In the Top 4 in the world ¾ World leading producer of polyols and gluconates ¾ 18 factories around the world including the most important cereal based biorefinery in Europe located in Lestrem (F)

4 Agricultural Raw Materials : Corn Starch potatoes

Our business from harvest to starch and starch derivatives

Turnover of 2,5 billion €

250 research contracts by year with universities and private partners worldwide. An active portfolio of more than 150 patents

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 3 Our mission From raw materials … …to Roquette products • Production of

CO Corn RN S TEEP GERM Wheat SO LUBL FI ES BER V EGE GLUT TATI EN W ON B ATER RAN

GL UTEN Corn SO Pea LUBL starch ES PULP

P Wheat ROT EINS FIBE starch R e l n b o u i l t P Potato starch o c n ROT S a EI r io NS f t c a r e f s t o n Pea l a o u i F l t starch l c n e i n a e C r o f t i o t r c P a r f DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 4 Our mission

plant Corn

Corn Steep Steeping (solubles)

Germ Grinding Corn germ meal Corn Feed Screening (fiber)

Gluten (protein) Separation

Refining

STARCH Raw material for our complete range of products

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 5 Our mission

• Wheat starch plant Wheat

Bran Milling

Kneading Gluten

Washing

Fibers and gums Screening Solubles Refining

STARCH Raw material for our complete range of products

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 6 Our mission • Potato starch plant

Potato

Rasping

Vegetation Separation water Solubles Proteins

Pulp Screening Refining

STARCH Raw material for our complete range of products

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 7 Our mission

• Pea starch plant

External Mill fibers

Separation/ STARCH Refining

Internal fibers Separation

Solubles

PROTEIN

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 8 CURRENT INTEGRATED PROCESSES - GLOBAL SYNOPTIC

Starch molecule STARCH = thousands of linked glucose Native starch Drying molecules

Modification Hydrolysis Enzymes Modified starches : Dextrins, Pregelatinized, Ethers-esters, Cationics, others

Hydrolized products : Dextrose Malto-dextrins Glucose syrups Hydrolysates

Biotechnology Hydrogenation

Fermentation Hydrogenated products : & Biocatalysis products : Hydrogenated Polyols : Sorbitol, Mannitol, New building blocks, organic Glucose syrups Isosorbide, , Xylitol, acids…

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 9 Our products

Sales by product line

Co-products Native starch

18% 10% Fermentation products Modified starch 2% 13%

Polyols 26% 19% 12% Liquid Dry sugars

ProcessingProcessing naturenature’’ss productsproducts……

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 10 Our applications

1% 12% 9% 49% 14%

15% in volume …… adaptedadapted toto thethe needsneeds ofof industryindustry

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 11 Our applications • Paper – Corrugated cardboard

Human 1% 12%

9% 49% 14% by volume

Paper - Corrugated cardboard15%

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 12 Our applications • Pharmacy - Cosmetology

Pharmacy - Cosmetology

1% 12%

9% 49% 14% Human food 15% Paper – Corrugated cardboard

by volume

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 13 Our applications • Chemistry – Bio-Industry

Pharmacy - Cosmetology 1% 12% Chemistry – Bio-industry 9% Human food 49% 14% Paper - Corrugated cardboard 15%

by volume

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 14 Our applications • Animal nutrition

Pharmacy - Cosmetology

1% 12% Chemistry - Bio-industry 9% 49% 14%

Human food 15% Paper - Corrugated cardboard

by volume Animal nutrition

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 15 Roquette Frères

• Corn starch (native and modified) • Wheat starch (native and modified) • Sugars (liquid and dry) • Polyols

Head office of the group and main production site DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 16 Innovation at ROQUETTE

Î Transforming innovative ideas into new, sustainable and competitive products

TARGET : being a major leader in the future bio-based economy with integrated biorefineries

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 17 Two Axes for the Programs of Innovation

VEGETAL BASED From integrated biorefineries NUTRITION and to generate new business CHEMISTRY with partners HEALTH

New monomers and new Ind. Functional Biotech processes. ingredients

New functionalized natural polymers

Microalgae Pea

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 18 Hubs for Innovation

Dedicated task-force to speed up the time to market for innovative new products

New Industrial Biotechnology & Hubs Center

Illustration of new expertises : New WB processes Agro-materials Microalgae

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 19 DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 20 ALGOHUB™ Program

Biodiversity Production

Supernatants Microalgae Biomass Microalgae Extracts

Animal Human Purified Production Nutrition Products cosmetics and pharma • Health • Omega-3 actives and ingr • Aquaculture Supplements • Eggs •Pigments • Ingredients • Antioxydants Recombinant • Anti-pathogens Proteins • Anti-inflammatories • Anti-Alzheimer • Enzymes • New functionalities

Concentrated & integrated Industry : ALGOHUB™ Program

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 21 ALGOHUB™ Program

Setubio Valorisation de la biodiversité

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 22 Biorefinery : A New Example For Sustainable Development

The refinery based on fossil resources Source Transformation Products Downstream process

Refining Chemical Oilfields & Formulation Transformation Cracking

Native Oil Naphta Monomers & polymers End Product The biorefinery based on renewable resources (cereals) Source Transformation Products Upstream process

Biotech Chemical Agricultural Starch Trans- Trans- Formulation fields production formation formation

Maize/Wheat Glucose Monomers & polymers End Product

Leading role of biotechnology Shared role between biotechnology and chemistry Leading role of chemistry

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 23 New Biorefineries : An Example of the Circular Economy

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 24 The New Cereal Based Biorefinery

New platform chemicals PROGRAM

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 25 PROGRAM

The Concept Definitions MeeM ting the needs of the present without compromising the ability of future generations to meet their own needs. ProcessingP starch and using chemical, biological and physical means to refined value added end-products for use in food and non-food applications.

PROCESSES : Š White Biotech (W.B.) Š Plant Based Chemistry Products with new W.B. processes New Chemical Products for Commodities, Specialties and Fine Chemical Markets Biopolymers

RRB3 – Ghent – June 4th 2007 10 The BioHub ® PROGRAM

Substitutes for petchem

Current products New products with new WB processes

Ö Biosolvents : Dimethyl Isosorbide Ö Active ingredients : Ö Bioplasticisers : Isosorbide diesters L-Methionine Ö Biolubricants : Isosorbide diesters Ö Chemical intermediates : Ö Biofluxing agents : Dimethyl Isosorbide Bio Succinic Acid Ö Biopolymers : Isosorbide Bio Glycolic Acid Ö Biocomplexing agents

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 27 An Example of a Biohub® Platform : Isosorbide a Sustainable Diol For Chemicals And Polymers

H

CH2 OH – (CHOH)4 –C (glucose) O Hydrogenation

CH2 OH – (CHOH)4 –CH2OH (sorbitol)

Isosorbide Isosorbide Derivatives for polymers O R-C (isosorbide) COOH – (CH2)n – COOH OH Diacids or other chemicals Fatty Acids

O OCH3 O C O O Polyesters R PEIT O O O Polyurethanes OC OCH3 Isosorbide Di-Esters Polycarbonates R Di Methyl Isosorbide « PVC plasticisers « sustainable co-solvent and fluxing Others polymers Personal & Oral care» agent»

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 28 Illustration of the Isosorbide Platform : Polysorb® ID 37 - New 100% Bio-Based Plasticizer

Î Polysorb® ID 37 is a blend of diesters obtained from esterification of Isosorbide with fatty acid

Î It’s synthesized by 9 fatty acid (vegetal based) 9 and isosorbide coming from dehydratation of sorbitol

Cereals (corn, wheat) Plants

Starch Oil (vegetal) Sorbitol

Fatty Acid (vegetal) Isosorbide

Isosorbide diester (IDE) : Polysorb® ID 37

► 100 % Bio-Based and Plasticizing Effect comparable to Phthalate Plasticizers

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 29 An Example of Bio-Based Building Block : Succinic Acid a Sustainable Di-acid for Chemicals And Polymers

H

Glucose CH2 OH – (CHOH)4 –C O Fermentation CO2

Succinic Acid Succinic Derivatives Succinic Acid for polymers COOH – (CH2)2 – COOH

Î Joint development with + Isosorbide or BDO , …

HO

BDO (1,4 Butanediol) OH Green Polyesters like PIS O (Polyisosorbide succinate) THF (Tetrahydrofuran) PBS (Polybutylene succinate) GBL O O (GammaButyrolactone)

Succinate esters

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 30 Bio-Sucinnic Acid As Monomer for Renewable Materials/Products

starch Enzymatic glucose hydrogenation sorbitol dehydration isosorbide hydrolysis

PolySuccinic-Isosorbide Enzymatic succinic starch glucose hydrolysis Fermentation acid

Enzymatic succinic PolyButylene-Succinate starch glucose Fermentation hydrogenation butanediol hydrolysis acid

CO2 neutral product cycle Bio-renewable Renewable Feedstock (bio) processes performance materials

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 31 DSM – ROQUETTE Partnership for Bio-Succinic Acid

Biodegradable Polymers (e.g. PBS, PSI)

Renewable Bio-SA Existing large-volume Feedstock Fermentation products like BDO

RQ-DSM Bio-SA derivatives Alliance

Industrial partners

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 32 D,L and L-METHIONINE Project : Production Diagrams

Oil Cracking Propylene Acroleine AMTP D-L Methionine products

Methanol Methyl HCN Mercaptan H2S Ammoniac Natural gas Salts

Cereals Starch Glucose L-Methionine

KT 700 = g 2008 €/k rket = 4 d ma Worl 2008 price

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 33 The BioHub® Program

Institut des Molécules et de la Matière Condensée de Lille (IMMCL)

To create new value chains through industrial innovation !

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 34 BIOHUB® PROGRAM : Main Figures

Î Global cost of the Programme = € 90 mio. (6 years )

Î Aids from the French Industrial Innovation Agency : € 42 mio. (€ 22 mio. as subsidy and € 20 mio. as reimbursable loans)

Î Industrial investments = € 700 mio. (starting after 2010)

Î Expected volumes and surfaces = 1.3 mio. tons corn or 150 000 ha

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 35 Many companies with very different backgrounds have started to engage in the biorefineries concept

NOT COMPLETE • Chemicals

• Agro Industries

• Biotech

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem Source Mc Kinsey 36 Chemical and Agro Industrial players have started to form partnerships to build biorefineries

Some Emblematic Examples

Announced Product Agro Industries Chemicals Volume kt Timeline

Ethylene/VCM 360 VCM (from ) 2010

Ethylene Brazil 350 2011 (from ethanol)

Ethylene 200 2009 (from ethanol)

Succinic acid Europe Demo plant End of (from starch) 2009

USA 1,3- propanediol 45 Operational

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 37 Building the Foundation for a Sustainable World

THANK YOU

DPCV/CRD/BI – IEA BIorefinery March 3rd 2010 - Lestrem 38