Soy.
A natural
renewable
feedstock
for
industry.
Soy Beans as Polymer
Building Blocks
Phil Sarnacke
Omni Tech International, Ltd.
August 16, 2007
United Soybean Board –
New Uses Committee: Target Areas
z Plastics
z Lubricants
z Coatings/Inks/
Adhesives
z Emerging Ind.
Opportunities
z Aquaculture
z
Goal: Commercialize a
sufficient number of new
industrial applications…to
collectively utilize
10 million bu. per
year 5 years from
launch
SOY OIL/MEAL
AS BUILDING BLOCKS
for PLASTICS/POLYMERS
Thermosets :
Polyurethanes, Unsat. Polyesters,
Rubber Cmpds.
08/16/07
Thermoplastics
Hydrogels
Total 2006 NA
Plastics Demand**
– 125 BILLION LBS.**
– THERMOSETS - 18 B lbs. **
– THERMOPLASTCS - 107 B lbs.**
** OTI estimates
North American
THERMOSET RESIN MARKET
POLYURETHANE 7.5 Billion lbs(-1%) (’06E)
Polyols: 3.3 Billion lbs. (’06E)**
UNSATURATED POLYESTER RESIN
1.95 Billion lbs. (-2%) (’06)**
** OTI estimate
Soybean Oil ……
O
O
Atomic Mass 888
15% Saturated triglyceride
85% Unsaturated triglyceride
O
Mixture of mostly:
O
O
O
C18:1 chains (Oleic):25%
C18:2 chains (Linoleic): 45%
C18:3 chains (Linolenic): 10%
Soybean Oil to Soy Polyol
Functionalization of Oil via:
HYDROXYLATION, FORMYLATION,
TRANESTERIFICATION,
SBO
EPOXIDATION, OR
OZONOLYSIS
Soy Polyol
Soy‐Based Polyols ……
• Oil is reacted to insert –OH groups
OH
O
CH2 – O ‐ C O
Soy Polyol
CH – O ‐ C
OH
O
CH2– O – C •Theoretical functionality varies from 1.0 to 8.8
•Process designed for partial conversion into –OH groups
•These are secondary –OH groups
Soy Polyol Producers/ Development
Programs
z
z
BIOBASED CHEMICALS
CARGILL
z URETHANE SOY SYSTEMS (SDSP)
z CHEVRON PHILLIPS CHEMICAL
z ARKEMA
z DOW CHEMICAL
■ Battelle Memorial Institute
■ Univ. Of Missouri
■ Bioplastics & Compos./Mich. State U.
■ Kansas Polymer Inst./Pittsburg State U.
POLYURETHANES 101
A-Isocyanate
B-
Soy
polyols
Courtesy of Dow Chemical
Polyurethane
Foam
SoyFoam Seats/Headrests
Courtesy of Ford Motor & Lear Corporation
•Ford Motor Company and Lear Corporation have joined forces to produce seat foam made from soy-based materials. The first application will appear in the 2008 Ford Mustang.
FORD, LEAR TO LAUNCH INDUSTRY'S FIRST SOY BASED
SEAT FOAM IN 2008 FORD MUSTANG
DEARBORN, Mich., July 12 –
Ford Motor Company [NYSE:F]
and Lear Corporation [NYSE: LEA] will mark an
automotive milestone in August when production of soybased foam for seats begins in the 2008 model year
Ford Mustang. America’s beloved pony car will use the
industry’s first soy-based flexible foam in the seat backs
and seat cushions beginning in August at the Auto
Alliance International factory in Flat Rock,
Michigan, home of the Ford Mustang.
PR Release (cont’d)
…The environmental advantages of soy-foam
include: a reduction of carbon dioxide (CO2)
emissions when compared to current petroleum-based
material, lower energy required to produce the material,
up to 24 percent renewable content, and a
reduction of dependence on volatile energy markets.
Ford and Lear collaborated with the
United Soybean Board - New Uses Committee …
Urethane Soy Systems Company, Bayer Corporation
and Renosol Corporation on soy-foam development.
Rigid Foam Insulation
Spray Elastomer
Carpet Underlay
Headrest
Pultrusion
USSC’s Soyol™ “bio-renewable” polyols
……
Unsaturated Polyester
Resins (UPE) 101
Di-Carboxylic Acid
Propylene glycol
Styrene Monomer
Unsaturated Polyester Resin
Ashland Envirez™ Resin
12%
13%
75%
Petrochemical
Soybean Oil
Ethanol
SMC / RIM Panels
2.3 Bushels Soybeans
0.6 Bushels Corn
Markets for
Unsaturated Polyester Resins
Rubber/Soy Meal Compound
Renewable Resource-Based
Green Materials from Soy MealNatural Rubber Blends Soy
meal A. K. Mohanty, Q. Wu and S. Selke
School of Packaging, Michigan State
University, East Lansing 48824, MI
Thermoplastics
Challenges for Thermoplastics
from Soy
z
Protein content in soy meal
z Economical upgrades to
concentrate/isolate
z Protein Plastic properties Profile
z Processing of soy protein as a plastic
z Degradability attribute
Fatty Acid Profiles of
Vegetable Oils
Canola
Sun
Soy
Corn
Cottonseed
Palm
0%
20%
Palmitic C16:0
Linoleic C18:2
40%
60%
Stearic C18:0
Linolenic C18:3
80%
Oleic C18:1
100%
Soy vs Other Oils
New
Thermoplastics/Thermosets
z
z
z
z
z
6412(RC)University of Kentucky– Bean development of epoxy fatty acid in the plant
7425 Ford Motor Co.
- Soy meal as a filler in polymer matrices for automotive
7426*University of Wisconsin
- Soy protein properties for thermoplastic applications
7437* Battelle Memorial Inst.
- Soy meal modification form a water swellable Polymer
7474*Global AgriTech
- Soy-based replacement for phthalate plasticizers
OPPORTUNITIES FOR SOY
DERIVATIVES
Plastics
•Composites
•Ag Films
•Urethanes
•Water swellable
polymers
Adhesives
Rubber
Compounds
Lubricants
Coatings
Specialty
Products