ATP-Funded Green Process Technologies - NIST Advanced ...

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Some PLA-based, nonwoven products are available in U.S. markets, from Faribault Mills (under Ingeo Blankets brand) and Bed, Bath & Beyond (under Natural Balance brand). However, direct PLA resin sales for fiber applications appear to be limited to overseas converters. Offshore textile products made from PLA resins are imported to the United States and make it possible for U.S. retail customers to enjoy the health and safety benefits of bio-based textiles. POSSIBLE FUTURE APPLICATION Bottles and beverage containers are a potential future application of corn-based PLA resins. Bottles are made by injection stretch-blow molding. In this process, thermoplastic resins are injection molded into a pre-form. With the use of compressed air and heat the pre-form is inflated to conform to the interior of a chilled mold. PLA bottles must have good impact resistance and clarity, remain unaffected by bottle contents, and have strong barrier properties to prevent change in contents during extended storage. By 2007, U.S. demand for beverage containers is projected to increase to $17.5 billion. Metal cans and paperboard containers continue to lose market share and polymerbased containers are expected to grow at 2 percent per year (Freedonia, 2003a). BENEFIT ASSESSMENT AND MODELING PLA resins for food packaging and fiberfill applications will lead to benefits for customers, end users, and society, including the following: • Avoided use of imported petroleum • Substantial net gains in energy efficiency and associated cost savings • Reduced greenhouse gas emissions • Reduced landfill requirements for end-of-life disposal Without the ATP-funded PLA technology, these benefits would not have been realized over the timeframe of this study. Instead, polymer products, if not displaced by ATPfunded PLA technology, would continue to be made from petroleum-derived resins, associated with higher costs, higher greenhouse gas emissions, and end-of-life land filling. Processed Volumes and Sales Estimates The following data points and assumptions for PLA processed volumes were estimated on the basis of available information from NatureWorks and from industry experts. • Production start-up was achieved in late 2002. Given negligible 2002 production volumes, Table 1 indicates production levels starting in 2003. 28 ATP-FUNDED GREEN PROCESS TECHNOLOGIES
Table 1: Projected PLA Resin Sales (Million Pounds per Year) Base Case Step-Out Scenario PLA Production PLA Production at Blair NE PLA U.S. Sales at Blair NE PLA U.S. Sales Year (1) (2) (3) (4) 2003 10 3.33 10 3.33 2004 30 10.00 30 10.00 2005 60 20.00 60 20.00 2006 100 33.33 120 40.00 2007 115 38.24 144 48.04 2008 132 43.87 173 57.71 2009 151 50.33 208 69.31 2010 173 57.73 250 83.25 2011 199 66.23 300 100.0 2012 228 76.00 300 100.0 2013 262 87.17 300 100.0 2014 300 100.00 300 100.0 2015 300 100.00 300 100.0 2016 300 100.00 300 100.0 2017 300 100.00 300 100.0 Compound Annual 14.72% 20.11% Growth Rate (2007–2014) (2007–2011) Notes: 1. Production start-up was achieved in 2003. As indicated by the shaded area in Table 1, full-capacity production levels are achieved in 2014 under a base case scenario and in 2011 under a step-out scenario. 2. Analysis covers a period of 15 years from the time of the Blair production start-up. As indicated by the shaded area in Table 1, there is an expectation that full production can be achieved on an accelerated basis compared with conventional industry expectations of 20 years to achieve full production. • Production design capacity is 300 million pounds per year. • In 2003, 2004, and 2005, production levels were estimated at 10 million, 30 million, and 60 million pounds, respectively. The 2006 production level for a base case scenario was estimated at 100 million pounds. • New polymers generally “make their mark” and gain industry acceptance within 20 years from start-up. In contrast, the Blair facility is projected to reach full capacity in just 12 years (base case scenario), with production levels growing at annual compound rates of almost 15 percent. Accelerated ramp-up is based on the following: – NatureWorks’ production and sales performance to date, including the recently implemented Wal-Mart relationship – Considerable marketing strength of the parent company (Cargill) – Faster growth rates expected for renewable polymers than for PET Case Study: Renewable-Resource-Based Plastics Manufacturing 29
Page 1 and 2: GCR 06-897 ATP-Funded Green Process
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Page 6 and 7: The ATP-funded Renewable-Resource B
Page 9 and 10: Executive Summary Green process tec
Page 11 and 12: Case Study: Renewable-Resource-Base
Page 13 and 14: feedstock and in agricultural crops
Page 15 and 16: Contents Abstract . . . . . . . . .
Page 17 and 18: 5. Mini-studies of ATP-Funded Green
Page 19 and 20: Abbreviations, Acronyms, and Defini
Page 21: Post-industrial scrap Post-consumer
Page 24 and 25: technologies on project participant
Page 26 and 27: Commercial-scale sorting of titaniu
Page 29 and 30: 2. Analytical Framework and Methodo
Page 31 and 32: Figure 1: Flow of Benefits from ATP
Page 33 and 34: eturns that is attributable to ATP
Page 35 and 36: if it proves difficult to identify,
Page 37 and 38: METRIC FOR GAUGING THE SPILLOVER GA
Page 39 and 40: 3. Case Study: Renewable-Resource-
Page 41 and 42: pointed to a need for enabling rese
Page 43 and 44: Figure 3: Manufacturing Lactic Acid
Page 45 and 46: Subsequent research efforts were di
Page 47 and 48: Pathways to Market As indicated in
Page 49: “Wal-Mart is going green. The ret
Page 53 and 54: Table 2: Fossil Energy Budgets for
Page 55 and 56: To illustrate the estimation of ene
Page 57 and 58: of avoided CO 2 emissions per pound
Page 59 and 60: ATP and Industry Partner Investment
Page 61 and 62: The net present value of the ATP in
Page 63 and 64: The net present value of the ATP in
Page 65 and 66: Table 10: Reduced Petroleum Use—P
Page 67 and 68: 4. Case Study: High-Speed Identific
Page 69 and 70: In addition, an active advisory boa
Page 71 and 72: Figure 6: Proposed Two-Stage Approa
Page 73 and 74: Technical Accomplishments In 2003,
Page 75 and 76: Titanium Alloy Sorting Titanium scr
Page 77 and 78: U.S. annual consumption in 2005 was
Page 79 and 80: Table 11: Approximate U.S. Titanium
Page 81 and 82: The primary application, however, r
Page 83 and 84: Table 12: Approximate U.S. Superall
Page 85 and 86: Figure 13: Aluminum Production Scra
Page 87 and 88: • Intermediate-size pieces of les
Page 89 and 90: Table 14: Avoided CO 2 Generation f
Page 91 and 92: To properly attribute well-timed an
Page 93 and 94: Given that 2005 cash flows represen
Page 95 and 96: OTHER BENEFITS The ATP-funded alloy
Page 97 and 98: 5. Mini-studies of ATP-Funded Green
Page 99 and 100: MOLECULAR GATES TECHNOLOGY FOR THE
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Both water disinfection and lead ab
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6. Green Technologies that Promote
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proposition was borne out in the tw
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ATP has funded a broad spectrum of
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7. Conclusions ATP provided early a
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which mini-studies have been comple
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BioCycle. 1999. “Food Residuals C
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Langston, L. 2006. “Crown Jewels:
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Vink, E., K. Rabago, D. Glassner, a
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