PHB Brasil

Sustainable polymer from sugar cane
- BIOCYCLE -
2012
The Concept
CO2
Energy
Compost
CO2
Boiler
Cane fields
Dispose
Energy
Bagasse
Sugar mill
Polymer
Sugar
PHB Production
1
Solvent
Molasses
Ethanol
Company Overview
The development of PHB in Brazil
1994
2004
Implementation of the Pilot Plant to

produce PHB / PHB-HV at Usina da
Pedra, Serrana -SP
PHB production process proves to be

economically viable
Focus on Material Engineering Market
Applications 1st generation
1991
2000
2008
Research grant establishes the

Production of Biodegradable
Plastics from Sugar via Bio
technological Route
PHB Industrial S/A was created along

with the BIOCYCLE brand.
Consolidation of productive process
COPERSUCAR - IPT
Applications, New Solvent, New

Patents 2nd generation
ORGANIZATIONAL STRUCTURE
Pedra Agroindustiral S.A. / The Balbo Group
More than 80 years of experience in the sugar
and alcohol industry
Industrial assets comprised of six mills in the state
of So Paulo and one in the state of Minas Gerais
Total annual production (1):
Pedra
Agroindustrial
S.A.
Balbo Group
20 Million tons of crushed Sugar Cane
50%
50%
650 Million kilograms of sugar

900 million liters of alcohol
More than 10,000 employees
Culture area of more than 180,000 hectares of

sugarcane (1)
PHB Industrial S.A.
Energy generation capacity of approximately

800,000 MWh (1)
Commercialization of CERs through Kyoto
Protocol
Major worldwide organic sugar producer
PHB Industrial S.A.

Leverages the collective experience and
relationships of Pedra Agroindustrial S.A. and the
Balbo Group
(1) 2010 / 2011 crop
3
Company Overview
PHBISAs technology has been developing and refining over 16 years of research
Serrana
Ribeiro Preto
Santos Port
Usina da Pedra
South
America
Brazil
So Paulo
PHB INDUSTRIAL S.A. Overview

PHBISA utilizes a completely renewable concept to 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 sustainable PP contra type.
Product with high performance and functionality
New technology frontier

5
Sugar Cane
Competitive advantage over other biomass
Fossil-fuel energy used to make the fuel

(input) compared with the energy in the
fuel (output)
9,3
2,0
1,0
Fossil-fuel
1,4
Corn
Beet
INPUT
Sugar Cane
OUTPUT
Sugar Cane presents the highest energetic productivity

compared to other biomass.
Fonte: Unica
Biopolymers - Productivity comparison & Demanded Area
Necessary area to produce

100.000 tpy of PHB
Biopolymer Production
(ton/hectare)
(thousand hectares)
45
4,39
32
3,09
23
2,20
PHB Sugar
Cane
PE from
Ethanol** *
PHB from
Corn
PHB Sugar
Cane
Source: PHBISAs Analysis /

* Braskems Green Polymers: A Partnership Beyond Renewable Raw Materials European Bioplastics Conference Nov09
PE from
Ethanol**
PHB from
Corn
Biocycle is a net CO2 consumer / cleaner, when considered the

entire lifecycle
1 kg of PHB rescue around
~4,4 kg CO2
Lifecycle CO2 - Rescue Comparison

Product
CO2 (kg) / Ton of Product
PHB Biocycle
(Sugar Cane)
4.400
PE Green
2.500
PHB (corn)
2.200
PLA (corn)
1.700
PP
(1.900)
PET
(3.200)
Source: Rescue CO2

1. PHBISA: Estudo LCA CETEA/ITAL & Estudos CTC / Unicamp
2. PE Braskem: Braskems Green Polymers: A Partnership Beyond Renewable Raw Materials 4 European Bioplastics Conference
3. PHB Milho:Metabolix
8
4. PE / PET / PLA: Cargill Dow LLC
Production Technology
Chemical Formula
Sugar
Nutrients
Water
Linear chain of poly (3-hydroxybutyric) acid (PHB)
CH3
CH
O
CH2
Laboratory Propagation
Prefermentation
Sterilization
Nutrient Broth
Fermentation
Syrup
Microorganism Settling
Effluent Treatment
Water
Solvent
PHB Extraction
Solvent Recovery
Cristallization
Land Field
Solvent
Water
Purification
Solvent
Drying
PHB
Sterilization
At this point, inputs are introduced into a

fermenter:
Sugar
The streams are mixed in the fermenter, along

with the bacteria, to begin the process of
converting the feedstock to PHBs
Prefermentation
Nutrients
Water
Sterilization
Nutrient Broth
Fermentation
Syrup
Fermentation Process
Bacteria act as biofactories with the ability to

turn a feedstock into PHB in an aerobic
environment
Effluent Treatment
Water
Solvent
PHB Extraction
PHBISA has achieved up to 90% content in

the biomass in this process
Solvent Recovery
Cristallization
Land Field
Solvent
Water
Purification
Solvent
Drying
10
PHB
Sugar
Nutrients
Water
Material is in liquid form with bacteria

fully suspended
Prefermentation
Sterilization
Nutrient Broth
Fermentation
The cells are separated from the

solution
Syrup
Cells are then separated and passed on

to the PHB extraction phase
Effluent Treatment
Water
Solvent
PHB Extraction
Solvent Recovery
Cristallization
Land Field
Solvent
Water
Purification
Solvent
Drying
11
PHB
PHB Extraction
Sugar
The solvent, a non-toxic ethanol production

by-product, is mixed
The cells react to the solvent by bursting,
leaving the PHB absorbed in the solvent
Prefermentation
Nutrients
Water
Sterilization
Nutrient Broth
The rest of the cell particles remain

undissolved, suspended in the solvent
Fermentation
Syrup
The bulk of the solvent plus dissolved PHB

is then filtered from the cell debris
At this point, the mixture of solvent and
dissolved PHB moves on to the
crystallization / purification steps while the
debris by-product is removed from the
batch
Effluent Treatment
Water
Solvent
PHB Extraction
Solvent Recovery
Cristallization
Land Field
Solvent
Water
Purification
Solvent
Drying
12
PHB
Sugar
Nutrients
Water
Crystallization / Purification
After the filter stage, the PHB and

separated it from the remaining solvent
Prefermentation
Sterilization
Nutrient Broth
In the purification stage, the separated

solvent is removed and recycled
Fermentation
Syrup
Once the PHB is at this high purity level,

it is steam dried and packaged for
delivery to converters and other end
customers
Effluent Treatment
Water
Solvent
PHB Extraction
Solvent Recovery
Cristallization
Land Field
Solvent
Water
Purification
Solvent
Drying
13
PHB
Production New Technology Frontier
Sugar
Nutrients
Water
Copolyester
Pre-fermentation
Sterilization
PCL
BIODEGRADABILITY
Compound
with
PHB Production
Nutrients
Fermentation
PLA
Syrup
Microorganism
Settling
Fermentation Process
PI 9103116-8
Effluents Treatment
Water
Solvent
PHB Extraction
Material
Engineer
ing
Wood Powder
Starch
Solvent
Crystallization
Water
Solvent
Process Extraction
Organic
Fertilizer
Sisal Fiber
Purification
Drying
Bagasse
PHB
PI 9302312-0 / PI 0405622-1 / PI 0501844-7
14
Other
COMPOSTABILITY
Solvent Recovery
Technical characteristics of the base polymer that can be improved

through polymer blends and alloys with PHB
Processing Technology viscosity, crystallization and reactive extrusion
Mechanical Properties tensile strength and impact resistance
Thermal Properties heat deflection, melting point, glass transition and
decomposition
Biodegradability velocity and rate
Cost
15
Applications developed by PHBISA
Traditional Polymer Replaced

Polypropylene
Process
Products
Extrusion
Recipients for nursering crops
Thermoforming
Automotive parts
Injection
Parts to crop monitored growth

Toys
Packaging parts caps
Polystyrene
Thermoforming
Trays for plants

Disposable cutlery
Polyurethane
ABS
Injection
Extrusion
Elastomers and foams

Isolation (construction)
Shoes
Automotive parts
Extrusion
Banking cards
Thermoforming
Such products have been obtained through joint efforts with potential
clients and partners
16
Major Players from Europe, America and Asia are investing in

different biobased technology streams, showing the market
trends
BASF
Germany
DuPont
USA
Biomax (PGA)
up to 200,000 ton
Mitsubishi
Japan
/
PTT
Thailand
ADM
USA
PHA**
50,000 ton
Green Pla
(PBS)*
30,000 ton
Cargill Dow
USA
Natureworks (PLA)
140,000 ton
Braskem
(Brazil)
Green PE
200,000 ton
Ecoflex (AAC)
74,000 ton
Dow
/
Mitsui
Green PE*
240,000 ton
17
www.biocycle.com.br
[email protected]
Tel: 55 16 3987-9130
Fax: 55 16 3987-9019

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Sustainable polymer from sugar cane

The development of PHB in Brazil

Implementation of the Pilot Plant to

PHB production process proves to be

Research grant establishes the

PHB Industrial S/A was created along

Consolidation of productive process

Applications, New Solvent, New

20 Million tons of crushed Sugar Cane

650 Million kilograms of sugar

Culture area of more than 180,000 hectares of

PHB Industrial S.A.

Energy generation capacity of approximately

PHB Industrial S.A.

PHB INDUSTRIAL S.A. Overview

Production process filled without GMO.

Biopolymer completely biodegradable, compostable and sustainable PP contra type.

Product with high performance and functionality

New technology frontier

Fossil-fuel energy used to make the fuel

Sugar Cane presents the highest energetic productivity

Biopolymers - Productivity comparison & Demanded Area

Necessary area to produce

Source: PHBISAs Analysis /

Biocycle is a net CO2 consumer / cleaner, when considered the

Lifecycle CO2 - Rescue Comparison

CO2 (kg) / Ton of Product

Source: Rescue CO2

Linear chain of poly (3-hydroxybutyric) acid (PHB)

At this point, inputs are introduced into a

The streams are mixed in the fermenter, along

Bacteria act as biofactories with the ability to

PHBISA has achieved up to 90% content in

Material is in liquid form with bacteria

The cells are separated from the

Cells are then separated and passed on

The solvent, a non-toxic ethanol production

The rest of the cell particles remain

The bulk of the solvent plus dissolved PHB

After the filter stage, the PHB and

In the purification stage, the separated

Once the PHB is at this high purity level,

Production New Technology Frontier

PI 9302312-0 / PI 0405622-1 / PI 0501844-7

Technical characteristics of the base polymer that can be improved

Applications developed by PHBISA

Traditional Polymer Replaced

Recipients for nursering crops

Parts to crop monitored growth

Trays for plants

Elastomers and foams

Major Players from Europe, America and Asia are investing in

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