Genomatica, Eni’s Versalis make bio-butadiene via renewable feedstocks

Versalis (Eni), a European producer in the polymers and elastomers industry, and Genomatica, a leader in bioengineering solutions, announced today that they 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 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 10 MMtpy produced.

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 says it 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. 

Meanwhile, 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-liter fermenters at their research centers at Novara and Mantova, and then made bio-polybutadiene, at the Ravenna R&D center, using both anionic and Ziegler-Natta catalysis.

Initial testing of the bio-BDE and bio-BR demonstrates good compatibility with industry standards, officials said. Versalis is continuing to test the bio-BDE within its other proprietary rubber and plastics downstream technologies such as SBR (styrene-butadiene rubber), SBS (styrene-butadiene-styrene rubber) and ABS (acrylonitrile butadiene-styrene).

The accomplishments demonstrate the common vision of the partners on the potential of this project: access to on-purpose butadiene from renewables will establish a competitive advantage and 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.