Recyclable Polyesters Made from CO2

The massive scale of global plastics production, which reached 390 million metric tons in 2021, has resulted in significant environmental challenges, including carbon emissions and pollution. A staggering 75% of discarded plastic ends up in landfills, while a mere 9% is recycled, causing a considerable amount to enter our ecosystems. Therefore, it is crucial to create affordable biodegradable plastics that minimize long-term environmental impacts and to develop carbon capture technologies that effectively reduce carbon emissions. Our project focuses on utilizing CO2 as a chemical resource to manufacture commodity polymer materials, aiming to decrease carbon emissions during the production process. By doing so, we intend to create highly biodegradable materials with enhanced chemical recyclability, promoting sustainability in the plastics industry. In Phase I, we successfully transformed a high CO2 weight content monomer, directly derived from CO2 and butadiene, into thermoplastic elastomers exhibiting promising mechanical properties and the potential to replace environmentally harmful petroleum-based materials. Progress has been made in developing a property database, which is still ongoing, and we have scaled up production to accommodate larger output. These activities have enabled us to initiate customer engagement and secure their letters of support. The preliminary life cycle analysis is nearly complete, identifying areas that require attention to achieve the expected low carbon emissions using CO2 as a raw material. In conjunction with this analysis, we have optimized the synthesis process to align with goals for reduced carbon impact and cost. Lastly, we have pinpointed key challenges that must be addressed in order to fully realize the benefits of using CO2 as a raw material. In Phase II, our primary focus will be on addressing the key challenges identified in Phase I to achieve a low carbon impact process. As we reach certain milestones, we will transfer successful processes to our scale-up plans, which will help identify and address gaps more effectively. Concurrently, our goal is to develop a range of formulations designed for the adhesive and sealant industry as well as creating consumer products that use thermoplastic polyurethanes (TPU), copolyester elastomers (COPE), and styrene-ethylene-butylene-styrene (SEBS). This approach will not only highlight our product offerings, but also promote strategic partnerships with CO2-capture enterprises in the upstream segment and leading thermoplastic elastomer (TPE) manufacturers, leveraging their well-established resources. The successful completion of Phase III and beyond will have the potential to revolutionize the plastics industry by offering environmentally friendly alternatives to conventional petroleum-based materials. The commercial applications of these innovative CO2-derived thermoplastic elastomers span various sectors, including automotive, packaging, and construction, where they can replace traditional materials with lower carbon footprint and enhanced. Our serviceable markets will be TPU/COPE/SEBS adhesives, sealant and synthetic rubber products. The total serviceable market size in 2022 is $6.64 billion. By fostering strategic partnerships with CO2 capture companies and key TPE manufacturers, our project can drive the development of a circular economy, reducing the demand for virgin plastics and the associated environmental impacts. This groundbreaking technology has the potential to contribute to global climate goals, mitigate plastic pollution, and promote sustainable practices in the plastics industry, ultimately benefiting society and the environment.