Sustainability
From bio-based feedstocks to bio-waste feedstocks
The availability of bio-based feedstocks like palm oil, but also sugar, in the region, has attracted investors wanting to develop greener alternatives in the plastics, food, and personal care markets. Turkish multinational Evyap Sabun moved its manufacturing to Malaysia almost 10 years ago, after shifting from tallow to palm oil as a feedstock for its products – especially soaps. Since starting the facility in 2014, Evyap doubled the capacity from 200,000 to 400,000 t/y and began producing intermediate products like fatty acids, as well as specialty chemicals. Currently, the company is investing in its third plant in the country to expand its specialty chemicals production from 15,000 t/y to 22,000 t/y; this is expected to be ready by the end of the year. The global bio-based personal care market is expected to grow at 5.67% CAGR between 2021-2031, reaching US$7.75 billion by 2031, according to Straits Research.
By comparison, for the bioplastics market, valued at US$7.6 billion, some reports project accelerated growth of over 10% per year within this decade. “We call bioplastics those polymers that are 100% renewable-based and/or biodegradable,” said Thomas Philipon, the CEO of TotalEnergies Corbion, a JV between energy and petroleum French company TotalEnergies and food ingredients Dutch company, Corbion.
Just as personal care ingredient players chose Malaysia or Indonesia as a manufacturing base for their palm oil-derived products, TotalEnergies Corbion decided to produce its 100% bio-based, recyclable, and compostable polylactic acid (PLA) in Thailand owing to the availability of sugar: “There were multiple factors at play, but a decisive one was the proximity to the feedstock. Lactic acid, which is the raw material of PLA, is derived from sugar. As the third largest producer of sugar cane in the world, after Brazil and the US, Thailand was a logical choice,” Philipon said.
Even though Thailand is the third biggest sugar producer in the world after Brazil and the US, ethanol production is minimal in the country, whereas Brazil and the US together produce 82% of the world’s ethanol. Most of the sugar-based ethanol produced in Thailand is mixed with gasoline, but with gasoline prices coming down, the demand for ethanol-for-fuel has declined, according to Supakrit (Tos) Aungwarapitikorn, managing director at HELM Thailand, a chemical distributor. However, more sugar manufacturers are looking at sugar-to-chemicals bioconversion, sensing opportunities in this space. HELM has partnered with Cargill in the US to produce renewable (sugar-based) butanediol (BDO), an intermediate polymer feedstock, and is considering a similar bio-based platform using Thailand’s sugar supplies.
Speaking about the key drivers pushing the growth in the bioplastics market, Philipon highlighted three main trends: a consumer-led desire to “do the right thing,” which pushes manufacturers to do the same by reducing their carbon footprint across the value chain; regulatory changes that tighten the grip on fossil fuels; and, finally, innovation, since bioplastics like PLA are something new with many unexplored potential applications. With the current bioplastics industry only accounting for 1% of the global plastics industry, there is plenty of room to grow and “no time to waste,” as Philipon put it: “The bioplastic market is believed to grow at 10 to 15% each year, and the engine of this growth is the replacement of petrochemical-based plastics. Based on our internal analysis, one kg of PLA saves 75% of CO2 emissions generated by one kg of either PT, PE, or PS.”
AGC Vinythai’s subsidiary, Advanced Biochemical (ABT) similarly showcases significant carbon reduction advantages resulting from the use of its renewable glycerin-based epichlorohydrin (ECH), commercialized under Epinity trademark brand. Epinity is used as a drop-in chemical, directly replacing propylene based ECH. After conducting a life cycle assessment, ABT found its bio ECH has a 67% lower global warming potential compared to petrochemical based ECH.
Other producers in the polymers space are making investments to change the feedstock of their current products with a lower-carbon, waste-based raw material. German specialty chemicals leader Evonik has been present in Thailand since 1989, producing high-quality precipitated silica (under the brand SIPERNAT) and aluminum silicates (under the brand ULTRASIL) at its Rayong site. Recently, the company announced it will replace the sand used to make precipitated silica with rice husk ash (RHA), a waste product. “We teamed up with a local bio power plant producer called Phichit Bio Power, and with Pörner Group, an Austrian engineering company that has the in-house technology to convert the ash into a water glass. We use the colorless liquid to precipitate silica using the same downstream process in our operations,” said Mathias Pascaly, the managing director of Evonik in Thailand.
By replacing the sand with RHA, Evonik can skip the power-intensive melting stage, reducing GHG emissions for Sipernat by 30%. The precipitated silica (Sipernat) is then sold to tire manufacturers, helping in the production of green tires.
As Evonik illustrates, the next level of innovation in bio-based platforms comes from the conversion of waste, as well as products with no defined use and whose removal does not have a negative impact or has a positive impact on the surrounding ecosystem, into new products. For example, in the feed-to-food value chain, Behn Meyer Group, one of the largest food ingredients and chemical distributors in Southeast Asia, has recently proven a new technology to upcycle food waste into a commercial supermarket product, through its newly created company, the Thai-based Nutrivo Ingredients, a producer of plant-based fiber proteins. Moreover, the company also invested in a Norwegian producer of renewable-based solutions from marine deposits of calcified algae. “By harvesting replenishable marine minerals from the ocean floor, we are bringing to the feed, food, and cosmetics industries a completely sustainable, chemical-free, natural ingredient,” said Dirk Lorenz-Meyer, chairman at the 180-years-plus company.
This type of new-generation investment with a focus on sustainability takes a holistic view of the entire emission chain of a product; sometimes, even a seemingly harmless waste product can have hidden downsides. For example, Meyer explained: “Organic fertilizers have been attracting more interest in recent years, but something that is relatively new and that we have been pursuing at Behn Meyer is the shift away from animal waste, which is the typical raw material for organic fertilizers. After being composted, animal waste-based fertilizers can still contain antibiotic residues, as well as viruses or other disease vectors. We have been moving to plant-based waste, mostly palm oil.”
“Everyone is responsible to stop global temperatures from rising. However, the execution of this intent must be done responsibly, taking into consideration each country’s energy position. For example, Malaysia cannot abruptly shift to full solar energy or wind energy because these alternatives are not sufficient to ensure energy security.”
Sharifah Zaida Nurlisha Syed Ibrahim, CEO, MMC Oil and Gas Engineering & Partner at DORIS MMC Sdn Bhd
Interestingly, whereas most companies have focused on palm oil as a feedstock, Behn Meyer found an opportunity in palm oil waste. This organic waste can be treated with enzymes to produce natural fertilizers. Growth in the bio-fertilizer markets beats both the bioplastics and biocosmetics markets, with a growth rate projected at almost 15% between 2022 and 2027, according to Research & Markets.
Also using palm oil waste as a feedstock, NeoSci, a Thai distributor of plant-based additives for animal feed, is looking to introduce to the market a new animal feed additive made from palm oil kernel; pyroligneous acid, also called wood vinegar, has been historically used as an insect repellent, but it could not be consumed by animals due to carcinogenesis content. The developer of the new technology for NeoSci identified a way to remove the harmful matter and has been testing the product across multiple species, including fish, shrimp, broilers, and swine. This will be used as a replacement for antibiotics. “We want to educate people on the long-term consequences of relying on antibiotics, and how it affects their health and that of future generations. Since Thailand is a well-known producer of palm oil, I believe we inherit credibility in making this product here,” commented Charttrawat (Tony) Apinyapanich, NeoSci’s CEO.
Stuck in the energy trilemma
In 2021, Indorama Ventures (IVL), became the largest issuer of sustainability-linked bonds (SLB) in Thailand. The 10 billion Baht (US$293 million) bond was AA-rated, the second-highest score obtainable. The Bangkok-headquartered PET producer also obtained US$300 from the International Finance Corporation (IFC) to recycle 50 billion PET bottles every year by 2025. This marked the first-ever “blue loan” – a financial instrument to fund the sustainable use of ocean resources - to be awarded to a plastic manufacturer. The investment community is clearly rewarding chemical companies, including plastic producers, for their sustainability efforts. In fact, a study by McKinsey found a correlation between improved shareholder returns and improved sustainability profiles. At the same time, investors can also castigate companies that do not show strong ESG credentials.
“Soon, businesses may not be able to access financial assistance unless ESG checklists are complied with. Whilst the world is unified in its sustainability intent, I firmly believe that each country must be allowed to develop its climate plans to meet the set targets within its own scope of resources rather than imposing other countries’ templates. Another region’s approach (e.g., Europe) may not be suitable for countries like Malaysia,” commented Sharifah Zaida Nurlisha Syed Ibrahim, CEO at MMC Oil and Gas Engineering, a contractor in the oil and gas sector in Malaysia.
ESG criteria may not only be a barrier for accessing financing, but also for imports. Under the EU’s Carbon Border Adjustment Mechanism (CBAM), importers of fertilizers and other commodities into the EU will have to declare the embedded greenhouse gas emissions (GHG) of the imported goods and buy the corresponding CBAM certificates, according to the weekly average prices of EU Emission Trading System (ETS) allowances expressed on € / ton of CO2 emitted. The CBAM enters into force in a transitional phase this October, and it will become a permanent system in January 2026.
“It all starts with awareness – industry players need to know how much waste they produce to understand the best approach to reduce their environmental liabilities associated with landfill disposal or incineration, both of which lead to long-term negative impacts. Waste cannot just be transferred from one’s backyard into the landfill, it must be managed properly.”
Ros Rasul, Managing Director, Intensive Energy Sdn Bhd (IESB)
Malaysia, as well as Indonesia, Thailand, and Singapore, continue to depend on fossil fuels within their energy mix. In Malaysia, petroleum, gas, and coal make up the bulk of the country’s energy source, with renewable energy accounting for just 6% of the total consumption. Indonesia’s energy supply comes in majority from oil (35%), coal (37%), and gas (18%), with the remaining consecrated to hydropower, geothermal, biofuel, and renewable sources. Thailand’s energy scene is dominated by gas (63%), followed by coal (21%), and the rest being green. According to a report by the International Energy Association, the region’ import needs will only accelerate as demand for energy grows.
But besides securing its energy needs, the region will also need to make sure its energy is clean and affordable. The so-called “energy trilemma” – or how to reconcile reliability, with affordability, and sustainability – is a challenging one for the region. In economic theory, a trilemma involves three mutually exclusive options, and this seems to be the case for many SEA countries. Speaking about the case of Malaysia, Sharifah commented: “Malaysia cannot abruptly shift to full solar energy or wind energy because these alternatives are not sufficient to ensure energy security. Malaysia has declared that, whilst supporting climate targets, gas will remain the main transition energy until an alternative is available.”
More immediately urgent in the country’s concerns is the cost factor. Malaysia has one of the cheapest energies in the world, thanks not only to its natural oil and gas resources but also to government subsidies. However, the government has recently removed subsidies for large industry suppliers, hurting the country’s competitiveness as a manufacturing base. “The electricity tariff for large industrial players grew by 41% effective January 1st, 2023. While I understand the strategy, I am concerned that this could impact the entire economy,” said Kenny Teh, the country’s managing director at Air Liquide, a major industrial gas producer.
“ABT’s bio-based ECH, Epinity is made from renewable raw materials (glycerine) with a more sustainable production process. The LCA found that Epinity's Global Warming Potential (GWP) - including biogenic carbon and direct land use change - is up to 67% lower than for petro-based ECH.”
Hiroshi Namba, Managing Director, Advanced Biochemical (AGC Vinithai)
Concurrent with the issues of energy affordability and security, it cannot be forgotten that SEA has been identified by the Intergovernmental Panel on Climate Change (IPCC) as one of the most vulnerable regions to climate change; typhoons, floods, and draughts have become more frequent and more violent in recent years. In the Vietnamese Mekong Delta, the ocean’s seawater has been flowing into the freshwater delta at unprecedented levels due to climate change. “Many fruit and rice growers have stopped producing due to high salinity levels,” said Dirk-Lorenz Meyer, board member at the Behn Meyer Group, which is currently working on solutions for more salt-tolerant seeds and crops.
Perhaps the one factor that reconciles the need for sustainability with that of profitability is consumer preference for greener products. Taking this trend into account, a country’s competitiveness is starting to be measured not only in the cost per unit produced but also in the CO2 footprint released. Large chemical companies like Covestro, which produces polycarbonates, specialty films, and elastomers in Thailand, see the country’s lack of a carbon reduction framework as a disadvantage: “Thailand is still on its way to providing infrastructure to use green energy or the frameworks to buy carbon credits, as other countries do. So this is part of our challenges as the production of performance materials is highly energy-intensive, which can render us uncompetitive unless we can switch to greener energy sources in line with our customers’ climate goals,” said Timo Slawinski, the managing director.
Consumer preferences are not effective without a reinforcing government policy. Speaking about the context of Malaysia, Peih Yoke Hoo, Malaysia’s managing director for Linde, the leader in industrial gases, including hydrogen, told GBR: “Companies with an international presence face pressures to meet global targets on emissions. Not many customers and suppliers are able to lock into the lower-carbon energy options as only limited applications are allowed. Reliable access to clean power is often a challenge for companies. The central issue lies in the uneven distribution and availability of clean power, forcing many companies to pay a premium on green energy or technology to meet their decarbonization targets. However, we have several global customers that are environmentally conscious and pay great attention to things like replacing natural gas with renewables in the context of our SMR (steam methane reforming) plant, because our carbon footprint is also their carbon footprint.”
Singapore is the only country in Southeast Asia to have introduced a carbon policy in the form of a carbon tax. However, at COP26, Indonesia signed the regulation to introduce a carbon cap-and-tax system to facilitate international carbon trading.
Article header image courtesy of Behn Meyer Article separator image courtesy of Evonik