TECNOLOGIE E PRODOTTI CHIMICI PER LA LAMINAZIONE A

Workshop
“BIOREFINERY FOR THE PRODUCTION OF ENERGY AND BIO-BASED PRODUCTS”
29-30 October, 2013
Camera di Commercio Industria Artigianato Agricoltura
Turin
Gianni Rizzuto
“General Manager”
Fiorenzo Bucelli
"Technical Director“
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Birth of the Company “Foundry Alfe CHEM”
First complete range of bio products
(lubricants and chemical auxiliaries for agriculture
activities and industrial processes)
Foundry Alfe CHEM decides to become
independent regarding the raw materials
(Bio Materials Production: In progress..)
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WHERE WE ARE
TURIN
MILAN
BRINDISI
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CONTINUOUS
RESEARCH & DEVELOPMENT
ONGOING
HIGH TECHNOLOGICAL
PRODUCTS
COMMITMENT TO
HEALTH, SAFETY AND ENVIRONMENT
LOW IMPACT ON THE ENVIRONMENT
LONG LIFE AND RECYCLING PRODUCTS
New specialized products for different types of processing, able to
ensure best efficiency and performance combined with the
safeguard of the environment
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STRUCTURE OF THE
TECHNOLOGY
PLATFORM ON
SUSTAINABLE
CHEMISTRY
BIOMASS
PLANT OILS
STRATEGIC ALLIANCE
COHERENCE
POLICY MEASURES
STRATEGIC RESEARCH
AGENDA
ACTION PLAN
BIOREFINERY WITH ECOCOMPATIBLE TECHNOLOGY
FOR PROCESSING OF
RENEWABLE RAW
MATERIALS
RESEARCH AND POLICY COMITEE(S)
CONSTITUTED BY :
AGRICULTURAL GROUP
INDUSTRIAL GROUP
ACADEMIC GROUP
SOCIO-ECONOMIC GROUP
COMMUNICATION AND EDUCATION GROUP SOCIAL IMPACT
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 By 2023, > 50% of oil will be consumed and by
2050 global energy demand will be double
 90% of lubricants may possibly be crop based
(Common Crop Sources: Rapeseed, Sunflower,
Soya, Palm)
 Bio-refineries are the main chemical,
technological and industrial production tools to
reach these goals
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Emerging crop-derived raw materials as ingredients from
renewable sources in chemical technologies of lubricants and
auxiliaries for industrial applications
Strong saving in the metal industrial process and production
Sustainability, environmental responsibility and renewable
inputs
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 Different products/markets
 Emerging consumer demand; bio-fuels, green
products, renewable materials
 Sustainable development/agriculture and rural
employment
 Positive environmental impact;
Ex: possibility of using urban organic waste as a
source of raw materials for specific technical
applications (Recycling & Biosustainability)
IN PROGRESS
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 Organic acids
 Polyacids
 Alcohols
 Polyalcohols
 Esters
 Polyesters
 Water soluble polymers
 Non water soluble polymers
 Others
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FATTY ACIDS
AMOUNT
(%)
PLANT SPECIES
USES
AREA
40
Rapeseed oil
Italy
C18:2
C18:1
28
Sunflower oil
C18:1
28
C18:2
10:0
22:0
18:1(6)
22:1
18:1(9)-12-OH
18:3-conj.
High oleic Sunflower
oil
Lubricant and chemical auxiliary for
industrial applications
Lubricant and chemical auxiliary for
industrial applications
Lubricant and chemical auxiliary for
industrial applications
91-95
48
71-74
58
90
51
Cuphea Koehneana
Brassica tournefortii
Coriander
Crambe
Castorbean
Akpi
Detergents, Food, Lubricants
Lubricants
Nylons, Detergents
Plasticizers, Nylons, Lubricants
Plasticizers, Lubricants
Enamels, Varnishes
20:1/22:1-wax
C18:0 (stearin)
C18:0 (stearin)
C18:1 (Olein)
95
92
92
92
Jojoba
Shea butter
Palm
Palm
Cosmetics, Lubricants
Cosmetics Personal Care
Lubricant, Cosmetic
Personal Care, Biodiesel, Lubricants
Africa
Morocco
Tunisia
Morocco, Ethiopia
Congo
Ivory
Coast,Congo,Gabon
Africa, Tunisia
West africa
C12/14
45-50
Coprah
Cosmetic, Personal Care
(STARTING
MATERIALS)
C18:1
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Italy
Italy
Congo, Bénin,
Nigeria
Benin
MAIN DRIVERS:
 Reduction of use and consumption of chemical
products in the industrial process
 Improved technical properties
 Ready and Sustainable supply
 Environmental legislation
 Minimum environmental impact
 Biodegradability
 FDA approvals (contact with food and beverages) and
packaging regulation compliance (cosmetic products
and pharmaceutical ingredients)
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LUBRICATION
FOUNDRY
• ROLLING OILS
• DRAWING OILS
• METALWORKING FLUIDS
• SPECIAL PRODUCTS FOR EXTRUSION
• PASTES AND GREASES
• AUXILARIES AND LUBRICANTS
• CLEANING AND DETERGENTS
• PROTECTIVE OILS AND COATINGS
• RELEASE AGENTS: ALUMINIUM, ZAMAK AND BRASS
• PLUNGER LUBRICANTS
• SAFETY HYDRAULIC FLUIDS
• COATING AND PAINTS
• CONTINUOUS CASTING RELEASE AGENTS
• HOT FORMING AND FORGING FLUIDS
• DIATHERMIC FLUIDS
• CHEMICAL FLUXES
• HEAT TREATMENT
 Despite the nowadays economical situation, some European
states are promoting incentive programs to develop lubricants,
hydraulic fluids and solvents based on materials coming from
renewable sources
 Potential for increased commercialization in number of end uses
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Product group
Bio Lubricants
Application
area
Market
total
Europe
volume
(t)
Hydraulic fluid 650.000
Chainsaw
50.000
lubricants
Mould release 100.000
agents
Other oils
3.600.000
Market
Market volume “Bio”
volume
2020
(Prevision)
“Bio”
(t)
2008
(t)
68.000
155.000
230.000
29.000
37.000
40.000
9.000
15.000
30.000
31.000
70.000
120.000
137.000
277.000
420.000
(Metalworking fluids,
Industrial gear oils,
greases,
Moto&Automotive gear
oils, Transforme oils)
TOTAL
4.400.000
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CLEANING AND
WORKING PLACE
HYGIENIC
CONDITIONS
REACHED (OPTIMIZATION)
% TARGET TO BE
100
90
WORKING PLACE
SAFETY
CONDITIONS
80
70
60
50
MILLS MACHINERY
PRODUCTIVITY
40
30
ENVIRONMENTAL
IMPACT AND
COMPATIBILITY WITH THE
END USE APPLICATIONS
20
10
0
1960
1965
1970
1975
1980
1985
1990
1995
2000
2005
2015
2010
TIME/YEARS
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ALUMINIUM
is a light metal, able to reduce
consumption of energy and fuels, and
easy to recycle then..
IT IS AN ECOLOGICAL METAL
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PRODUCTIVE SCENERY
ALUMINIUM
is the most widely used material for
packaging of:
beverages, food, pharmaceuticals; thermal
insulation and others,
then.. It needs bio-based lubricants and
chemical auxiliaries for its industrial
process.
---------------It means: more ecological and
environmentally friendly industrial process
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THE DEVELOPMENT OF AGROCHEMICAL TECHNOLOGIES ALLOWS THE USE OF CHEMICALS BASED ON
RENEWABLE RESOURCES FOR INDUSTRIAL APPLICATIONS, SUCH AS:
 LUBRICANT ESTERS
 WETTING AGENTS
 ANTIOXIDANTS
 CLEANERS
 SOLVENT BASED ESTERS
 NATURAL BASES
 FILMS
LUBRICANTS AND CHEMICAL AUXILIARIES PLAY A VERY IMPORTANT ROLE IN THE
ALUMINIUM PRODUCTION FROM FOUNDRY DOWN TO ROLLING AND FORMING,
PROTECTIVE/COATING, DETERGENTS AND FINISHING LINES.
NON FOOD CROPS:
EMERGING INDUSTRIAL RAW MATERIALS ON A GLOBAL PERSPECTIVE
Technology is an important issue and R&D activities are fundamental
Future actions:
 Market development
 Demonstration plant on commercial scale to validate product performance,
process viability and market acceptance (Al example)
 Need to develop confidence in supply chain sectors
 Consistent feedstock supply at full commercial scale
 Realistic growers contracts that reflect risk/reward
Looking at the current industrial scene there are already positive examples where the
use of bio-based lubricants and auxiliary chemicals has become an undeniable
success, and this is the case of Aluminum and its alloys.
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