ETB Global Makes LEGO Bricks, Latex Gloves, and Car Tires Sustainable

27-02-2023

Butadiene is a key raw material for plastics and rubber, used in products like LEGO bricks and car tires. Currently, it is derived from petroleum, but start-up ETB Global has developed a way to produce it from bio-ethanol, an alcohol made from plant residues.

The start-up established itself at the end of 2020 on the Brightlands Campus, located at the Chemelot chemical site in Geleen, the Netherlands. The technology has proven successful in the lab, and the goal is to have it ready for commercial applications by 2026. To achieve this, ETB Global plans to build a demonstration plant for bio-butadiene production. The design for this plant is expected to be completed by summer, with construction slated to begin in the fourth quarter of this year.

“This plant will produce 100 kilograms of bio-butadiene per day. While not a commercial volume, it’s sufficient to demonstrate that we can create products from it and showcase them,” 

says ETB Global CEO Noah Vladimir Hirsch Trembovolsky.

22.5 Million Tons of CO2 Emissions

Butadiene is one of the building blocks (monomers) used in manufacturing popular plastics like ABS (Acrylonitrile-Butadiene-Styrene), SBR, NBR, and BR, as well as rubber and other chemical compounds. It is a gas created during the cracking of petroleum. Butadiene is found in countless everyday products, from LEGO toys and car tires to latex gloves, medical devices, computers, construction helmets, and even perfume and paint.

Currently, 95% of butadiene is derived from petroleum, amounting to about 15 million tons per year and resulting in 22.5 million tons of CO2 emissions.

Bio-Butadiene

ETB Global has developed a technology to produce butadiene from bio-ethanol, made from agricultural waste streams. The process occurs in a reactor using a patented catalyst. This bio-butadiene can then be used to make bioplastics and bio-rubber.

The start-up’s founders began developing the technology in 2013 in their Moscow lab.

“At the time, oil prices were sky-high, just as they are now, and the industry was seeking alternatives for producing essential chemical building blocks like butadiene,” says Trembovolsky. “The question was whether we could create butadiene from something else. Interestingly, this was already done in the past—early butadiene was produced from bio-ethanol. After World War II, the industry switched to petroleum because it was more efficient.”

Butadiene became a by-product of naphtha crackers, which primarily produce ethylene, another crucial raw material for plastics.

Footprint Now Just as Important

Today, with high oil prices once again and the pressing need to address climate change, there is a second compelling reason to revert to bio-ethanol: reducing carbon footprints. Environmental impact is now as critical as efficiency. Additionally, geopolitical events like the war in Ukraine have pushed the chemical industry toward alternative sources. Russian oil, for example, is no longer widely available.

“Ethanol can be made anywhere and from any biomass, whether agricultural or other waste,” says Trembovolsky. “It’s a vital raw material for the chemical industry. We can use it to produce both ethylene and butadiene.”

Another start-up, Syclus, plans to build a major plant at Chemelot to produce over 100,000 tons of bio-ethylene annually from bio-ethanol starting in January 2026. ETB Global intends to use the same bio-ethanol for its production.

A Long Journey

Developing the catalyst to produce bio-butadiene was a lengthy process involving years of research. Initial experiments were conducted in the lab, and after achieving success, the first patents were filed. ETB Global then began engaging with the chemical industry. Initially, the focus was on economic feasibility and energy efficiency. Over time, the process’s low CO2 footprint became a significant advantage.

The process consumes much less energy than naphtha cracking, as it operates at lower temperatures in a reactor. All 14 necessary reactions occur simultaneously in one step, making it far more efficient than traditional methods.

Advantages

The process offers several benefits. CO2 emissions and energy consumption are three times lower compared to traditional butadiene production. Additionally, no waste is generated, as by-products include green hydrogen and bio-ethylene, both of which can be utilized by other chemical companies at Chemelot. The reactor can also be seamlessly integrated into existing chemical production chains.

Pilot Plant

After successful lab tests, the process was scaled up from grams to kilograms. In 2015, a pilot plant was built in Moscow and became operational a year later. However, oil prices plummeted to record lows at that time, making it difficult for the start-up to compete with fossil-based butadiene producers.

ETB Global then shifted its focus to promoting the sustainable aspects of its technology at conferences in Europe and the U.S., where the chemical industry was already transitioning toward greener alternatives. In 2019, Trembovolsky connected with a representative of the “Redefining Chemistry” program at the Brightlands Innovation Factory, which was seeking innovative start-ups for the Brightlands Campus.

Relocation to Chemelot

Unlike many other parts of the world, the EU requires companies to pay for emissions and imposes increasingly strict regulations on fossil-based raw materials and fuels. This environment provides fertile ground for start-ups like ETB Global.

“Our market is global, so we hadn’t focused much on domestic markets,” says Trembovolsky. “But to accelerate and scale up, we needed to be close to end-users and where the transition is happening. Brightlands Campus emerged as the best choice.”

In 2020, the start-up joined Chemelot’s transition program and relocated to the Netherlands by the end of the year. Trembovolsky moved with his family from Moscow to Limburg.

New Laboratory

After the outbreak of the war in Ukraine, ETB Global had to transfer its patents from Russia to the EU and could no longer use its Moscow lab. A new laboratory is being built on the Brightlands Campus, expected to be operational this summer.

Since 2022, ETB Global has received support from Ernest Lempers, an internationally experienced entrepreneur from Maastricht, who joined as CFO. He invested in the company and became a shareholder.

“If we were to produce all butadiene using our method, the CO2 savings would equal the amount absorbed by a forest the size of Canada,” says Lempers.

Alternative to SABIC’s Cracker

ETB Global needs €10 million to fund the demonstration plant at Chemelot and is currently seeking investors and subsidies. Once operational, the start-up plans to license the technology. Whether this requires building its own flagship factory, partnering with customers, or forming a joint venture remains to be decided.

One thing is certain: demand for bio-butadiene at Chemelot is likely to grow. Petrochemical giant SABIC may shut down one of its naphtha crackers at the site, jeopardizing the production of ethylene and butadiene. Syclus and ETB Global could step in to fill that gap.

“This makes Chemelot an excellent candidate for Europe’s first commercial bio-butadiene plant,” says Trembovolsky.

Green Chemistry Accelerator

In recent months, ETB Global has received support through the Green Chemistry Accelerator program. This initiative, run by the Green Chemistry New Economy (GCNE) platform, Invest-NL, and Dutch Regional Development Agencies (ROMs), helps start-ups in green chemistry achieve their primary goals within 100 days. Tailored guidance accelerates financing for pilots and demonstration facilities.

ETB Global was one of five start-ups selected for the program, alongside Paques Biomaterials, Relement, Susphos, and Torwash—all promising game changers in green chemistry. The program concluded with a final event at Change Inc. in Amsterdam on February 16.

Transforming the Chemical Industry

Through the program, Trembovolsky connected with a community of like-minded start-ups.

“I love it,” he says. “We face the same challenges, serve the same markets, and share the same vision. We all want to transform the chemical industry. The program’s tailored approach ensured that each start-up got exactly what it needed. For us, that meant gaining a clearer understanding of our financial strategy. Now we know how much we need to spend and how much we need to raise.”

The program also helped shift the start-up’s focus from long-term goals to immediate needs.

“Most start-ups concentrate on their ultimate goal, which is often years away. This program taught us to prioritize what we need right now—a crucial shift in our mindset. It also made it easier for us to connect with potential investors and partners.”

This article originally appeared on Change Inc. as part of a campaign with Green Chemistry New Economy. Read the full series on our site or at Change Inc.