Zeon to Build Research Plant for Bio-Based Butadiene and Isoprene Production in Japan

Japanese chemical manufacturer Zeon Corporation has announced plans to construct a research plant at its Yokaze site in Yamagata Prefecture, focusing on directly producing butadiene and isoprene from plant-based materials. This move aligns with Zeon’s STAGE30 mid-term business plan, which prioritizes achieving carbon neutrality and advancing a circular economy.

Earlier this year, in February, Zeon partnered with Yokohama Rubber to build a pilot facility for high-efficiency conversion of bio-based ethanol into butadiene. Located at Zeon's Tokuyama plant in Yamaguchi Prefecture, the facility is slated for 2026 operation and will validate a continuous production process while collecting data for large-scale manufacturing.

The pilot facility will explore two core technological pathways:

1. Catalytic ethanol conversion, developed in collaboration with AIST. Using dual-function catalysts such as MgO-SiO₂ or zirconium-based materials, this method enables one-step butadiene production via ethanol dehydrogenation, condensation, and dehydration. However, challenges include catalyst coking, frequent regeneration requirements, and balancing the high costs of pure ethanol with the energy demands of processing hydrous ethanol.

2. Biological synthesis, developed with Tokyo University of Science and RIKEN. This method uses enzyme catalysis or microbial metabolism to directly synthesize butadiene from sugars or 1,4-butanediol. Key obstacles include controlling byproducts like propylene, overcoming the complexity of metabolic pathways, and reducing the high costs of engineered strain cultivation. Additionally, improving product purification efficiency and metabolic flux control remains critical to scaling up this technology.

Zeon’s efforts are expected to accelerate the transition to plant-derived chemicals, supporting global initiatives for sustainable materials.