Biobased Propylene Glycol from Glycerol for Antifreeze and Personal Care Products

How Glycerol is Converted to Propylene Glycol

Core Production Steps:

1. Feedstock Sourcing
• Crude glycerol is obtained from biodiesel production, oleochemical refining, or soap manufacturing.
• The glycerol is purified to remove methanol, salts, and water.
2. Hydrogenolysis Reaction
• Purified glycerol is reacted with hydrogen gas over metal catalysts (commonly Cu–Zn–Al or Ru–based) at 180–220°C and ~20–30 bar.
• Produces propylene glycol (1,2-PG), along with minor byproducts like ethylene glycol and water.
3. Separation and Purification
• PG is recovered through distillation and vacuum stripping, yielding ≥99.5% purity grades for food, pharma, and industrial applications.
4. Formulation and Use
• Bio-PG is blended into antifreeze solutions, personal care creams, oral hygiene products, and pharmaceutical excipients.

Case Study: ADM’s Bio-Based Propylene Glycol (USA)

Highlights:

• ADM operates the largest bio-PG facility in the U.S., producing PG from corn-based glycerol.
• Markets USP-grade and industrial-grade PG under VICAM™ and PG USP labels.
• Serves cosmetics, food, pharmaceutical, and automotive markets with verified carbon footprint reduction.

Timeline & Outcome:

• 2008: Pilot-scale validation of glycerol hydrogenolysis process.
• 2010: Full-scale commercial plant commissioned in Decatur, Illinois.
• 2015–2019: Market expansion into global cosmetics and antifreeze suppliers.
• 2022–2023: Lifecycle analysis showed ~60% GHG reduction vs. petro-PG.
• 2024: ADM expanded product portfolio into bio-based lubricants and polyols using PG as a building block.

Global Startups and Companies

• ADM (USA) – World’s leading commercial producer of biobased PG from corn-derived glycerol.
• Oleon (Belgium) – Produces PG from oleochemical glycerol, targeting cosmetics and pharma.
• Cargill (USA) – Offers biobased PG blends for food and care products.
• Metabolic Explorer (France) – Developed bio-PG from fermentation-based glycerol, targeting industrial-grade PG.
• Sichuan Vinylon Works (China) – Bio-PG from glycerol for antifreeze applications in Asian markets.

India’s Position

• India is a major producer of crude glycerol from biodiesel and soap industries.
• Companies like Godrej Industries, Southern Online Bio, and Emami Biotech generate glycerol as a byproduct.
• India imports a significant volume of propylene glycol, presenting a strong import substitution opportunity.

Commercialization Outlook

Market & Demand

• Global PG market: ~$4.2 billion (2024); projected CAGR: ~5.6%
• Key segments:
• Antifreeze & de-icing: Automotive, aviation
• Personal care: Moisturizers, oral care, shampoos
• Pharma: Solvent and stabilizer
• Food & flavorings

Key Drivers

• Surplus glycerol availability from biodiesel and soap production.
• Growing preference for clean-label and non-petrochemical cosmetic ingredients.
• Push for green automotive fluids in cold-chain logistics and aviation.
• Favorable carbon footprint and non-toxic profile of bio-PG.

Challenges to Address

• High hydrogen costs and pressure containment increase CAPEX.
• Catalyst deactivation and byproduct formation impact yield.
• Glycerol purification remains a cost barrier in using crude glycerol directly.
• Lack of domestic industrial-scale hydrogenolysis units in India.

Progress Indicators

• 2008–2010: ADM and Cargill pilot and scale bio-PG from refined glycerol.
• 2012–2016: Oleon and Metabolic Explorer target cosmetics-grade PG in EU.
• 2018–2021: Bio-PG gains traction in natural personal care and organic oral hygiene products.
• 2022: India’s MoPNG funds studies on glycerol valorization in biofuel plants.
• 2024: Growing startup and institutional interest in decentralized bio-PG micro-refineries.

Globally, biobased propylene glycol from glycerol is at TRL 9, with fully commercial production in the US and Europe. In India, TRL is 5–6, with successful pilot studies but no active commercial-scale deployment yet.

Conclusion

Biobased propylene glycol from glycerol is a compelling example of industrial symbiosis, converting a biodiesel byproduct into a value-added, sustainable chemical for antifreeze and personal care use. ADM’s commercial success and Oleon’s cosmetic applications show the maturity and flexibility of the technology. For India, the combination of abundant glycerol feedstock and a large downstream market in pharma, automotive, and personal care makes this a strategic circular economy opportunity. A focused push on hydrogenolysis scale-up, crude glycerol valorization, and technology localization could unlock bio-PG as a competitive import substitute.

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