Michelin, IFPEN, and Axens advance BioButterfly™, validating industrial-scale production of polymer-grade bio-based butadiene from bioethanol for sustainable rubbers.
Michelin, IFP Energies nouvelles (IFPEN), and Axens have announced substantial progress in the BioButterfly™ research and development program, positioning it as the most mature technology currently available for producing bio-based Butadiene from Bioethanol. Supported by ADEME, Région Nouvelle-Aquitaine, and Bordeaux Métropole, the project represents a major step forward in decarbonizing the Synthetic Elastomers value chain. Since the commissioning of its first industrial-scale demonstration plant in July 2023, the initiative has achieved several critical technical and operational milestones that strengthen confidence in the technology’s scalability and commercial readiness.
A key achievement of the BioButterfly™ project has been the successful validation of multiple bioethanol feedstocks at the demonstration facility. Both conventional bioethanol and advanced, second-generation bioethanol derived from non-food biomass were tested under industrial conditions. Results confirmed that each feedstock can be efficiently converted into bio-based butadiene, ensuring that the final product is 100% bio-sourced. This outcome highlights the flexibility of the process and its ability to adapt to different bioethanol supply streams, an important advantage as global markets evolve toward diversified and sustainable raw material sourcing.
Beyond the production of bio-based butadiene itself, the project has moved further downstream to validate end-use applications. The butadiene produced at the demonstration plant was successfully used in a polymerization unit to manufacture butadiene rubber (BR) and styrene-butadiene rubber (SBR). These polymers are essential materials for numerous industrial applications, particularly in tire manufacturing and technical rubber goods. The successful synthesis of BR and SBR marks a decisive milestone, confirming that bio-based butadiene can be seamlessly integrated into existing rubber production processes without compromising performance.
Equally important, the bio-based butadiene generated through the BioButterfly™ process has been verified to meet strict polymer-grade quality specifications. Compliance with these demanding standards is essential for ensuring consistent product performance in high-value applications. This validation demonstrates that bio-based butadiene can serve as a direct, drop-in alternative to fossil-derived butadiene, while offering a significantly improved carbon footprint and contributing to overall emissions reduction across the value chain.
From a development perspective, the BioButterfly™ initiative is widely regarded as the most advanced technology of its kind. The use of an industrial demonstration plant has played a critical role in de-risking scale-up by providing real-world operational data, performance feedback, and reliability insights. These learnings will be instrumental for future plant owners and investors as the technology moves toward broader deployment. The project partners are now targeting full technology homologation by mid-2026, a key milestone that will enable commercialization and industrial rollout.
Overall, the progress achieved by the BioButterfly™ project reflects the shared commitment of Michelin, IFPEN, and Axens to accelerating the transition toward a more sustainable, bio-based synthetic elastomers industry. By combining industrial expertise, advanced research capabilities, and process engineering excellence, the partners aim to bring this innovative solution to market and support the global shift away from fossil resources toward renewable, circular alternatives.
