Overview Of Scion Research : Bioplastics. Alan Fernyhough, 20 th October, 2011
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1 Overview Of Scion Research : Bioplastics Alan Fernyhough, 20 th October, 2011
2 Scion who we are NZ Forest Research Institute Ltd One of 8 Crown Research Institutes Established in M NZD turnover 340 science and support staff Based primarily in Rotorua Christchurch, Wellington and Auckland
3 Scion what we do Forestry skills transitioned to bioeconomy skills Core Purpose: innovation & growth in...forestry, wood & biomaterials Three Research Groups New Forests and Forest Science (biosecurity, breeding programs, fire) Sustainable Design (environment, climate change, optimising land value, bioenergy) Manufacturing & Bioproduct Development (~80) Polymers & Chemicals Wood & Fibres (inc. pulp/paper & packaging) Biotransformations (biomaterials/bioenergy, industrial biotech, wood and plant fibre, advanced packaging)
4 Bioplastics Roadmap (Updated 2011) & Bioplastics Research at Scion
5 SCION BIOPLASTICS ROADMAP: PRIORITIES & OPPORTUNITIES Enhanced exports for sectors using plastics (packaging or parts) - drawing on distinctive performance & lower footprint manufacturing technologies Support New Zealand manufacturers & primary exporters/brand owners in bioplastics and related materials technologies/expertise Outcome 1: New manufacturing and packaging technologies implemented for bioplastics & related biomaterials Outcome 2: Increased NZ biomaterial content in exported plastic products Outcome 3: Reduced materials/ manufacturing costs associated with new biomaterials Outcome 4: NZ made biopolymer/chemical manufacturing demonstrated in plastics Outcome 5: Scion maintained as an internationally recognised leading Centre of Expertise in integrated bioplastics technologies
6 Scion Bioplastics Research Summary Make: new bio-monomers, polymers & additives Extractions (NZ resources) Chemical reactions & polymerisations Microbial polymerisations & gene technologies Biopolyesters & precursors... Functional chemical/polymer additives Modify: plastics for new performance Extrusion compounding & reactive extrusion / processing Long wood fibres Functionalised pulps & biomasses Extractives/additives/polymers/minerals (where feasible from NZ/above) Mould: demonstrator plastic products (testing/industry transfer) Injection Moulding / Extrusion Thermoforming / Film Foam (Rotational Moulding)
7 Scion Bioplastics Research Summary Make Modify - Mould Example NZ biomasses & waste streams Wood & Forestry Processes Pine Bark Other NZ Natural Fibres/Biomasses Other NZ Natural Extractives NZ Processing Waste Streams NZ Minerals
8 Scion Bioplastics Research Three Example Commercial Developments using functionalised biomasses 1. BioPeg : Controllably Degradable Bioplastics 2. KiwiPlast : Bioplastics From Fruit Waste 3. LignoMaxx : Lignotech STEX Functional Additives
9 1. Controllably Degradable Bioplastics The Technology? Biomass modified bioplastics Compatibilised / stabilised forestry residues Plastics processability & stability Mechanical integrity Differential degradation rates Demonstration Product/Process Specific 1 st Application: Erosion Control Peg Two component design by Mulford Replaces steel or ABS Natural, renewable and degradable materials Tough enough to be hit with a hammer
10 1. Controllably Degradable Bioplastics: Commercialisation Status Compounded via Clariant under license Biopegs moulded by Mulford (Ludowici) Biopegs marketed by Maccaferri Plastics What s new? / Future Wider synergistic applications Safely degradable Tree protectors, plant pots,... Water/marine applications Controlled release of actives Horticulture Animal health / Vet. safely degradable
11 1. Further New Products: Biomass Modified Bioplastics: Recyclable, Compostable Cosmetics Pot Biobased and natural NZ resources Heat resistant PLA base Tolerant to hot-fill oils, waxes
12 2. KiwiPlast: Bioplastic Products from Fruit Wastes The Technology? Processed fruit waste biomass-bioplastic Compatibilised / stabilised Effective full utilisation of whole fruit waste/residues Plastics processability / stability Mechanical integrity Demonstration Product/Process Specific 1 st Application: Zespri Spife Existing polystyrene spife Natural, renewable: kiwifruit residue derived End-of-Life compostable
13 2. KiwiPlast - Commercialisation Status Commercial processing-compounding (Scion & industry) Injection moulding trials (Scion & industry) Materials & processing logistics substantially addressed Initial test marketing / consumer study What s new? / Future New designs / similar products Further testing Wider synergistic applications Packaging Other applications & other biomass residues
14 2. New Bio-spifes: Manufacturing Trials
15 2. New Products & Further Manufacturing Trials: Packaging Film & Thermoformed Trays
16 3. LignoMaxx Bio-additive for Plastics & Bioplastics The Technology: Steam Explosion (STEX) of Biomass Stage 1: Lignotech STEX Biomass Treatment Stages 2 & 3: Modifications & Extrusion Enhances (for biomass): Flow Reactivity Compatibility Functionality Uniformity/reproducibility innovative, sustainable, plastically processable functional biomaterial injection moulded etc
17 3. LignoMaxx: Pallet Trial (US): 40wt% STEX DDGS Demonstration Product Applied to DDGS (Dried Distillers Grains & Solubles) By-product of US corn ethanol production Non-food source feedstock/readily available US Freight pallet Status US National Composites Centre Passed tests/specifications (pallets) What s new? & Future Improved mouldability Further commercial trials Other products / biomasses Up-cycling plastics / recyclates
18 Examples of other Bioplastics Research
19 Microbial Bioplastics (PHAs) - from Biomass/Wastes The Technology O 2 N 2 PHA Polyester wastewater/wastes microbes PHA filled bacteria Downstream extraction to polymer & processing / products
20 What s new? / Future % PHA Mixed culture P- effluent Mixed culture S-effluent Mixed culture A- feed Mixed culture C-feed Y88 T G - feed PHA Productivity Various biomass/sugar feedstocks & wastes Whole cell processing : avoids expensive extraction Downstream integrated processing Continuous scale-up production & harvesting Modified/New PHA biopolymers - gene technologies
21 Waste To Gold Pilot Plant: Waste to Energy (Scion-RDC) Future: Scale Up / Adapt for Waste to Plastics?
22 Long Fibres can improve Impact Strength of PLA Impact Strength (KJm -2 ) PLA PLA + 30% LFF PLA + 30% LRF PLA + M PLA +30% MLFF PLA +30% MLRF
23 Lignin Research for every 1 litre biofuel from wood ~1 kg of lignin is co-produced replacing 10% of NZ s oil imports with softwood liquid biofuel could generate ~1 Mt lignin Biofuels Pulp / Fibres Lignin in plastics & composites Lignin in adhesives & coatings Lignin in fibres Lignin chemicals & intermediates Co-products o extractives o lignin Controlled chemical/enzymatic breakdown & reactions: monomers/resins/chemicals (VTT-LigniVal & others) Monitoring/altering lignin in plants/trees Lignin extraction/fractionation Lignin analytical methods
24 Polymers, Biomasses, Extractives & Additives: Screening & Databases dw/d(logmw) GPC polymer 190 O C molecular 190 O C CE MB weight: 240 O C degradation; 240 O C CE MB chain extension, branching, processing rheology correlations.,... E' [Pa] E'' [Pa] 1E8 1E DMTA : thermal PS commercial tray (black) resistance AT Butane only under AT Butane 2% CESA load/hdt; AT Butane 1% Methylal service temperatures, E Molecular weight Rheology : processing stability/windows; melt strength enhancements; recycling; crosslinking,.. A C control no CESA A C 190C 2% CESA A C 220C nocesa A C 220C 2% CESA A C 200C nocesa A C 240C 2% CESA A C 200C 2% CESA PLA 3051D Temperature [ O C] TGA : thermal stability: processing windows/ stabilisation strategies G' [MPa] Temperature [ O C]
25 Polymers, Biomasses, Extractives & Additives: Screening & Databases UV /accelerated weathering : degradation-durability; colour; aging effects/inhibition Solid State 13 C NMR FTIR, NMR, GC-/, LC-/,MS,UV, ICP,..: chemical composition & changes,... Microbial/fungal challenge/decay tests degradation-durability, 0.2 Microscopy: morphology compatibility, dispersion, Heating cycle (free of thermal history) -0.2 Heat Flow (W/g) BM untreated moulded BM 10pct Gly moulded.001 DSC/MDSC thermal transitions, 44BM 25pct Gly moulded BM extruded BM powder untreated.001 reactions & crystallinity in polymers Temperature ( C) V4.5A TA Exo Up Universal Instruments
26 Petroleum Fuels, Chemicals & Plastics PETROLEUM REFINING FUELS & OILS CRUDE OIL PETCHEM FEEDSTOCKS (~3%) ADDITIVES: chemicals/polymers; fillers/fibres COMPOUNDING & PROCESSING POLYMERISATION CHEMICAL BUILDING BLOCKS/MONOMERS PLASTIC PRODUCTS extrusion, moulding foaming,.. POLYMERS PE,PP,PVC,PS,PET,..
27 Biomass BioFuels, BioChemicals & BioPlastics BIOMASS REFINING BIOMASS SUGARS EXTRACTIVES LIGNIN, ADDITIVES: (fibres/fillers; chemicals/polymers) COMPOUNDING & PROCESSING PULPS (FIBRES) FUNCTIONALISED BIOMASSES POLYMERISATION CHEMICAL BUILDING BLOCKS/MONOMERS BIOPOLYMERS BIOPLASTIC PRODUCTS extrusion, moulding foaming,..
28 Thank You
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