Bast fibre crops for lignocellulosic markets. Jan E.G. van Dam

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1 Bast fibre crops for lignocellulosic markets Jan E.G. van Dam

2 Cellulose production World production biomass 170x10 9 t / y Human consumption 6x10 9 t / y 3.5% Food 62% Wood for energy, paper, furniture and construction 33% ProBIB 2008 Cellulose 50-70x10 9 t/y Non-food 2.3x10 9 t / y Non-food use (clothing, chemicals) 5%

3 World fibre production 40,000 35,000 30,000 World fibre production (kton) Cotton Synthetic (petro-based) Man-made cellulose fibres * 25,000 20,000 15,000 10,000 5,

4 Cellulose production cellulosic fibres 10 3 ton/yr major producing countries cotton China, Brazil, India, Pakistan, USA, Uzbekistan flax 300 EU, China hemp 90 China, EU jute Bangladesh, India kenaf 350 China, Thailand ramie 280 China, Brazil abaca 70 Philippines, Ecuador coir 500 India, Sri Lanka sisal 300 Brazil, Kenya, Tanzania

5 Flax markets and products Flax : 90% classical textile markets long fibers: linen clothing (60%) and household textile (15%), upholstry (15%) high prices ca 2000 / t in competition with textile fibers (synthetics, cotton, viscose); fashion sensitive technical uses 10%: fibre composites in automotives and sport (tennis, squash rackets) or boats; insulation blankets shives : particle boards, animal bedding

6 18-19 October CELC Masters of Linen

7 EU Short fibre market price

8 European Hemp Industry State of the Art Total Hemp cultivation area in the EU around ha. Competition with energy crops! EIHA members Non-EIHA members

9 Hemp production data Production volume per ha: average 8 tons of straw (30% fiber ; 55% shives; 15% dust) and 1 ton of seeds tons / ton / ha fibre shives seeds total /ha March nd FIBRA meeting, Roma 9

10 EU Hemp markets and products Specialty (thin) paper market (ca 0.50 /kg incl 25% shives) 55% Competes with: Wood pulp, (eucalyptus from south America); Cotton short fiber (lint); Flax short fiber (tow); Kenaf fiber Producers: LCDA, Agrochanvre Insulating wool in building applications mulch agricultural fleece non-woven 30% Competitors : paper pulp, flax fiber, glass wool, mineral wool, PUR, PS Producers: Hock, Cavac, Technichanvre; Suppliers: Eurochanvre, Agrofibre, Hemptechnology, Hempflax, Planète Chanvre Plastic reinforcing fiber (ca 0.75 /kg, <5% shives) 15% Producers: Hempflax, Hemptechnology, Agrofibre, Eurochanvre, PlanèteChanvre

11 Hemp fibres main applications Automotive Non-automotive Insulation Pulp & Paper Agrotextiles

12 European Hemp 2010 Hemp fibre applications: 25,589 tonnes (EIHA 2012)

13 EU Hemp markets and products Hemp Shives (50 70 %) for horse and other animal bedding and horticulture Competitors: wood pellets, cereal straws Hemp Shives (15%) in light weight concrete, particle boards Competitors: Wood chips / flax shives / straws Hemp Shives March nd FIBRA meeting, Roma 13

14 European Hemp 2010 Hemp Shives Applications: 43,621 tonnes (EIHA 2012)

15 European Hemp 2010 Hemp Seed Applications: 5,991 tonnes (EIHA 2012)

16 Hemp based construction Renewable Hemp house (UK, Fr) Hemp in concrete (Hempcrete) Soprema roofing membranes (Flax door panels) Grow2Built CELC

17 Jute exports (FAO)

18 Jute production (FAO) Jute fibre kt/y : 2006/ / / / / /12 Bangladesh India Myanmar Nepal World

19 Kenaf production (FAO) Kenaf and 2006/ / / / / /12 Allied fibres : China India Indonesia Thailand VietNam Jute fibre / / / / / / Cambodia kt/y : Bangladesh Pakistan India Myanmar Brazil Nepal Cuba World Other Africa Near East World October Kick-off meeting, Bologna 19

20 Kenaf production (FAO) Kenaf and 2006/ / / / / /12 Allied fibres : China India Indonesia Thailand VietNam Jute fibre / / / / / / Cambodia kt/y : Bangladesh Pakistan India Myanmar Brazil Nepal Cuba World Other Africa Near East World

21 Markets kenaf products Product fibre form fibre price range /ton Sacking, hessian, canvas woven fabric / textile High Ropes, cordage twined Composites fabric / non-woven / chopped fibre Non-woven tissue non-woven Geotextile nets, non-woven - Insulation non-woven - Paper and board pulped Fibre boards refined / milled / chipped - Absorbent (moisture / oil) core particles / non-woven - Green chemicals fermented and biorefined Bio-fuel, activated carbon combustion and carbonized - Mulch, compost composted

22 Cellulose feedstock Shift of market demand for cellulose Carbohydrate source for 2 e generation bio fuels Biorefinery and green chemistry Effects on paper industries: Digitalisation Interest for alternative fibre sources

23 Cellulose price increase 2011 Straw / ton Wood chips 100 Pulp Raw hemp Flax Raw cotton Dissolving cellulose 1750 Viscose / rayon 2000 Celluloid 3300

24 kton/year Kenaf production decline africa latin america near east far east world 200 Transition point? 0 Year

25 Fibre composite market

26 Markets bast fibre products Product fibre form fibre price range /ton Sacking, hessian, canvas woven fabric / textile High Ropes, cordage twined Composites fabric / non-woven / chopped fibre Non-woven tissue non-woven Geotextile nets, non-woven - Insulation non-woven - Paper and board pulped Fibre boards refined / milled / chipped - Absorbent (moisture / oil) core particles / non-woven - Green chemicals fermented and biorefined Bio-fuel, activated carbon combustion and carbonized - Mulch, compost composted

27 Polymer and Fibre Technology Nanofibre from cellulosic pulp refiner conditions properties Diameter nm High specific surface High strength and modulus Translucent Durable Biodegradable Renewable, CO 2 neutral chemical modification adhesion

28 Economic feasibility Market demands Technical performance / availability Cost of processing / modification Acceptable costs range of treatment Investment for implementation Economic scale of fibre processing / modification

29 Background Bast Fibre projects Farmers & Industry facing decline of natural fibre demand Modernizing and innovation in fibre production Novel (bulk) markets for fibre application packaging pulp, paper & boards composites & building geotextiles & horticultural non-wovens

30 Background Jute is biobased: Renewable, ca. 2,500,000 ton/a Jute is produced in India and Bangladesh ( ) kt / yr India (62%) Bangladesh 873 (35%) Nepal 17 (0.6%) Similar to kenaf (= meshta) in China / Thailand

31 Jute (Corchorus capsularis) Bast fibre Cellulose: Hemicellulose: Lignin: Ash: Fibre length (mm): 2 (1-5) Fibre width (μm): 20 (10-25) Core: Cellulose: Hemicellulose: Lignin: Ash: 0.8 Fibre length (mm): 0.6 ( ) Fibre width (μm): 20 (17-24)

32 Bast fibre reinforced composites Different technologies for composite production Different binders and products Much attention for natural fibre reinforced polymer composites Fibre reinforced polymers are successful new outlet Creating new market demand

33 Bast Fibre composites Bast fibre have mechanical properties in the range of glass fibre in reinforced polymer composites PP Jute E-glass Strength (MPa) Stiffness (GPa) Elongation (%) Bast fibres increase the strength / stiffness of a polymer Less polymer needed for the same performance

34 Conclusions The use of kenaf in different consumer products has been demonstrated When supplies of kenaf raw materials match the demand of industries it may play a significant role in the bio-economic developments

35 Advantages of jute fibre Jute has low weight Jute E-glass PP Density (g/cm 3 ) Jute is an insulator: heat, sound Jute is cheaper than glass fibre and PP Cost (INR/kg)

36 Jute composites project objectives Development of pilot scale jute-pp granules for (injection) moulding purposes With optimized performance Meeting industry s requirements To open up market outlets for jute based composites

37 Examples Injection moulded products Glove box Audi A2 Loudspeaker Housing Audi Glove box Daimler (prototype) Werzalit

38 Examples Injection moulded products Handy NEC Vacuum cleaner Fan Rotor Ironing device

39 Examples Injection moulded products Tableware: Cup & Soup bowl Chair IKEA Grinding Disk Shaving Brush

40 Technology to produce jute-pp granules: Materials Jute Sliver Homogeneous weight over length wt.% Moisture content < 8% PP Sabic 575P & DOW D Mixture of different grades to obtain good flow MAPP coupling agent improved bonding between hydrophilic jute and hydrophobic PP 1% for 10% of Jute

41 Technology to produce jute-pp granules: Process Twin screw extruder Berstorff ZE 40-38D Feeding PP upstream Melting of PP Feeding of Jute sliver downstream Using in house designed feeder Compounding section Granule production Gala under water pelletizer

42 Technology to produce jute-pp granules: Results Free flowing granules Dried after recovery from pelletizer Suitable for injection moulding Drying prior to moulding required (preheating) 15 kg/h

43 Characteristics: Morphology 50 wt.% Jute-PP Good Fibre-Matrix Adhesion Scanning Electron Microscopy (SEM)

44 Characteristics: Processability - 50 wt.% Jute-PP - Temperature 200 C maximum In this example 185 C - Limited running distances: In this example good flow with 4 injection points - In-mould coating with PUR foam Injection moulded door trim panel of VW Polo

45 Characteristics: Comparison to other Natural Fibres Flex Flex Charpy Strength Modulus Impact (MPa) (GPa) (kj/m 2 ) 40% Jute % Jute % Flax % Hemp JuPP board Woodstock

46 Characteristics: Colours Dull colours well possible 25 wt.% Jute-PP + 2% pigment Basic colour of jute-pp is brown Injection moulded Coloured test specimens

47 Outlook The developed bast fibre-pp composites have a competitive performance profile Drying of Jute-PP granules prior to (injection) moulding is very important for suitable processing and products Durability, impact strength and colour limitations should be taken into account

48 Processability cellulosic fibres Compatibility matrix and fibre Adhesion / surface interaction / charge Dispersion / blending conditions Fibre aspect ratio (L/D) Thermostability ( o C) Moisture content / oxygen Resulting composite properties

49 Conclusions potential market outlets for jute based composites Industry s requirements Processing Mechanical performance Electric extension cable cover

50 Fibre based geotextiles with prolonged lifetime Dunes replanting with jute fabric

51 Demands functional lifetime geotextile

52 Experimental plot Regge & Dinkel, March 1999

53 Durability increase by acetylation Conclusions: 3-5 x life time extension of jute, flax and cocos Very well rooting of plants After 5 yrs only cocos can be retraced

54 Geotextiles and horticultural mats markets EU project FP7 BIOAGROTEX ( ) technical textiles for agrotextiles / (recycled jute non-wovens / Up-scaling production acetylation (UK / NL / BE) Other innovative methods of modification

55 Nano cellulose fibre technology Nanofibres from flax, kenaf or wood pulp fibres Refining in aqueous conditions Properties Diameter nm Large specific surface High strength and modulus Translucent Durable (in dry conditions) Biodegradable (moist cond.) Renewable, CO 2 neutral

56 Valorisation piramid

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