Advanced Composites: Enhanced Performance and Sustainability

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1 Advanced Composites: Enhanced Performance and Sustainability Jerrold E. Winandy, USDA FS Forest Products Lab

2 Driving Forces & Challenges to Achieving Sustainable Economies Urbanization Rapid Technological and Information Change Climate Change and Variability Globalization Accountability Energy Invasive and Exotic Species Changing Wood Resource Small Diameter Wood Waste Utilization & Recycling Plantation/Short Rotation Woody Crops Genetic selection/genetically Modified Species

3 USDA Forest Service Forest Products Laboratory 1 st Tenet of Resource Sustainability: To achieve true resource sustainability, always choose the material that has the maximum utility and minimum long-term impact on the environment.

4 USDA Forest Service Forest Products Laboratory 2 nd Tenet of Resource Sustainability: When using biobased materials is appropriate, a fundamental under- standing of those biomaterials, their conversion processes, and their engineering potentials is a basic requirement for sustainable forestry.

5 FPL Advanced Composites Research Program Nanocrystalline-Cellulose Composites Enhanced Hyper-performance performance Composites Advanced Structures/Housing Resource Sustainability & Bio-based Economy Small Diameter & Underutilized Species Hazardous-fuels Timber Fuels Reduction Value-added added Use of Exotic/Invasive Species Integrated Biomass Technologies

6 FPL s Strategic Plan for Composites Research Wood composites, alone or in combinations with other natural fibers or alternative materials, are the means to sustainable forestry. No other technology is as adaptable, or as compatible with how we currently use building materials or can it add more value or functionality/serviceability. Biocomposites are a critical technology as we evolve to a biobased economy.

7 USDA, Forest Service Forest Products Laboratory Mission: Engineered Composites Science Mission: Engineered Composites Science Develop a fundamental understanding of wood and biocomposite materials and then use that knowledge to enhance existing and develop new technologies and products that meet user needs, promote forest resource sustainability, and empower the conversion to a bio-based economy.

8 Wood & Biocomposites: the science of taking biomaterials apart & reconstructing them for specific engineering uses. Performance of Bio-Composites = f (materials( & process) Chips/Flakes/Strands/Fibers Nanoscience Fiber surface activation NCC-reinforced Composites Resins Hot:UF/PF/pMDI Cold:PR, Urethane Thermo-plastic Ceramic/Inorganic Processing Dry- or Wet-formed and Hot/Cold Pressed Melt-blended and Extruded/Molded

9 Wood-based Composite Technologies: Advantages Generally accepted worldwide Add value to diverse species and materials: Small-diameter timber Fast-grown plantation timber Ag- & Lignocellulosic-residues Exotic/Invasive species Recycled lumber and EWC-panels Timber removed as Hazardous-fuel

10 Wood-based Composite Technologies: Advantages Light Strong Easily worked Cost effective

11 Wood & Competitive Materials in Residential Buildings 5% 11% 40% Solid Wood Others Engineered Wood Metals Plastics 39% 5% ~9.3 billion M 3, 2002 [estimate by Freedonia Group, 2002]

12 Wood-based Composite Technologies: Limitations Current performance limits broader applications in Commercial/Non-Residential construction and Advanced Materials markets Public and Engineering communities perceive problems with: Fire Structural performance/creep Durability & water-related related issues Service-life Timber harvesting is not seen as Green

13 Four Problems in Developing the Next-generation of Engineered BioComposites (EBC) Identify and exceed user needs Develop more robust EBC s Develop advanced EBC s with high performance and reliability for commercial /non-residential construction Develop new eco-friendly, cost- competitive technologies for harvesting, processing, and end-of of-life reuse.

14 The Future of Advanced Woodand Lignocellulosic-Composites I. Nanotechnology II. III. IV. Biorefinery: Biofuels & Bioenergy Advanced Bio-based Composites Advanced Structures V. Sustainability and Enhancing Transition to a Biobased Economy

15 I.Nanotechnology and Wood- & Bio-composites With engineered biocomposites, nanotechnology will not be a science in itself. It will become the fundamental scale for approaching a problem, similar to how we now think of using a material science-type approach. Nanotechnology will become a standard for a basic type of approach to science. It will provide a tool by which we quantify or model the relation- ship between Materials-Process Process-Performance. Performance.

16 Nanocrystalline Cellulose, Nano-activated activated Fiber Surfaces, & Nano-reinforced Composites Using commercial wood pulp H 2 S0 4 hydrolysis Dispersed In PPpolymer matrix TEM image of cellulose nanocrystals

17 Major Technology shifts require Strategic Reinvention

18 Major Product advances require continual refocusing of Strategic Vision Trus-joist/Weyerhaeuser, Inc

19 II.Likely Scenarios for the Forest Biomass Biorefinery Stand Alone Biorefinery (without fiber production) Integrated Biomass Technologies (EtOH Composites Paper Energy)

20 Integrated Biomass Utilization 1a. Biofuels: EtOH from Hemicellulose EtOH

21 Integrated Biomass Utilization 1b. Value-added added Biobased Adhesives Pharmaceuticals, and Biochemicals.

22 Integrated Biomass Utilization 2. Value-added added Composites & Paper

23 Integrated Biomass Utilization 3. Energy from Biomass

24 III.Problem Areas for Advanced Composites Research Understand base materials and the relationship between materials, their processing and properties Define performance requirements for existing and develop the next generation of composites Address resource sustainability and educate users that wood and wood-based composites are the means to sustainable forestry

25 Enhance Perform ance and Durability for th e existing state EW C & MDF:Enhance structural strength & enhance durability state-of-art MDF:Define the effects oftherm al treatm ents strength and utility EW C:Developing Fire-and D ecay- Resistant Engineered W ood Com posites EW C:Define cardinalth resh olds of tem p.and MC for decay art in EW C:

26 Advanced Bio-Composites: Corrugated Fiberboard (1940 s) FPL Spaceboard (1970 s-80 s) 3D Engineered Fiberboard Lightweight Systems Furniture Packaging Engineered Pallets Emergency Structures Biomemetic/Smart Systems Bamboo Composites Bamboo Hi-Shock Board Corrugated Paperboard vs. 3D-Engineered Fiberboard

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28 Three-dimensional Engineered Fiberboard (3DEF)

29 Use of 3DEF for Emergency Structures (Post hurricane/tornado/tsunami) 3DEF panels as floor panels 3DEF panels as roof panels Roofs Floors 3DEF panels as wall panels Walls

30 Inorganic-bound Wood-fiber Composites Cement Non-sintered Ceramics Silicates

31 Wood Thermoplastic Composites Basic research on WTPC over the last years has formed the basis for phenomenal recent and future growth for WTPC in Building & Construction 20 Market Share (%) WTPC Decking Year

32 Advanced Biocomposites Low-cost, Rapidly-built, ADA-accessible, Biocomposite Surfaces Four Field Trials: CA, WI, MD, NY Commercialized in 2005

33 IV.Advanced Structures will require Advanced Engineered Materials: FPL is developing the bio-based based technologies to pioneer these future materials

34 Engineering and Materials Enhanced Wood Materials

35 Engineering and Materials Deconstruction & Reuse 3 Trillion (10 12 ) Bd.Ft. = 23.5 Billion (10 9 ) m 3

36 V. V.To develop a sustainable bio- based, rather than a petro-centric economy, we must develop value- added bio-composites to promote long-term resource sustainability and economic development Hazardous-fuels reduction Forest & Range residues Post-industrial wood waste Post-consumer wood waste Exotic/Invasive remediation Recycling WPC lumber Biocomposites: Juniper/Salt-cedar, Fibers from Chicken-feathers, Corn Stalks, Guayule, Agave,, & Sterile Digested Bovine Biomass MDF-CFF

37 To develop a sustainable bio-based based economy, rather than a petro-centric society, we need to develop value-added added bio- composites to promote long-term resource sustainability and economic development Ag-residue Biocomposites Chicken-feather MDF OSB from Burnt Pine WPC from Invasive Juniper and Salt-cedar

38 FPL s Advance Composites Science Research Program fpl.fs.fed.us /rwu4706 Value-added Uses for Exotic-Invasive Species Leadership in Development of New WTPC Building Products Define Field (Solar, biological, Thermal) Performance of WTPC Building Products Sustainable Forestry and Resource Management Hazardous Forest Fuels Utilization Playground Safety and ADA-accessibility