Introduction to bioplastics and biocomposites...5 The evolution of bioplastics Starch polymers PHA...

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Introduction to bioplastics and biocomposites

IfBB – Institute for Bioplastics and Biocomposites www.ifbb-hannover.de 14.02.2019

Dipl.-Ing. (FH) M. Neudecker

Prof. Dr.-Ing. A. Siebert-RathsProf. Dr.-Ing. H-J. Endres

Bio2AN – Rotorua - Scion – 14.02.2019 Sou

rce:

Chi

na H

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Introducing bioplastics

Polymer production Processing Use End‐of‐LifeRaw material 

production

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Agenda

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Defining bioplastics

Bioplastics market data

Land use for bioplastics

Pros and cons of bioplastics

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Bio-degradable?

Compostable?

Polymers fromrenewable resources?

Sustainable?Degradable?

Water soluble?

Renewable?

Bio-compatible?

Opposite ofconventional plastics?

Biogenicmacromolecules?

Oxodegradable?

Bioplastics?

„White“Biotechnology?

Natural fiber reinforced plastics?

What are Bioplastics?

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The evolution of bioplastics

Starch polymers PHA

4th Bioplastics generation

Residue utilization, bioeconomy

3rd Bioplastics generation

Bio-PA, Bio-PE, Bio-PET, PTT, Bio-PP

2nd Bioplastics generation

Starch blends PLA PBAT PBS

1st Bioplastics generation

Generations of technical bioplastics

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Bioplastics

Old Economy New Economy

Rubber

Regenerated Cellulose

Cellulose Acetates

Linoleum

etc.

Novel Drop-Ins

PLA

PHA

PEF

Starch Blends

etc.

Bio-PA

Bio-PE

Bio-PET

Bio-PP

DefinitionOld and New Economy Bioplastics

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No new material group classification in the class and the spectrum of plastics.

Classification into:

• Degradable petro-based bioplastics

• Degradable (predominantly) bio-based bioplastics

• Non-degradable, bio-based bioplastics

Facts about bio-based plastics:

• Renewable raw material base• Raw material production for bio-based plastics requires less energy• Novel material properties (except drop-ins)• Various disposal options (material recycling, composting, climate-neutral

energy recovery)

But still, what are Bioplastics?

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Non-degradable

Petro-based

Bio-degradable

Bio-based

Bio-degradablepetro-based

1. Cellulose AcetatesRubber, Casein…

4.Polylactide,

Starch blends,Cellulose Hydrates,

Polyhydroxyalkanoate

2.Polyethylene

PolypropylenePolyvinylchloride

…

3.PolycaprolactonePolyvinyl alcohols

Polyesters (PBAT, PBS,..)

…

5.Bio-PA, Bio-PE

Bio-PET, PTT,…

Bio-degradable and bio-based

Bio-basednon-degradable

Source: H.-J. Endres, A. Siebert-Raths; Engineering Biopolymers, Carl Hanser-Verlag, 2011

Definition of Bioplastics“The bioplastics cross"

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9Seite 9

www.alibaba.com

www.greenject.de

https://de.dreamstime.com www.bakerross.de

www.innovativeindustry.net

https://www.asdreports.comPLA

https://http://www.pbat.info/en.html

joyforce-chem.com

Conventional plastics

www.pressreleasefinder.com

Bioplastics applications

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Non-degradable

Petro-based

Bio-degradable

Bio-based

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Market figures for bioplastics

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New economy bioplastics production capacities 2017

www.ifbb-hannover.de/de/facts-and-statistics.html

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Market figures for bioplastics

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New economy bioplastics production capacities 2022

www.ifbb-hannover.de/de/facts-and-statistics.html

2017 = 2.27 million tons

2022 = 4.31 million tons

+ 190 %Mainly pushed

by PLA & Bio-PP

+ 8.2 %

New

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Market figures for bioplastics: Land area usage

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Global land area = 13.4 billion ha = 100%

Agricultural area = 5 billion ha = 36.5%

Pasture = 3.5 billion ha = 26.1%

Arable land = 1.4 billion ha = 10.4%

Food & Feed = 1.24 billion ha = 9.25%

Biofuel = 53 million ha = 0.39%

Bioplastics 2022 = 1.04 million ha = 0.008%

www.ifbb-hannover.de/de/facts-and-statistics.html

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Same for the Drop-Ins / Others often comparable but some show weaknesses

Biodegradability / new, special and unique material properties

Independence from oil (for the bio-based) as a finite source of raw __material

Is getting better but needs to be improved / Often only little or outdated __information's

Competitive for some materials like PLA, but most are still more expensive

• Performance compared to conventional plastics

• Special features

• Feedstock

• Processing and material data basis

• Price

Pros and cons of bioplastics

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Contact:

Dipl.-Ing. (FH) Marco Neudecker

Hochschule Hannover - University of Applied Sciences and ArtsIfBB – Institute for Bioplastics and Biocomposites

Faculty II – Mechanical and Bioprocess Engineering

Heisterbergallee 10A30453 Hannover

Germany

Phone: +49 5 11 / 92 96 – 22 32Fax: +49 5 11 / 92 96 – 99 28 23

E-mail: marco.neudecker@hs-hannover.deInternet: http://www.ifbb-hannover.de

Thank you for your attention

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Processing

Polymer production Processing Use End‐of‐LifeRaw material 

production

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Agenda

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(Bio)Plastics Overview & market share

“The bioplastics processing challenges”

Processing bioplastics

Bioplastics processing hints & information´s

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Plastics Overview & market share

Source: www.plasticseurope.org

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Source: www.plasticseurope.org A

Europe ~ 19 %

Injection molding ~ 16 %

Extrusion~ 33 %

Source: Ceresan study

Plastics Overview & market share

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Biolastics Overview & market share

~ 1.2 %* of world plastics production

* Comparison between production data 2017 and production capacity data 2022

Extrusion & injection molding are also the biggest applications for bioplastics

New economy bioplastics production capacities by region 2022

www.ifbb-hannover.de/de/facts-and-statistics.html

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“The bioplastics processing challenges”- The bad news (does not apply for drop-ins)

• Very limited material data available

• Limited processing knowledge available

• Limited information on pre-treatment / drying available

• Bioplastics need to provide "better" data if they want to displace traditional plastics in technical applications

• No/not enough bio-based additives available

• No/not enough bio-based master batches on the market

• Often higher material prices due to low production capacities

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• Bioplastics are also just plastics

• Processing them is normally as complex as switching from one plastics type to another, if there specific needs are observed

• They have very interesting an unique properties which can be beneficial

• Prices drop down with increasing production capacities and demand

“The bioplastics processing challenges”- The good news

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Processing Bioplastics- The bioplastics processing project

Manufacturing and Processing of Bio-Based Plastics and Establishment of a Competence Network within the

Biopolymer Network maintained by the FNR (project management)

Task III

Integration Into The FNR Network

Task II

Knowledge Transfer

Task I

Determination Of Process Data

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Decision-making aids for a switch over from oil-based plastics to bio-based plastics (concerning twin screw extrusion)

Source: © IfBB

Processing instructions

Processing Bioplastics - Thermoplastics – Extrusion

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Processing Bioplastics - Thermoplastics – Injection Molding

• Rheological properties

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Processing Bioplastics - Thermoplastics – Injection Molding• Filling pressure vs. melt temperature

low viscositycf.

PA 6

Increased viscosity cf.

PBT filled

High viscositycf.

PC amorphous

0

100

200

300

400

500

600

700

160 180 200 220 240 260 280 300

fillin

g pr

essu

re [b

ar]

melt temperature [°C]

(Bio-PE+NF) JELUWPC Bio PE H50-500-20(Bio-PE) FKuRTerralene HD 3505

(Bio-PA 6) EvonikVestamid Terra HS16

(PBS) Showa DenkoBionolle 1020MD

(PHB) MetabolixP1004

Various bioplasticstool: tension rod 1A i.a.w ISO 527

In cooperation with UL TTC

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Processing Bioplastics - Thermoplastics – Injection Molding

• Dimensional stability (Traffic light rating)– Shrinkage and warpage of bioplastics

Processed according to ISO 294 In co-operation with UL TTC

Flow direction (FD)

Cross-flow direction (CD)

FD/CD

Test plate 60 x 60 x 2 mmAnisotropy factor FD/CD

not measurable, caused by surface structure

almost isotropic despite high filler (60 wt-%)

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Bioplastics processing hints & information´s- List of contents

Processing Bioplastics

Go to:hs-h.de/processing-bioplastics

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Further hints & information´swww.materialdatacenter.com

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Further hints & information´s

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Contact:

Dipl.-Ing. (FH) Marco Neudecker

Hochschule Hannover - University of Applied Sciences and ArtsIfBB – Institute for Bioplastics and Biocomposites

Faculty II – Mechanical and Bioprocess Engineering

Heisterbergallee 10A30453 Hannover

Germany

Phone: +49 5 11 / 92 96 – 22 32Fax: +49 5 11 / 92 96 – 99 28 23

E-mail: marco.neudecker@hs-hannover.deInternet: http://www.ifbb-hannover.de

Thank you for your attention