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What Is The Future For Bioplastics?
What is a Bioplastic?
To be classified as biobased, the material must be
organic and contain some percentage of recently
fixed (new) carbon found in biological resources or
crops. This definition is the basis of ASTM D6866
Definitional Clarification
Renewable does not mean compostable
Nylon 11, Brazchem PE
Non renewable does not mean non compostable
ECOFLEX , polybutylene succinate (PBS)
Compostability is a disposal option-not compositionally defined
Why the Drive to Use Renewable Feedstocks?
Oil Independence
Environmental Pollution
Global Warming
Human Health Concerns.
Legislation
Products
Plastics Trends - Facts
Non Renewable Renewable
Disposables Durables
Feedstocks
Facts or Wishful Thinking?
Global demand for bioplastics will increase more than
fourfold to 900,000 metric tons in 2013. (Freedonia)
Global production of bioplastics will increase
six-fold to 1.5 million tonnes by 2011, up from 262,000
tonnes in 2007. (European Bioplastics )
Production capacity of bio-based plastics is
projected to increase from 360,000 tons in 2007
to about 2.3 million tons by 2013. (European Bioplastics )
Facts or Wishful Thinking?
Increasing demand for biobased, durable products in electronics
and automotive applications.
By 2011 durables are expected to account for almost 40% of
bioplastics -compared with 12% today. ( European Bioplastics)
Can Today’s Compostable Bioplastics Meet the Durables Needs?
Key Compostable Bioplastics -The First
Generation
Starch/PLA/ECOFLEX
Compounded Biobased
Compostable
O
OHHO
H CH3
L-Lactic Acid
O
OHHO
H3CH
D-Lactic Acid
(0.5%)
Polylactic Acid -PLA
100% Renewable and compostable
Compostable Bioplastics –Second Generation
Poly Hydroxy Alkanoates
(PHA’s)
,
Short Chain Length (SCL)
PHB,PHBV
SCL-co MCL
PHBH,PHBHP,
PHBHO,PHBHN
Product Company Location Capacity/mt Price/#
PLA Natureworks USA 150,000 0.85-1.20
PLA Hisun China 5,000 1.25
PHA’s Metabolix/Telles USA 300/50,000
(2010)
2.50-2.75
PHBH Meredian/Kaneka USA 150,000? n/a
PHBV Tianan China 2,000 2.40-2.50
Materbi Novamont Eu 80,000 2.0-3.0
Cereplast Cereplast USA 25,000 1.50-2.50
HDPE/LDPE/PP
.
Brazchem SA 200,000
(2010)
0.80-1.00
Biobased Polymer Capacities for Major Players
Major Markets for Compostable Bioplastics
Starch Blends PLA SCL-PHA’sStarch Blends
Compostable Bioplastics Do Not Meet the
Needs for Durables
Starch Blends
Hydrolytic stability
Distortion Temp.
Vapor transmission
Shelf Life
Areas of Concern
PLA
Hydrolytic Stability
Distortion Temp.(amorph.)
Vapor Transmission
Shelf Life
Impact Resistance
Melt Strength
SCL PHA’S
Hydrolytic Stability
Shelf Life
Melt Strength
Processability
Economics
“Ageing”
Traditional Path to Maturity For Plastics
Copolymers
Impact modifiers
Rheology
Modifiers
Plasticizers
Nucleating agents
Rigid/Flexible
Low/High Temp
Biobased/PetroBase Polymer
Additives
Fillers/fibers
Pigments
Lubricants
Mold release agents
ModifiersBlends Chemical Resit.
High Heat
Ductile
Will Biopolymers Follow the Traditional Path to Maturity?-Yes
Copolymers
Acrylics
Joncryls
CitroflexEBS
PLA/Ecoflex
PLA/PHBV
PLA/PCBase Polymer
PLA
Additives
Talc
Kenaf
ModifiersBlends
Isosorbide
2,5 FDCA
Blends of PHBV/ PLA Already Occurring -
Why?
Improved Temperature Performance over PLA
Improved processing window over PHBV
Wider mechanical property spectrum
Almost completely renewable resource based
Still Compostable
Heat Distortion Properties of PHBV/PLA Blends
COURTESY OF PETER HOLLAND BV
Samples Held up to 12minutes at 100 C
100%PLA
90%PLA/10%PHBV
80%PLA/20%PHBV
70%PLA/30%PHBV
60%PLA/40%PHBV
50%PLA/50%PHBV
2Minutes
Deformed
12Minutes
Not
Deformed
Heat Distortion Temperatures of PHBV/PLA Blends
COURTESY OF PETER HOLLAND BV
Sample Load MPa HDT oC
100% PLA 0.45 52.0
90/10 0.45 53.4
80/20 0.45 54.5
70/30 0.45 54.6
60/40 0.45 63.0
50/50 0.45 66.3
PHBV/PLA Blended Product
Courtesy of Peter Holland BV
Will this Path Serve Durable Markets ?
Not Likely with Only 100% Renewable Products.
Renewable/Petro based Blends are Developing
Low Biobased content Durable Copolymers are Appearing
To Cross the Frontier to High Biobased Durables:
A New Approach is needed
Bioplastics – Present and The Future?
Compostables
PLAPHA’s (PBS)
Starch Blends PLA/PHA
PTTTPU’s
Biobased Durables
Low New “C” Content
PETNylon 4.10,6.10, 10.10, 10. Nylon 11
PE, PPNYLON 6
PET, NYLON 6PBT, PMMA,PC
Biobased Durables
High New “C” Content
Bioplastics Frontier1994-2009 2010-2015?
The New Frontier Landscape
Succinic acid - (DSM, Bioamber, Roquette, Mitsubishi Chemical)
3-hydroxy propionic acid - (Cargill, Codexis)
Acrylic acid - (Ceres, Rohm & Haas)
Aspartic acid - (China)
Levulinic acid - (China)
Sorbitol - (Cargill, ADM, Roquette)
Ethylene/ethylene glycol - (Brazchem, India Glycols)
Propylene/propane 1,3 diol - (Brazchem, DuPont / Tate & Lyle)
Butylene/butane diol - (Genomatica)
Lysine/caprolactam - (Draths)
Terephthalic acid - (Gevo)
Adipic acid
Isoprene - (Goodyear, Genenco)
The Future For Bioplastics Will Depend On…
Moving from Single Use Compostable to Durables
Performance and Price improvements for Existing Bioplastics
Renewable Building Block Developments
Recycling Infrastructure Developments
The Voyage continues
Thank you