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© 2009 Society of Chemical Industry and John Wiley & Sons, Ltd
*Correspondence to: Li Shen, University Utrecht - Group Science, Technology and Society (STS), Heidelberglaan 2 Utrecht 3584 CS, the Netherlands.
E-mail: [email protected]
25
Perspective
Present and future development in plastics from biomassLi Shen,* Ernst Worrell and Martin Patel, University Utrecht, the Netherlands
Received August 13, 2009; revised version received September 23, 2009; accepted September 25, 2009
Published online December 7, 2009 in Wiley InterScience (www.interscience.wiley.com); DOI: 10.1002/bbb.189;
Biofuels, Bioprod. Bioref. 4:25–40 (2010)
Abstract: Biobased plastics have experienced fast growth in the past decade thanks to the public concerns over the
environment, climate change and the depletion of fossil fuels. This perspective provides an overview of the current
global market of biobased plastics, their material properties, technical substitution potential and future market (for
2020). In addition, the technology and market development of three biobased plastics, namely polylactide (PLA),
biobased polyethylene (PE) and biobased epoxy resin, are discussed in detail. The emerging biobased plastics mar-
ket is still small compared to traditional biobased polymers and biomaterials. The global capacity of the emerging
biobased plastics was only 0.36 million tonnes in 2007. However, the market grew strongly between 2003 and 2007
(approx. 40% per year). The technical substitution potential of biobased plastics replacing petrochemical plastics is
estimated at 90%, demonstrating the enormous potential of biobased plastics. Global capacity of biobased plastics
is expected to reach 3.45 million metric tonnes in 2020. Starch plastics, PLA, biobased PE, polyhydroxyalkano-
ates (PHA) and biobased epoxy resin are expected to be the major types of biobased plastics in the future. © 2009
Society of Chemical Industry and John Wiley & Sons, Ltd
Keywords: biobased plastics; biopolymer; market projection; production; material property; PLA; biobased PE;
epoxy resin
Introduction
Polymers abound in nature. Wood, leaves, fruit,
seeds and animal furs all contain natural polymers.
Biobased polymers have been used for food, furniture
and clothing for thousands of years. Every year about 17 x
1010 metric tonnes biomass are produced by nature, of which
only 3.5% are utilized by mankind.1 Apart from wood used
for conventional applications, for example energy, paper,
furniture and construction, only a minor part of the total
biomass is currently used for materials, for exampe clothing
and chemicals.
Th e subject of this perspective is biobased plastics. We
defi ne biobased plastics as man-made or man-processed
organic macromolecules derived from biological resources
and used for plastic and fi ber applications (without paper
and board). Table 1 lists the main types of emerging
biobased plastics.2
Biobased plastics have a history of more than a century –
much longer than petrochemical plastics. Th e fi rst artifi cial
thermoplastic – celluloid – was invented in the 1860s.3 Since
then, numerous inventions have been patented for new
compounds and materials made from biological resources,
such as ethylene produced by the dehydration of biobased
26 © 2009 Society of Chemical Industry and John Wiley & Sons, Ltd | Biofuels, Bioprod. Bioref. 4:25–40 (2010); DOI: 10.1002/bbb
L Shen et al. Perspective: Present and future development in plastics from biomass
Table 1. Main emerging biobased plastics for non-food applications.2
No Biobased plastics (group) Type of polymer Types/Structure/Production Method
1. Starch plastics PolysaccharidesPartially fermented starch; Thermoplastic starch (TPS); Chemically modifi ed starch (e.g., starch acetate)Starch blends; Starch composites
2. Cellulose polymers Polysaccharides Organic cellulose esters; Regenerated cellulose
3. Polylactide (PLA) PolyesterBiobased monomer (lactide) by fermentation, followed by polym-erisation
4 Polytrimethylene terephthalate (PTT) PolyesterBiobased 1,3-propanediol (1,3-PDO) by fermentation plus petro-chemical terephthalic acid (or DMT)
5. Polyamides (PA)
Polyamide
a. PA11 Biobased monomer 11-aminoundecanoic acid from castor oil
b. PA610 Monomer sebacic acid from castor oil
c. PA6 Biobased monomer caprolactam by fermentation of sugar
d. PA66 Biobased adipic acid by fermentation
e. PA69 Biobased monomer obtained from oleic acid via azelaic (di)acid
6. Polyhydroxyalkanoates (PHAs) Polyester Direct production of PHA by fermentation
7. Polyethylene (PE) Polyolefi nBiobased monomer (ethylene) obtained from ethanol which is produced by fermentation of sugar.
8. Polyvinylchloride (PVC) PolyvinylMonomer vinyl chloride can be obtained from biobased ethylene (from ethanol).
9. Other thermoplastics*
a. Other polyesters (PBT, PBS, PBSL, PBSA, PBST, PBAT, PET, PEIT PVAc, Polyacrylates, PTN, PTI, thermoplastic elastomers)
Polyester Various carboxylic acids, various alcohols
b. Other ethylene-based com-pounds (e.g., polystyrene and EPDM rubber)
VariousEthylene by dehydration of bio-ethanol, reacted with other com-pounds
c. Methanol-based compounds (e.g., phenolic resins, urea formal-dehyde resins, melamine formalde-hyde resins)
VariousSyngas by gasifi cation of biomass, and synthesis of methanol, reacted with other compounds
d. Propylene-based compounds (e.g., PP, polyacrylates, PUR, PA )
VariousThermochemical propylene production via bionaphtha plus steam-cracking or via biomethanol, followed by a methanol-to-olefi ns process and polymerisation.
10. Polyurethanes (PUR) Polyurethanes Biobased polyol from vegetable oils, plus petrochemical isocy-anate.
11. Thermosets Cross-linked polymers
a. Epoxy resins Epoxy resin
Diglycidyl ether of bisphenol A derived from bisphenol A and epichlorohydrin (ECH). ECH produced by glycerine-to-epichlo-rohydrin (GTE) process; glycerine is a byproduct of bio-diesel production.
b. Epoxidized vegetable oils Epoxide Addition of oxygen to alkenes
c. Thermosets based on 1,2-PDO and 1,3-PDO
Unsaturated polyesterPolycondensation of unsaturated and saturated dicarboxylic acids with diols.
d. Alkyd resins Alkyd resinCondensation polymerization of polyols, organic acids and fatty acids or triglyceride oils.
*Abbreviations: DMT = Dimethyl terephthalate; PBT=polybutylene terephthalate; PBS=polybutylene succinate; PBSL=polybutylene succi-nate-co-lactate; PBAT=polybutylene adipate-co-butylene terephthalate; PET=polyethylene terephthalate; PEIT=polyethylene-co-isosorbite terephthalate; PVAc=polyvinyl acetate; PTN=polytrimethylene naphthalate; PTI=polytrimethylene isophthalate; EPDM=ethylene propylene diene M-class rubber; PP=polypropylene.
© 2009 Society of Chemical Industry and John Wiley & Sons, Ltd | Biofuels, Bioprod. Bioref. 4:25–40 (2010); DOI: 10.1002/bbb 27
Perspective: Present and future development in plastics from biomass L Shen et al.
ethanol in the 1940s.4 However, many inventions made in
the 1930s and 1940s remained in the laboratories and were
never commercially exploited, due to the development of
cheap, synthetic polymers from crude oil in the 1950s. Th e
petrochemical industry has since taken off and plastics have
become a daily necessity.
In Western Europe in 2007, 43% of all plastics are used for
packaging, 21% are used in building and construction, 8%
for automobiles, 5% for electrical and electronic appliances,
and the remaining 23% are used for various other applica-
tions.5 Th e vast majority of the polymers used are polyole-
fi ns, i.e., polyethylene (PE) and polypropylene (PP) which
together represent 54%, followed by polyvinyl chloride
(PVC, 14%), which dominates in building and construction,
and polyethylene terephthalate (PET, 8%).5
Biobased plastics have experienced a renaissance in the last
few decades. Many new polymers from biobased feedstocks
were developed, for example polylactic acid (PLA) from
sugars. One of the earlier drivers was to provide the market
with biodegradable plastics in order to solve the problem of
increasing amounts of waste and limited landfi ll capacity.
Today, public concerns about the environment, climate
change and limited fossil fuel resources have become more
important drivers.
Th is perspective provides an overview of the market,
material properties, applications, the technical
substitution potential of emerging biobased plastics
between 2003 and 2007, and the projections of the future
market until 2020. An extensive description of all poly-
mers listed in Table 1 can be found in Shen et al.2 In this
perspective, three biobased plastics, namely PLA, biobased
PE and biobased epoxy resins, are highlighted for their
recent developments.
Market of biobased plastics
Current market volumes
Before discussing the market volume of emerging biobased
plastics, it is worthwhile to understand the market size of
traditional non-food biobased polymers and materials. Th ese
include paper and board, man-made cellulosics (fi bers and
modifi ed cellulose), non-food starch and alkyd resins. Th ese
biobased polymers and materials have been produced and
consumed in large quantities for long time. So far, the paper
industry has been the largest non-food biobased material
producer in the world. Th e global paper and board produc-
tion was approximately 365 million metric tonnes (Mt) in
2006.6 Together, non-food starch (without starch used for
fuel ethanol*), man-made cellulose polymer† and alkyd resin
account for approximately 20 Mt per year, of which non-
food starch takes the lion’s share (75%, without starch used
for fuel ethanol), followed by man-made cellulose polymers
(20%, without paper) and alkyd resin (5%).‡
Compared to the traditional non-food biobased polymer
and material market, the emerging biobased plastics market
is relatively small. Th e global capacity in 2007 was estimated
at 0.36 Mt, equivalent to only 0.1% of the world’s paper and
board production and 0.2% of the global petrochemical
plastics production. However, the emerging biobased plas-
tics market is growing rapidly. Between 2003 and 2007, the
average annual growth rate was close to 40% worldwide
(Fig. 1) and nearly 50% in Europe.§
Th e developments in the past fi ve years in emerging
biobased plastics are spectacular from a technological point
of view. Starch plastics and PLA have been the frontrunners
in the renaissance of biobased plastics. Th ey were the only
biobased plastics produced on a large scale in 20037 (Fig. 1).
Today, starch plastics and PLA are still the most important
biobased plastics in the market but other types of biobased
plastics will soon be produced on a large scale, such as
biobased polyethylene (PE) and biobased epoxy resin (made
from biobased ethylene and epichlorohydrin, respectively).
Recent technological breakthroughs have allowed the
substantially improvement in the material properties of novel
* In Europe starch used for fuel ethanol was approximately 1.9 Mt in 2007.2
† Including cellulose esters (e.g., cellulose acetate), cellulose ethers (e.g., car-
boxymethyl cellulose) and regenerated cellulose (e.g., viscose).
‡ The information on current capacity of the emerging biobased plastics was
collected from 30 companies who produced at least at pilot scale in 2007.
These 30 companies are the current major players of starch plastics (8 com-
panies), cellulose films (2), PLA (7), PTT (1), biobased PA (1), PHA (6), biobased
PE (1), biobased epichlorohydrin (1) and biobased PUR (3). The capacity
information for 2007 was collected by means of a questionnaire, via personal
communication with companies and industry associations and through publicly
available company announcements.
§ The capacity information for 2003 was obtained from Crank et al. 7 and up-
dated by personal communication with companies.
28 © 2009 Society of Chemical Industry and John Wiley & Sons, Ltd | Biofuels, Bioprod. Bioref. 4:25–40 (2010); DOI: 10.1002/bbb
L Shen et al. Perspective: Present and future development in plastics from biomass
biobased plastics, such as heat-resistance (e.g., for PLA) and
tensile strength (e.g., for PHA). Th is makes biobased plastics
eligible for a wider variety of applications. Moreover, many
old processes have been revisited, with ethanol dehydration
probably the most prominent one. Many fi rst-of-its-kind
plants are being (or will be) constructed. Hence, we are at the
very beginning of the learning curve for biobased plastics.
Most of the plant capacities are still small (e.g., the capacity
of Tianan’s PHA plant is only 2 kt 8(metric kilotonnes)), but
others are very sizable (e.g., Braskem’s biobased PE plant will
be 200 kt9). With a growing demand for biobased plastics,
it can be expected that turn-key plants with large capaci-
ties will be commercially available within a few years, thus
allowing accelerated growth.
Technical substitution potential
Table 2 provides an overview of the typical physical,
mechanical and thermal properties of emerging biobased
plastics. Note that there are no diff erences in terms of mate-
rial properties between biobased plastics and their petro-
chemical counterparts which have identical chemical struc-
tures (e.g., PE).
In order to understand to what extent biobased plastics
could replace petrochemical plastics from a technical point
of view, we estimated the maximum technical substitution
potential. Th is was done by interviewing industrial experts
based on the material properties and applications of biobased
plastics. Th e outcome of the interview is shown in Table 3
(for plastics applications) and Table 4 (for fi bers) in ‘% substi-
tution’. Complete substitution (100%) is achieved when
petrochemical plastics are replaced by chemically identical
biobased plastics (e.g., PE). In all other cases, the substitu-
tion percentages are lower than 100% because petrochemical
plastics can only be replaced partially by fully biobased or
partially biobased plastics. Depending on the type of plastic,
between 20% and 100% of the current volume could be in
principle replaced by biobased plastics. Th e substitution
potentials of 8 out of the 16 plastics are 100% (Table 3).
By multiplying the substitution percentage by the
consumption volume of the respective petrochemical
polymer in 2007, volume estimates are obtained for each
biobased plastic. Th us, the overall maximum technical
substitution potential for plastic applications** is estimated
at 205 Mt, which corresponds to 90% of the total global
plastic consumption in 2007. For fi bers (Table 4), the substi-
tution potential is estimated at 35 Mt, or 87% of the world’s
fi ber consumption in 2007. Th erefore, the total maximum
technical substitution potential of biobased plastics and
fi bers replacing their petrochemical counterparts is esti-
mated at 240 Mt, or 90% of the total consumption of plas-
tics and fi bers in 2007. Th is substitution potential is purely
based on the technical properties of the biobased plastics.
It does not account for resource availability and economic
viability. As a note of caution, the substitution potential of
90% should be regarded as indicative because it has not yet
been proven that the large-scale production of all biobased
plastics (including fi bers) shown in Table 3 and Table 4 is
technically feasible.
Market projections of biobased plastics
Th e market projections of biobased plastics for 2020 were
carried out as follows:
** Important plastic applications are injection moulding, blow moulding, extru-
sion and foaming; in contrast, the use of polymers for coatings and fibres is
usually excluded.
Figure 1. Global production capacities of emerging biobased plastics in 20037 and 2007.
2007: 360 kt
Starchplastics 43%
PLA 42%
Cellulosefilm/PHA/PTT/P
A/PUR 11%
Bio-basedmonomers
(e.g., ethylene,ECH) 3%
2003: 100 kt
Starchplastics
25%
PLA 75%
Growth 38% per year
© 2009 Society of Chemical Industry and John Wiley & Sons, Ltd | Biofuels, Bioprod. Bioref. 4:25–40 (2010); DOI: 10.1002/bbb 29
Perspective: Present and future development in plastics from biomass L Shen et al.
Tab
le 2
. Typ
ical
phy
sica
l and
the
rmal
pro
per
ties
, ren
ewab
le c
ont
ents
, bio
deg
rad
abili
ty a
nd c
om
mer
cial
isat
ion
stag
es o
f em
erg
ing
b
iob
ased
pla
stic
s.i D
ensi
ty(g
/cm
3 )
Tens
ile
stre
ngth
(M
Pa)
Youn
g’s
mod
ulus
(GP
a)
Flex
ural
m
odul
us(G
Pa)
T m (o C)
T g (o C)
Ren
ewab
le
cont
ent
(wt
%)
Bio
de-
grad
able
Dev
elop
men
t p
hase
, end
of
2008
Sta
rch
pla
stic
s [1
]1.
20-1
.35
20-4
01.
0-1.
7-
h~
60-
40-1
00%
Yes
& N
oaLa
rge
scal
e
PLA
[2]b
1.24
53-1
00-
3.83
140,
220
55 t
o 70
100%
Yes
Larg
e sc
ale
PH
A [3
]c1.
17-1
.25
18-4
01.
2-3.
0-
50-1
90-1
3 to
410
0%Ye
sP
ilot
scal
e
Cel
lulo
se fi
lm1.
45 [4
]70
-125
[5]
--
--
100%
Yes
Med
ium
sca
le
Bio
bas
ed P
TT [6
]d1.
3566
n/a
2.7
228
45 t
o 55
35%
No
Sm
all s
cale
Bio
bas
ed P
ET
[7]d
1.31
522.
7-
220-
225
75~
30%
No
Res
earc
h
Bio
bas
ed L
DP
E [4
]d0.
9210
-18
0.15
-0.2
010
5-13
0-3
010
0%N
oP
ilot
Bio
bas
ed P
P[8
]d, e
0.
9133
-35
-1.
45-1
.55
160-
170
-13
to 0
f
-18
to -
15 g
100%
No
Pilo
t
PA11
[9,1
0]1.
0557
-1.
1718
0-18
945
100%
No
Med
ium
sca
le
PA61
0 [1
1]1.
0855
-2.
0022
5-
~60
%N
oS
mal
l sca
le
Bio
bas
ed P
A66
[9]d
1.14
83-
2.83
269
65 t
o 85
100%
No
Res
earc
h
Bio
bas
ed P
A6
[9]d
1.14
81-
2.70
228
65 t
o 75
100%
No
Res
earc
h
Bio
bas
ed P
UR
--
--
--
8-90
% [1
2]N
oS
mal
l sca
le
Bio
bas
ed L
ER
d, j
--
--
--
30%
No
Sm
all s
cale
a Th
e b
iod
egra
dab
ility
of s
tarc
h p
last
ics
dep
end
s on
the
cop
olym
er b
lend
ed w
ith
ther
mop
last
ic s
tarc
h (T
PS
). S
tarc
h p
last
ics
are
only
bio
deg
rad
able
if t
he c
opol
ymer
is
also
bio
deg
rad
able
.bTh
e th
erm
al p
rop
erty
of P
LA is
for
amor
pho
us, s
emi-
crys
talli
ne a
nd c
ryst
allin
e P
LA.
c PH
As
here
incl
ude
P(3
HB
), P
(3H
B-c
o-H
V),
P(3
HB
-co-
HH
x) a
nd P
(3H
B-c
o-H
A).
dTh
ese
bio
bas
ed p
last
ics
are
chem
ical
ly id
entic
al w
ith t
heir
pet
roch
emic
al c
ount
er-
par
ts. T
here
fore
, the
phy
sica
l and
the
rmal
pro
per
ties
are
also
iden
tical
.e R
efer
s to
PP
hom
opol
ymer
f For
isot
actic
PP
g For
atac
tic P
Ph N
ot a
pp
licab
le o
r no
t av
aila
ble
i See
the
full
nam
es o
f the
ab
bre
viat
ions
in T
able
1.
j LER
= L
iqui
d E
pox
y R
esin
.
[1] D
ata
from
var
ious
sta
rch
pla
stic
s p
rod
ucer
s; s
ee S
hen
et a
l.2 .[2
] Nat
ureW
orks
LLC
10; P
UR
AC
11
[3] S
udes
h et
al.12
[4] S
chm
itz &
Jan
ocha
13
[5] I
nnov
ia14
[6] K
uria
n15
[7] K
öpni
ck e
t al
.16
[8] W
hite
ley
et a
l.17
[9] K
ohan
et
al.18
[10]
Ark
ema19
[11]
Tor
ay20
[12]
Dat
a fr
om v
ario
us b
iob
ased
pol
yol/P
UR
pro
duc
ers;
see
She
n et
al.2
30 © 2009 Society of Chemical Industry and John Wiley & Sons, Ltd | Biofuels, Bioprod. Bioref. 4:25–40 (2010); DOI: 10.1002/bbb
L Shen et al. Perspective: Present and future development in plastics from biomass
Tab
le 3
. Tec
hnic
al s
ubst
itut
ion
po
tent
ial o
f bio
bas
ed p
last
ics
(pla
stic
ap
plic
atio
ns in
clud
ing
the
rmo
pla
stic
s an
d
ther
mo
sets
, exc
lud
ing
fib
ers)
.
% s
ubst
itutio
n*LD
PE
HD
PE
PP
PV
CP
S *
*P
ET
PU
RPA
AB
S†
PC
PB
TP
MM
AO
ther
P
olya
cr-
ylat
es
Ep
oxy
resi
nS
ynth
. ru
bb
erO
ther
Sta
rch
pla
stic
s8
88
88
4
PLA
1010
1020
105
PH
A20
2010
1020
1010
105
Cel
lulo
se fi
lms
1010
1015
Bio
bas
ed P
E72
62
Bio
bas
ed P
P57
Bio
bas
ed P
VC
‡80
Bio
bas
ed P
ET‡
35
Bio
bas
ed P
TT‡
520
3020
100
5
Bio
bas
ed P
UR
‡80
Bio
bas
ed P
A30
Bio
bas
ed p
olya
cr-
ylat
es‡
100
Bio
bas
ed e
pox
y re
sin‡
75
Bio
bas
ed A
BS
‡90
Bio
bas
ed P
B‡
80
Sum
per
cent
ages
100
100
100
100
4810
098
7010
020
100
1910
075
800
(1,0
00 t
)LD
PE
HD
PE
PP
PV
CP
S *
PE
TP
UR
PAA
BS
†P
CP
BT
PM
MA
Oth
er
Pol
yacr
-yl
ates
Ep
oxy
resi
nS
ynth
. ru
bb
erO
ther
Tota
l%
su
bst
2007
Glo
bal
co
nsum
ptio
n §
37,1
0030
,700
44,9
0035
,280
16,1
0515
,498
12,2
852,
730
7,45
53,
150
954
1,40
066
01,
150
10,8
896,
930
227,
186
100
Tech
nica
lly
rep
lace
able
vo
lum
es37
,100
30,7
0044
,900
35,2
807,
730
15,4
9812
,039
1,91
17,
455
630
954
266
660
863
8,71
10
204,
698
90
Not
e: S
ee a
bb
revi
atio
ns in
Tab
le 1
.*T
he v
alue
s on
sub
stitu
tion
pot
entia
l (in
the
up
per
tab
le) w
ere
esta
blis
hed
bas
ed o
n in
terv
iew
s w
ith in
dus
tria
l exp
erts
(see
tex
t).**
PS
(all
typ
es) a
nd E
PS
† AB
S/S
AN
, inc
lud
ing
also
oth
er s
tyre
ne c
opol
ymer
s.‡ P
artia
lly b
iob
ased
pol
ymer
.§ Fo
r P
E, P
P, P
VC
, PS
, PU
R, A
BS
, PA
, PC
and
PB
T, d
ata
are
for
2007
bas
ed o
n th
e p
roje
ctio
n of
Kun
stst
offe
.21 T
he P
ET
dat
a is
als
o p
roje
cted
for
2007
but
bas
ed o
n th
e d
ata
for
2006
from
Pla
stic
sEur
ope22
and
ann
ual g
row
th p
roje
ctio
n ac
cord
ing
to K
unst
stof
fe.21
For
PM
MA
, the
con
sum
ptio
n d
ata
is fo
r 20
06;21
no
pro
ject
ion
for
2007
is a
vaila
ble
. For
oth
er
pol
yacr
ylat
es, d
ata
are
for
2003
23. F
or e
pox
y re
sin
and
syn
thet
ic r
ubb
er, c
onsu
mp
tion
dat
a ar
e fo
r 20
00.24
,25
© 2009 Society of Chemical Industry and John Wiley & Sons, Ltd | Biofuels, Bioprod. Bioref. 4:25–40 (2010); DOI: 10.1002/bbb 31
Perspective: Present and future development in plastics from biomass L Shen et al.
1. Th e companies’ expected production capacity was
collected by a questionnaire, via personal communica-
tion with companies and with the industry associations
European Bioplastics and Japan Bioplastics Association,
and through publicly available company announce-
ments. About 70 companies worldwide were investi-
gated in our market projection, including both current
producers and the future producers of biobased plastics.
Th e current activities range from lab scale to large,
commercial scale.
Th e questionnaire was sent to all the member compa-
nies of the European Bioplastics association. Seven out
of about 50 companies replied. About 25 companies’
data were collected via personal communication or
communication with industry associations. Company
capacity data which could not be obtained by the ques-
tionnaire or personal communication was collected
from company announcements in the public domain.
Th e companies were requested to provide projections
of their planned capacity expansion. Th e companies’
views were collected in the fi rst half of 2008 and
once more in March 2009 in order to account for the
economic crisis.
Our questions primarily focused on the period
2007–2020. Th e projections for 2009–2013 are based on
concrete plans, which are currently being implemented;
in contrast, the statements made for the year 2020 have
more of a visionary character. Th e projection prepared
on this basis is referred to as ‘projection based on
company announcements’.
Th e result of Step I was compared to the technical market
potentials of biobased plastics and fi bers.
2. In the survey, we also asked companies to provide their
expectations of the growth rate of the biobased plastics
sector as a whole, for the next 10–20 years. We then used
the average growth rate to derive the projection for 2020,
which we refer to as the ‘projection based on industry
expectations’.
3. Th ree scenarios (BAU, HIGH and LOW) were
constructed in the third step not only taking into
account the companies’ announcements and their
expectations but also considering technical barriers, the
estimated market size for bulk applications, cost compet-
itiveness and the raw material availability for the produc-
tion of biobased plastics until 2020. Th ese scenarios are
referred to as ‘PRO-BIP 2009 Scenarios’.††
4. Finally, the outcome from Steps 1, 2 and 3 was compared
to the projections prepared in the earlier study by Crank
et al.7
Table 4. Technical substitution potential of biobased man-made fibers (both staple fibers and filament).
% Substitution* PET PA Acrylic Other Synthetic CellulosicPLA 10 0 5 0 5
PTT 20 20 5 0 5
PHA 5 0 5 0 5
Biobased PET 65 0 0 0 0
Biobased PA6, PA66 0 80 0 0 0
Sum Percentages 100 100 15 0 15
(1,000 t) PET PA Acrylic Other Synthetic Cellulosic Total % subst.2007 World fi ber consumption26 30,804 3,836 2,407 575 3,081 40,703 100
Technically replaceable volumes
30,804 3,836 361 0 462 35,463 87
Note: See abbreviations in Table 1. *The values on substitution potential (in the upper table) were established based on interviews with industrial experts (see text).
†† PRO-BIP is the short name of the project ‘Product overview and market
projection of emerging bio-based plastics’. See Shen et al.2
32 © 2009 Society of Chemical Industry and John Wiley & Sons, Ltd | Biofuels, Bioprod. Bioref. 4:25–40 (2010); DOI: 10.1002/bbb
L Shen et al. Perspective: Present and future development in plastics from biomass
Projection based on company announcements (Step 1)
According to company announcements, the worldwide
capacity of biobased plastics is expected to increase from 0.36
Mt in 2007 to 2.32 Mt in 2013 and to 3.45 Mt in 2020 (Fig. 2).
Th e announced capacities are (ordered by size): starch plastics
(1.30 Mt), PLA (0.83 Mt), biobased ethylene (0.61Mt), PHA
(0.44 Mt), biobased epichlorohydrin (ECH, 0.21 Mt) and other
biobased plastics such as biobased PTT, PA 11, PA 610 and
biobased PUR (total approximately 0.06 Mt). Based on these
announcements, the capacity breakdown can be presented by
regions over time. As shown in Fig. 3, the leading position of
the USA and Europe in the years 2003 and 2007 changes to a
more balanced regional distribution by the year 2020.
During the preparation of this study, the world economy
experienced a dramatic downturn, with very serious
decreases in demand (in 2008/2009). As a consequence,
the oil prices dropped from $130/barrel in July 2008 to
$40/barrel in December 2008, followed by an oil price level
of $40–60/barrel in the fi rst half of 2009. Most interviewed
companies are still optimistic about their long-term plans
(we re-contacted the major players in March 2009). Some
companies have, however, delayed their expansion plans.
For instance, Dow announced that its bio-PE project will
be delayed to 201227 and Telles postponed the start-up of
its 50 kt PHA plant from end 2008 to the second quarter of
2009.28 However, it is not clear whether these delays are the
Figure 2. Worldwide capacities of biobased plastics until 2020 based on company
announcements (the most recent data used for making this graph were received in
March 2009; the reported values refer to the capacities at the end of each year).
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
2003 2007 2013 (projection) 2020 (projection)
Cap
acit
y (m
illio
n t
on
nes
per
yea
r)
Note: Category “other” includes cellulose films, PTT from bio-based 1,3-PDO,bio-based polyamide andPUR from bio-based polyols; category “Bio-based monomers” includes primarily bio-based
epichlorohydrin.
OtherBio-based monomersPHABio-based EthylenePLAStarch plastics
Figure 3. Breakdown of worldwide capacity of biobased plastics by region, projection of 2020 is based on company
announcements (the most recent data used for making this graph were received in March 2009; the reported values refer to
the capacities at the end of each year).
Note: "Unspecified region" in the right figure means that there are no concrete plans about the location of these capacities.
2020: 3.45 million tonnes
Europe 26%
US 30%
Asia-pacific
19%
S.America18%
Unspeci- fied 7%
2003: 0.10 million tonnes
Europe25%
USA 74%
Asia- Pacific 1%
2007: 0.36 million tonnes
Europe 36%
USA 33%
Asia- Pacific
29%
S.America 1%
© 2009 Society of Chemical Industry and John Wiley & Sons, Ltd | Biofuels, Bioprod. Bioref. 4:25–40 (2010); DOI: 10.1002/bbb 33
Perspective: Present and future development in plastics from biomass L Shen et al.
consequence of the global economic crisis or whether there
are other reasons.
As described earlier, the maximum technical substitu-
tion potential of biobased plastics is 240 Mt. Th e worldwide
capacity of biobased plastics in 2007, i.e., 360 kt, was only
0.15% of this potential market; and even the projected
capacity in 2020 will only meet approximately 1.5% of the
technical potential market (Fig. 4).
Projection based on biobased plastics industry
expectations (Step 2)
Our company survey also included the question about
the development of the biobased plastics sector as a whole
(Step 2). According to this survey, the biobased plastics
industry expects that production will grow on average by
19% per year during 2007 and 2020. Th e resulting projec-
tion in 2020 (3.44 Mt) is very close to the projection for 2020
from Step I), which is based on company announcements
(3.45 Mt).
PRO-BIP 2009 scenarios: BAU, HIGH and LOW (Step 3)
Th e projections based on the company announcements
are not necessarily consistent across the various types of
biobased plastics. For example, starch plastics producers
are rather optimistic about their future development, in
comparison with PLA producers. For this reason, inde-
pendent projections have been prepared. Th ree scenarios
were built for 2020 (Step 3): business-as-usual (BAU), HIGH
and LOW. Th ese scenarios were designed considering
four major infl uencing factors, namely technical barriers,
Figure 4. Comparing the projections for 2020, based on company announcements with the market potential,
based on the maximum technical substitution.
0%
10%70%
80%
90%
100%
Plastics (including thermoplastics and thermosets)Synthetic fibres (including staple and filament)Capacity of bioplastics (including plastics and fibres)Potential capacity of bioplastics on a technical basis
267,900 kt
240,000 kt
360 kt
3,450kt
World plastics consumption
2007†
Max. technicalsubsitution
potential of bio- based plastics†
World bio- based plastics
capacityin 2007‡
World bio- based plastics
capacityin 2020‡
† See data in Table 3 and Table 4. The overall maximum technical substitution potential for plastics and fibres is 89% (the blue line in the graph).‡ See data in Figure 3. The projection in 2020 is based on company announcements. The most recent data used for making this graph were received in March 2009; the reported values refer to the capacities at the end of each year.
236,550 kt technical substitution potential
34 © 2009 Society of Chemical Industry and John Wiley & Sons, Ltd | Biofuels, Bioprod. Bioref. 4:25–40 (2010); DOI: 10.1002/bbb
L Shen et al. Perspective: Present and future development in plastics from biomass
bulk applications, cost competitiveness and raw material
availability. We identify starch plastics, PLA, biobased PE
and biobased epoxy resin as the four most important plastics
for the future biobased plastic sector.
Th e BAU scenario assumes a steady growth of the four
key plastics and a modest growth for cellulose fi lms, PHA
and biobased PUR. Th e remaining plastics are expected to
contribute little to the overall growth. Th e BAU projection
results in a global production capacity of approximately 3 Mt
for 2020, which is somewhat more modest compared to the
companies’ targets (approx. 3.45 Mt).
Th e HIGH scenario shows an optimistic future and a fast-
growing sector. Th e four key plastics will grow strongly and
a steady growth rate is assumed for cellulose fi lms, PHA
and biobased PUR. Th e major technical barriers will be
overcome for biobased succinic acid, biobased PA6, PA66
and biobased PP. Th e HIGH scenario projects that the global
production will reach 4.40 Mt by 2020, approximately 30%
higher than the projections aimed at by the companies
(approx. 3.45 Mt).
Th e LOW scenario describes a relatively pessimistic future.
Th e four key plastics will have slow growth rates and the
growth from the remaining plastics will be insignifi cant. Th e
LOW scenario projects that only 1.47 Mt capacity will be
installed by 2020. Th is is approximately 60% lower than the
projections aimed at by the companies (approx. 3.45 Mt).
Comparison with Crank et al.7 (Step 4)
Table 5 shows the comparison with an earlier projection
made by Crank et al. (i.e., PRO-BIP 2005). For 2020, the
projections based on company announcements (3450 kt),
based on the industry expectation (3440 kt) and based on
the PRO-BIP 2009 BAU scenario (3000 kt), lie between the
former projection with and without policy and measures
(PM). Th us the 2020 projections from this study coincide
well with the earlier projections published in 2005 by Crank
et al. (2005).
Production, properties and applications of three selected biobased plastics: PLA, biobased PE and partially biobased epoxy resin
Emerging biobased plastics are still at an early stage of
commercialization. Only a few have entered large-scale
production, while most are still in the pilot or R&D stage
(Table 2). In the past, for starch plastics and PLA, eff orts
have been made to overcome key technical challenges. In
the past decade, the fi rst large-scale plants have been set up
and a niche market has been established. For starch plastics,
the technique of native starch blend-extruded with other
compounds is nowadays well understood and applied by
multiple players. For PLA, important remaining challenges
include downstream processing of lactic acid, alternative raw
materials, plastic processing and material property improve-
ments. For biobased PE, PA 11 and cellulose fi lms, the tech-
nologies are relatively mature and therefore relatively little
technical challenges will be encountered. For PHA, compa-
nies’ expectations are high and the fi rst large-scale plant (50
kt p.a.) is currently being constructed. However, the time
and eff ort required to overcome the technical challenges,
the market price and the material properties will strongly
determine the market uptake of PHA. Being the fi rst large-
scale plant of its type, the uncertainties are still relatively
Table 5. Worldwide production capacity of biobased plastics until 2020, comparison of old and new projections.
All values in kt
Announced by companies
Expected by industry
PRO-BIP 2009 For comparisons
BAU HIGH LOWCrank et al. without PM 7
Crank et al. with PM 7
2003 100 100 100 100 100 71 71
2007 360 360 360 360 360
2010 1,275 2,200
2013 2,320
2020 3,450 3,440 3,000 4,400 1,470 2,500 4,175
© 2009 Society of Chemical Industry and John Wiley & Sons, Ltd | Biofuels, Bioprod. Bioref. 4:25–40 (2010); DOI: 10.1002/bbb 35
Perspective: Present and future development in plastics from biomass L Shen et al.
high. Shen et al.2 elaborated in detail on the production,
properties and application of the biobased plastics listed in
Tables 1 and 2.
In this perspective, we select three biobased plastics as
examples and report the latest technology and market devel-
opments. Th e three types of plastics are PLA (polyester),
biobased PE (polyolefi n) and (partially) biobased epoxy resin
(thermoset). PLA is one of the most important biobased
plastics today (Fig. 1); biobased PE is likely to be produced
on a large scale (>500 kt) in the near future and will be oper-
ated by big chemical companies; and biobased epoxy resin is
an emerging opportunity for renewably sourced thermosets.
PLA
PLA is an aliphatic polyester, produced via the polymeriza-
tion of lactic acid which is a sugar fermentation product.
With the start of the NatureWork’s production plant in
2002, PLA became the fi rst biobased plastic produced on a
large-scale (name plate capacity 150 kt p.a. in 2009). In 2007,
the world’s largest lactic acid producer PURAC started to
produce lactide for technical applications on a large scale
(capacity 75 kt p.a. lactide in 2008, plant located in Th ai-
land). Recently, a new company, Pyramid, announced its
plan to produce 60 kt p.a. PLA in 2012 in Germany.
Production and material properties of PLA
Lactic acid is produced by fermenting glucose, which can be
obtained from various sugar sources. NatureWorks’ PLA is
produced from maize and PURAC’s lactides are produced
from cane sugar, potato starch and tapioca starch. In the
future, it is expected that cellulosic biomass will be used to
produce PLA. NatureWorks expects to use cellulosic feed-
stocks to produce PLA in the timeframe 2013–2018.29
Specifi c production of either of the isomers of lactic acid
– i.e., L (+) or D (-) lactic acid – can be achieved by using
an appropriate lactobacillus.30 Polymerization of L-lactide
results in PLLA and polymerization of D-lactide results
in PDLA. Th e majority of current commercial PLA is poly
(meso-lactide), which is a mix of L-lactide (> 95%) and D-
lactide (<5%).
Poly (meso-lactide) can be used in a wide range of applica-
tions, such as fi lm- and tray- packaging, bottle packaging and
textiles. Th is type of PLA exhibits no stereochemical struc-
ture. It is highly amorphous, does not rotate polarized light
and is optically inactive. It has a relatively low glass-transition
temperature (Tg = 55-60 oC), low vicat-soft ening point and
low heat-defl ection temperature. End products made from this
PLA are not suitable for applications requiring high tempera-
tures (similar to PET).
Th e recently announced heat-resistant PLA is based on
stereocomplex technology. Stereocomplex formation between
PLLA and PDLA occurs when L-lactide unit sequences and
D-lactide unit sequences coexist in one system.31 PURAC
describes the synthesis as a transesterifi cation process in the
presence of a catalyst; the starting materials are obtained
from separately polymerized L-lactide and D-lactide.32
Stereocomplexation of PLA sometimes is also called stereo-
complex (sc) crystallization or racemic crystallization. Melt-
blending PLLA and PDLA with a D/L ratio of 1:1 produces
sc-PLA crystals with a melting temperature (Tm) of 210-240 oC, which is about 30–60 oC higher than the Tm of homo-
crystalline PLLA. Th e crystal growth rate of sc-PLA was
reported to be comparable with that of PA6 and PE.32
Current and future applications of PLA
Th e current applications of PLA cover a wide range, for
example packaging (cups, bottles, fi lms and container),
textiles (shirts, furniture textiles), non-wovens (diapers),
agricultural mulch fi lms (usually blended with TPS) and
cutlery. Stereocomplex PLA is potentially suitable for melt-
spun fi bers and biaxially stretched fi lms. An example is
the heat-resistant PLA fi bers used for automobile textiles,
developed by Mazda and Teijin.33 Also, there is a potential
of foamed PLA used as insulation material, for example PLA
foam developed by Synbra, Sulzer and PURAC; foamed PLA
is a biobased alternative for expanded polystyrene (EPS)
foam.34 Furthermore, PLA blends and composite products
experience increasing demand. For example, NEC and
UNITIKA announced a mobile phone housing made from
PLA reinforced with kenaf fi ber.35 Mazda, PURAC and
Nishikawa Rubber of Japan collaborated on the development
of heat-resistant automotive interior parts based on a combi-
nation of starch with stereocomplex PLA (Reichert R and
van der Pol M, PURAC, private communication).
Table 6 shows the results of interviews on current and
future market shares of PLA. Presently NatureWorks’ PLA
is primarily used in the packaging and the textile sector.
For the future, NatureWorks sees the market potential not
36 © 2009 Society of Chemical Industry and John Wiley & Sons, Ltd | Biofuels, Bioprod. Bioref. 4:25–40 (2010); DOI: 10.1002/bbb
L Shen et al. Perspective: Present and future development in plastics from biomass
only in textile and packaging, but also in transportation and
E&E (electrical appliances and electronics). PURAC sees the
future PLA market mainly in textiles, buildings and trans-
portation, while packaging and E&E have a relatively lower
importance.
Biobased PE
Biobased polyethylene (PE) is produced from biobased
ethylene. In nature, many plants produce ethylene when their
fruit are ripening. Industrial biobased ethylene is produced
from ethanol through a chemical dehydration process. Th e
emergence of biobased PE on the market is not a new phenom-
enon. In the 1970s, India used a small amount of its ethanol to
produce ethylene and subsequently, PE, PVC (polyvinyl chlo-
ride) and styrene.36 In the 1980s, subsidized by the Brazilian
Government, small producers in Brazil produced in total 150
kt of ethylene per year; this ethylene was then converted into
PE and PVC.37 In the early 1990s, the subsidies for biobased
ethylene were stopped in Brazil, due to low oil prices. Conse-
quently, production ceased. Today, given the public concern
about global warming and limited fossil fuels and as a result
of the increased oil price prior to the economic crisis in 2009,
biobased PE has become attractive again. In 2007, three large
chemical companies, namely Braskem, Dow-Crystalsev and
Solvay, announced the production of biobased ethylene on
a large scale in Brazil; the planned annual capacities are 200
kt of PE in 2010 by Braskem, 350 kt of PE in 2012 by Dow-
Crystalsev and 60 kt of ethylene in 2010 by Solvay.27, 38-40
Table 6. Main applications for PLA – share of total production by market sector (interview results).
Sector
% of total production
2007 2020
Nature Works Nature Works PURACPackaging 70 20 10
Building 20
Agriculture 1
Transportation 20 20
Electrical appli-ances and elec-tronics (E&E)
1 10 10
Textiles (fi bers and fabrics)
28 50 40
Total 100 100 100
Production of biobased ethylene
At present, biobased PE is exclusively produced from sugar-
cane-based ethanol. In a sugar mill, the harvested sugarcane
is cleaned, sliced and shredded, resulting in sugarcane juice
as the main product and bagasse as the byproduct. In Brazil,
the bagasse is typically combusted to generate heat and power
to fuel the sugar mill. Th e power surplus from bagasse is
usually sold to the grid. Th e sugarcane juice is then fermented
to ethanol under anaerobic conditions. Ethanol is distilled to
yield hydrous ethanol (95.5 vol.-%).41 Ethylene is produced by
dehydrating ethanol at temperatures varying from 300oC to
600oC in the presence of heterogeneous catalysts.42
Biobased ethylene as a building block
Ethylene is an important platform chemical in the chemical
industry. PE is by far the most important product made
from ethylene (Fig. 5). In addition, ethylene is an important
intermediate to produce PVC, PET, PS and polyols for poly-
urethanes (PUR). Figure 5 shows the intermediate chemi-
cals and fi nal plastics which can be derived from ethylene.
In 2007, the global consumption of all ethylene-derived
polymers was approximately 185 million tonnes including
plastics and fi bers.21 Today, biobased PE and PVC have been
scheduled for production on a large scale. In the future, more
biobased plastics may be expected from biobased ethylene.
Applications of biobased PE
Biobased PE can, just as petrochemical PE, be used for a
large variety of applications (Table 7). For biobased PE,
Braskem will off er grades for food packaging, cosmetics
and personal care, automotive parts and toys.38 Dow-
Crystalsev will produce biobased PE mainly for food pack-
aging industry and for agricultural and industrial purposes
(Gregorio M; Dow Chemical, private communication).
Partially biobased epoxy resin
Approximately 75% of all epoxy resins are liquid epoxy
resins (LER), which are derived from diglycidyl ether of
bisphenol A; the remaining 25% are composed of various
epoxy resins.24 In this perspective, we limit ourselves to
LER. Th e key materials to produce LER are epichlorohydrin
(ECH) and bisphenol A. Today, bisphenol A is exclusively
manufactured from petrochemical resources, whereas ECH
can be produced from biobased glycerol.
© 2009 Society of Chemical Industry and John Wiley & Sons, Ltd | Biofuels, Bioprod. Bioref. 4:25–40 (2010); DOI: 10.1002/bbb 37
Perspective: Present and future development in plastics from biomass L Shen et al.
fi ve years, this production process has become superfl uous
because of the large availability of biobased glycerol as a
byproduct of biodiesel production. Th us the reverse process,
which produces ECH from glycerol, has now become
economically attractive.
In the 1920s and 1930s, several publications and patents
described the synthesis of glycerol-derived ECH or dichlo-
ropropanol by the reaction of glycerol with HCl (aqueous
or gasous), in the presence of catalysts (e.g., acetic acid).44-48
However, these approaches were never used to produce ECH
and subsequently, epoxy resin.
In April 2007, Solvay started the production of ECH
from biobased glycerol in Tavaux, France (10 kt per year)
based on its EpicerolTM process patent.49 Meanwhile,
Solvay announced the building of a biobased ECH plant in
Th ailand with an annual capacity of 100 kt and which will
start production in 2009.50 In 2007, Dow Epoxy announced
the set up of a glycerol-to-ECH plant (150 kt per year) in
Shanghai, using Dow’s proprietary technology. Th e plants
are scheduled to start up in 2009/2010.51
Figure 5. Ethylene as a platform chemical.
Ethylene (100%)
Polymerization
Ethylene oxideproduction
Ethylbenzeneproduction
Ethylene dichloride(EDC) production
Ethylene glycolproduction
Styreneproduction
Meltpolymerization
Polyurethaneproduction
LDPE, LLDPE,HDPE
EDC
VCM
Polymerization
PVC
Styrene
EPS, HIPS,GPPS
SAN, ABS
Ethylbenzene Ethylene oxide
Ethylene glycol
PET
Terephthalicacid
PUR
Polymeri-zation
Polymeri-zation
58% 13% 7% 13%
Others
9%
Note: percentages showed in the graph are on weight basis, according to globalethylene consumption in 200443.
Vinyl chloridemonomer (VCM)
production
Table 7. Market segments in Western Europe (figures in % for 2005) for HDPE, LDPE and LLDPE.21
Market segment HDPE LDPE LLDPEFilms 18% 74% 82%
Blow moulding small parts 19% 1% 5%
Blow moulding large parts 12%
Pipes and extruded products 19% 4% 3%
Extruded coating 11% 1%
Caps and closures 4%
Petro tanks 3%
Injection moulded parts 14%* 4% 5%
Cable 4% 3%
Textiles 3%
Other 8% 2% 1%
Total: 12.7 (Mt) 5.2 (Mt) 4.3 (Mt) 3.1 (Mt)
*Excluding injection moulded HDPE caps, closures and petro tanks.
Th e conventional, petrochemical process to produce ECH
is the chlorohydrination of allyl chloride, which in turn is
produced by propylene chlorination. Until recently, ECH
was also used to produce glycerol. However, in the past
38 © 2009 Society of Chemical Industry and John Wiley & Sons, Ltd | Biofuels, Bioprod. Bioref. 4:25–40 (2010); DOI: 10.1002/bbb
L Shen et al. Perspective: Present and future development in plastics from biomass
Production of biobased ECH from glycerol
In biodiesel production, glycerol is obtained as a byproduct
of the transesterifi cation of crude vegetable oil. For example,
in palm oil biodiesel production, approximately 10 kg of
glycerol is obtained for every 100 kg biodiesel.52 According to
Solvay’s patent,53 glycerol reacts with HCl at a temperature of
80–120 oC. Th e reaction is carried out with catalysts such as
hexanedioic acid. Th e output of the reaction is a pseudoazeo-
tropic mixture, containing 1,3-dichloropropanol, HCl and
water. Th rough either steam stripping or distillation, HCl
and water are separated from 1,3-dichloropropanol, which
is then further purifi ed and dehydrochlorinated into ECH
(Fig. 6). Solvay claims that this process leads to fewer byprod-
ucts and lower water consumption.
Partially biobased epoxy resin in the future
For every 100 kg LER, approximately 30 kg ECH and 80 kg
bisphenol A are required based on the reaction stoichiometry.
Since bisphenol A is petrochemically derived, the share of
the biobased component in LER is approximately 30 wt-%.
Th e global consumption of epoxy resins was estimated at
1.15 Mt for the year 2000,24 of which LER accounted for 860
kt (76%). If all these LER were obtained from biobased ECH,
260 kt per year of biobased ECH would be required (860 kt ×
30 kg ECH/100 kg LER). It is likely that a substantial part of
demand for ECH in 2010 can be covered by the biobased ECH
capacities announced by Dow (150 kt) and Solvay (110 kt).
Applications of epoxy resin
Epoxy resins are primarily used for protective coatings and
in electrical and structural applications. Biobased LER is
chemically identical with petrochemical LER and therefore
there are no diff erences regarding applications.
Conclusions
Th e historical use of natural products for plastics production
demonstrates that biobased products are neither fi ctional
nor new. Instead, for many decades, biobased products have
been an industrial reality on a million-tonne scale (e.g.,
paper and board). Today, the combined volume of non-food
and non-plastics applications of starch and man-made cellu-
lose fi bers is 55 times larger than the total of all emerging
biobased plastics (approx. 20 Mt versus approx. 0.36 Mt in
2007). Th is demonstrates that the production of biobased
products on very large scale is not unprecedented and that
related challenges, for example concerning logistics, can be
mastered. If emerging biobased plastics succeed in following
this example, it is possible that they can substitute their
petrochemical counterparts in large quantities.
Between 2003 and 2007, the annual growth rate of the
emerging biobased plastics was nearly 40%, resulting in a
global capacity of the emerging biobased plastics of 0.36
million tonnes in 2007. Th e global production of biobased
plastics is likely to grow strongly in the next decade and
to reach 2.3 million tonnes in 2013 and 3.5 million tonnes
in 2020. Th e maximum technical substitution potential of
biobased plastics (including man-made fi bers) replacing
their petrochemical counterparts is estimated at 240 million
tonnes, or 90% of the total plastics and fi bers based on the
2007 market demand. Based exclusively on the technical
feasibility (and hence disregarding economic and other
aspects), the growth potential for biobased plastics is hence
enormous.
Of all the emerging biobased plastics, we highlighted
three products –PLA, biobased PE and partially biobased
epoxy resins. PLA is a new polymer. In the past decade,
it has experienced technological breakthroughs that will
allow a wider range of applications. Biobased PE, which was
applied on a large scale in India and Brazil before the 1990s
is now being revisited. Th e economic feasibility of biobased
ethylene opens up enormous opportunities for renewably
sourced ethylene-derived chemicals and plastics in the
future. Th e increasing availability of biobased glycerol from
biodiesel production makes it possible to produce biobased
Figure 6. Conversion of glycerol into epichlorohydrin according to the Solvay EpicerolTM
process.
O
ClH2O
BaseClCH2-CHOH-CH2Cl
HClcatalyst
OHCH2-CHOH-CH2OH
(glycerol) (1,3-dichloropropanol) (epichlorohydrin)
© 2009 Society of Chemical Industry and John Wiley & Sons, Ltd | Biofuels, Bioprod. Bioref. 4:25–40 (2010); DOI: 10.1002/bbb 39
Perspective: Present and future development in plastics from biomass L Shen et al.
epichlorohydrin. Based on the announced capacity expan-
sions, it is likely that by 2010 a large part of liquid epoxy
resins in the market will be partially renewably sourced.
To conclude, several factors clearly speak for biobased plas-
tics. Th ese are the limited and uncertain supply of fossil fuels
(i.e., oil and gas), economic viability, environmental consider-
ations (e.g., savings of non-renewable energy and greenhouse
gas abatement), innovation off ering new opportunities (tech-
nical, employment, etc.) and rejuvenation in all steps from
chemical research to the fi nal product and waste manage-
ment. Challenges that need to be successfully addressed in
the next years and decades are the low performance of some
biobased plastics (e.g., thermoplastic starch), their relatively
high cost for production and processing and the need to
minimize agricultural land use and forests, in order to avoid
competition with food production and adverse eff ects on
biodiversity and other environmental impacts.
Acknowledgements
Th e authors thank European Bioplastics (www.
europeanbioplastics.org) and the European Polysaccha-
ride Network of Excellence (EPNOE, www.epnoe.org) who
funded the PRO-BIP 2009 study,2 on which is article is based.
Th e authors also thank Juliane Haufe for her contribution for
the section on biobased PE, Ruud Reichert and Hans van der
Pol from PURAC (the Netherlands), and Erwin Vink from
NatureWorks LLC for their valuable comments.
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Li Shen (MSc)
Li Shen (MSc) is a junior researcher and PhD
candidate at the Department of Science,
Technology and Society (STS), Utrecht Uni-
versity, the Netherlands. Her current research
focuses on the environmental impact assess-
ments of biobased products (mainly fibers
and plastics), as well as recycled products.
Prof. Dr Ernst Worrell
Prof. Dr Ernst Worrell is Professor of Energy,
Materials and the Environment at Utrecht
University, and Director of Energy Use & Ef-
ficiency at Ecofys. He previously worked at
Lawrence Berkeley National Laboratory and
Princeton University. His research focuses on
energy and material efficiency improvement,
as well as waste management.
Dr Martin Patel
Dr Martin Patel is Assistant Professor at
Utrecht University in the Department of Sci-
ence, Technology and Society (STS) where he
is co-ordinating the research cluster ‘Energy
and Materials Demand and Efficiency’. The
cluster has its core expertise in the process
industries and is known for the assessment of
biobased chemicals.