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1 French fishermen to demo marine litter collection system PRW 23 June 2016 SHARE The demonstration is being hosted in collaboration with the Waste Free Oceans Foundation. A live demonstration of marine litter collection will take place off the French coast early next month to highlight to the media how such waste is dealt with. Last December the European Commission highlighted the fight against marine litter as a priority for the successful development of its ‘Circular Economy Package’. The demonstration is being organise of the Brittany coast by Alain Cadec, a member of the European Parliament, chairman of the Fisheries Committee, and chairman of the Department of Côtes d’Armor, and Thierry Burlot, president of the Waste Sorting Centre Kerval Centre Armor and vice-president of the Bretagne Region in charge of the Environment. The event is being hosted in collaboration with the Waste Free Oceans Foundation (WFO). The demo will take place on 8 July at the port of Erquy, off the north French coast. Fishermen from the Fisheries Committee of the Department of Côtes d’Armor will demonstrate how they collect floating marine litter with the help of a specially-designed WFO trawl device. Once it is collected, the waste will be transferred to a nearby sorting centre, where it will be sorted before being processed. Cadec said: “Organising this marine litter collection enables us to initiate a collaboration between the fishing industry and the local recycling sector. “This demonstration is a concrete local example of the circular economy in which fishermen have an important role.” Bio-based Solutions of the Future Sreeparna Das – Jun 15, 2016 “Climate change is real. It is happening right now. It is the most urgent threat facing our entire species, and we need to work collectively together and stop procrastinating. We need to support leaders around the world who do not speak for the big polluters, but who speak for all of humanity, for the indigenous people of the world, for the billions and billions of underprivileged people out there who would be most affected by this. For our children’s children and for those people out there whose voices have been drowned out by the politics of greed.I thank you all for this amazing award tonight. Let us not take this planet for granted. I do not take tonight for granted. Thank you so very much.” – Leonardo DiCaprio, Acceptance speech at Oscar Awards 2016
2 If DiCaprio didn’t have enough fans already, he definitely earned many more after making this speech! The actor’s fan following of course is a subject for discussion on other forums. Here, we must focus on the environmental aspects and how it is impacting the world of chemicals. Bio-based or renewable alternatives to petrol-based chemicals have already made significant inroads into this industry. And this segment has consistently been on the rise. The Global Renewable Chemicals Market is projected1 to reach USD 84.3 Billion by 2020 (CAGR of 11.47% between 2015 and 2020). To give a sense of how significant this market value is, let’s look at the stats for Specialty Chemicals Market. It is projected2 to reach USD 470 Billion by 2020 (CAGR of 5.42% between 2015 and 2020). Interesting to note here is that the renewable chemicals market, which is one-fifth the size of specialty chemicals, is expected to grow at double the pace during the same time frame! Top Bio-based Materials of 2016 There are several interesting bio-based solutions that exist in the market. At the 9th International Conference on Bio-based Materials held recently in Germany, winners for the Bio-based Material of the Year 2016 were declared. Organized by the Nova-institut, the competition focused on new developments in the bio-based economy, which have had (or will
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have) a market launch in 2015 or 2016. The following table lists the nominees and the
winners along with details of their innovative products.
Product,
Renewable
Company, Feedstock Application Status
content
Country
Touch of Countertop at an
Coffee beans,
Nature™, espresso bar
berries, cork
Orineo – 75%-80% opened by OR WINNER
powder, olive
Belgium Coffee in Ghent,
leaves
Bio-based resin Belgium
Designed for
textile coating
but not
Non-fossil-
Impranil® eco, commercial yet.
based inputs, i.e.
Covestro – 43%-65% Samples
not in direct
Germany (renewable available in WINNER
competition
Waterborne carbon content) 2016,
with the food
PUDs commercial
chain.
availability
depends on
market feedback
REWOFERM®
European
SL 446, Evonik 100%
sourced sugar Commercial
Nutrition & (biodegradable
and oil product for
Care GmbH – under both
(fermentation home and WINNER
Germany aerobic and
with a natural, fabric-care
Sophorolipid- anaerobic
non-GMO formulations
type conditions)
yeast)
biosurfactant
Tetra Rex®
Tetra Rex® milk carton in
Bio-based, 1000 ml size
Bio-ethanol
Tetra Pak launched in
derived entirely
International January 2015.
from sugarcane;
S.A. >80% 100 million NOMINEE
Wood fibers
Renewable packs are
used for
package for expected to be
paperboard
chilled liquid delivered
food globally in
2016.
Myralene™-10, Sugarcane juice Cleaning solvent
Amyris, Inc. – from Brazil (can (graffiti-, ink-,
US 100% move to tar-, adhesive- NOMINEE
Solvent made cellulosic or remover; paint
from β- next gen strippers; metal
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farnesene feedstocks) cleaning fluids,
etc.)
Production and
SIPDRILL RS,
sales of
SIP Ltd. – UK β-Farnesene
SIPDRILL RS
Renewable derived from
73%-85% expected to NOMINEE
alkene-based sustainable
begin in the
drilling base sugar sources
fourth quarter of
fluid
2016.
What does the Future Hold?
The best way to know the commercial bio-based solutions of the future is to take a look at the
ongoing R&D projects. There are several interesting European bio-based projects that are
working on developing innovative new solutions.
First, let’s take a look at some of the interesting results of recently concluded projects.
PHBOTTLE - New Biodegradable Packaging (with antioxidant properties)
Made from Wastewater Sugars
Duration: 2012 to 2015
Funded by the 7th Framework Program, the consortium comprises of 12 partners (8
companies and 4 technology centers) from multiple countries. AINIA, Spanish Food R&D
Center acted as the project coordinator.
The main goal of the project was to develop a biodegradable material based on PHB
(Polyhydroxybutyrate) using fruit juice processing wastewater as the feedstock.
Key Results:
On April 18th, 2016 the results of the project were presented at an international workshop in
Brussels.
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1. The first world-wide PHB-based packaging prototype developed using sugars in
wastewater from juice industry.
2. Up to 30% of the sugars could be converted into PHB using microbial fermentation.
3. Microencapsulation technology was used to improve antioxidant property.
4. Cellulose fibers (from rice hulls) were used to improve rigidity of the packaging.
5. Tests have shown that 60% of the packing degrades within 9 weeks. It can be also
decomposed in composting plants producing compost and CO2.
Initial targeted application is juice packaging but it can be used in other segments as well like
cosmetics, pharmaceutical, automotive, computer parts, etc.
Source: phbottle.eu/ 3,4
CARBIO - Carbon-Flax Hybrid Structures for Automotive Applications
Duration: Jan 2014 to Dec 2015
6 Part-funded by Innovate UK, the project is led by Composite Evolution. Other partners include UK-based composites manufacturers, automotive consultancy, one university and a big OEM viz Jaguar Land Rover. The aim of the project was to develop lighter, cost-effective and environment friendly composite structures for automotive applications. These parts also offer improved noise, vibration and harshness (NVH). The technology involves inclusion of an innovative flax- bioepoxy composite into carbon fiber components. Partners worked on developing and testing flax/carbon hybrid bio-composite materials as per automotive OEM specs. Key facts: 50/50 carbon/flax composite vs carbon Cashew Nut Shell Liquid (CNSL)-based fiber with equal bending stiffness:- Bio-Epoxy vs Synthetic Epoxy: > 15% cheaper > Enhanced toughness > 7% lighter > Better damping > 58% higher vibration damping > Sustainability
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Properties Unit Test method Carbon Flax Carbon/Flax
Density g/cm3 Not specified 1.5 1.3 1.4
Thickness mm Not specified 2.8 3.2 2.7
Flexural 3 point flexure test method
GPa 47 12 44
modulus ISO 14125
Flexural 3 point flexure test method
MPa 870 180 560
strength ISO 14125
Damping loss centre point impedance
- 0.012 0.028 0.019
factor method ISO 16940
Property Comparison of Carbon / Flax Hybrid vs Carbon & Flax
source: carbioproject.com 5,6
Road to commercialization:
• Composites Evolution has developed some flax/carbon hybrid fabrics which offer
similar benefits, whilst also having unique aesthetics.
• An automotive roof prototype using Composite Evolution’s Biotex Flax has been
developed and was on display at the recently concluded JEC World, 2016 event in
Paris.
• The prototype carbon/flax roof components are current being tested and results are
expected in the next few months.
• The project partners (including Jaguar Land Rover) are investigating opportunities
for the carbon/flax hybrid composites in other components as well where weight, cost
and noise/vibration are important, including doors, bulkheads, spare wheel well,
center console, seats, closures etc.
The project partners are also targeting other market sectors where the carbon/flax hybrid
technology could bring significant benefits including sports applications (skis, boards,
bikes, rackets…) and motorsport.
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DIBBIOPACK - Smart and Multifunctional Bio-based Packages for Food,
Cosmetics & Pharma
Duration: 1st March 2012 - 24th Feb 2016
The recently concluded 4 year-long project was supported by the European Commission
through the Seventh Framework Program for Research and Technological Development. It
brought together 19 partners from 10 countries who worked together on a budget of 7.8
million euros.
Their objective has been to add functionalities to packaging (food, cosmetics and
pharmaceuticals) for enhancing product preservation while reporting on product condition
within the packaging itself. By using cutting-edge nanomaterials, bioplastics packaging
offers mechanical, barrier and durability properties similar to those found in conventional
plastics.7
Key results:
• FOOD:
o Trays for processed food in an oxygen-free atmosphere made from
biodegradable and compostable materials.
o Biodegradable labels and having an antimicrobial effect on the inside.
o Integrated oxygen sensor in the RFID tag that provides the user with full
details on content and its condition.
• COSMETICS: Biodegradable labels that can be either:
o On the inside (antimicrobial effect) or
o On the outside (for information or decoration purposes)
• PHARMACEUTICALS: Bottles of biodegradable and compostable material for use
with:
o External biodegradable labels
o An oxygen- absorbing effect on the cap
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o Sealing effect
o Minimum weight
Demonstrators have been built at Aitiip Technological Centre’s facilities and there are
products at an early commercialization stage that can be introduced into the market in short-
term.
Further the road ahead involves:
• Defining rules to exploit the results and findings on a commercial scale
• Obtaining intellectual property protection for the newly developed processes
InnoREX – Metal-free Polymerization of PLA Technique Development
Project
Duration: 1 December 2012 – 31 May 2016
The project has received funding from the EU Seventh Framework Program (FP7/2007-2013).
The InnoREX consortium consists of 5 RTD partners (Fraunhofer amongst others), 6
industrial partners and an association (AIMPLAS).
Aim of the project is to develop an alternate technique for polymerization of PLA without
the use of metal-based catalysts as they are harmful for the environment and are a health
hazard.8
Innovative solutions to replace the traditional polymerization process include:
• Replacing batch processing with continuous processing to improve energy savings
and cost efficiency. Commercially well-established co-rotating twin screw extruders
will be used. This has so far been difficult to do since the short residence time and
static energy input of the extruder didn’t allow the dynamic control of the reaction.
Use of alternate energy (microwaves, ultrasound, laser light) with rapid response
time can help overcome this issue.
• Replacing metal catalysts by organic catalysts to develop a safer solution. Low-
intensity but highly-targeted alternate energies can help increase catalyst activity as
per industry standards.
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Project’s approach to industrialization of the PLA polymerization process includes:
• LUDOVIC SOFTWARE INTEGRATION: Analysis of the thermo-mechanical
behavior evolution along the extrusion process will be done within the Ludovic
software to optimize the management of experimental trials and PLA product quality.
• DEMO: A working polymerization line including the incorporation of alternative
energy, online characterization technology and a purification device to remove the
catalyst will be developed as a demonstrator.
• NEW PRODUCTS & NEW APPLICATIONS: End-user project partners will
develop new PLA grades, PLA blends and PLA-based composites, which will aim to
enter new markets along with existing ones.
Following project is scheduled to be concluded later this year.
PLACARD – Cardanol-based Plasticizers for Soft PVC
Duration: 1 January 2014 – 31 August 2016
This project is co-funded by the EU within the Eco-innovative initiative of the
Competitiveness and Innovation Framework Program, CIP. Project partners include 2 Italian
companies, 1 university and a trade association (EuPC - Brussels-based association
representing European Plastics Converters).
Aim of the project is to replace traditional plasticizers with a bio-based one obtained by
the chemical modification of cardanol.9
Expected results are:
• Production of 1 ton of PLACARD plasticizer at the end of the project;
• Production of 1000 tons/year of Placard-based PVC products two years after the end
of the project;
• Reduction of the environmental impact of plasticizer for soft PVC, by substituting
oil derived products with bio based ones (reduction of 1.1 ton of CO2 per ton of new
plasticizer);
• Increase of PVC waste mechanically recycled thanks to the improved thermal
stability of Placard based products;11
• Market up-take of more environmentally friendly soft PVC products with mechanical,
physical and durability properties comparable to those of conventional soft PVC;
• Development of a sustainable process, business models and market structuring for
systematic replication.
Volatility at
Miscibility with Processing
Properties room Gelation
PVC Equipment
temperature
Same as used for
PLACARD vs Comparable to
Comparable Comparable standard soft
DEHP better
PVC
In addition to having properties comparable with DEHP, PLACARD offers additional benefit
of being environmentally friendly and is characterized by reduced migration.
Conclusion
It is quite exciting to see several new and innovative ideas being brought one step closer to
reality through these projects. Also, good to see that multiple market applications are being
targeted that broadens the horizon further for bio-based materials. As I wrap up this overview,
I would leave you with the following piece of interesting and important news:
The U.S. Department of Agriculture (USDA) has announced10 the availability of $21
million for Bioeconomy R&D. This is a step taken further by the Obama administration to
strengthen the US bioeconomy. So far European Bioeconomy has been leading the way and
with this latest investment, US Bioeconomy could flourish further as well. A lot has been
done in the field of biofuels. America has more than doubled its renewable energy production,
and is importing less than half its oil. USDA has also worked to strengthen markets for bio-
based products with almost 2,500 products that have the USDA's BioPreferred label. In
2016, the aim is to support the development of regional systems in sustainable bioenergy
and bio-based products, as well as education and training for the next generation of scientists.
Next time, we might have an article dedicated to US-based R&D projects…
Do you know of other interesting projects developing unique bioplastics for new
applications? Share it with us in the comments section below!
References
1. http://www.marketsandmarkets.com/PressReleases/renewable-chemical.asp
2. http://www.marketsandmarkets.com/Market-Reports/global-specialty-chemicals-
165.html
3. http://aijn.org/articles/ph-bottle-project/
4. http://phbottle.eu/
5. http://carbioproject.com/
6. http://www.compositesevolution.com/news/carbio-project-develops-carbonflax-
hybrid-automotive-roof/
7. http://www.dibbiopack.eu/
8. http://www.innorex.eu/
9. http://www.placard-ecoinnovation.eu/
10. http://www.usda.gov/wps/portal/usda/usdahome?contentid=2016/05/0122.xml&conte
ntidonly=true12 Moving Bio-based Innovations from Labs to Markets Sreeparna Das – Jun 23, 2016 The growing number of conferences and industry events dedicated to Bio-based Industry is an indicator of the positive shift towards bioeconomy globally. Several factors are contributing to this shift but one of the main challenges that exist today is the difficulty to move from LABS to MARKET! In order to bridge this gap, Bio-Based Chemicals World 2016 was held recently at Amsterdam. The goal of this event was to focus exclusively on commercialization and adoption of bio-based chemicals. The event provided a perfect platform for detection of practical solutions by connecting Technology Providers → Chemical companies → Brands. Hans Van Der Pol, Sr. Director, Bio-based Innovations at Corbion shared his personal experience with the attendees on how to make an innovation a commercial success. He said, “It is important to leverage core competences, work with complementary partners with aligned objectives, and apply what you have learnt and stay nimble.” He further added, “But most importantly, always look at facts not fiction, avoid ‘tunnel vision’ on your technology, the technology should be ‘best-in-class’ throughout the process, and be patient as developments take time with sometimes unexpected results along the way…”. Apart from him, there were 35 other speakers from chemical companies, associations, universities and more. In this review, we’re highlighting some of the most interesting innovations and updates related to the bioplastics industry. Taking a Stock of Feedstock When analyzing the difficulty in adoption of bio-based raw materials, three main aspects come into the picture: 1. Cost 2. Regulatory Compliance
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3. Feedstock
o Access to the feedstock
o Quality of the feedstock
o Consistency of the feedstock
At the event, a lot of companies talked about manufacture of chemical intermediates using
novel (and propriety) feedstock and technology.
While many are sugar-based, some are exploring and using non-food crop sources like
methane gas, household garbage, CO2 and also insects and whisky leftovers!
Company Feedstock Product
Non-recyclable Bio-fuel and
Enerkem household renewable
garbage chemicals
Celtic
Whisky leftovers Bio-fuel
Renewables
Chitin &
Ynsect Insects
Chitosan
High value
Photanol CO2
chemicals
Mango Waste methane
PHA
Materials gas
Non Food Crop Sources
The Star Bio-based Chemicals at the Event - FDCA, Bio-SA and PDI
These bio-based chemical intermediates are versatile and show a lot of promise. Let’s take a
look at each of them one by one.
FDCA → PEF
2, 5-Furandicarboxylic acid (FDCA) is an important chemical intermediate and several
chemical companies are currently working on manufacturing it.
• AVA-CO2 offers a patented conversion process of 5-HMF to FDCA
• Wageningen UR has successfully prepared FDCA semi-aromatic polyesters
• Avantium, along with BASF is working towards making FDCA and PEF a
commercial reality
• Corbion is also working on manufacture of FDCA for PEF14
There are several applications of FDCA, which include:
• Polyesters (like PEF)
• Polyamides
• Polyurethanes
• Other chemical building blocks and polymers
Out of these BASF + Avantium JV and Corbion are focusing their energies on FDCA for
PEF, which is being talked about as a PET replacement. Applications of PEF include bottle,
film and fiber.
PEF versus existing packaging materials
Source: Avantium and BASF
Corbion has developed a propriety process to produce FDCA and is currently looking for
partnerships to scale up.
The JV between Avantium and BASF has partnered with brands like Coca Cola, Danone and
ALPLA for PEF bottles.
Bio-SA → PBS
Bio-based succinic acid is another versatile chemical intermediate that presents interesting
possibilities. One of its key applications is in the manufacture of polybutylene succinate
(PBS).
At the event, Reverdia + Wageningen UR and Succinity presented facts and updates
regarding this bio-based chemical.15
Reverdia uses a patented yeast technology to produce bio-based succinic acid,
Biosuccinium™.
They are working together with Wageningen UR and plastic product manufacturers RPC
Promens and Teamplast to develop innovative PBS compounds.
Example: Injection molding grades for re-usable trays (for agriculture) and luxury
packaging applications…
Succinity (a joint venture between BASF and Corbion) uses a propriety fermentation
technology to manufacture BBSA (bio-based succinic acid). At a commercial level, new
ecovio® TA and IA grades from BASF are partly based on Succinity’s Bio-based Succinic
Acid (BBSA) that are used in applications like single-serve coffee capsules.
BBSA can enable the production of biodegradable PBS with up to 100% bio-based content
(according to EN 13432). Targeted applications include food packaging & service, paper
lamination and also durable applications like automotive.
Source: Succinity
Benefits of PBS include:
• High heat distortion temperature
• Good processability16
• Good compatibility with other polymers and fillers
PDI → PU
Bio-based pentamethylene diisocyanate (PDI) is an interesting new isocyanate building
block for Polyurethanes. Developed by Covestro, it contains up to 70% renewable carbon
(according to ASTM-D6866 standard). In addition, it offers improved carbon footprint cradle-
to-gate in comparison to HDI.
Covestro’s Desmodur®eco N 7300 is an example of a PU manufactured using PDI.
Source: Covestro
Innovative Bio-based Solutions
Here’s a quick review of innovative BIO solutions presented at the event.
Russian Dandelion Rubber – Wageningen UR
Based on their research, they find it to be comparable to Hevea in terms of molecular mass,
curing behavior, rolling resistance and wet grip.
Yield is somewhere between 5-15% based on dry root weight.
Step towards commercialization includes the testing done in tires by Apollo Vredestein.17 PHA From Waste Methane Gas – Mango Materials BioFoam® (PLA-based) – Synbra Technology This PLA-based foam can match properties of EPS. It is biodegradable, based on non-GMO renewable feedstock, and is food contact approved. It is ideal for insulation and packaging applications. A recent commercial product that was launched in the Italian market in May 2016 is the Greeny Eco Box. It is a take-away packaging for ice cream. Partially bio-based Compostable Film – TIPA In comparison to conventional polyolefin films, TIPA claims that its 100% compostable film can completely disintegrate in 26 weeks! (ASTM D6400 certified)
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Source: TIPA
Targets for future… 2020 and beyond
Global bio chemicals market is expected to have a healthy growth rate and is projected to
reach at least $12.2bn by 2021. Several companies and brands in attendance shared their
targets w.r.t. inclusion of renewable materials in their products.
IKEA, for example, plans to focus a lot on development of renewable polymers for plastics
applications across their product offer. They’ve set a goal of 300,000 tons of renewable
material by or before 2020!
Similarly, LEGO’s vision is to find and implement sustainable alternatives to its current
raw materials by 2030.
And there are several more such big brands like adidas, coca cola, etc. Such steps towards
sustainability by big brands and such industry events provide a good boost to the Bio-based
Chemicals industry. It might finally help move several innovations stuck in LABS out to the
MARKETS!
Defining Moment for Bioplastic Feedstock Developments
Don Rosato – Apr 15, 201619
The recent decline of crude oil prices during 2015 forward has hampered the
growth of bioplastics, yet the remarkable technology achievements in biochemical
building blocks of the past two decades will continue strong during this transition
period.
With declining oil prices bioplastics will experience increased competition from fossil fuel
based, volume plastics, particularly in the packaging market. Yet bioplastic companies will
continue to demonstrate the same technical marketing business ingenuity they have exhibited
over the past 25+ years by specialty feedstock/resin niche market development, by holding in
place their existing technology, further focusing on added production efficiencies, and in
some limited cases withdrawing from the bioplastic market segment as a result of non-
competitiveness. This first Bioplastic Feedstocks article will be followed by a Bioplastic
Materials and Bioplastic Applications reviews.
Advances in Bioplastic Feedstock
Let’s now start by taking a current, broad ranging, summary look at recent bioplastic
feedstock advances.
• Braskem is the only global supplier of bio-polyethylene based on sugarcane, with 200
kilotons per year plant in Rio do Sul, Brazil. Sugar feedstock has exhibited a low but
stable price, despite lower ethanol prices as a result of low crude oil and in turn
gasoline prices. Bio-polyethylene market prices average 40% higher than standard
fossil fuel based polyethylene. Braskem has put on hold its sugar cane based bio-
polypropylene program until crude oil to ethanol pricing improves. Elsewhere in
Europe, Sabic is planning to enter the bio-polyethylene and bio-polypropylene market
segments using bio-naphtha from Neste Oil based on hydrocracked waste oils and fats
feedstocks.
• In the bio-polyester segment, bio-PolyButylene Succinate (PBS), bio-
PolyTrimethylene Terephthalate (PTT), and bio-PolyEthylene Terephthalate (PET) are
based on a range of renewable content feedstocks such as bio-diacids (succinic acid)
and bio-diols (ethylene glycol, 1,3 propanediol).
• BioAmber has brought on line 30 kilotons per year plant in Sarnia (Ontario) Canada,
the largest in the world. Other succinic acid producers include US based Myriant (14
kilotons), Italy based Riverdia (10 kilotons), and Spain based Succinity (10 kilotons).
Thailand based PTTMCC Biochem will take 15 kilotons per year of succinic acid
from BioAmber and react it with 1,4 butanediol at its 20 kilotons per year bio-
PolyButylene Succinate (PBS) plant.
• DuPont’s Sorona PTT is manufactured from 1,3 PropaneDiOl (PDO) and Terephthalic
Acid (TA). Its PDO is built off its Susterra molecule that establishes it as an
alternative to fossil fuel based glycols. Further, the well-established DuPont Tate &
Lyle alliance manufactures their glucose variety PDO at their 64 kilotons per year
plant in Loudon, Tennessee, United States. Elsewhere. China’s Zhangjiagang Glory
Industrial at its 65 kilotons per year glycerol type PDO and 2,3 ButaneDiOl (BDO)
plant to captively manufacture its own PTT. Finally, China based Suzhou Shenghong
Group is in the early planning stages of PDO (glycerol based) and PTT project.
• Coca-Cola’s renewable content bottle program continues to grow slowly due mainly to
low crude oil prices and high priced Mono Ethylene Glycol (MEG) monomer and bio-
PET polymer materials. Sugar cane derived MEG are produced by only two global20
suppliers namely, Greencol Taiwan Corporation and India Glycols. Italy’s M&G
Chemicals is developing a China based bio-MEG and bio-ethanol facility. India’s JBF
Industries is considering a bio-MEG plant in South Carolina, potentially working with
Coca-Cola.
Coca-Cola’s Bio-Based PET PlantBottle
PlantBottle Manufacturing Process (Green; 30% Bio-MEG, or Component B)
• Bio-based systems such as 1,5 FuranDicCarboxylic Acid (FDCA) and Purified
Terephthalic Acid (PTA)/paraxylene are opening new feedstock pathways to bio-PET.
Furthermore, FDCA is a PTA feedstock replacement option. New York based
Anellotech is pilot manufacturing development of bio-toluenes and bio-xylenes by
thermal catalytic converting of biomass. Other companies namely Vertimass and
Virent are pioneering similar bio-aromatics feedstock routes to bio-PET. Soon to be
publicly announced will be The Netherlands based Avantium’s European FDCA
commercial scale plant, with Japan’s Mitsui & Company being a major customer.
Avantium has been providing FDCA development samples from a Geleen, The21
Netherlands 40 tons per year pilot facility. Their FDCA two step catalytic process
converts sugars via proprietary “YXY” technology.
• Mitsui & Company and Avantium are cooperating on PolyEthylene Furanoate (PEF)
joint development based on FDCA and MEG to replace PET, targeting end use
applications such as PEF bottles in Japan and thin films starting from Japan to across
Asia.
• In an adjunct area, Gevo (US) is converting bio-isobutanol into bio-paraxylene and
producing sample quantities for Toray Industries (Japan) for bio-PET fiber
development.
• Princeton University spinoff company, Liquid Light Inc. (US) has advanced a
laboratory scale photosynthesis process that transforms ethanol processed waste CO2
into bio-MEG.
• In the bio-acrylic field due to competitive pricing pressures strong feedstock
development transitions have occurred at a rapid rate. For example, Germany’s BASF
and the US’ OPX Biotechnologies have pulled out of bio-acrylic acid development
with US based Cargill and Novozymes respectively. Archer Daniels Midland (ADM,
US), Arkema (France), and Nippon Shokubai (Japan) are developing bio-acrylic acid
from glycerine, with only ADM having a pilot plant thus far.
• Technology innovator Novomer (US) is developing their acrylic acid via specialized
catalysts to make propiolactone from carbon monoxide and ethylene oxide. Then they
take their polypropiolactone and with pyrolysis it becomes glacial acrylic acid.
Depending on economics, the ethylene oxide can be renewably or fossil fuel based. No
commercialization evident at present.
• With regard to bio-MMA (Methyl MethAcrylate (MMA), state of the art French
technology took the lead here. Arkema (France) in concert with Global Bioenergies
(France) jointly developed bio-MMA with isobutene feedstock derived from glucose.
Elsewhere at a very early development stage, Evonik’s Creavis Division (Germany)
plus LanzaTech (Germany) is focused on fermentation processing to change syngas
into a purified 2-HydroxyIsoButyric Acid (2-HIBA) to arrive at bio-MMA.
• Lucite International (US, division of Japan’s Mitsubishi Rayon)) is exploring multiple
biochemical feedstock routes to bio-MMA primarily including bio-methanol, bio-
acetone, and bio-ethylene, with the goal of fitting them into currently used acrylic
manufacturing schemes. Additionally, serious R&D efforts are investigating unique
single step fermentation process methods to bio-MMA.
• Itaconix (US) and Leaf Technologies (France) are pursuing maleic acid like, naturally
occurring itaconic acid (or methylene succinic acid) as a feedstock for acrylic resins.22
Renewable Feedstocks (L) in Relation to Conventional Petrochemical Routes (R)—
Plastics Institute of America
Commercializing Renewable Feedstocks : Projects
Global chemical industry companies are continually seeking new feedstocks and products
derived from renewable sources to reduce dependence on petroleum longer term. Numerous
strategic partnerships, investments and construction projects are making inroads in this drive
to convert to biobased feedstocks and products. Let’s take a technology snapshot of some
recent noteworthy development projects to commercialize renewable feedstocks as follows:
Methane to Lactic Acid Fermentation Technology
Let’s begin with milestone methane to lactic acid fermentation technology in development.
Methane is a greenhouse gas that is approximately 20 times more harmful than carbon dioxide
(CO2). Generated by the natural decomposition of plant materials and a component of natural
gas, methane is also produced from society’s organic wastes such as waste-water treatment,
decomposition within landfills, and anaerobic digestion. If successful, the technology could
directly access carbon from any of these sources. NatureWorks and Calysta Energy, a
company specialized in the development of industrial products from sustainable sources, are
collaborating to develop a process for fermenting methane into lactic acid. Last year, Calysta
announced it had successfully fermented methane into lactic acid, the building block for
NatureWorks Ingeo lactide intermediates and polymers that are used in consumer and
industrial products. Currently, Ingeo relies on carbon from CO2 feedstock fixed or sequestered
through photosynthesis into simple plant sugars, known as ‘first generation materials.’ The
US DOE (Department of Energy) has awarded $2.5 million to NatureWorks to transform23 biogas into the lactic acid building block in support of the NatureWorks/Calysta development program. NatureWorks/Calysta Energy’s Methane to Lactic Acid Fermentation Technology Key goals are to provide a simplified, lower cost Ingeo production platform and diversify NatureWorks’ feedstock portfolio. While the critical lab scale first stage of the project has confirmed methane conversion to lactic acid, much additional development work remains. A full demonstration of commercial feasibility may require up to five years of development effort. The companies will share commercialization rights for select products developed under the agreement. Disruptive Carbon Capture Process Scheme Next, let’s review plastic from disruptive carbon capture technology. Newlight Technologies is using its patented GHG (GreenHouse Gas) to-plastic bioconversion technology to harness methane-containing GHG that would otherwise become part of the air. Disruptive carbon capture technology that is patented by Newlight Technologies uses air and green-house gas to produce AirCarbon, a PHA (PolyHydroxyAlkanoate) based bioplastic material.
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Newlight Technologies Disruptive Carbon Capture Process Scheme
First, GHG carbon is captured, diluted with air, and directed into a conversion reactor. The
air/GHG stream is then contacted with a micro-organism-based biocatalyst. The biocatalyst
works by separating carbon and O2 from an air stream containing GHG, and then re-
assembling the molecules into a long chain PHA-based bioplastic. Once synthesized,
AirCarbon is then removed from the reactor system and processed into pellets.
Newlight’s biocatalyst is said to generate a polymer conversion yield over nine times higher
than previous greenhouse gas-to-PHA conversion technologies and fundamentally shifts the
cost structure of the greenhouse gas to a plastic conversion process. Newlight says its
AirCarbon plastic can significantly out-compete oil-based plastics, such as polypropylene and
polyethylene, on price. Newlight has signed a 20 year take-or-pay contract with Vinmar
International for a total of up to 19 billion pounds of AirCarbon PHA over the 20 year period.
Vinmar International Ltd is a privately held plastics and chemicals marketing, distribution and
project development company headquartered in Houston, Texas. The contract launches
AirCarbon to world-scale volume.25
Hemicellulose Xylan Feedstock
Continuing, let’s evaluate a biobased, non-conventional building-block namely, Xylan
complex polysaccharides. The main hemicelluloses in angiosperms (flowering plants), xylans
make up 25-35% of the lignified tissues in grasses and cereals. This highly complex
polysaccharide, made from units of xylose (a pentose sugar) is present in large quantities in
agricultural and forestry by-products. Biobased and biodegradable Xylan is both sustainable
and economical. Xylan is being extracted from cereal husks by Chalmers University spin-out
company Xylophane AB using technology developed at the Chalmers University of
Technology in Sweden. Isolated by an extraction process from an agricultural by-product, the
material is not based on feedstock competing with food production. Xylan in powder form is
blended with additives to form a barrier material that can be used in food packaging. The
barrier product named Skalax is dissolved in water and coated onto food packaging substrates
using reverse roll, rod or curtain coating processes.
Xylophane AB’s Hemicellulose Xylan Feedstock
Xylan Manufacturing Process26 Tomato Waste Feedstock for Automotive Applications Finally, let’s examine a tomato waste fiber source that is bioplastic feedstock filler mechanically blended for potential use in plastic composites. Ford Motor Company with H. J. Heinz, the food processor, are investigating the use of tomato fibers to develop sustainable composites for auto applications. Heinz researchers were looking for innovative ways to repurpose the peel, stem, and seed by-product from more than 2 million tons of tomatoes used annually to produce Heinz ketchup. Tomato by-products are shipped to Ford facilities where they are processed into small, dry pellets that can be used in manufacturing. Ford is testing the fiber in a polypropylene composite. Ford/Heinz’s Raw Form Tomato Waste Fiber (L), Tomato By-Product Pellets (R) The goal is to develop a strong lightweight material that meets Ford vehicle requirements while also reducing overall environmental impact. Odor is a key concern that is being carefully monitored. Still in the very early stages of research, Ford is testing the tomato fiber composites’ durability for potential use in wiring brackets and car console storage bins. Ford Focus Electric Vehicle—Tomato Waste Feedstock to Renewable Content Car Parts Ford has been working with plant fibers for more than a decade, and last year introduced cellulose fiber-reinforced console components and rice hull-filled electrical cowl brackets. The company is also working with coconut-based composite materials and recycled cotton material for carpeting and seat fabrics. The company's commitment to reduce, reuse and recycle is part of its global sustainability strategy to lessen its environmental footprint while accelerating development of fuel-efficient vehicle technology worldwide.
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Conclusion
In conclusion, the road ahead looks bright for bioplastic feedstock development. The biobased
economy is holding promise as rapid development of biochemicals based on biomass offers
customers alternate supply chains compared with the traditional petroleum routes. The
‘Plastics Industry’ is undergoing dramatic transformation as bioplastics primarily derived
from renewable feedstocks continue to gain recognition in a market dominated by petroleum-
based products. Biobased raw materials will shift to non-food sources, for example,
lignocellulosic biomass, algae, drought resistant plants, waste products and greenhouse gases.
Collaborations between companies from agricultural, forestry and the chemical sectors will
become increasingly important. Just as it is common for a petrochemical company to have
interests in oil extraction, it will also become normal for chemical companies to look to
ensure renewable feedstock availability.
Today (L) versus Tomorrow (R) in Bioplastic Feedstock Development— Plastics
Institute of America
Interdiction des sacs plastiques : comment faire face ?
Publié le 24/06/2016 Comptanoo.com
Depuis ce premier juillet, aucun commerce n’est censé continuer à distribuer des sacs
plastiques à usage unique. Comment ne pas être hors la loi ?28 Que dit exactement la loi pour juillet 2016 ? Le décret publié le 31 mars, instaure l'interdiction d'utilisation et de mise à disposition de sacs de caisse en matière plastique à usage unique, d'une épaisseur inférieure à 50 micromètres. Tous les emballages en plastique sont visés, même lorsqu’ils sont biodégradables, dès lors que l'épaisseur est inférieure à cette norme. Par contre, plusieurs types d'emballages demeurent autorisés pour peu que leur caractère réutilisable et non jetable dans la nature soit visiblement inscrit : les sacs en matière plastique réutilisables dont l'épaisseur est supérieure à 50 micromètres (µm), les sacs alimentaires distribués au rayon fruits et légumes ou poissonnerie par exemple quelle que soit leur épaisseur (ceux inférieurs à 50 µm doivent comporter une inscription visible et intelligible sur leur pourcentage en matière végétale ainsi que la norme correspondante), les sacs en papier kraft, tissu ou carton, les sacs dits compostables d'une épaisseur supérieure à 50 µm, c'est-à- dire fabriqués à base de matières bio-sourcées. Quels sont les lieux de vente concernés ? Tous les types de commerces sont visés : commerces de proximité, commerces itinérants, marchés, halles commerçantes, galeries commerciales, hyper et supermarchés, supérettes, y compris celles en station service, … Attention : les commerces qui continuent à distribuer les sacs prohibés depuis le 1er juillet pour écouler les stocks, s’exposent à une mise en demeure, qui, si elle n’est pas suivie d’effet, peut se transformer en sanctions prévues par le Code de l’environnement. Quels sacs pour être en règle ? La législation impose à cette date qu'un sac plastique soit à la fois biodégradable et compostable, y compris par les consommateurs. C’est la norme NF T51-800 pour les bioplastiques qui sert à garantir les caractéristiques du compostage domestique. Plusieurs possibilités s'offrent aux commerçants dans le choix des sacs. Des matières telles que le tissu ou le papier permettent de proposer des emballages conformes à la vente de produit au détail et en vrac. Concernant les sacs en matière plastique nouvelle génération répondant à la norme NF T51- 800, les fabricants proposent différents modèles, dont la composition varie en fonction des marques mais tous contiennent des matières végétales et sont confectionnés à base de blé, maïs, riz, ou encore fécule de pomme de terre. Pour garantir qu’un sac est considéré comme biodégradable et compostable, un logo de l'organisme certificateur doit être apposé sur le sac, accompagné d'un code permettant la traçabilité du fabricant. A titre d’exemple, la marque « Ok Compost Home » répond aux exigences de la norme NF T51-800 et certifie le compostage domestique. Ndlr : Serpbio a participé à la mise en place de cette norme et réalise également ce genre de certification Vers un renforcement des interdictions à partir de 2017 Dès le 1er janvier 2017 tous les sacs plastiques, non compostables et non réutilisables, disponibles en rayon des magasins ainsi que pour les blisters de presse et de publicité non recyclables, seront interdits également. À partir de cette même date, la composition en matière bio-sourcée des sacs compostables devra évoluer progressivement : 30 % en 2017, 40 % en 2018, 50 % en 2020 et 60 % en 2025. Par ailleurs, la production et la mise à disposition de sacs oxo-fragmentables sont prohibées dans la mesure où ils ne sont ni compostables, ni bio-assimilables par les micro-organismes.
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En 2020, ce sont les couverts, assiettes et gobelets en plastique qui seront interdits de
commercialisation, à l'exception de ceux fabriqués à base de matières bio-sourcées.
Pour avoir des informations pratiques complémentaires, il est conseillé de se rapprocher
des chambres consulaires dont vous dépendez (CCI, CMA, ou Chambre d’agriculture).
Sacs plastique: ce qui devient interdit, ce qui va être
disponible
Publié le 25/06/2016 à 14:13 | AFP
Un new-yorkais transporte des sacs plastiques le 5 mai 2016
Inscrite dans la loi sur la transition énergétique, l'interdiction des sacs plastique fins va entrer
en vigueur en deux temps: le 1er juillet 2016 pour les sacs de caisse et le 1er janvier 2017
pour les sacs d'emballage des fruits et légumes.
- Pourquoi interdire les sacs plastique fins?
Ces sacs sont à l'origine d'un énorme gaspillage: fragiles, ils sont souvent jetés sitôt rentrés
chez soi et la marchandise déballée. Selon le gouvernement, il y a chaque année, 5 milliards
de sacs fins en plastique distribués aux caisses et 12 milliards aux rayons fruits et légumes.
Une partie se retrouve dans les océans, où ils sont une catastrophe pour une partie de la faune
marine, qui les ingère. Ils viennent aussi alimenter les gigantesques "mers" de plastique
formées par de grands courants marins.
- Quels sacs interdits le 1er juillet?
Les sacs fins en plastique ne pourront plus être distribués à la caisse des grandes surfaces, des
petits commerces (boulangeries, pharmacies, boucheries, etc.) et des marchés. Les sacs dont
l'épaisseur est supérieure à 50 microns seront encore autorisés. Depuis une dizaine d'années,
la grande distribution a commencé à faire payer les sacs de caisse, qu'ils soient fins ou solides,
ce qui a fait passer le nombre de sacs qu'elle distribuait à ce niveau de 12 milliards à 700
millions. Certaines enseignes proposent aussi des sacs en papier payants.
- Et les sacs pour les fruits et légumes?
Les sacs ultrafins utilisés pour les fruits et légumes seront interdits au 1er janvier 2017. Après
cette date, il faudra les remplacer par des sacs en papier ou des sacs qui sont à la fois
"biosourcés" et "compostables de manière domestique", selon le décret paru en mars 2016.
Plusieurs industriels se positionnent sur ce marché: BASF, Carbios, Sphère, Novamont, etc.
- Qu'est-ce qu'un sac biosourcé et compostable?
Un sac biosourcé est composé en partie de matière organique (amidon de maïs ou de pomme
de terre) et contient encore du plastique, mais qui pourra se dégrader totalement. La loi
prévoit des sacs biosourcés à 30% en 2017, 40% en 2018, 50% en 2019 et 60% en 2025. Un
matériau compostable a la faculté - dans certaines conditions et même s'il contient du
plastique - de se dégrader tout seul et de se transformer en eau et en CO2. Le compostage
nécessitant un certain taux d'humidité, de chaleur, d'aération, la norme "compostage30 domestique" correspond à ce qui peut se faire à la maison, en quelques semaines, et pas dans des conditions industrielles optimales. - Est-ce plus cher? A priori, oui. Le coût d'un sac fin en plastique, en général produit en Asie, est d'environ 0,5 centime. Ceux biosourcés, qui pourraient être fabriqués en France et en Europe, coutent une poignée de centimes. - Que deviendront les sacs biosourcés jetés dans un poubelle? Si une ville a une collecte séparée des biodéchets (matière organique), ces sacs pourront être mis dans le bac ou le sceau dédié. Si un particulier fait du compostage individuel, il pourra le mettre dans son compost. En revanche, en l'absence de collecte séparée, le sac se retrouvera dans la poubelle d'ordures ménagères classique et finira soit enfoui, soit incinéré. - Y a-t-il de faux sacs biodégradables? Les sacs oxo-dégradables, que certains disaient biodégradables, ne le sont pas et ne sont pas autorisés. Ce sont des sacs en plastique qui sous l'action de la chaleur et de la lumière se décompose en minuscules granules de plastique. La pollution est moins visible mais néanmoins réelle, surtout pour la faune marine. - Comment font nos voisins? Il existe une grande disparité entre les Européens. Les Danois ou les Finlandais consomment quatre sacs par habitant et par an, les Français 80, les Portugais et les Polonais plus de 400. Mais l'Union européenne a imposé aux Etats de rendre payants les sacs fins non biodégradables au plus tard au 31 décembre 2018 ou de prendre des mesures pour réduire leur consommation annuelle à 90 sacs par habitant et par an fin 2019.
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