Biopolymer Processing Technologies

51 Pages·2010·0.813 MB·English

by  Pira International Ltd

biomaterials > e-book
Biopolymer Processing
Technologies
The objective of this report is to provide an analysis of the current biopolymer
industry from a perspective of markets, trends and drivers, economics and
regulations, types of biopolymers, properties and characteristics of biopolymers,
applications and future outlook.
WWW.INTERTECHPIRA.COM
Biopolymer Processing Technologies
IntertechPira Business Intelligence
Providing knowledge for niche, emerging and high-growth industries
Published by
About viewing this ebook
Services
IntertechPira This document will attempt to open in IntertechPira provides events, market research, publications, strategic and technical consulting to
19 Northbrook Dr
full page viewing mode by default for niche, emerging and high-growth industries. Market coverage includes lighting and displays, clean
Portland, Maine 04105
a more immersive reading experience energy, home and personal care, industrial biotechnology, performance materials and chemicals.
USA
and to maximize screen space. Press IntertechPira is a division of Pira International.
the “esc” key at any time to return to
Events
T [phone] normal viewing mode and access the
IntertechPira events combine productive networking, high calibre presentations and targeted
F [phone] document viewing and navigation tools marketing opportunities for key decision makers across the globe in niche, emerging and high
E [email protected] in your pdf reader. growth industries.
W www.intertechpira.com
Market Research
Pira International Ltd acknowledges product, service and company names referred to in this Our ongoing research programmes with an established and extensive network of worldwide experts,
report, many of which are trade names, service marks, trademarks or registered trademarks. consultants and researchers in over 50 countries give us a headstart when sourcing technical and
The facts set out in this publication are obtained from sources which we believe to be reliable. However, we market intelligence. With access to unique, proprietary databases we can deliver the hard-to-find
accept no legal liability of any kind for the publication contents, nor any information contained therein nor information you need.
conclusions drawn by any party from it. No part of this publication may be reproduced, stored in a retrieval
system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or Publications
otherwise without the prior permission of the Copyright owner. IntertechPira offers a range of reports and reference and technical books for niche and emerging
industries. Our market reports set the industry standard for establishing market sizes and forecasting
© Copyright Pira International Ltd 2010 (IntertechPira is a division of Pira International) future developments, while our technical books provide you with a comprehensive overview of the
latest technology developments.
Publisher
Strategic & Technical Consulting
Rav Lally
Our bespoke consulting services across a range of niche, emerging and high-growth industries offer
[email protected]
a wealth of experience, helping your business plan its strategy with confidence and crystallise
business decisions.
Head of editorial
Adam Page Business Support
[email protected] You get high quality business support which is cost effective and when you need it, with an
exceptional client retention record as a testament to our dedicated and thorough processes.
Head of market research IntertechPira has a track-record of meeting and exceeding client expectations.
Nick Waite
IntertechPira Membership for Biomaterials
[email protected]
Membership includes 3 conference places at each of our Biomaterials events as well as extensive
access to our wide range of ebooks, journals, webinars and training modules. Contact Michael
Head of US publishing
Mooney at [phone] or [email protected] for more information.
Charles E. Spear, Jr.
[email protected] Find out more
www.intertechpira.com
Assistant editor
Contact: Pira International Sales
Mina Odavic
Bill Allen
[email protected]
[phone]
[email protected]
Customer services manager
Denise Davidson
[email protected]
T [phone]
WWW.INTERTECHPIRA.COM
table of contents
Executive Summary 3 4
Introduction
Biopolymer Growth Drivers
Biopolymer Processing
Biopolymer Applications Biopolymer Processing Applications for Biopolymers
Biopolymers on the Horizon Feedstocks Early Applications
Biomass Conversion Technologies Legislation
1 Four Key Sugar-Based Biopolymers Biopolymer Applications
4Polyhydroxyalkanoates (PHA) Biopolymer Process Conversion Issues
4Polyhydroxybutyrate (PHB) Key Conversion Processes
4Poly (3-Hydroxybutyrate-co-3-Hydroxyvalerate) 4Extrusion
Objective and Methodology (PHBV) 4Extrusion Trends
Objective 4Polylactic Acid (PLA) 4Extruding Biopolymers
Scope Blends & Compounds Injection Molding
Methodology 4Injection Molding Trends
Definitions and Acronyms 4Injection Molding Biopolymers
4Thermoforming 49
2 4Thermoforming Biopolymers
4Other Conversion Processes
5
Biopolymers: State of the Industry
Background
Polymer Industry Today
Biopolymers Biopolymers on the Horizon
Future Outlook

List of Tables and Figures
WWW.INTERTECHPIRA.COM
biomaterials > e-book > biopolymer processing technologies
Executive Summary
Introduction biopolymers and new ones will be integrated into a multi-crop bio-
The future state of the biopolymer industry is very much linked to refinery capable of making many products The future state
the dynamics and economics of the fossil-fuel industry on a global
of the biopolymer
basis. For example, what happens in China or the Middle East will The success of biopolymers is directly related to the state of the
industry is very
have consequences on the availability and price of oil, which in turn economy and competitive position of alternative / traditional
much linked to
has consequences on the economic attractiveness of biopolymers. fossil-fuel (petroleum, gas, coal) based feedstocks and polymers.
the dynamics and
Regional regulations, consumer perceptions on the environment Indeed, biopolymers will find future success and grow in demand as
and process technology will also have impact; however it is the cost society is increasingly forced to cope with higher energy costs and economics of the
and availability of fossil fuels that will most impact the commercial consumers finally recognize that a reduced carbon-footprint is good fossil-fuel industry
production and use of biopolymers, based on competitive position. for business and the environment. on a global basis.
Worldwide recognition of depleting fossil-fuel reserves has driven a Biopolymer growth will partly come from substitution of traditional
slow shift to employ more biorenewable resources and reduce fossil- petrochemical-based polymers (petropolymers). Worldwide
fuel consumption where possible. Despite this recognition, fossil-fuel consumption of all polymers peaked in 2009 at about 240 million
consumption will continue to grow for at least the next twenty years, tonnes (about 530 billion pounds), valued at about $600 billion,
while bio-fuel consumption is also growing, but at a faster rate. noted in Figure 0.1.
As biorenewable resources, including all forms of biomass, become FIGURE 0.1 Global consumption of all polymers by region, 2009 (%)
an increasingly important raw material and energy source, biomass
conversion refineries will broaden technology and provide chemical Globally, biopolymers represent a small sub-sector of the much larger
feedstocks, some of which will be converted to biopolymers. Unlike polymer industry as illustrated by Figure 0.2. Estimated biopolymer
oil refineries, a bio-refinery will be capable of processing many consumption was about 880 thousand tonnes in 2009, including the CLICK TO VIEW
different types of biomass, including sugars, cellulose, lignins and many polymer compounds that contain starch. The sector represents
various plant oils. only about 0.4% of the overall global polymers industry.
The difference in the production of biopolymers today vs. the future FIGURE 0.2 Global consumption of biopolymers by product, 2009 (%)
is how the ‘process footprint’ will be structured. For example, today
As noted in the figure, there are many types of biopolymers
most biopolymers are produced in stand-alone single-technology
currently available. This is due to the broad definition of what is
facilities, based on a single feedstock like corn. Tomorrow the same
CLICK TO VIEW
4
CHAPTER ES 1 2 3 4 5 TOC
WWW.INTERTECHPIRA.COM
biomaterials > e-book > biopolymer processing technologies
Executive Summary
classified as a biopolymer. As described earlier, our definition of four key factors seem to have the greatest impact on the future
biopolymers are those polymers that are derived from biomass demand for biopolymers:
sources, including chemical / monomer building blocks, polymers
derived from these building blocks and in vivo polymer types. 1. Fossil fuel cost; the increasing cost for oil, gas and
coal is not new, but what is new is the potential for
The underlying backbone of this definition is based on the concept ‘economic de-linkage’ of fossil fuel costs as was seen in
of bio-renewability; meaning the raw material is renewable. In other 2008. In July of 2008, oil prices spiked to over $135/
words, the polymer or its monomers can be produced (grown) again barrel. Although prices have declined since, a steady-
and again through agricultural or other biologic routes. Therefore, state of $75-85/barrel is not considered an attractive
biopolymers are often referred to as biorenewable polymers, which price range by consumers. Furthermore, the fear of
support the business and environmental goals of sustainability. This higher prices is now branded in public memory; most
concept should not be confused with polymers that are recyclable consumers and industries believe that costs will escalate
and compostable; many thermoplastics are, but not all of these again in the future.
plastics are biorenewable. a. Biopolymer demand is directly affected by the
relative competitive cost of petropolymers,
Biopolymer Growth Drivers which is strongly influenced by the cost of
The impact of the recent, very severe recession has created much fossil fuel feedstocks. Oil priced at $75-85
uncertainty regarding the speed that markets will recover. On does not support capitalization of biopolymer
September 21, 2010, the US government indicated that the projects compared to prices above $100/bbl.
economy is now improving and that 2010-2011 will be a period of 2. Environmental regulations and the ‘carbon footprint’;
renewal for industry. environmental regulations will play a key role in
motivating more biopolymer consumption longer-term.
More recently, the threat of a double-dip recession has been Green house gases (CO ) are believed by many as the
2
negated by economists, although the economy could still be cause of global warming. This perception, whether right
impacted by continued socio-political events, such as high or wrong, has a strong impact on the promotion and
unemployment and potentially higher oil pricing, as worldwide acceptance for the use of biopolymers. Biopolymers are
consumer demand picks up. Either way, the economic consensus perceived as natural and cleaner, with a lower carbon
seems to predict a full recovery is most likely to be seen after 2011. footprint compared to fossil fuel based polymers.
Driven by the current economic forces and environmental issues, Furthermore, changes in global regulations are also
5
CHAPTER ES 1 2 3 4 5 TOC
WWW.INTERTECHPIRA.COM
biomaterials > e-book > biopolymer processing technologies
Executive Summary
beginning to have impact. phenomenon; they are less impacted by the
3. Global economies; today, the chemical and polymer global fluctuations that impact fossil-fuel
industries are completely global, with supply derivatives. Market impacts are simply based
agreements extending between all the major regions on the competitive price-point for fossil-fuel
of the world. Therefore, fossil fuel feedstocks, chemical derivatives vs, biopolymers.
and polymer derivatives are traded on a global basis. 4. Biorenewable technologies; continued improvement
Amplifying this global interconnectivity of trade flow is in production and process technology that is used
the global relationship with the Middle East as a key to produce building block chemicals and monomers,
supply source and China as a key consumer. polymers, compounds and other components such
a. As the world’s largest supply region for low as natural fiber will provide better performance and
cost fossil-fuel and chemical production, economic incentives to motivate biopolymer acceptance
the Middle East acts as the ‘price-point’ for by the market. In the future 2nd generation cellulose
determining the competitive basis for global conversion technology for non-food crops such as grass
chemical and polymer production economics. and wood will by-pass the issue of ‘food for fuels’ by
b. China on the contrary is the largest consumer using biomass waste, which is then converted to bio-
for Middle East hydrocarbon raw materials, monomers.
including polymer consumption, and will soon
be the largest polymer derivatives producer. There are many new biopolymer suppliers and technologies
c. The polarity created between the largest that have created a broad portfolio of grades suitable for both
supply and demand regional centers of the commodity and performance end uses. Examples of some of these
Middle East and China can substantially key players are shown below in Table 0.1:
impact other global economies, as well as
global currency fluctuations. Therefore, more TABLE 0.1 Biopolymer producers, 2009
mature, slower growing economies such as
the US and Europe are far more prone to the The large number of producers is beneficial to the industry because
economic impacts of the Middle East and it provides the overall production and marketing asset base with
China relationship. greater economic strength, as compared to previous years. This CLICK TO VIEW TABLE
d. Biopolymer manufacturing costs however, larger asset base can be defined as a ‘critical mass’ that is large
tend to be more of a ‘local-regional’ enough to self-perpetuate, as long as the drivers for market growth
6
CHAPTER ES 1 2 3 4 5 TOC
WWW.INTERTECHPIRA.COM
biomaterials > e-book > biopolymer processing technologies
Executive Summary
continue to provide equal or better performance and economic The general composition of woody plant (tree) ligno-cellulosic
attributes. biomass is shown in Figure 0.3 below:
Based on assessing future market, technology and economic drivers, FIGURE 0.3 Raw material biomass to building block intermediates
it is not unreasonable to assume a conservative compound annual and monomers
growth rate (CAGR) of 10% per year. Growing at this conservative
Food crops such as corn will have substantially higher levels of
growth rate, today’s (2009) biopolymer demand of 880 thousand
hemicellulose (starches and sugars) and lower levels of lignin. The CLICK TO VIEW
tonnes would reach 2.3 million tonnes by 2019. This is believed
hemicellulose, cellulose and other starches/sugars contained in the
very doable; in fact it is conceivable that this level could easily be
biomass are key starting materials for producing the key chemical
exceeded during the next ten years under the right circumstances,
building blocks and derivatives that are used for polymerizing
reaching a demand of 3.6 million tonnes by 2019.
biopolymers. In some cases, the biopolymer is actually produced
directly by the plant and then can be extracted and purified directly
The biopolymer market is a growing and fertile market that has
as a polymer.
reached a stage of serious consideration and market acceptance.
Biopolymers are here to stay – the question is ‘not if, but when’?
As noted by this figure, today’s commercial biopolymer technology
Worldwide, we will continue to undergo an extended period of
is focused on using glucose (dextrose), a 6-carbon sugar from food
energy transition and uncertainty with regards to the cost of fossil
crops, as a starting material because it is the most economic to
fuels vs. alternative biorenewable approaches. There is no doubt
convert by fermentation chemistry to basic chemical building blocks
another oil shortage is coming, but we don’t know when. There
for biopolymer feedstock. Glycerol is also used for the polyol chain of
is however sufficient asset critical mass that has been added to
monomer products. However, the most abundant biomass component
many biopolymer sectors that will drive new technologies and new
is cellulose and lignin; however conversion is high-cost and tedious by
approaches in achieving biorenewable solutions, many that are
today’s standards. Yet, cellulose and lignin represent long-term target
sustainable at today’s competitive fossil fuel price-points.
resources for 2nd/3rd generation conversion technology.
Biopolymer Processing
The building block chemicals are molecules with multiple functional
Current biomass conversion technology normally begins with
groups that have the potential to be transformed into new families
biomass derived starches, sugars and oils that are then converted to
of useful molecules. Examples are shown in Table 0.2 below:
key building block chemicals via biologic or chemical conversions,
and subsequently converted to biobased chemicals and polymers.
7
CHAPTER ES 1 2 3 4 5 TOC
WWW.INTERTECHPIRA.COM