Durable Bioplastics

74 Pages·2.883 MB·English

by  iSmithers Rapra Publishing

bioplastics > e-book
Durable Bioplastics
This e-book examines the scientific and technical
advances in the area of durable bioplastics right up to
the very latest developments.
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Durable Bioplastics
IntertechPira Business Intelligence
Pratima Bajpai
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table of contents
3 4
Executive Summary Processing Durable Bioplastics Conversion and End-use Applications
Feedstocks 4 Starch Plastics Issues
Production and Properties of Bioplastics 4 Polylactic Acid (PLA) Conversion Processes
4 Bio-based Polyamides (Nylon) 4 Production 4 Injection Molding
4 Production of Polyamides 4 Properties 4 Extrusion
1
Introduction and Methodology 4 PA11 from Castor Oil 4 Polyhydroxyalkanoates (PHA) 4 Thermoforming
Scope 4 PA 610 from Castor Oil 4 Production 4 Blow Molding
Objective 4 PA 66 from Bio-based Adipic Acid 4 Properties 4 Transfer Molding
Methodology 4 PA 69 from Bio-based Azelaic Acid 4 Bio-based Thermosets 4 Reaction Injection Molding
Definitions and Abbreviations 4 PA6 from Bio-based Caprolactam 4 Other Bio-based Thermoplastics 4 Compression Molding
4 Properties of Polyamides 4 Polyesters Applications of Durable Bioplastics
4 Poly(trimethylene terephthalate) (PTT) 4 Other Ethylene-based Compounds 4 Automobile Industry
from Bio-based PDO 4 Methanol-based Compounds 4 Electrical/ Electronics
4 Production 4 Propylene-based Compounds 4 Building and Construction
2
State of The Industry 4 Conversion of Biomass to 4 P oly(butylene terephthalate) from
Introduction 1,3-propandiol Bio-based BDO
Supply Chain 4 Conversion of 1,3-PDO to PTT 4 Production
Production of Bioplastics 4 Other Products from PDO 4 Properties
5
Growth in Durable Bioplastics 4 Properties 4 P oly(butylene succinate) (PBS) Future Trends
Government Initiatives 4 Bio-based Polyethylene (PE) from Bio-based Succinic Acid
Drivers 4 Production 4 Production
Barriers for Commercialization and Issues 4 Properties 4 Properties
4 Polyvinyl Chloride (PVC) from Bio-based PE 4 Bio-based Polyethylene Terephthalate
4 Production 4 Production References
4 Properties 4 Polyethylene Isosorbide Terephthalate (PEIT)
4 Polyurethane (PUR) from Bio-based Polyols 4 Production
4 Production of PUR 4 Properties
4 Production of Fossil Fuel-based PUR 4 Other Polyesters Based on PDO
4 PUR from Bio-based Polyol List of Tables and Figures
4 Properties
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bioplastics > e-book > durable bioplastics
Executive Summary
Plastics are the biggest consumers of fossil fuel outside energy technology advances in White Biotechnology are the major drivers Investment plans
and transport. The term bioplastics encompasses numerous to move from fossil-based polymers to bio-based polymers in both for the next five
different plastics. Bioplastics are bio-based and biodegradable and low- and high-value polymer categories and markets. It is expected
years already
can be used in short-life, disposable products; however, they can that the bio-route is cheaper than the fossil-route at oil prices above
quadruple current
also be used in long-life (i.e. durable) applications. It should be US$50 a barrel. The bio-based polymer business was only 1,000 kt/
production
remembered that bio-based plastics are not always biodegradable, annum or 0.4% of the total polymer business in 2010, but based on
and biodegradable plastics are not always bio-based. The goal currently known technologies, the annual growth rates are forecasted capacities of bio-
in nondisposable applications of bioplastics is not to achieve at 20% till 2020. New technology developments and related based plastics.
biodegradability, but to create items from sustainable resources. product introductions could, of course, increase these estimates.
There are a number of bioplastics that are either commercial or in
very active development. Initial market interest in bio-based plastics came from producers
of one-time-use applications or of applications that generate a lot
Plastics are predominantly made from crude oil. When plastics of plastic waste. Currently, there are many more durable bio-based
made from petroleum are burned, they release the carbon polymers than there are biodegradable bio-based polymers. Also,
dioxide contained in the petroleum into the atmosphere, which the volume of bio-based thermoset plastics exceeds the volume of
may contribute to global warming. The use of bioplastics offers bio-based thermoplastics, or thermo-softening plastics.
significant advantages in an ecological and economic sense.
A number of market studies forecasted that growth rates of Investment plans for the next five years already quadruple current
the market for bio-based polymers would hit 17% per annum production capacities of bio-based plastics. Presently, more than
through 2020, given the development of new technologies. twenty bio-based polymers are already commercial, and six are at
Plastics consumption is expected to grow from approximately from pilot scale. About half of them are bio-based versions of well-known
250,000 kt/annum at the beginning of this century to >1,000,000 traditional polymers, while the other half are new to the market.
kt/annum by the year 2100, due to an increasing world population
and prosperity. Such consumption would, in turn, require 25% of The early thermoplastic bio-based polymers TPS, PLA, PHA, and
current oil production to meet that market demand, without the PBS had an installed global capacity of about 435 kt/annum at
development of technological advances. the end of 2009 with capital investment plans that would increase
that by another 1,250 kt/annum over the next decade. There are
However, public concern about climate change, limited fossil also currently eight bio-based polyamide products commercially
resources, increased cost of fossil resources, and important available and five others in development. A similar type of
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bioplastics > e-book > durable bioplastics
Executive Summary
development is going on in aliphatic polycarbonates, although of bioplastics. While algae-based plastics are in their infancy, once
these are in the early stages. they are into commercialization they are likely to be applied in a
wide range of industries.
Feedstocks that are used to produce bioplastics are, in fact,
biomaterials that are derived from biomass. The various feedstocks Current biomass conversion technology normally begins with
are: sugar and starch bioproducts obtained through fermentation biomass-derived starches, sugars and oils that are then converted to
and chemical processes, such as alcohols, acids, starch and xanthium key building-block chemicals via biological or chemical conversions,
gum, and derived from feedstocks including corn, sugarcane, sugar and subsequently converted to bio-based chemicals and polymers.
beets, rice, potatoes, sorghum grain and wood; oil and lipid-based
bioproducts obtained through chemical processes, such as fatty There are two basic processes for the manufacture of bioplastics:
acids, oils, alkyd resins and glycerin, and derived from feedstocks Direct extraction from biomass, which yields a series of natural
including soybeans, castor oil, rapeseed and other oilseeds; cellulose polymer materials; alternatively, the renewable resources/biomass
derivatives and plastics, such as cellulose acetate (cellophane) and feedstock can be converted to bio-monomers by fermentation or
triacetate, cellulose nitrate, alkali cellulose and regenerated cellulose, hydrolysis and then further converted by chemical synthesis to
and derived from wood pulp and cotton linters; protein (chitin, soy bioplastics. Bio-monomers can also be microbially transformed to
protein, zein, wheat gluten, silk); and, finally, biomass. Many of these bioplastics like polyhydroxyalkanoates. Vegetable oils offer another
are used to produce bioplastics such as biopolyethylene, polylactic important carbon platform to polyols (precursors for polyurethanes,
acid (PLA), polyhydroxyalkanoate (PHA), epoxy resins, alkyd resins, polyesters) and other functional monomers/macromers.
regenerated cellulosics, and many more.
Bioplastics are generally used in similar applications as
Algae can serve as an excellent feedstock for plastic production petropolymers (i.e. petroleum-based plastics). Process conversion
because of its high yield and the ability to grow in a range of issues to consider for bioplastics are:
environments. Algae bioplastics mainly evolved as a by-product
of algae biofuel production, where companies were exploring Many of the early bioplastics lack the same thermal and
alternative sources of bio-based fuels. In addition, the use of mechanical performance of their analogous petropolymers.
algae opens up the possibility of utilizing carbon, neutralizing Bioplastic grade innovation has provided improved thermal and
GHG emissions from factories or power plants. On the heels of mechanical performance, but the nature of bioplastics must still
traditional methods of utilizing feedstocks of corn and potatoes as be considered, and rarely can a bioplastic be substituted directly
plastics, algae-based plastics have been a recent trend in the era for a petropolymer in a conversion process. For extrusion and other
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bioplastics > e-book > durable bioplastics
Executive Summary
molding processes, bioplastics may require a change in screw Few companies have developed and commercialized bio-based
design because bioplastics tend to be more shear sensitive than polyols for polyurethane production. The application possibilities
traditional petropolymers; however, a new screw does not always of these bio-based polyols rapidly increase due to improved
solve all conversion problems. Rather, bioplastics may require functionalization technologies. Bio-based polymers not only replace
new designs for extrusion dies and new molds for injection or existing polymers in a number of applications, but also provide new
blow-molding tooling, because the dies and molds designed for combinations of properties for new applications.
traditional petropolymers don’t always fit bioplastic rheological
characteristics. Power is a major cost for extrusion and molding In a more recent and unusual innovation, NEC Corporation of Japan
processes; however, with bioplastics, there can be other costs, as announced the development of a new durable bioplastic produced
well as additional compounding of compatibilizing agents and from nonedible plant resources. The bioplastic is created by bonding
other polymers. Bioplastics tend to be more sensitive to variation cellulose fibers from various types of plant stems, with cardanol—a
in heat cycling, dissipation, cooling and overall heat history than primary component of cashew nut shells—which achieves a level of
traditional petropolymers. Conversion speed needs to be more durability that is suitable for electronic equipment and has a high
closely monitored, as the above issues will have an impact on biomass composition ratio of more than 70%.
conversion performance and final product quality.
The durable plastics market is anticipating new materials made
A variety of methods—injection molding, extrusion, thermoforming, from renewable-based feedstock. Experts say that there are several
blow molding, transfer molding, reaction injection molding, and properties for durable plastics that cannot be met by compostables.
compression molding—are used for conversion. Each method has Bioplastics represent just 1% of the 230m tonnes of plastics
its advantages and disadvantages and is better suited for specific consumed worldwide. The increasing demand for bio-based, semi-
applications. durable and durable products for household goods is driving
development of building blocks for existing plastics as well as
Several durable bio-based plastics, with varying bio-based content new materials from renewable resources. Applications of durable
(starch-polyolefin blends, PTT, PEIT, PE, PP, PVC, PUR, polyamides, bioplastics include automotive, electronics/electrical, durable
alkyd resins, epoxy resins, thermosetting polyesters), have been biomedical materials, consumer goods, building and construction,
or will soon be commercialized, and even more are currently textiles, and coatings, etc. The application of bioplastics in the field
being developed. The growth prospects of the bio-based durable of construction is considered to be a more sustainable activity when
plastics in the next decades are much greater than for bio-based compared with commercial PVC because bioplastics use less carbon
biodegradable plastics. sources and produce fewer GHG emissions.
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bioplastics > e-book > durable bioplastics
Executive Summary
IntertechPira’s internal estimate put the global demand for
bioplastics at 800,000 tonnes in 2009, and that figure is expected
to reach 3.6 million tonnes by 2019.
The progress made in bio-based plastics is impressive, and a large
number of companies are now producing a wide range of products.
Overall, even though bioplastics are generally more expensive than
regular plastic, the variety of uses and benefits could outweigh
the cost: Bioplastics cut down on municipal waste, reduce GHGs,
are environmentally friendly, and can be used as a fuel. And, with
developing technologies, these benefits will only increase and the
cost will be competitive in the market.
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