Bio-based Plastics – Research, Development and

Bio-based Plastics –
Research, Development and Applications
Dr. Stephan Kabasci
Fraunhofer UMSICHT,
Department Bio-based Plastics
16 February 2016, Neuss
© Fraunhofer UMSICHT
Outline
1. Introduction
2. Bioplastics
3. Exemplary NRW-NL Co-Operations
1. FP7 ECOplast
2. FP7 SPLASH
3. 3D-Printing
Slide 2
© Fraunhofer UMSICHT
1. Introduction – Fraunhofer-Gesellschaft
Joseph von Fraunhofer
1787 – 1826:
Itzehoe
Lübeck
 Researcher
 Inventor
 Entrepreneur
Rostock
Bremen
Berlin
Potsdam
Hannover
Teltow
Nuthetal
Braunschweig
Magdeburg
Paderborn
Cottbus
Oberhausen
Dortmund
Halle
Leipzig
Schkopau
Duisburg Schmallenberg
Dresden
Sankt Augustin
Aachen
Ilmenau Jena
Chemnitz
Euskirchen
Main Site
Darmstadt
Kaiserslautern
St. Ingbert
Saarbrücken
Karlsruhe
 Leading organization for applied
research in Europe
 66 Institutes, 13 of which in NRW
Slide 3
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Würzburg
Wertheim
Institute
Erlangen Branch
Sulzbach-Rosenberg
Nürnberg
Pfinztal
Stuttgart
Freiburg
Efringen-Kirchen
Freising
München
Holzkirchen
1. Introduction – Fraunhofer-Gesellschaft
Research fields
Health & environment
Mobility & transport
Communication & knowledge
Energy & resources
Security & prevention
Production & service
Slide 4
© Fraunhofer UMSICHT
1. Introduction – Fraunhofer UMSICHT
 History
 Founded
1990
 Fraunhofer-Gesellschaft
1998
 Mission
 Pioneer for Sustainable Energy
and Raw Materials Management
Oberhausen,
Osterfelder Straße 3
 Divisions
 Energy I Processes I Products
 Director
 Prof. Dr.-Ing. Eckhard Weidner
Chem. Eng. at Ruhr-Universität Bochum
Slide 5
© Fraunhofer UMSICHT
KEYNOTES
Prof. Dr.-Ing.
Eckhard Weidner
1. Introduction – Department »Bio-based Plastics«
25 scientists and technicians at your service
 Development of polymers and additives from renewable resources
 Examples: adhesive ingredients,
plasticizers, impact modifiers
 Focus: polycondensation, polyaddition
 Use of bio-based polymers for material and product development
 Long term experiences in the sectors of blown and
cast film production, injection molding and foaming
 Special knowledge in processing of cellulose acetate,
PLA and other bio-based polyesters
 Development of:
 composites using natural fibers and/or bioplastics
 Biodegradable materials for special applications
(agriculture, geotextiles)
 Methods for the conservation of cultural heritage
(wood, plastic)
Slide 6
© Fraunhofer UMSICHT
1. Introduction – Department »Bio-based Plastics«
Material Development Chain
Core competencies Fraunhofer UMSICHT
 Tailor-made material
development
 Plastics
Processing
Marketing
Distribution
Plastics
Processing
Mixing
Compounding
Twin screw
extrusion
Market
Applications
Products
Conversion
Bio-based
plastics
Biopolymers
Additives
Fillers
Natural Fibres
Bio-based
feedstock
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© Fraunhofer UMSICHT
 Project partners
 Raw material producers
and suppliers
 Applications and market
entrance
 Industry, R&D-institutes,
Universities
2. Bioplastics - Definition
A generally accepted definition of the term
»bioplastics« does not exist.
Two different categories can be distinguished:
 Plastics based on
renewable resources
( = Bio-based Plastics )
Origin
 Biodegradable plastics
Property
Slide 8
© Fraunhofer UMSICHT
2. Bio-Based Plastics - Wide Range of Application Fields
Adapted from:
Fachagentur Nachwachsende
Rohstoffe FNR
(Renewable Resources Agency)
Data: German Market, 2008
Slide 9
© Fraunhofer UMSICHT
2. Bio-Based Plastics - From Nature to Materials
Adapted from:
Fachagentur Nachwachsende
Rohstoffe FNR
(Renewable Resources Agency)
Slide 10
© Fraunhofer UMSICHT
3.1 Exemplary Multinational Project ECOplast
Innovative Biocomposites for Automotive Applications
 Goals
 Innovative biocomposites using
bio-based polymers as matrix
 Use of natural fibres, nanofillers,
and mineral fillers as
reinforcements
 Adaptation to conventional
plastics processing in automotive
industry
 Use of innovative plastics
processing technologies
 Duration: 2010 - 2014
FP7-NMP-2009-2.4-1 / GA nº 246176
Slide 11
© Fraunhofer UMSICHT
3.1 Exemplary Multinational Project ECOplast
Innovative Biocomposites for Automotive Applications
 Main Results
 Reduction of volatiles and odor
of PHB composites
(AIMPLAS, Biomer)
 Development of stereoblock
PLA (Corbion Purac)
 Processing in twin-screw
extruder yielded best results
 Compatibilization methods for
natural fibres (Fraunhofer
UMSICHT) and wood fibres (VTT)
 Increase in heat deflection
temperature of wood fibre
composites
Slide 12
© Fraunhofer UMSICHT
3.1 Exemplary Multinational Project ECOplast
Innovative Biocomposites for Automotive Applications
 Main Results
 Requirements concerning odor
and durability in heat and
humidity were met
 Fogging tests showed insufficient
results. Further research is
needed here
 Compression molding technology
developed to reinforce PHB with
long fibers
 Tests with nanocellulose show
promising results but dispersion
still has to be improved
Slide 13
© Fraunhofer UMSICHT
3.2 Exemplary Multinational Project SPLASH
Sustainable Polymers from Algae
 Goals
 Developing a new bio-based
industrial platform that uses
microalgae as a raw material
 Sustainable production and
recovery of hydrocarbons and
(exo)polysaccharides from algae
 Conversion into renewable
polymers (polyesters and
polyolefines)
 Duration: 2012 - 2016
Slide 14
© Fraunhofer UMSICHT
3.2 Exemplary Multinational Project SPLASH
Sustainable Polymers from Algae
 Work in progress ...
 Algae species:
Botryococcus braunii
 UMSICHT-tasks:
 Lipids analytics
 Cracking of Lipids to Ethylene
and Propylene
Slide 15
© Fraunhofer UMSICHT
3.3 Exemplary Binational Project 3D Printing Material
Industrial Development Co-Operation
 FKuR Kunststoff GmbH, Willich, NRW
 Fraunhofer spin-off company
 Biopolymer development,
compounding and worldwide
distribution
 Helian Polymers B.V., Venlo, NL
 From trading company to production
 High quality filaments for 3D printing
 Brand: colorFabb
Slide 16
© Fraunhofer UMSICHT
3.3 Exemplary Binational Project 3D Printing Material
Industrial Development Co-Operation
 Material properties are the key for high quality printing results
 High melt strength and elasticity for stable printing process
 Low shrinkage and warpage lead to exact geometry after printing
 Wide process window for the solidification offers accurate print results
 Sufficient layer adhesion behavior is important for product stability
 Different filler materials provide additional options for design, quality
and performance
Slide 17
© Fraunhofer UMSICHT
3.3 Exemplary Binational Project 3D Printing Material
Industrial Development Co-Operation
 Co-Operative Development
 PLA/PHA filaments developed by Helian Polymers
 Broad portfolio of 30 colors
 Natural Fibre Filaments
 Natural fillers and fibers for new aesthetics
 Joint development with FKUR
 Currently 2 grades: woodFill and bambooFill
Slide 18
© Fraunhofer UMSICHT
FRAUNHOFER UMSICHT
Department
Bio-based Plastics
Foto: photocase.de
Thank you for attention
Start Co-operating!
Fraunhofer UMSICHT
Osterfelder Straße 3
46047 Oberhausen
info@umsicht.fraunhofer.de
http://www.umsicht.fraunhofer.de
© Fraunhofer UMSICHT
Dr. Stephan Kabasci
+49 208 8598-1164
stephan.kabasci@umsicht.fraunhofer.de
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© Copyright Fraunhofer UMSICHT, 2016
Contact:
Fraunhofer-Institut für Umwelt-, Sicherheits- und
Energietechnik UMSICHT
Iris Kumpmann
Head of Public Relations
Osterfelder Straße 3
46047 Oberhausen, Germany
Tel.:
+49 208 8598-1200
E-Mail: iris.kumpmann@umsicht.fraunhofer.de