Industrial Biotechnology (IB) and Bio-based Routes to ...€¦ · Report on Industrial Biotechnology (IB) and Bio-based Routes to Sustainable Composite Materials 3 Executive Summary

Industrial Biotechnology (IB) and Bio-based Routes to Sustainable Composite Materials August 2018

Dr. R. Rowlands-Jones Formulation Lead Knowledge Transfer Network

Report on Industrial Biotechnology (IB) and Bio-based Routes to Sustainable Composite Materials 2

Contents Executive Summary 3

Background 6

Overview of Sustainable Composites 8

Technology Needs 13

UK Position 15

Recommendations 21

Cross sector Collaboration 21

Knowledge Transfer 22

Key Recommendations 22

Appendices 25

Workshop Delegates 25

Reference Material 25


Executive Summary

The Composite Leadership Forum (CLF) 2016 UK Strategy identified an opportunity to grow the current composite product market from £2.3bn to £12bn by 2030. Action is required to produce a Composite industry that is sustainable into the future. Increasing the market penetration of composites will reduce environmental impact through light-weighting and durability, but there is a need to incorporate circular economy principles alongside rapid development of composite materials. There is a need to develop cost-effective bio-based raw materials to further reduce environmental impact and de-couple prices from oil.

While some polymers and chemical feedstocks have traditionally been produced economically from bio-based resources (e.g. rubbers, some phenolics, furans and acrylates), in general bio-based feedstocks at present are not economical compared to petro chemical derived equivalents. This report highlights the technical challenges from the Chemistry and Composites Sectors in developing and manufacturing sustainable composites, the opportunities for Industrial Biotechnology to provide disruptive solutions. It provides a series of recommendations for how the UK can build on its leading positions in Composite Materials development and Industrial Biotechnology to build a sustainable composites market for the future.

Investment in the development of sustainable composite materials now is essential in delivering UK growth through the multi-sector application of composites. In the short term, drop-in replacements for fossil-derived monomers will be preferable, minimising disruption to current supply chains and legislation. In the longer-term we need to consider the advantages of higher oxygen content and chirality of biomass as a future feedstock. Improvements in Life Cycle Assessment (LCA) and understanding waste management are essential to realistically integrate solutions. The IB sector can leverage activities in KTN’s Materials for Composites SIG to disseminate opportunities and technical asks from growth sectors identified in the CLF 2016 strategy.

https://compositesuk.co.uk/leadership-forum/about-clf

https://compositesuk.co.uk/system/files/documents/Strategy%20final%20version_1.pdf


Key challenges and developments which will make bio-based composite materials economically competitive with oil-based materials:

1. The development of platform molecules (bio-derived building blocks) as alternatives to fossil-derived base chemicals provides an opportunity to capitalise on the inherent oxygen content and chirality of various biomass resources, which should not be dismissed as synthetically chirality is difficult to achieve.

2. The maximum impact is likely to be realised in the development cost-

effective processes for obtaining aromatic compounds, or effective alternatives from biomass sources such as alternatives to styrene, maleic anhydride and phthalic anhydride. Developing Furanic monomers offers an alternative to Phenolics.

3. Understanding the coupling of bio-based polymers with new bio-based

monomers will be key to future success in materials development and manufacturing at scale with the required cure temperatures and times.

4. There is an opportunity to add value to UK composite materials sector by

developing areas where bio-based materials can add value in terms of the materials properties or health and safety.

5. Mapping the industry end user material properties to potential sustainable

feedstocks including an understanding of the scale required is essential to recovering high value chemicals at required scale from bio-sources (Lignin) through catalysis and developing bio-based composite materials.


Key Recommendations:

1. Investment in the development of sustainable composite materials now is essential in delivering UK growth through the multi-sector market growth opportunity of composites set out in the CLF 2016 strategy. Dedicated funding to kick start the currently limited collaborations between the IB and composites sectors.

2. The chemical diversity in platform molecules (bio-derived building blocks) brings challenges, but also opportunities for innovation and new Intellectual Property. Disseminate the opportunities in the UK BioChem 10 list (top bio-based chemicals for the UK: Challenges and Opportunities) to Chemistry and Composite Materials Sectors.

3. Incorporate circular economy principles alongside rapid development of

composite materials. Develop best practice in design. Design for repair and end of life (circular economy), Bio/recycled content and environmental impact (LCA) need to be integral to design process. Develop capability in life cycle assessment and costing to show the benefits of composites.

4. Sustainable residue (waste) collection include smart tracking to enable

valorisation of waste streams. To accelerate commercially viable recycling, the composites and Chemistry and IB sectors must work with the waste management industry. Enabling development of markets for recyclates with associated standards and support creation of Glass Reinforced Polymer (GRP) recycling supply chain.


Background There is a global need to reduce CO2 emission from Chemical Industry and Automotive and Aerospace sectors. Routes to achieve this include light-weighting of vehicles, improved sustainability of material manufacture from IB & bio-based routes and innovations in the reuse and recycling of materials. The Composite Leadership Forum 2016 UK Strategy identified opportunity to grow current £2.3bn composite product market to £12bn by 2030 [1]. Investment in composite materials is essential in delivering UK growth through the multi-sector application of composites. Action is required to produce a Composite industry that is sustainable into the future. Increasing the market penetration of composites will reduce environmental impact through light-weighting and durability, but there is a need to incorporate circular economy principles alongside rapid development of composite materials. There is a need to develop cost-effective bio-based raw materials to further reduce environmental impact and de-couple prices from oil. While some polymers and chemical feedstocks have traditionally been produced economically from bio-based resources (e.g. rubbers, some phenolics, furans and acrylates), in general bio-based feedstocks at present are not economical compared to petro chemical derived equivalents.

With the launch of the UK bioeconomy strategy, definitive targeted industry needs to replace or augment traditional fossil-based materials and products are actively being sought and included. There has been an increase in light-weighting applications to Advanced Propulsion Centre (APC) funding round 7 and with funding secured for batteries for Electric Vehicles, light-weighting and sustainability are the next innovation challenges for the aerospace and automotive sectors, which will require disruptive solutions from the Chemical and IB sectors. Fibre reinforced polymer composites can improve environmental impact in many cases by reducing weight and increasing durability. Making composites better, faster and cheaper, so breaching new markets, is the primary way the Composites industry can have a positive environmental impact.

However, there are challenges to overcome:

• to improve recycling and disposal methods and supply chains; • to incorporate more bio-based materials; • to understand the impact of the products we produce both to the factory gate and

through life;

What is a Composite? A composite material is composed of at least two materials, which combine to give properties superior to those of the individual constituents. This work refers to fibre reinforced polymer (FRP) composites, usually with carbon, glass, aramid, polymer or natural fibres embedded in a polymer matrix. Other matrix materials can be used and composites may also contain fillers or nano-materials such as graphene. The many component materials and different processes that can be used make composites extremely versatile and efficient. They typically result in lighter, stronger, more durable solutions compared to traditional materials.


• to include environmental impact at design stage; • to spread good practice in resource and energy efficiency and structure business models

to promote this.

The increasing emphasis on life cycle analysis and the fluctuating, but rising price of oil and its derivatives are two of the challenges faced by the UK Composites sector which could be addressed by developing bio-based chemical feedstocks e.g. for composite resin systems.

The aim of this study is to determine the role of IB and biocomposites to provide disruptive solutions to the sustainability and recyclability aspects of composite materials and new pathways to precursors and resins. To identify the future strategic insights and funding needs with specific technological challenges to be identified a desk study to develop insight on the UK players and what the supply chain with look like, together with two workshops (York 26 Feb 2018 and Manchester 28 March 2018) of key stakeholders from both the technology providers (IB) and materials producers from both academia and industry, were completed to develop a technology needs and gap perspective and identify where the UK has specific leading position. A series of recommendations are provided for how Innovate UK can support this opportunity.

This report focuses on fibre reinforced polymer composites. There are many types of fibre which can be used to reinforce polymer matrix composites. The most common are carbon fibres and fibre glass. Fibre reinforcement in thermoplastics has three basic forms; short, long or continuous (several feet to several thousand feet).

Industrial Biotechnology (IB) is defined as “the use of biological substances* for the processing and production of enzymes, chemicals, materials and energy”. * plants, algae, marine life, fungi, micro-organisms

What is Industrial Biotechnology?

Industrial Biotechnology (IB) integrates product improvements with pollution prevention and involves working with nature to maximize and optimize existing biochemical pathways that can be used in manufacturing. The industrial biotechnology revolution rides on a series of related developments in three fields of study of detailed information derived from the cell: genomics, proteomics, and bioinformatics. As a result, scientists can apply new techniques to a large number of microorganisms ranging from bacteria, yeasts, and fungi to marine diatoms and protozoa.


Overview of Sustainable Composites Composite materials can in many cases reduce the life cycle environmental impact via weight reduction and durability, but the raw materials have relatively high environmental impacts. For the higher volume glass fibre composites, the resin matrix is typically the largest component of the life cycle assessment. Therefore, innovations to replace all or part of the resin feedstocks with bio-based materials could reduce the overall impact of a composites part. It is essential that the processing route for new bio-based materials does not negate the benefit of the bio-sourced materials. Bio-sourcing of materials is gaining increased market interest, particularly from the Automotive and Construction sectors and the recent 2016 UK Composites Strategy made several recommendations regarding sustainability:

1. Develop capability in life cycle assessment and costing to show the benefits of composites

2. Develop markets for recyclates with associated standards and support creation of Glass Reinforced Polymer (GRP) recycling supply chain

3. R&D to integrate industrial biotechnology into the supply chain and optimize value from natural fibres

4. Reduce waste and develop energy efficient manufacturing technologies

5. Develop best practice in design, and business models, for environment

Legislative drivers in the EU via the Waste Framework Directive (WFD) have extended the producer responsibility and are tending to limit ‘recyclable’ to landfill. The WDF requires re-use/ recycle/recover 70% of construction waste by 2020. The End of Life Vehicle Directive (ELV) requires 85% reuse/recycle.

Glass fibre reinforced plastic (GFRP) manufacture in the UK is approximately 130kt/year and predominantly uses unsaturated polyester resin (UPR) with some epoxy and polyurethane resins. This relates to approximately 50kt UPR usage in UK annually. Epoxy resin use in composites is much lower. Producing bio-based glycols and polyols, used as the backbone of UPR and polyurethane, is relatively straightforward and large-scale supply of these materials is emerging through companies like Bioamber and Myriant. The key challenge lies in the aromatic compounds such as styrene, maleic anhydride and phthalic anhydride. Several UPR manufacturers have part bio-based UPR analogues on the market. The maximum impact is likely to be realised in developing cost-effective processes for obtaining these aromatic compounds, or effective alternatives from biomass sources.

What does Sustainability mean?

Brundtland Commission, 1987

Sustainable development is the kind of development that meets the needs of the present without compromising the ability of future generations to meet their own needs.


The term Thermoplastic Composite refers to a composite with a thermoplastic material as the matrix. Thermoplastics commonly used in composites include, but are not limited to:

PE – Polyethylene PP – Polypropylene PBT – Polybutylene Terephthalate PA – Polyamide (nylon) PPS – Polyphenylene Sulfide PEI – Polyester Imide PEKK – PolyEtherKetoneKetone PEEK – PolyEtherEtherKetone

There are many factors that need to be considered when selecting a thermoplastic matrix; operating environment (e.g. operating temperatures, exposure to sun, water, chemicals), mechanical properties (e.g. strength, stiffness and toughness) and cost (financial and environmental). There are two major materials in epoxy resins; Bisphenol A and Epichlorohydrin. Feedstocks


Images courtesy of Dr. Thomas Farmer, University of York, Green Chemistry Centre of Excellence.


Where bio-based materials add value

In the first instance drop in replacements for fossil-derived monomers will be preferable e.g. fit into current supply chains, existing manufacturing processes and legislation. Longer-term we need to consider the opportunities for using the high oxygen content of biomass as a feedstock. The chemical diversity in platform molecules (bio-derived building blocks) brings challenges in terms of processing, but there are also opportunities for new chemicals and processes leading to new intellectual property. Some bio-based feedstocks have inherent chirality, which should not be dismissed as synthetically chirality is difficult to achieve.

Biomass already contains many polymers (e.g. cellulose, starch, lignin chitin, protein etc.), which composites can also use, so understanding the coupling of these bio-based polymers with new bio-based monomers will be key to future success in materials development and manufacturing at scale with the require cure temperatures and times.

In some cases, bio-based materials can add value in terms of the materials properties. One example is polyfuryluryl alcohol, where fire resistance and mechanical properties are comparable to phenolic resins, but the smoke and carbon monoxide release is much lower and the material handling is easier due to minimal toxicity. Another example is Fumaric acid, which is more reactive than its isomer maleic acid, but is not commonly used in unsaturated polyester resin (UPR) production as the fossil-derived sources of fumaric acid are brown in colour (due to oxidation from the processing). Fumaric acid can be produced from bio-based sources by different processing routes yielding colour pure material. There is an opportunity to add value to


UK composite materials sector by developing areas where bio-based materials bring an added bonus in terms of material properties or health and safety.

UPR

Polytransesterification of maleate (MA) or itaconate (IA) diesters and various diols has been used to produce UPRs. Curing via the C=C is typically used to create coatings etc. IA can be used as a replacement for the petrochemical derived MA. IA has been produced industrially from the fungal fermentation of glucose (a bio-based process) since the 1960’s and can be co-polymerised with other bio-based monomers to tailor the final properties of the resin/coating. T. J. Farmer et al., Int. J. Mol. Sci., 2015, 16, 14912-14932.

Itaconic Acid vs Maleic Acid

The maximum impact is likely to be realised in developing cost-effective processes for obtaining aromatic compounds, or effective alternatives from biomass sources such as alternatives to styrene, maleic anhydride and phthalic anhydride. The development of platform molecules (bio-derived building blocks) as alternatives to fossil-derived base chemicals provides an opportunity to capitalise on the inherent oxygen content and chirality of various biomass resources.


Technology Needs

The desk study and outputs from the two workshops revealed the following technology needs:

1. Extraction of high value chemicals What routes are available? e.g. Fermentation

2. Understanding where bio-based materials add value e.g. Improved Fire Smoke Toxicity (FST) performance, bio-inspired functionality

3. Monomers for bio-resins (what are we already making?) e.g. Routes to Bisphenol A and Epichlorohydrin.

4. Bio-based alternatives (to petrochemicals) e.g. Alternatives to Styrene, bio-based succinic acid

5. New design and approaches to deliver improvement requirements e.g. Improved interfacial adhesion, Chemical indicators to determine state of cure, de-bondable systems.

Delegates at the two workshops were asked to highlight areas where the UK had a leading position and identify what expertise and/or capability the UK needs or can leverage to build on the UK leading position for the five topic areas above.

Composites Sector Improvement requirements:

1. Improve availability and reliability of Life Cycle Assessment data. Include LCA in every funded project.

2. Develop more detailed avoided impact scenarios. Economic recycling processes which are contamination-tolerant.

3. Optimise biorefinery processes. Low impact carbon fibre and precursors.

4. Sustainable residue (waste) collection include smart tracking to enable valorisation of waste streams. Design and manufacture with recycled fibres.

5. Chemistry solutions to improve existing or deliver new composite processing techniques. Cost-effective, scalable processes for chemicals from bio sources. Energy efficient manufacturing technologies.

Chemical and IB sector challenges:

1. Improved molecular weight control to manage viscosity and facilitate impregnation

2. Monomers and additives for high rate consolidation and cure control of highly reactive resins

3. Improved interfacial adhesion

4. Monomers for controllable breakdown for reuse


5. Development of de-bondable systems

6. Chemical indicators to determine state of cure

7. Chemical markers for bond certification

Fossil-derived Base Chemicals don’t contain any inherent chirality and methanol is the only oxygen containing base chemical from fossil fuels. Biomass resources have oxygen containing and chiral building blocks (platform molecules), which are not available from fossil-derived base chemicals.

The UK has existing capability and a leading position in IB and recently completed a piece of work to identify the top value-added chemicals from Biomass. Build on the UK BioChem10 list to identify opportunities for bio-based routes to sustainable monomers for composite materials. The analysis shows a range of biochemical with potentially good market attractiveness which are also relevant to sustainable composite materials.

Market attractiveness versus UK strength of Biochemical opportunities


UK Position

The UK has industrial activity in Bio-based composite materials e.g. Scott Bader (Resins) and Bitrez (Resins), Cambridge Biopolymers and Cambond. There is also a number of companies in the polymers in composites area which include:

• FAC Technology• Revalutech Ltd• Interface Polymers• Polychemtech Ltd• FGV Cambridge Nanosystems• Axion Recycling

• Elektron Technology• Sam Weller & Sons• Shannon R&D Ltd• Haydale Composite Solutions• Composites Braiding Ltd• KW Special Project Ltd

Bitrez Ltd have developed a low free formaldehyde CURAPHEN phenolic polymers Curaphen phenolic polymers have been designed for application in the area of specialist coatings and as matrix resins for the design of lightweight composites. Bitrez developed specialist grades within their Curaphen range early in 2015 in order to satisfy specific concerns raised as a result of the reclassification of formaldehyde and reduction of threshold limits under REACh (Registration, Evaluation, Authorisation and Restriction of Chemicals). As formaldehyde levels remain in pre-preg after manufacture, a significant amount of pre-preg on the market today contains the carcinogenic chemical. However, by simply switching to a low free from formaldehyde resin from within the Curaphen portfolio, toxic emissions are reduced, and worker’s health and safety is protected.

Composites UK, is the trade association for the UK Composites sector and works closely with the Composites Leadership Forum. Composites UK has a number of cross-sector working groups which include the Sustainability Sub-group, Chaired by Steven Brown (Scott Bader). The Sustainability Sub-Group works to overcome these challenges, progress and promote good practice and disseminate new developments. They work with other relevant organisations to accelerate progress and reduce duplication.

Current Sub-group members:

• ARTIS• Ben Ainslie Racing Ltd• Composite Braiding Ltd• Eco-Composites Ltd• ELG Carbon Fibre Ltd• Filon Products Ltd• Margent Farm Ltd• Meggitt Polymers & Composites

• National Composites Centre• Pentaxia Ltd• Prodrive Composites Ltd• Scott Bader Company Ltd• Sigmatex (UK) Ltd• V-Carbon UK Ltd• Warwick Manufacturing Group

https://compositesuk.co.uk/industry-support/sub-groups/sustainability-sub-group

http://www.scottbader.com/

http://www.cambridge-biopolymers.com/

http://cambond.co.uk/

https://www.revaluetech.co.uk/

https://interfacepolymers.com/

http://www.polychemtech.com/

https://www.haydale.com/

http://www.bitrez.com/




UK Leading Position The UK has a leading position in IB and a Composites sector which is looking for disruptive solutions to incorporate circular economy principles alongside the rapid development of next generation sustainable composite materials. With strategic intervention and cross sector collaboration the Chemical and IB sectors can deliver these disruptive solutions to the sustainability and recyclability aspect of composite materials and new pathways to precursors and resins.

Other areas identified as UK leading positions include:

• Electrochemistry expertise; bioelectrocatalytic redox of starting materials and intermediates catalysis (e.g. Harwell). Need to change the mindset to include other catalytic routes.

• Block Chemistry Engineering; Separations, Analytics, IB

Examples of innovative materials from bio-based feedstocks

• DuPont Sorona, a high-performance polymer is made with renewable, plant-based ingredients, for use in everything from carpets to ski jackets to sarees with exceptional softness, high durability, stretch, and strain resistance.

• Furan dicarboxylic methyl ester (FDME), a revolutionary biobased monomer from a renewable feedstock with applications in packaging, textiles and engineering plastics.

• Poly(lactic acid) polymers and their derivatives from naturally occurring l-lactic acid.

• Bio-based Succinic Acid as a building block for polyester Resins and Composites. It has improved UV stability and Excellent Mechanical Properties.

• Bitrez Ltd low free formaldehyde CURAPHEN phenolic polymers Curaphen phenolic polymers have been designed for application in the area of specialist coatings and as matrix resins for the design of lightweight composites structures in industries such as aerospace, rail and construction.


Lignocellulostic Biorefinery Network (LBNet) UK BioChem 10. Top bio-based chemicals for the UK: Challenges and Opportunities

Initiate the identification of the most promising bio-based chemicals for production in the UK. The aim is for this list to provide a collaborative focus for industry and academia and speed up innovation in the bio-based chemicals sector in the UK. Aim is to bring together complimentary teams from academia and industry, and develop the best ideas for proof of concept studies (up to £50,000) to initiate work in this area and prime it for opportunities arising from the Industrial Strategy Grand Challenge.

Green Chemistry Centre of Excellence (GCCE) An internationally-leading academic facility for pioneering pure and applied green and sustainable chemical research through its technology platforms on microwave chemistry, alternative solvents, clean synthesis and bio-based mesoporous materials. GCCE’s facilities allow them to work from grams to kilograms with a strong emphasis on waste valorisation and clean technologies.

PET vs. Bio PET When considering replacements with bio-based materials the entire Life Cycle Assessment needs to be considered. A recent case-study replacing PET bottles with BioPET bottles.

EG comes from bioethylene – e.g. from corn, switch grass and wheat straw. TA comes from lignocellulosic biomass from forest residues or corn stover- transformed to iBuOH then to p-xylene. Woody-biomass based PET bottles have 21% less GWP and require 22% less fossil fuel than their fossil based counterpart, but perform worse in other categories such as ecotoxicity and ozone depletion impacts. Comparative life cycle assessment of fossil and bio-based polyethylene terephthalate (PET) bottles Chen, L; Pelton, REO; Smith, TM; Journal of Cleaner Production; 137, (2016), 667-676


Workshop Outputs



Key challenges and developments which will make bio-based composite materials economically competitive with oil-based materials:

1. The development of platform molecules (bio-derived building blocks) as alternatives to fossil-derived base chemicals provides an opportunity to capitalise on the inherent oxygen content and chirality of various biomass resources, which should not be dismissed as synthetically chirality is difficult to achieve.

2. The maximum impact is likely to be realised in the development cost-effective

processes for obtaining aromatic compounds, or effective alternatives from biomass sources such as alternatives to styrene, maleic anhydride and phthalic anhydride. Developing Furanic monomers offers an alternative to Phenolics.

3. Understanding the coupling of bio-based polymers with new bio-based

monomers will be key to future success in materials development and manufacturing at scale with the required cure temperatures and times.

4. There is an opportunity to add value to UK composite materials sector by

developing areas where bio-based materials can add value in terms of the materials properties or health and safety.

5. Mapping the industry end user material properties to potential sustainable

feedstocks including an understanding of the scale required is essential to recovering high value chemicals at required scale from bio-sources (Lignin) through catalysis and developing bio-based composite materials.


Recommendations

Investment in the development of sustainable composite materials now is essential in delivering UK growth through the multi-sector application of composites. In the short term, drop-in replacements for fossil-derived monomers will be preferable minimising disruption to current supply chains and legislation. In the longer-term we need to consider the advantages of higher oxygen content and chirality of biomass as a future feedstock. The chemical diversity in platform molecules (bio-derived building blocks) brings challenges, but also opportunities for innovation and new Intellectual Property. Cross sector Collaboration

The Legislative drivers of WDF and ELV will require the UK Composites sector to innovate in the development of sustainable composites. Improvements in Life Cycle Assessment (LCA) and understanding waste management are essential to realistically integrate solutions. To accelerate commercially viable recycling, the composites sector must work with the waste management industry. Sustainable feedstocks are available which can utilise IB approaches to develop a sustainable composites market. Need to develop sustainable residue (waste) collection including smart tracking to enable valorisation of waste streams. To meet the 2030 opportunity for market growth of £2.3bn to £12bn, in the CLF 2016 Composites Strategy, we need to innovate now. Ideally a dedicated funding to kick start the currently limited collaborations between the IB and composites sectors. A £2m Innovation Challenge in Bio-based routes to sustainable composite materials, with focus on platform chemicals (bio-derived building blocks) as an alternative to base chemicals (crude oil derived) and develop sustainable residue (waste) collection including smart tracking to enable valorisation of waste streams leading on to £8m Accelerating Innovation in Sustainable Composite Materials.

£2M Call – Resource £2M Capital zero £8M Call – Resource £4M Capital £4M The Bio-Based Industries Joint Undertaking (BBI JU) is the largest and most ambitious initiative launched by the EU to develop competitive and sustainable bio-based industries. With a total budget of €115million, the 2018 call is built around four strategic orientations: Feedstocks, Process, Products and Market uptake. The UK IB and Composites sectors need to collaborate at a strategic level, via IBLF and CLF to capitalise on the BBI JU €115m funding opportunity. There is also potential for connectivity with other programmes/industries, for example:


• MIB proposal for EPSRC Bioengineering Innovation Hub. Successful in initial round and now developing support for next phase of competition. For further details contact Kirk Malone (MIB).

• Leverage activities in KTN’s Materials for Composites SIG to disseminate opportunities and technical asks from growth sectors identified in the CLF 2016 strategy.

• Support regional activities and clusters e.g. ERDF (Aaron Hunter- Hethel Innovation)

Action: Innovate UK and KTN Chemistry & IB team.

Knowledge Transfer

Simple glossary of definitions for the Chemical and Composites Industries on what Bio-based really means. Explanation of the differences between biodegradable and biocompostable. Definitions of Bio-based materials for example what percentage needs to be from bio-based sources to be classed as a bio-based material? How to distinguish between bio-based and bio-derived and bio-designed? UK has a leading position in Biocatalysis, but there is a need to change the mindset to include other catalytic routes.

Action: KTN Chemistry & IB team. Disseminate the findings from the UK BioChem 10 report to the Chemistry and Composite Sectors and build on this to develop action plan for cross-sector CR&D in Sustainable Composite Materials. Action: Innovate UK and KTN.

Key Recommendations

• Investment in the development of sustainable composite materials now is essential in delivering UK growth through the multi-sector application of composites. CR&D programmes: £2m Innovation Challenge in Bio-based routes to sustainable composite materials, with focus on platform chemicals (bio-derived building blocks) as an alternative to base chemicals (crude oil derived) leading on to £8m Accelerating Innovation in Sustainable Composite Materials.

• The chemical diversity in platform molecules (bio-derived building blocks) brings challenges, but also opportunities for innovation and new Intellectual Property. Disseminate the opportunities in the UK BioChem 10 list (top bio-based chemicals for the UK: Challenges and Opportunities) to Chemistry and Composite Materials Sectors.


• Develop best practice in design. Design for repair and end of life (circular economy), Bio/recycled content and environmental impact (LCA) need to be integral to design process. Develop capability in life cycle assessment and costing to show the benefits of composites.

• Sustainable residue (waste) collection include smart tracking to enable valorisation of waste streams. To accelerate commercially viable recycling, the composites and Chemistry and IB sectors must work with the waste management industry. Enabling development of markets for recyclates with associated standards and support creation of Glass Reinforced Polymer (GRP) recycling supply chain.

These recommendations fit to the Innovate UK 5-point plan

• turn scientific excellence into economic impact and deliver results through innovation, in collaboration with the research community and government ensure focus on driving productivity & growth in bio-based raw materials. The UK has world class bioscience (IB) capability that is currently being transformed into commercial products through several years targeted support in IB. However, composite materials are an area where IB could have an impact.

• accelerate UK economic growth by nurturing high-growth potential SMEs in key market sectors, e.g. the development of medical composites which is a growing area for SME’s such as Victrex and renewables sectors (Marine & offshore wind). Provides different target industries/sector for the vibrant IB community of companies.

• build on innovation excellence throughout the UK, build on the momentum in the growth of Composite materials in UK & globally. Also fits with Innovate UK’s criteria of supporting UK manufacturing and supply-chains.

• develop Catapult centres within a national innovation network strengthen the proposal to extend the HVM Catapult to include a National Composite Materials Centre (NCMC) with a focus on composite precursors and manufacturing. HVM Catapult also has CPI as member organization which helps IB companies de-risk through their open access IB facilities which is essential when embarking on new capex intensive projects, which IB undoubtedly needs for success.

These recommendations also fit to sector strategies (CLF):

• In line with manufacturing strategy to develop new materials and use IB as an enabling technology.

• Develop cost-effective bio-based raw materials for use in composite end products.

• Develop markets for recyclates & support creation of Glass Reinforced Polymer (GRP) recycling supply chain.

• Integrate Industrial Biotechnology into the supply chain and optimise value of natural fibres giving new properties and functionality if required.

• Reduce waste and develop energy efficient manufacturing technologies.


• Launch of UK Bioeconomy strategy: composites could indeed be a downstream beneficiary industry of bio-based feedstocks and technologies.

• This also aligns with aspects of the Composites and Chemistry Sector deals and light-weighting aspects of automotive sector.


Appendices

Workshop Delegates

Industry: Composites UK Scott Bader Bitrez Ltd Victrex plc Johnson Matthey Unilever R&D BAE Systems Novamat Solid Solutions Management Ltd Jaguar Land Rover Focal Limited Iceni Diagnostics Ltd NNFCC Bioeconomy Consultants

RTO/Other: Centre for Process Innovation Knowledge Centre for Materials Chemistry National Composites Centre GrantTree IPO KTN

Academia: University of Manchester, Green Chemistry Centre of Excellence Manchester Institute of Biotechnology University of York, Green Chemistry Centre of Excellence University of York, CNAP BIOCATNET University of Bristol Northumbria University Newcastle University University of Edinburgh University of Exeter Imperial College London

Reference Material

Composite Leadership Forum 2016 UK Strategy Composites Recycling Report, July 2016 UK BioChem 10, Draft report, 2018 Technology Overview Biocomposites, Materials KTN 2014.

https://compositesuk.co.uk/system/files/documents/Strategy%20final%20version_1.pdf

https://compositesuk.co.uk/system/files/documents/Recycling%20Report%202016%20-%20Light%20Background.pdf

https://netcomposites.com/media/1211/biocomposites-guide.pdf

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Industrial Biotechnology (IB) and Bio-based Routes to ...€¦ · Report on Industrial Biotechnology (IB) and Bio-based Routes to Sustainable Composite Materials 3 Executive Summary