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Sustainable fibre sources
and bast fibre crop markets
Jan E.G. van Dam
30-07-2015
Outline
Wageningen UR – Food and Biobased Research
Natural Fibre technology / process and product innovation
Cellulose markets /
Bast fibre niche markets
Market study FIBRA – EU & China
Wageningen UR
Domain: healthy food & living environment
Turnover in ca 700 M€
Fast increase in number of students
Extensive international network
Forty locations, main hubs in Brazil, China and Chile
…to explore the potential of nature to improve the quality of life…
Organisational structure Wageningen UR
Wageningen International
IMARES
Wageningen Academy
RIKILT
Food & Biobased Research
Livestock Research Central
Veterinary Institute
Alterra LEI Centre for
Development Innovation
Plant Research International Applied Plant
Research
Agrotechnology & Food Science
Animal Sciences Environmental Sciences
Social Sciences Plant Sciences
Agrotechnology & Food Sciences
Group
Animal Sciences Group
Environmental Sciences Group
Social Sciences Group
Plant Sciences Group
Supervisory Board
Executive Board
Concern Staff Facilities & Services
Wageningen University
Research Institutes
Food & Biobased Research
Agrotechnology & Food Sciences
Agrotechnology & Food Sciences
Group
Youtube
https://www.youtube.com/watch?v=sDUXUII_9Wg
https://www.youtube.com/watch?v=ffK0mVhEXEI
Expertises Biobased Products
Sustainable logistics & chains
Biomass production and pretreatment
Proteins, lipids and carbohydrates
Biobased materials
Biobased chemicals
Bio-fuel technologies
Expertise Natural Fibre Technology
Fibre raw material resources / supply chains
Fibre extraction and processing
Fibre product development
Fibre qualification / analysis
Composite and fibre board manufacturing
Paper/paperboard manufacturing and testing
Cellulose extraction/modification (nano-fibres)
Lignin characterization and application development
Resin/polymer processing application
Coatings/adhesives/colloidal systems
Refinery into valuable components
Products and Market(s)
Developing:
● Added value products from Bio-based residues
● Added functionality products
● Packaging
● Textile
● Fibres
Bioplastics
Fibres & products
Biocomposites
Bulk & fine chemicals
Pro
du
cts
Markets
Paper and board
Textile
Packagin
g
Build
ing a
nd c
onstr
uction
Auto
motive
Cosm
etics a
nd P
harm
acy
Bioeconomy and biobased economy
Circular BioEconomy
Transition to the bio-based economy
• Total annual growth of dry weight biomass by photosynthesis in green plants 175 billion tons (175 Gton / 2500 EJ)
• For human consumption (food, feed, non-food) 6 Gt is harvested each year (or 3.5% of total plant production)
• Current world wide land use: • 10-12% cultivated terrestrial surface • or 50% of the suitable arable land area
If 15% of the Global energy demand for human needs in 2050 is provided by biomass
10 Gtons (160 EJ) is needed (or 6% of total plant production)
Including population growth and increase in standards of living
Transition to the bio-based economy
World Biomass demand in 2050
Food/feed 10 Gton biomass for 3 billion ton
Energy: 10 Gton equivalent to 160 EJ
Chemical industry: 1 Gton for 0.3 Gton product
Specialties: 1 million ton
Wood & paper pulp,
composites: 3-4 Gton
Bio-based economy Opportunities
• Value addition in materials, and ‘green’ chemicals
• sufficient renewable resources available for
– food
– feed
– energy
– materials
– chemical industry
• Position of bast fibre crops in the bioeconomy?
Transition to the bio-based economy
• If there is enough biomass available
• How to change to the bio-based economy?
• There is not one strategy………..
• Required: sophisticated combination of resources and processes leading to defined value added products
Competing claims for biomass resources
Sustainable production
food supply security
land use (ILUC)
deforestation
rural development
Rapid expansion of demand for energy purposes
DEVELOPMENT OF BIOREFINERY
Food
Biomass production
1st Agro logistics Food pretreatment
Food production Conversion
Non-
food: • Feed
• Compost
• Waste
management .
Agri sources Agro-food production By products & waste
Logistics& storage production Imports
Conversion
Production
$
$
$
Biobased
Products • Biobased
materials
• Green
chemicals
• Bio-fuels
• Bio-energy
Production Performance materials Base&platform chemicals Performance chemicals Bio Energy
Pre-treatment & conversion
The bio-based economy: linking of markets
Cellulose production
World production biomass Human consumption 170x109 t / y 6x109 t / y
ProBIB 2008
Cellulose 50-70x109 t/y Non-food 2.3x109 t / y
Wood for
energy,
paper,
furniture and
construction
33%
Non-food
use
(clothing,
chemicals)
5%
Food
62%
3.5%
Cellulose Matrix
Cellulose Matrix niche bast fibres
World fibre production
World fibre production 1920-2006 (kton)
0
5,000
10,000
15,000
20,000
25,000
30,000
35,000
40,000
1915 1925 1935 1945 1955 1965 1975 1985 1995 2005
Cotton
Synthetic (petro-based)
Man-made cellulose fibres *
EU-China fibre trade
22
Exports of flax fibre from EU to China for yarn spinning, weaving, and finished linen textile products manufacturing Imports of hemp and flax linen goods from China to EU
Fashionable industries
• Short living trends
• Exclusive branding
• Poor quality products
• Very cheap for customers
• Flax linen industries supply and demand fluctuations
• Unpredictable prices
• Unreliable customers
• Incomplete supply chain
Cellulose production
cellulosic fibres 103 ton/yr major producing countries
cotton 25.000 China, Brazil, India, Pakistan, USA, Uzbekistan
flax 300 EU, China
hemp 90 China, EU
jute 2.500 Bangladesh, India
kenaf 350 China, Thailand
ramie 280 China, Brazil
abaca 70 Philippines, Ecuador
coir 500 India , Sri Lanka
sisal 300 Brazil, Kenya, Tanzania
Cellulose feedstock
• Shift of market demand for cellulose
• Carbohydrate source for 2e generation bio fuels
• Biorefinery and ‘green chemistry
• Effects on paper industries:
• Digitalisation
• Interest for alternative
• fibre sources
Cellulose price increase
• Straw 50-100 € / ton
• Wood chips 100
• Pulp 650-900
• Raw hemp 350 - 650
• Flax 1500-1800
• Raw cotton 1700 - 2500
• Dissolving cellulose 1750
• Viscose / rayon 2000
• Celluloid 3300
Kenaf production decline
0
200
400
600
800
1000
1200
kto
n/y
ea
r
Year
africa
latin america
near east
far east
world
Transition point?
Fibre crop markets
market Products Niche markets for bast fibre
1 Textiles fabrics of cotton, linen,
viscose, lyocel, acetate Apparel, carpet backing, upholstry sacking, geotextiles
2 Twine Ropes, cordage Agricultural twine, baler &
binder twine, packaging
3 Non-woven needle punched, wet laid, air laid,
hygienic tissues, diapers, wipes, filters
Padding, insulation, geotextiles, filters mulch fleece
4 Pulp, paper and board
newsprint, writing, specialty paper, corrugated boards
Security paper, cigarette paper Wrapping paper, filters
5 Cellulose dissolving pulp
viscose, lyocel, cellulose derivatives, CA CMC HEC
-
6 Cellulosic Films packaging, membranes, -
7 Building materials Veneer*, plywood*, fibre boards,
Insulation, plaster and blocks Particle boards Insulation materials , fibre concrete
8 Cellulosic fibre composites
moulded compounds, laminates, mineral matrix fibre composites
Automotive interior parts,
9 Green chemicals bioethanol, organic acids, furans,
biopolymers -
Composites & building materials
• Polymer composites in automotive – Compression moulding – Injection moulding – NMT prepregs – Sheet moulding
• Fibre boards (MDF, HDF) – Particle (shives) boards
• Mineral fibre composites – Cement / lime/ magnesite / clay
• Insulation rolls and blankets
16-18 June 2014 NAROSSA, POZNAN 29
Fibre composite market
Trends in fibre reinforced composites
Agrofibre compounds for injection moulding /
3D printing / forming
Biopolymers (PLA/ PHA/ bioPP)
Cement composites /light weight construction
Fibre boards and panels Injection moulded products from natural- fibre/plastic granules
Economic feasibility
Market demands
● Technical performance / availability
Cost of processing / modification
● Acceptable costs range of treatment
● Investment for implementation
Economic scale of fibre processing / modification
‘Glove box’ Audi A2
Examples Injection moulded products
‘Glove box’ Daimler (prototype)
Werzalit
Loudspeaker Housing Audi
Ironing device Fan Rotor
Handy NEC
Examples Injection moulded products
Vacuum cleaner
Tableware: Cup & Soup bowl
Examples Injection moulded products
Shaving Brush
Chair IKEA
Grinding Disk
Polymer and fibre technology trends
• Nanofibre from bast fibre/wood pulp
• refine conditions
• properties
• Diameter 50-100 nm
• High specific surface
• High strength and modulus
• Translucent
• Durable
• Biodegradable
• Renewable, CO2 neutral
(bio)chemical modification
Fibre based construction
Biobased building: Renewable Hemp house (UK, FR) Hemp in concrete (Hempcrete) Roofing membranes Flax door panels, insulation Separation walls Grow2Built / CA’PEM
NAROSSA, POZNAN 16-18 June 2014
Flax and Hemp building products
Crop Plant part Product By-product Use in building and construction
Flax / Hemp
Seed Oil
Linoleum Paints & coatings Putty
Press cake -
Stem
Fiber (bast)
Fabric: curtains, wall coverings, batten, bags & canvas Twine: Ropes & twine, lines Non-woven: Insulation mats Paper: Sheets, Foam, fluff Cellulose: Polymer and mineral composites.
Shives (hurts) Particle boards, mineral composites
Flax insulation
Hemp Insulation
Flax composite boards
Prefab hempcrete elements
Linoleum flooring
On going R&D
Fire retardant building materials
Fibre cement / concretes
Biobased resins and polymer composites
Biobased building in relation to indoor climate and health
1st International Conference on Biobased Building Materials Cerlmont Ferrant France, 21 07 2015
16-18 June 2014 NAROSSA, POZNAN 44
Fibre based geotextiles with prolonged life-
time
Dunes replanting with jute fabric
Experimental plot Regge & Dinkel, March
1999
Demands functional lifetime geotextile
Durability increase by acetylation
Conclusions: • 3-5 x life time extension of jute, flax and cocos
• Very well rooting of plants
• After 5 yrs only cocos can be retraced
Geotextiles and horticultural mats markets
EU – project FP7 BIOAGROTEX (2008-11) technical textiles for agrotextiles / (recycled jute non-wovens / Up-scaling production acetylation (UK / NL / BE) Other innovative methods of modification
EU Hemp markets and products
Hemp Shives:
horse and other animal bedding and horticulture 50-70%
Competitors: wood pellets, cereal straws
light weight concrete, particle boards 15%
Competitors: Wood chips / flax shives / straws
NAROSSA, POZNAN 16-18 June 2014 50
Hemp Shives Applications: 43,621 tonnes (EIHA 2012)
European Hemp 2010
NAROSSA, POZNAN 16-18 June 2014 51
Other market developments
• Ramie: multi-purpose crop animal feed & mushroom growing medium
• Soil remediation
• Folk medicine
• Forage & animal feed (bird seeds,
• Animal bedding & absorbants
16-18 June 2014 NAROSSA, POZNAN 52
SWOT
Strength EUR CHN
Weakness / risks EUR) C
HN
Established production + + Relative small scale industry + +
Full commodity market + + Eroding market position + +
Diversity of market outlets + + Interdependency in production and supply chain + +
Ecological positive image + + Labour intensive production + +
Good seed varieties available + + Obsolete retting & degumming methods + +
Well known agronomics + + climate dependency of crop productivity + +
limited fertilizer, pesticide, chemicals + + Annually variable qualities + +
Mechanisation of crop production + - Fashion trend dependency of top quality market product + +
Strong fluctuating market prices + +
Opportunities /chances Threats
Ecological & sustainable products + + Low profits for chain partners + +
High quality products + + Loss of skilled chain partners + +
Diversification and new innovative products + + Alternative production methods + +
Non-traditional bulk markets + - Competing low cost fibre products + +
Competing arable crops + +
Poor organization of the sector + -
16-18 June 2014 NAROSSA, POZNAN 53
SWOT of Flax and Hemp
Europe and China
• Small holders involved in the whole production and supply chain.
• Competition among producers is high on local and international levels
• High demands on the product quality, high risks of crop failure
• Suppression of production costs and increasing wages are scrutinizing the competitiveness of the sector and affects the quality of the products
16-18 June 2014 NAROSSA, POZNAN 54
SWOT of Flax and Hemp
Europe and China
• High prices for maintaining production of top quality textile fibres results in lower competitive with bulk products like manmade fibres and cotton
• High costs of production contra-productive for lower-end fibre bulk market products, (building materials and composites) where cheaper and established products are available.
16-18 June 2014 NAROSSA, POZNAN 55
SWOT of Flax and Hemp
Europe and China
• Ecological and sustainable preference of increasingly conscious consumers can be exploited as niche market
• Diversification of the markets for bast fibres the decline of production area may be reversed both in Europe and China.
• Mechanisation of the production of fibres of different quality standards is of interest.
• The trade of fibres as commodity product needs further expansion, when the sector is to survive in the 21st century.
16-18 June 2014 NAROSSA, POZNAN 56
Thank you for
your attention
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