Hall2C Wednesday 11h15 - Dr Sudhakar Muniyasamy

Contents

DEVELOPMENT OF SUSTAINABLE BIOBASED COMPOSITE PRODUCTS FROM AGRICULTURAL WASTE

Sudhakar Muniyasamy and Sunshine BlouwCSIR-MSM, Nonwoven and Composite Research Group

Port Elizabeth 6001E-mail: [email protected]

Industrial Efficiency Conference 2015, 21&22 July 2015, ICC-Durban

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INTRODUCTION : World Plastics Production, Consumption and Demands and its related Environmental problems

SUSTAINABLE BIO-COMPOSITES FROM RENEWABLE RESOURCES: Opportunities and Challenges in the Next Generation of Materials, Processes and Products

OBJECTIVES : In Support of Bioeconomy Strategy

RESEARCH AND DEVELOPMENTS: Value Added Industrial Biobased Composite Materials and Products from Agricultural biomass

SUMMARY

WAY FORWARD

CONTENTS

3

World Plastics Production and their Consumptions

Note: Based on preliminary estimates by European Market Research & Statistics Working group. Includes thermoplastics, thermosets, adhesives, coatings and dispersions. Fibers are not included

Source: Plastics Europe 2013, WG Market Research & Statistics

Plastics are a global success story 1950: 1.7 Mt 1976: 47 Mt 1989: 100 Mt 2002: 204 Mt 2007: 257 Mt 2011: 279 Mt 2012: 288 Mt 2013: 299 Mt

4

World Production of Plastic Materials by Regions in 2013

China Ranks First Europe Ranks Second

Source : PlasticsEurope 2014

Does not include other plastics (thermosets, adhesives, coatings and sealants) nor PP-fibres

5

Plastics Demands by Segment and Polymer type in 2013

Source : PlasticsEurope 2014

Packaging, building & construction and automotive are the top three markets for plastics

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Environmental Impact of Plastics

• Most of the fossil fuel based plastics takes more than 100 years to degrade and are not only to pollute the environment but actually harm many living organisms.

• Plastics are cheap to produce but very expensive to clean the environment.

• Future generation will suffer from the pollution caused by plastic.

www.epa.com 2013

http://www.epa.com/

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Current Situation in South Africa

SA is leading countries in the worlds with mechanical recycling.

SA currently only uses mechanical recycling and no other energy from waste plant yet operational.

280 000 tons produced in 2013. 220 400 tons were plastics packaging. 20% all plastics manufactured were

recycled in 2013 with 4.1% increase from 2012 recycling rate.

Plastics SA announced Zero Plastics to Landfill by 2030.

*Mechanical recycling refers recover plastics waste via mechanical pro-cesses (grinding, washing, separating, drying, re-granulating and compounding), and converted into new plastics products, often substituting virgin plastics

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Agricultural Wastes & Undervalued Biomass for Developing Green Materials

Lignin(Paper Industry)

Crude Glycerol(Biodiesel Industry)

Jute fibre Flax fibre Hemp fibre Prepared kenaf fibre

Switchgrass

Natural Fibres from Agricultural feed stock

By-products and Co-products from Biofuel industry

Value-added uses: Economic Benefit + Replacement for Petro-based Products + Reduced GHG Emission

Lignin(Bioethanol Industry)

Post harvested Agricultural Residues

Sugarcane Bagasse Maize stalks

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R&D to Support SA Industrial Sectors Identified as Strategic

IPAP focused sector

Aerospace

Automotive

Rail transport Equipme

nt

Renewable Energy

Agro-processin

g

Plastics

Contribution to SA GDP -

R3.4bn (7% of GDP)

R44.2 billion

(2.54% of GDP)

-

R7.7bn (16. % of

GDP)

R50 bn (-R7bn trade

deficit) Sector objective

Substantially diversify and deepen the components supply chain.

Substantially diversify and deepen the components supply chain.

Metal fabrication, capital and rail transport equipment

Increase local content on renewable energy components

Value addition of waste stream to increase beneficiation

Address environmental concerns regarding plastic manufacturing and waste disposal

Source: IPAP 2014/15

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Why Green composite Materials? Limited petroleum resource Increasing cost of petroleum Reduction in ‘Greenhouse’ gases New sustainable materials for

various structural applications

Made from Renewable resources Recyclable Biodegradable (end of life) Economically viable Environmentally acceptable

Benefits

Green Composites : Opportunities and Challanges

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Non-Renewable Energy Process Product(s) Landfill or Incineration

Conventional

Waste

Fossil Energy

Bioprocess

Biobased

By-product(s)

Bioprocess Bioproduct(s)Renewable Bioresource

Recycle into bioresource

Biomass

Why Green Materials

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WORLD BIOPLASTICS DEMAND

Global production capacities of bioplastics by market segment

1.1 million metric tons in 2013.

1.4 million metric tons in 2014

About 6 million metric tons in 2019,

Annual growth rate (CAGR) of 32.7% for

the five-year period, 2014 to 2019.

Bioplastics Demand

Bioplastic Economic : Strengthening International competitiveness of bio-based products

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Agricultural Biomass for Biobased Products

Biomass Manufacture

CelluloseStarchHemicellulose

LigninOil

Biobased Products

Reuse

IntermediatesAdditives (Modifier)Adhesives, Coating,

Microfibrillated cellulose nanofibres

The Conversion Chain

Biocomposites

Biodegrade Recycle

Disposal Use

Sugarcane bagasse Maize stalk

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MOTIVATION

• Waste management in South Africa faces numerous challenges due to growing

population and economy, leading to increased volumes of waste generated.

• This puts pressure on waste management facilities, which are already in short supply.

• Farmers also experience major challenges in handling agricultural wastes.

ANTICIPATED BENEFITS: • Waste management strategy• Environmental benefits (Low carbon economy)• Creation of green jobs

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OBJECTIVES

• IDENTIFY GAPS IN THE PLASTIC MARKET TO MEET THE LOCAL PLASTIC DEMANDS

• TO PERFORM TECHNO-ECONOMIC STUDY IN COLLABORATION WITH CSIR-ECD (ENTERPRICE CREATION DEVELOPMENT) TO DEVELOP THE MANUFACTURING INDUSTRY

• TO HAVE IMPACT TO COMMUNITIES

• CREATE GREEN JOBS

• “TO TURN WASTE INTO PROFIT”

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OVERVIEW OF R&D INITIATIVE

Maize Stalk

Sugarcane Baggasse

Asanda et al 2015(118) Carbohydrate polymer

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Extraction of cellulose nanocrystals and nano fibres from Maize stalk residues

Asanda et al 2015(118) Carbohydrate polymerAsanda et al 2014 , Composite Part A

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AFM characterizations of Nanocellulose

A

Cellulose nanofibres (CNFs) Cellulose nanocrystals (CNCs)

Asanda et al 2015(118) Carbohydrate polymer

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Development of Biodegradable Green Composites based from Natural Fibre/Bioplastics

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Optimized biodegradable green composites based from PLA/cellulose fibres for Packaging Applications

• Targeted optimized composite made from maize stalk residue.

• Such green composites have the potential of substituting their petroleum-based counterparts such as polypropylene (PP) with added advantages of compostibility and low carbon economy.

0 10 20 300

20

40

60

80

100

120

140

160

180

Tensile Strength (Mpa)Elongation (%)

Micro crystaline cellulose fibres (%)

Neat Biopoly-mer

Mechanical properties

Data from CSIR MSM-PE ongoing research activities

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Preparation of PFA composites

Furfuryl alcohol (FA) Acidified FA

Acidified FA-particle mixture

P-toluene sulfonic acid

7 days

1. 50 C for 5 ⁰days

2. 100 C for 1h⁰3. 160 C for 1h⁰

Maize particles

PFA compositeTensile properties

Data from CSIR MSM-PE ongoing research activities

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COMPOSTIBILITY AND BIODEGRADATION TESTING FACILITY

C Substrate Microbial Transformation CO2 + H2O + New Microbial Biomass

SA does not have Industrial composting set up.. This facility can support for testing biodegradable and compostable materials

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BIODEGRADATION TESTING OF POLYMERIC MATERIALS AND PLASTICS

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ISO Standard

s

Title Test Duratio

n

Test Validity

14852:1999

Determination of the ultimate aerobic biodegradability of plastic materials in an aqueous medium - Method by analysis of evolved carbon dioxide

6 months

At least 60% biodegr. reference material

14855:1999

Determination of the ultimate aerobic biodegraability and disintegration of plastic materials under controlled composting conditions - Method by analysis of evolved carbon dioxide

6 months


17556:2003

Plastics - Determination of the ultimate aerobic biodegradability in soil by measuring the oxygen demand in a respirometer or the amount of carbon dioxide evolved

6 months (2 years)


14855:1 Determination of the ultimate aerobic biodegradability and disintegration of plastic materials under controlled composting conditions - Method by analysis of evolved carbon dioxide; Amendment 1: Use of activated vermiculite instead of mature compost

6 months


14855:2 Determination of the ultimate aerobic biodegradability and disintegration of plastic materials under controlled composting conditions - Part 2: Gravimetric measurement of carbon dioxide evolved in a laboratory-scale test

6 months


20200:2004

Plastics - Determination of the degree of disintegration of plastic materials under simulated composting conditions in a laboratory-scale test

List of Standard Biodegradation Tests, Guides and Practices Available at the CSIR-MSM,PE for Analyzing the Environmental Degradability of Plastic Materials

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CEN Standard

s

Title Test Duratio

n

Test Validity

EN-ISO 14852:2004

Determination of the ultimate aerobic biodegradability of plastic materials in an aqueous medium - Method by analysis of evolved carbon dioxide (ISO 14852:1999)

6 months At least 60% biodegr. reference material

EN-ISO 14855:2004

Determination of the ultimate aerobic biodegraability and disintegration of plastic materials under controlled composting conditions - Method by analysis of evolved carbon dioxide (ISO 14855:1999)


EN 14046:2003

Packaging - Evaluation of the ultimate aerobic biodegradability of packaging materials under controlled composting conditions - Method by analysis of released carbon dioxide

45 days (to be extended)


EN 14047:2002

Packaging - Determination of the ultimate aerobic biodegradability of packaging materials in an aqueous medium - Method by analysis of evolved carbon dioxide


prCEN/TR 15822

Plastics - Biodegradable plastics in or on soil - Recovery, disposal and related environmental issues


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ASTM Standards

Title Test duration

Test validity

D6954-04 Standard Guide for Exposing and Testing Plastics that Degrade in the Environment by a Combination of Oxidation and Biodegradation

D5988-03 Standard Test Method for Determining Aerobic Biodegradation in Soil of Plastic Materials or Residual Plastic Materials After Composting

1 year At least 70% biodegr. reference material

D6002-96 (2002)

Standard Guide for Assessing the Compostability of Environmentally Degradable Plastics

D5338-98 (2003)

Standard Test Method for Determining Aerobic Biodegradation of Plastic Materials Under Controlled Composting Conditions

45 days (to be extended)


D6691-01 Standard Test Method for Determining Aerobic Biodegradation of Plastic Materials in the Marine Environment by a Defined Microbial Consortium

D5209-92 Standard Test Method for Determining the Aerobic Biodegradation of Plastic Materials in the Presence of Municipal Sewage Sludge

D5511-02*

Standard Test Method for Determining Anaerobic Biodegradation of Plastic Materials Under High-Solids Anaerobic-Digestion Conditions


D5526-94 (2002)*

Standard Test Method for Determining Anaerobic Biodegradation of Plastic Materials Under Accelerated Landfill Conditions


D5510-94 (2001)

Standard Practice for Heat Aging of Oxidatively Degradable Plastics

D5272-92 (1999)

Standard Practice for Outdoor Exposure Testing of Photodegradable Plastics


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BIODEGRADABILITY AND COMPOSTABILITY OF BIOBASED MATERIALS

SEM Analysis

PLA/tough biopolymer blends PLA/MCC blends

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BIODEGRADATION STUDIES OF GREEN COMPOSITE MATERIALS AND ITS CONSTITUENTS UNDER

COMPOSITING CONDITIONS

100

90

80

70

60

50

40

30

20

10

0

Bio

degr

adat

ion

(%)

180160140120100806040200

Incubation Time (Days)

Neat Bioplastic

Maize Stalk residues

Bioplastic/Maize stalk Biocomposite

Biofillers enhances the biodegradability of polymer matrix

Completion of carbon cycle in short span

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OVERVIEW OF R&D INITIATIVE

CSIR PATENT: POLYMERIZATION OF FURFURYL ALCOHOL (FA) TO DEVELOP SUSTAINABLE MATERIALS

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OVERVIEW OF R&D INITIATIVES: BIOCOMPOSITES FOR PACKAGING

Maize stalk residues have potential of substituting non-biodegradable petroleum Polypropylene (PP) with added advantage of biodegradable and low carbon economy.

Making the technology adaptable for real-world applications and possible commercialization.SA exports fruits and paying carbon tax OUTCOME : IP opportunities PARTNERSHIP (INDUSTRY)

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OVERVIEW OF R&D INITIATIVE: BIOCOMPOSITES FOR GREEN BUILDINGS (4 PROTOTYPES)

BIO-BRICK

ROOF PANELS

THERMAL INSULATION MATERIAL

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CONCLUSIONS AND ACKNOWLEDGEMENTS

• 4 PROTOTYPES

• 6 RESEARCH PUBLICATIONS

• IP DEVELOPMENT (Opportunities)

• PROPOSAL SUBMITTED FOR MANUFACTURING INDUSTRY

• PARTNERSHIP (INDUSTRY)

BCOC

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Research Project Team Members: Research Group Leader: Dr. Sunshine Blouw, CSIR- Material Science & Manufacturing, Fibre & Textile Competency Area

Research Scientist Dr. Sudhakar Muniyasamy (Joined in July 2013)Dr. Tshwafo Motaung

Ph.D. studentMr Asanda MtibeMr Osei Ofosu

Undergraduate Research Assistant Mr Abongile Gada Ms Sandisiwe BalaMr Thuso Tserane Anelisa Billi

POTENTIAL IMPACT: Human Capital Development

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ACKNOWLEDGEMENTS

RESEARCHER • Dr Linda Z. Linganiso (Senior Researcher)

FUNDING• DEPARTMENT OF ENVIRONMENTAL AFFAIRS, DBSA Green Fund• DST –BCoC• CSIR

Thank you

Contact Us: Dr Sunshine Blouw; e-mail: [email protected]

mailto:[email protected]