“Go Green Strategies and Their - Industrial Green Chemistry...China. It is blended with BASF’s...

6th -8th December,2013 3rd IGCW Convention, Mumbai

“Go Green Strategies and Their

Applications to Polymers and

Additives”

Dr. R. Rangaprasad, Director,

SIES School of Packaging

&

Packaging Technology Centre,

Navi Mumbai


Presentation Coverage

• Global Thought process

• Government Bio-based Manifesto

• Go Green Strategy

• The Evolving Paradigm

• From Crude oil to Biorefinery

• Bio plastics

• Bio additives

• Future Building blocks

2


Global Thought Process

3

• The world is becoming increasingly sensitive to the

growing scarcity & possible drying up of

petroleum, source of virtually all the plastics.

• All countries have embarked upon study of

replacement of oil-based products by bio-sourced

equivalent or innovative products.


The Concern!

• Oil prices will rebound to more than $100/barrel once the economy recovers and will exceed $200 by 2030.

• Output from the world's oil field is declining at a rate of 9%.

4


The Evolving Paradigm

• The general strategy for bio-polymers & bio

additives is to replace crude oil by biomass

• Biotechnology combined with traditional

chemical engineering, separation and

conversion techniques, to obtain end

products, bio blocks and bio platforms.

5


Government Manifesto

• US National Bio-economy Blueprint (2012)

• European Commission's strategy and action

plan, "Innovating for Sustainable Growth: a

Bio economy for Europe”

• Dutch bio based economy manifesto

6


Bio Based Materials Forecast

7

6th -8th December,2013 3rd IGCW Convention, Mumbai 8

Type ValueBio-PE 38.9

Bio-PE 17.2

PLA 16.2

Starch derivatives 11.3

Biodegradable

polyester10.0

Bio-PA 1.6

PHA 1.5

What is the market?

Consumption of Bio-plastics : 2010-2020

Market Shares of Main Bio-plastics


New Industrial Processes,

Biotechnology, Biorefinery,

Platform Blocks


•Green Plastics, also called Bio plastics, are plastics that are

biodegradable

•Usually made mostly or entirely from renewable resources.

• Focus on environmentally friendly processing.

•Green plastics are the focus of an emerging industry focused on

making convenient living consistent with environmental stability.

Green Plastics & Bio Plastics


Green Plastics vis-à-vis Bio

Plastics

• Bio plastics are composed of a polymer, combined

with plasticizers and additives, and processed using

extrusion or moulding.

• What makes green plastics "green" is one or more

of the following properties:

– They are biodegradable

– They are made from renewable ingredients

– They have an environmentally friendly processing

approach.

11


Definition of Green

• Because different compounds can satisfy some or all of these criteria to different degrees, there are different "degrees of green" in green plastics. To evaluate how "green" a plastic material is, we need to ask three questions:

– How quickly can the plastic be re-integrated into the environment after it is no longer being used?

– How quickly are the ingredients that go into making the plastic created in the environment?

– How much pollution or waste is created during the process of actually making the plastic?

12


Renewable Resource

• A renewable resource is a natural resource that is created

in the environment faster than it is used up by people.

• Many people think of "renewability" as a fixed trait: some

things (like trees, grass, and wind) are renewable, while

others (like oil and coal) are not.

• In fact, whether a resource is renewable depends on both

how fast it is replenished and how fast people use it. As a

result, some resources are more renewable than others, and

some resources may or may not be renewable depending on

how they are used.

13


Rate of Renewal

• The rate of renewal ("sustainable yield") of a resource defines how quickly it can be replenished by the environment.

• Solar energy, tides, rainfall, and winds are considered perpetual resources for energy because they renew much faster than they could ever be used. (Can you imagine us "using up" the wind, so that we would have to wait until the earth made more?)

14


Rate of Renewal

• Living organisms provide the majority of resources that are

generally considered "renewable", because they generally

renew themselves within a reasonable amount of time

relative to how quickly they are used.

• Agricultural feed stocks and marine feed stocks are two

major categories of living organism feed stocks. Within this

category, some organisms renew faster than others: for

example, it takes much longer to grow a new tree than it

does to grow grass.

15


Rate of Renewal

• Most of the resources that are considered "non-renewable" are based on coal, oil, natural gas, and other substances that take so long for the environment to create that almost any use of these resources at all will cause them to be used up before any more is created.

• Petro-chemical feedstocks are feedstocks derived from petroleum principally for the manufacture of chemicals, synthetic rubber, and a variety of plastics.

16


Rate of Use

• Imagine you live in a small village by a river. A turbine on the river spins, and it can generate enough electricity for the entire village every day.

• Clearly, their hydroelectric power is a completely renewable resource. However, as the size of the village grows, their energy use grows.

• If eventually the needs of the village far outstrip the energy that can be provided by the turbine, then the hydroelectric energy from the river is no longer a renewable resource for the village: the rate of use has exceeded the rate of replenishment.

17


Rate of Use

• The same issue exists for the use of plants. As long as our

use of (for example) corn remains moderate compared to

the amount of corn produced, corn is a renewable resource.

• However, if our use of corn increases dramatically without a

corresponding increase in corn crop production, then corn

will cease to be a renewable resource: we will use it all up,

and we will either have to cease production until the corn

renews itself or (worse) it will become extinct, so it will not

replenish at all.

18


'Green' Plastics or Biopolymers:

The Emerging Landscape:

19

Major chemical companies

are investing big money in

new plants and

technologies to produce

plastics from annually

renewable sources, not from

petrochemicals Starch polymers may make more of an

impact on the U.S. market as Plantic of

Australia teams up with DuPont and

Bemis Co. to supply sheet, film, and

pellets. Shown here: Hot rollers at

Plantic drying starch polymer, which is

extruded opaque but ends up clear.


Plastics from Bacteria

20

Bacteria do much of the work of making new biopolymers. Metabolix genetically modifies bacteria

that ferment starch into PHA polymer, which they store inside their cells the way animals store fat or

plants store starch.

http://d2n4wb9orp1vta.cloudfront.net/resources/images/cdn/cms/Bacteria.jpg


Plastics from Sugarcane

21

Braskem, Dow, and Solvay are all building big plants in Brazil to use

ethanol from sugar cane to make PE and PVC. (Photo: Solvay)


Corporate Initiatives

• Start-up Novomer has catalyst technology that makes PEC and PHA polymers out of by product CO and CO2 gases from cement kilns.

• The world’s first major fermentation plant for compostable PHA biopolymer will start up this year, producing 110 million lb of Mirel resin from Metabolix’s Telles joint venture.

• A micro-brewery ferments PHBV commercially at Tianan in China. It is blended with BASF’s Ecoflex and blown into film for electronics packaging.

• Purac built a big new lactic acid fermentation plant in Thailand and is building a new lactide monomer plant—the first such commercial facility in the world. Availability of lactide will make it easier for additional suppliers to make PLA.

22


Several strategic “Green”

routes to Bio-additives

• Bio-additive ways differentiate by the more or less degree of modification of the used natural products:

• Direct use of natural additives: natural fibres, Cashew nut shell liquid (CNSL)

• Additives mainly derived from products coming from natural sources: fatty acid salts and esters

• Additives made out of a minor part of natural source

• Use of building bricks issued from natural products to build new chemical structures

• Use of biopolymers as bio carbon content enhancers in fossil plastics

23


Bio Based Polymer additives

24


Illustrations of Bio additives

• Starch used as filler

• Natural gums such as arabic gum used as colloids

• Pine derivatives: pine tar, rosin, terpene used as tackifiers and processing aids

• Vulcanized vegetable oils or factices used in rubber formulations

• Phenol derivatives used as antioxidants

• Liquid depolymerised natural rubber used as a cross-linkable polymeric plasticizer

• Natural waxes such as carnauba wax

25


Present & Future: Development of

Specific or General-purpose Bio-

platforms and Bio-blocks

• Ford and Ohio State University are looking at dandelions

as source of an impact strength modifier for plastics parts

such as cup holders, floor mats and interior trim.

• Iowa State University researchers have invented a process

for manufacturing isobutylene thanks to a natural enzyme

that converts the glucose found naturally in plants to make

isobutylene. This one can be chemically converted to

synthetic rubber, impact modifier for plastics and isooctane.

26





• Performance of green tea extract, or its individual

components catechin and epicatechin, was compared

in polypropylene samples. The obtained results showed

the interest of these natural materials as a potential

source of antioxidants for plastics.

• Scientists of York University extract limonene from

orange peel and found that the process also breaks

down limonene into monomers that could be used to

make bio based materials.

27





• LanzaTech wins the Frost & Sullivan 2011 Global Green

Excellence Award for Technology Innovation in "green

chemistry".

• LanzaTech's technology uses gas fermentation process that

produces ethanol and high-value chemicals from renewable,

non-food resources including industrial flue gases and other

waste gases.

• LanzaTech's technology also uses carbon monoxide and

carbon dioxide to produce acetic acid and 2, 3-Butanediol

(2,3-BDO), key building blocks used to make plastics and

hydrocarbon fuels.

28


Examples of Bio-plastics Polymerized from Bio-

monomers

Versatility of the Bio-block Way

Bio-monomers and Bio-blocks: Deciding

arguments for a Panel of Fossil Molecule

Counterparts


MANY FEEDSTOCK CHOICES


THE 'GREEN MAGIC' OF THE

GAMESA ZERO-WASTE EVENT IN THE MAKING

• SITUATION: 8,500 tons of solid waste

• London 2012 Olympic Games

• 11 million people in attendance

• London Organizing Committee of the Olympic and Paralympic Games (LOCOG), commit to making 2012 the very first ‘zero-waste’ Olympic and Paralympic Games, with sustainability at the heart of their vision.

• SOLUTION: Compostable foodservice ware / Comprehensive waste stream management

• 120 million pieces of packaging– 14.3 million Ingeo lined paper cups

– 7.5 million heat resistance Ingeo lids

• All responsibly made http://www.natureworksllc.com

• All responsibly disposed of

• Closed loop system, diverting all from landfill

31

http://www.natureworksllc.com/


Conclusion

• Plenty of feedstock options for polymers & additives

• Companies looking at alternate feed-stocks

• Bio based feed-stocks promising

• Discovery of shale gas & possible new options

• Economics of Bio based plastics & additives

• Immediate solution is hybrid plastics: Example: Cereplast®

• Futuristic solutions: PLA, PHB.

32


Thank You for your attention

“Go Green Strategies and Their - Industrial Green Chemistry...China. It is blended with BASF’s...

Documents

Transcript of “Go Green Strategies and Their - Industrial Green Chemistry...China. It is blended with BASF’s...