SUSTAINABLE MATERIALS MANUFACTURING · SUSTAINABLE MATERIALS & MANUFACTURING ... Moon et al, Chem...
Transcript of SUSTAINABLE MATERIALS MANUFACTURING · SUSTAINABLE MATERIALS & MANUFACTURING ... Moon et al, Chem...
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SUSTAINABLE
MATERIALS
&
MANUFACTURING
Opening doors into next-generation sustainable practices in
manufacturing
Soydan Ozcan
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Disruption in Additive Manufacturing: Bio-BAAM and Biodegradability
Composite Materials Recyclability, Challenges and Opportunities
&
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Towards a Green Bio-economy via Innovative Bio-manufacturing: Unlocking the Potentialgg the Potential
Developing Bio-economy: What is at stake?
1) Reducing dependence on fossil resources andaddressing climate change
2) Increasing the resilience, sustainability andproductivity of primary production systems and the food chain
3) Building competitive bio-based industries and manufacturing in US, particularly in rural areas
4) Moving towards a zero-waste society
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• Fuel efficient car parts
• Bullet-proof suits
• Flexible displays and batteries
• Packages, building materials
• Furniture, electronics
• Food product
• Cosmetics
• Special papers
• Paper coating
• Flexible batteries
Three Main Mission in Bio-Manufacturing
1 Value Added Forest Products
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Redefining biorefinary:Develop value added byproducts from Biorefineries
• We import 49% of the petroleum used.• We send close to $1billion per day overseas to buy oil.
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Next Generation Agribusiness
Next Generation Agribusiness ("NGA") is about growing perennial crops and turning those crops into finished
products in the same community.
It combines the two powerful economic drivers of agriculture and manufacturing.
Farm in rural America, just as important, manufacture in rural America
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Bio-Materials are high in Value chain and pull can come from Manufacturing
Value
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Cellulose Fibrils are in many forms and functionality
Microfibril matrix Microfibril
Nanofibril
Nanocrystal
amorphous regions
Parallel stack of cellulose chains
Fiber
Moon et al, Chem Soc Rev, 2011
Adapted from Nutrition Resources, 2006
Dufresne et al, J Appl Polym Sci, 1997
Advantages:Abundant, renewable resource with price stability • compostable •biocompatible • high strength and modulus • lightweight • shear thinning thickener (stable against temperature and salt addition)
2014: Thomas Reuters names nanocellulose as one
of the top 10 technologies that will change the world by
2025.
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CNC composite forAnionic Exchange Membrane
RSC Advances, 2015US Patent 9,340,461, 2016
Journal of Materials Chemistry A, 2015
Metal oxide nanoparticlesfrom CNF template
3D-printed thermoset fromcellulose/epoxidized
soybean oil
Patent Appl. No. 62/180,181 2016
OHOHOH
OOO
Si NH2
SiO
O ONH2
Interfacial engineering toimprove mechanical properties
Carbohydrate polymers, 2015
Ozcan GroupResearch in
Nanocellulose
3D-printing thermoplasticwith cellulosic fiber and PLA
NanoToday 3: 417-420 (2015)
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Neat-ABS Neat-PLA 25%CNF-ABS 40%CNF-PLA 30%CF-ABS Al 6061-0 Al 6061-T4
Spec
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Stre
ngth
(N.m
/g)
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40%CNF-PLA• ~93% of specific strength of Aluminum 6061-T4 alloy.
• Stronger and lower cost than CF-ABS composite
• 100% BIO• 40%CNF-PLA: 0.4x$2/lb + 0.6x$3/lb = $2.6/lb
• 30%CF-ABS: 0.3x$12/lb + 0.7x$3/lb = $5.7/lb
$2.6 / lb
$5.7 / lb
~93%
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Materials solutions are most of the time in composites
High Mechanical
High Tg Polymer
Process temp is lower than 200C
Printable
High Volume
Low Cost
Biodegradable compostable
Bio-derived
Printable
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BAAM-printing of Bamboo with PLA
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Neat Bio-Based Polymer Feedstock• Non-uniform extrusion
• Significant curlingNeeds modification!!!
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Shop architect’s design is this year’s winner of the Panerai Design Miami/ Visionary Award
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Biomanufacturing: Fully bio-based, sustainable composites for large scale additive manufacturing
• A newly developed fully bio-based, sustainable composite system (bamboo fiber-biopolymer) was for the first time 3D-printed in large scale.
• A contemporary pavilion system was additively manufactured for an architecture expo as a part of a large collaborative project.
• ~10,000lbs biodegradible material was printed at up to a 40lbs/hr rate.
• The developed bio-composite system offers advantages over commonly used carbon fiber-ABS in terms of embodied energy, carbon footprint, cost and end-of life.
additive manufacturingggggg
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ENERGY C-FOOTPRINT COST
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Addressing Critical Challenges
Five/Ten Year Technical Goals• 25/50% lower carbon fiber–reinforced
polymer (CFRP) cost• 50/75% reduction in CFRP embodied energy • 80/95% composite recyclability into useful
products
Impact Goals• Enhanced energy productivity• Reduced life cycle energy consumption• Increased domestic production capacity• Job growth and economic development
IACMI - National Institute
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A Quick QuestionAn aluminum can that is thrown away will still be a can _____ years from now A) 100B) 300C) 500D) 800
www.etsy.com
500
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Sustainable Materials & ManufacturingEnd of Life
Products and infrastructure
Landfill Stock
Resource stock
Dissipation
Material
Ore
Excavation
Collection Disposal
Product
1
III ExcavationExcavation
1I
infrastructure
Excavation
Collection
Excavation
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Opportunity• In North America, 29 million pounds (~13,200 MT) of carbon fiber waste
estimated going to landfill per year. In the form of
– Pre-preg, primarily aerospace production scrap– Secondary amount is cured production trim– Some pre-preg scrap has to be oven cured prior to landfill– Regulations vary based on constituents in resin system– Adds cost/time burden on composite manufacturers
• It is difficult to estimate amount of end-of life composite
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Challenges• Supply Chain, need to know where material comes from and what it
contains (fire retardants, etc), and available in what format– Sorting, Classifying, labeling
• For value added products, higher fiber volume fraction preform, aligned fibers etc. which could be achieved by new methods of preforming
• Development of standard for products will give confidence to designers and end users.
• Today Landfill fee/tax is not a driver for C-fiber recyling in US. However further legislation or banning landfill will drive recycling
• Life Cycle Assessment studies for recycling processes is needed.
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Recycling Proposals Received
Automotive component and 3D printed tool both use reclaimed CFApproved
Recycling aircraft components into 3D printed automobilesIn contracting
Automotive component uses CF reclaimed from scrap prepregIn review cycle
Profitably recycling glass and carbon compositesIn review cycle
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Soydan [email protected]
(865) 241-2158
Thank You!
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SUSTAINABLE MATERIALS & MANUFACTURING
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Big Area Additive Manufacturing
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Composite Materials Recyclability, Challenges and Opportunities
Soydan Ozcan
IACMI- The Composites Institute
09/014/2016, JEC- Knoxville TN
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Our Vision and Mission Vision:
Our collaboration of industry, research institutions and state partners is committed to accelerating development and adoption of cutting-edgetechnologies in recycling and re-manufacturing of composites
Mission:
To lead and grow a composite recycling industry that fully diverts fiber scrap and end-of life composite products into value-added productsEconomic: Grow manufacturing and create jobs across the composite industryEducation: Support the training of a workforce prepared for and accomplished in the skills required by the composite recycling industry.Environment: Reduce the amount of composite landfill through re-use in new applications with reduced energy and environmental footprints.
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>Composite Recycling Activities
CRTC
Vartega
Adherent Technology
Materials Innovation
TechCHZ Tech
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Driving Forces for Sustainable Materials & Manufacturing
Social
Environmental Economical
SUSTAINABLE
• Growing public concern about environmental issues
• Corporate social responsibility
• Economical viability
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Concluding Remarks
• Well recognized that composite recycling needs “market pull” to elevate demand and value, and improve reclamation business case, It is so critical to develop supply chain.
• Achieving Technological barriers in manufacturing technologies yielding product sales, creating confidence in using reclaimed fibers and, most importantly, fund increased R&D into new product areas
• Early manufacturing and development efforts will generate standardization and also process knowledge that feeds new applications/opportunities
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Big Area Additive Manufacturing (BAAM)
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Conventional AM• Small (< 1 cubic ft)• Slow (< 5 ci/hr)• Expensive (~$100/lb)• Takes days to go through 1 kg spool
– Not exciting for material manufacturersBig Area Additive Manufacturing• Large (> 1000 cubic ft)• Fast (>2500 ci/hr)• Cheap (<$5/lb)• One machine can go through a gaylord in a day