Mar 27, 2014 - Copolymers/blends flexible additives and lignin as rigid segments. ⢠Extensive lignin purification ... Polyurethane foam,. Polyisocyanurate foam.
Lignin-Derived Plastics for Composite Matrix Applications
Joshua Perkins & Amit Naskar Material Science and Technology Division Oak Ridge National Laboratory Oak Ridge Carbon Fiber Composites Consortium Meeting March 27, 2014
Technology Overview Commercial-grade plastics with properties well beyond those of today’s lignin-derived plastics • Thermoplastics • Thermosets
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Concept of utilizing biomass-derived lowvalued co-products for carbon-neutral Presentation_name materials and sustainable manufacturing.
Technology Description – Status Quo Plastic products globally consume ~4% petroleum or ~25% petrochemicals.
Tough and high performance lignin-based thermoplastics need to be developed. Styrenic copolymer vs. Lignin-based copolymers 3
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Technology Description – New Insights All lignins are not the same!
Transient rheology data of organosolv lignin from different poplar genotypes Different lignins may find distinct commercial use. 4
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Technology Description – How it Works • Copolymers/blends flexible additives and lignin as rigid segments.
Lignin + Reactive additive à Thermoplastic product • Extensive lignin purification and separate synthesis steps are not necessary. Appropriate processing is the key!
• Assumptions and Limitations: • Novel and new recipe! • Structure-property-processing relation remains unknown. 5
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Technology Leadership:
Saito et al. Green Chemistry, (December 2012)
Chemistry and Properties
Saito et al. RSC Advances, (in press)
ORNL Researchers have developed a new methodology to convert lignin into value-added thermoplastic 6
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Technology Description – Quantitative Impact and End-of-Project Goals >50% constituent of a Bio-thermoplastic composition can be replaced by lignin @ $0.30/lb Lignin-based thermoplastics with:" • >10 MPa strength" • > 100% elongation" ! High performance composite part : " • ≥ 10% elongation" "
Commercial products under consideration: • Partially or fully carbon-neutral formulations
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Recyclable biopolymer for composites in automotive applications
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Technology Status • ORNL’s new technology uses unique chemistry of lignin exploited during thermal extrusion processing. • This technology is built on previous work at ORNL. Formula(on descrip(on
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Peak stress Strain at Stress @ 100% Time line (MPa) Break (%) strain (MPa)
Composi(on A
1.8
38
no data
Aug. 2010
Composi(on B
3.0
69
no data
Aug. 2011
Composi(on C
3.3
100
2.9
Aug.2011
Composi(on D
5.5
310
3.2
Aug. 2013
Composi(on D+
6.4
240
5.3
Aug. 2013
New Composi(ons
10 -‐ 20.0
200 -‐ 10
>10 -‐ N/A
Mar. 2014
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Market Opportunity:
ORNL Specialty Resin @ ≤ $1/lb
= $ per lb.
$1.17
$1.12 $2.54 $2.22
$1.19
$1.67
Automotive OEMs want alternative cost-effective solutions for interior components. Substitute needed for following resins: • Vinyl ester • Epoxy • Thermoplastic resins (PU, ABS, Nylon)
Entire market for these materials is much larger than composites industry. • i.e. expected 2015 epoxy market : 3.86 billion pounds
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Technology Summary • The technology leverages previous ORNL investments in lignin. • TRL-5: We expect to hit target properties this year! – 6.4 MPa tensile strength – 240% ultimate elongation
(need 10 MPa) (need 100%)
• The major obstacle will be to market this new product against petroleumderived plastic. • Intellectual Property – U.S. Patent Application No. 13/288,360; November 2011 – US Patent Application 14/058,657, filed October 21, 2013. – New invention disclosure: ORNL ID 201303165
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Acknowledgement Research sponsored by UT-Battelle, LLC ORNL Laboratory Director’s R&D Fund
Thank you!
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