Lignin-Derived Plastics for Composite Matrix

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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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Competitive Differentiation Technology   Feature  

ORNL   Other  lignin-­‐ Petroleum-­‐ Engineered   Thermosets   Technology   derived  resins   derived  resins   Plas(cs  

Low-­‐cost   feedstock   Purity   requirement   Processing   cost   Toughness     Carbon-­‐ neutral   Odor-­‐free     Transparency     9

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Applications – Target Customers – Current Practice Applica(on   Descrip(on  

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Target  Customers  

Current  Prac(ce  

Automo&ve  Semi-­‐ Structural  Parts    

Headliners,   Plasan,   Instrument  panels,   CSP,   Interior  components   Faurecia  

Petroleum-­‐based   plas&cs  

Resin  Addi&ves  

Phenolic  powder   resins,   Epoxy  resins  

3M,   Ashland,   Georgia-­‐Pacific  

Petroleum  products    

Foam  Addi&ves  

Polyurethane  foam,   Polyisocyanurate   foam  

3M,   BASF,   Dow  

Petroleum  products  

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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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