WEBINAR BIOBASED POLYMERS AND COMPOSITES FOR TECHNICAL .

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WEBINARBIOBASED POLYMERS AND COMPOSITESFOR TECHNICAL APPLICATIONSJune 5th 4 – 5 pm (CET)June 26th 10 – 11 am (CET) Fraunhofer WKI

Biobased Polymers and Compositesfor Technical ApplicationsSource: Fraunhofer WKIM. Sc. Madina ShamsuyevaResearch AssociateFraunhofer WKIApplication Center HOFZET Fraunhofer WKISource: China HopsonProf. Dr.-Ing. Hans-Josef EndresHead of the Application Center HOFZETHead of the IfBBSource: China HopsonChristian Schulz B. EngPublic RelationsHannover University ofApplied Sciences and ArtsIfBB

Chronology of the relevant eventsCollaborative projectsLondonWorkshop25.-26.10.2018in London ONBonnHanoverBMBF Canada Day17.-18.10.2017 in BonnWebinar05. and 26.06.2018from Hanover Fraunhofer WKI

Aim and motivationWhy should you join this webinar?The following questions are going to be answered today: What are biopolymers and biocomposites? How are these materials manufactured and tested? What are current applications of these materials? What is sustainable production? What are the challenges? What is LCA and which factors are important? Where can you find information about performance characteristics and availability ofbiopolymers? Introduction into a consecutive workshop in London (CAN) in October 2018 Fraunhofer WKI

Biobased polymers and composites for technicalapplicationsWebinar Introduction IfBB and the HOFZET Introduction to bioplastics and biocomposites Selected research projects Sustainability assessment Databases Information about the consecutive workshop in London (CAN) in October 2018 Fraunhofer WKI

Hans-Josef EndresBorn on 17th of April 1966, married, 2 daughters (23 and 18)Educational background: Dipl.-Ing. graduate of the Ruhr University Bochum, 1985,mechanical engineering, strong focus on material research PhD (Dr.-Ing.) received from University of Bochum, 1995Professional experience and activities: 9 years of employment with industrial companies including a position asdepartmental director at Thyssen-Krupp, overseeing a staff of 230Source: China Hopson Professor at Hannover University of Applied Sciences & Arts, since 1999 Director of the IfBB - Institute for Bioplastics and Biocomposites, 2011 Head of Application Center for Wood Fiber Research, Fraunhofer Wilhelm-Klauditz-Institut WKI, 2012 Co-opted Professor at Technical University of Braunschweig, 2016Achievements: engaged in bioplastics and biocomposites research for more than 25 years; established the IfBB - Institute for Bioplastics and Biocomposites as a new institute; established a new Fraunhofer Application Center for Wood Fiber Research; authored various publications and received numerous honors and prizes for his researchin bioplastics and biocomposites Fraunhofer WKI

IfBB and HOFZET Fraunhofer WKI

Application Center for Wood Fiber ResearchHOFZET Operating since 07/2013 Today 15 employees Close collaboration with industryHOFZETHOFZET Technology forWood-basedPanels Material Analysisand IndoorChemistry Surface Technology Center for Light andEnvironmentallyFriendly Structures QA HOFZET Fraunhofer WKI Fiber analysisand modification Biobased (hybrid)composites Technical textiles Plastics andcompositesprocessing Recycling Material analysisIfBB Bioplastics Plastics technology Material analysis LCA DatabasesWolfsburgHanoverBraunschweig

Organizers of the ofer ProjectCentre for CompositeResearchSource: Google MapsWebinar05. and 26.06.2018 Fraunhofer WKIWorkshop25.-26.10.2018

Research focus of the HOFZETMaterialdevelopment Plastics Organic sheets Materialprocessing Injectionmolding Compounding /extrusion 3D printing Fraunhofer WKIManufacture ofconstructionpartsMaterial and partanalysisEnd of LifeEco balance Autoclave CT Recycling Hot press SEM Pyrolysis Fiber-spraying Mechanicaltesting LCA

HOFZETResearch fields – process development Bio-hybrid composites Natural fibers Short fiber-reinforced composites Surface modification Technical (hybrid) textiles Organic sheets Function integration Recycling Benninger ZellSurface modification offibers Fraunhofer WKI Madina ShamsuyevaFiber-spraying Manuela LingnauInjection molding center Manuela LingnauExtrusion center

HOFZETResearch fields – material and product development C. Hopson F. Bittner Plastic compounding M. ShamsuyevaHybrid textilefabricationFunction integration M. ShamsuyevaElectrically conductivebiocomposites FourFourmotorsmotors Fraunhofer WKIM. Kruszewski Construction parts Fraunhofer WKI

Introduction to bioplastics Fraunhofer WKI

What are bioplastics?Bio-basedBio-basedBio-degradableand biobased1.4.Cellulose acetates,rubber, casein Polylactide,starch blends,cellulose hydrates,polyhydroxyalkanoate5.Bio-PA, Bio-PEBio-PET, PTT, NondegradableDegradable2.PE, PP, PVC, .: Historical development Fraunhofer WKI3.Polycaprolactone,polyvinyl alcohols,polyesters(PBAT, PBS,.) Petro-basedBiodegradableH.-J. Endres, A. Siebert-Raths, Engineering Biopolymers, Carl Hanser Verlag 2011

Generation comparisonBioplasticsNew EconomyNovel chemistryDrop-InsNatural rubberPLABio-PARegenerated cellulosePHABio-PECellulose acetatePEFBio-PETLinoleumStarch blendsBio-based resinsetc.etc.etc. Fraunhofer WKISource: IfBBOld Economy

TrendsGeographical shift of production capacities Bioplastics production capacity New Economy2016 2021Figures: IfBBData sources: FAO, IfBB 2013 – 2017 IfBB – Biopolymers, facts and statistics 2017, ISSN 2510-3431 Fraunhofer WKI

TrendsMarket segments 2016 Bioplastics production capacity New Economy 20161 Contains regenerated cellulose and biodegradable cellulose ester2 Bio-based content amounts to 30%3 Contains durable starch blends, Bio-PC, Bio-TPE, Bio-PUR (except thermosets), Bio-PA, PTT Fraunhofer WKIFigures: IfBBData sources: FAO, IfBB 2013 – 2017 IfBB – Biopolymers, facts and statistics 2017, ISSN 2510-3431

TrendsMarket segments 2021 Bioplastics production capacity New Economy 20211 Contains regenerated cellulose and biodegradable cellulose ester2 Bio-based content amounts to 30%3 Contains durable starch blends, Bio-PC, Bio-TPE, Bio-PUR (except thermosets), Bio-PA, PTT Fraunhofer WKIFigures: IfBBData sources: FAO, IfBB 2013 – 2017 IfBB – Biopolymers, facts and statistics 2017, ISSN 2510-3431

Market overview in summary Average growth of more than 350 %, mostly in Asia ( 80 % until 2021)*:2.0 m tonnes 9.2 m tonnes Driver: Bio-based, non-biodegradable (Bio-PE, Bio-PET 30 etc.)*:63 % (2016) 82 % (2021) Biodegradables (PLA, PHA, starch blends, etc.) growing steadily:0.7 m tonnes (2016) 1.6 m tonnes (2021) Packaging still most important application sector:70 % (2016) 83 % (2021)* Land use doubles, but is overall low:670,000 ha (2016) 1,320,000 ha (2021)** Deviations possible by changes in Coca-Cola’s Bio-PET strategy. Fraunhofer WKIData sources: FAO, IfBB 2013 – 2017 IfBB – Biopolymers, facts and statistics 2017, ISSN 2510-3431

Global land use1 PLA,PHA, PTT, PBAT, starch blends, drop-ins(Bio-PE, Bio-PET, Bio-PA) and other2 Material use excl. paper industry3 Calculations include linseed oil only*Also includes area growing permanent crops as well as approx. 1 % fallow land. Abandoned landresulting from shifting cultivation is not included. Fraunhofer WKIFigures: IfBBData sources: FAO, IfBB 2013 – 2017 IfBB – Biopolymers, facts and statistics 2017, ISSN 2510-3431

Introduction to (hybrid) biocomposites Fraunhofer WKI

Composites Composite material is made from at least twoconstituents Main constituents: Reinforcing fibers providing strength Matrix holding the reinforcing fibers together andprotecting from environmental damagesShort fiber-reinforcedpolymer compositesWood fiber-reinforcedPP (compound) Fraunhofer WKICarrier box made fromwood fiber-reinforced PPLong / endless fiber-reinforcedpolymer compositesVarious natural fibertextilesTailgate made from variousnatural and carbon fiberreinforced epoxy

BiocompositesBio-basedMatrixBiobased Matrix- Bio-PA GF- Bio-PP GF- Bio-Resin GF- Bio-Resin CF- ConventionalFibers- PA GF- PP GF- PP CF- ConventionalComposites- PLA NF- Natural rubber CRF- Bio-PA CRF- - PE NF- PP Wood flour- PA CRF- PP CRF- Bio-basedFibersBio-basedFiberPetrobased Matrix Fraunhofer WKIGF: glass fibersCF: carbon fibersNF: plant fibersCRF: rayonSource: H.-J. Endres, T. Koplin, C. Habermann,Technology and Nature Combined, Kunststoffe International , 2012

Bio(-hybrid) compositesshort fibers (l sBio(-hybrid) hermosettingslong / continuous fibers (l 4mm)textile structures: fabrics, fleeces, hemp Fraunhofer WKIbiopolyesterviscoseglassaramidcarbon

Bio-hybrid fiber-reinforced polymersMotivation Flexibility regarding mechanical properties Weaving technique, localized reinforcement, etc. Integration of new properties Acoustic damping, etc. Large choice of reinforcing materials andmatrices High material availability Sustainable production Good disposal / recycling possibilities Fraunhofer WKI Manuale LingnauAramid, carbon, glass andflax fiber-reinforced epoxide Fraunhofer WKI

Bio-hybrid fiber-reinforced polymersIndustrial applications Sport and leisure industry Jones Snowboards Automobile industry Building industry Furniture Design und Interior Fraunhofer WKIThe snowboard feature a combination ofbiax glass, triax glass, flax and basalt

Advantages and disadvantages of plant fibersAdvantagesDisadvantagesRenewable resourcesInsufficient supply chainsLow densityLack of dataAcoustical dampingNew materials (e.g. simulation?)New optical appearanceLow thermal resistanceLow priceHydrophilicity / polarityDisposal behaviorVariable fiber morphologyExtensive knowledge in textile technologyInferior mechanical propertiesetc.etc.Source: WKI Fraunhofer WKI

Selected projectsProductdevelopment Fraunhofer tabases

Selected projects:Next generation Bio-Hybrid-Car Demonstration of technical performanceof bio-hybrid composites WKI Ecological, technical and economicassessment Creation of database (material combinations,mechanical performance, ) Processability and industrial usabilityfor automotive application Four Motors Realization of 500 Cars Project start: 09/2017 Project partner: Porsche AG, Four Motors Project funding: BMEL (FNR) Four Motors Fraunhofer WKI

Selected projects:Next generation Bio-Hybrid-Car Fraunhofer WKI

HOFZET / IfBB – selected projectsInteReStAim: Function-integrative and resource-saving lightweightconstruction structure for aviation Feasibility study on use of biobased hybrid partsinstead of conventional parts made of petrol-basedmaterials or metal edm aerotec Demonstration of the technology concept viamanufacture of helicopter structureHelicopter cabin CAD model Duration: 2016 – 2019Load Fraunhofer WKI Florian BittnerIn-situ CT analysis (3-point bending) Fraunhofer WKI edm aerotecExemplary helicopter model

HOFZET / IfBB – selected projectsSLC (Small load carrier)Aim: Development of a universal sustainable, biobased, small load lightweight carrier In order to optimize the logistics chain between automotive manufacturers, suppliers andservice providers, a small load carrier system (SLC system, German: KLT) is utilized inindustry Current SLC generation is produced from polypropylene (PP)In the project, a large proportion of the PP is going to bereplaced with wood fibers or cellulose fibers Economic and ecological advantages Significant strengthening and stiffening effect Reduction of the wall thicknesses leads to the lower weight Fraunhofer WKI Hasan MezdegiNew generation SLC Fraunhofer WKI

IfBB – selected projectsSeaArtAim: Development of marine biodegradable artificial seagrass toprovide suitable conditions for the restoration of natural seagrassmeadows Studies on marine biodegradability of bioplastics and naturalmaterials H. Behnsen, IfBB Material characterization in terms of degradability, technical andmechanical properties and feasible production methods Material development regarding degradability and mechanicalproperties Duration: 2016 – 2020 C. Arndt, IfBB C. Arndt, IfBB Fraunhofer WKI

ProBioFunctionally-integrated, three-dimensional and variableproduction of bio-hybrid components with maximumorganic content (ProBio) Fraunhofer WKI

ProBio Development of bio-hybrid-fiber-reinforced composites (bio-HFC) with the highest possibleproportion of bio-based components Reinforcing fibers and / or plastic matrices Technologies Hot pressing Fiber-spraying facility Weaving machineFraunhofer WKI Marek Kruszewski Surface modificationWeaving machine with Jacquardtechnology Improvement ofcompatibility between fibers Function integrationFraunhofer WKI Madina ShamsuyevaFiber-spraying facility Fraunhofer WKI

Hybrid textile for composite applications Fraunhofer WKI Carsten AßhoffHybrid fabrics (CAD)Multi-layer fabrics (CAD) Combination of various fiber types in one textile Different reinforcing fibers (e.g. cellulose-based fibers and carbon) Reinforcing fibers and matrix fibers (e.g. cellulose-based and polyamide) Fraunhofer WKI

DeFiCoatDevelopment of specially coated natural fibers forefficient application in engineering thermoplastics(DeFiCoat)Funding code: 031B0502 Fraunhofer WKI

DeFiCoat Aim Improvement of the thermal stability of cellulose-based fibers Processability at temperatures 200 C Expansion of the application spectrum of natural fiber-reinforced composites (NFC) Improved mechanical properties, thermal stability and chemical resistance Pursued approach Coating of the natural fibers with an optimized thermosetting coating Coating should act as an isolating layer between fibers and melted thermoplastics Duration: 1.11.2017 – 31.10.2019 Fraunhofer WKI

DeFiCoat Madina ShamsuyevaFlax fabrics – mechanical propertiesFlax fabric, uncoatedFlax fabric, coated with dilutedepoxy resin, in curved state Preliminary resultsFlax fabric, coated with dilutedepoxy resin It is possible to coat the fabrics homogeneously with diluted epoxy resin The fabrics remain deformable Fraunhofer WKI

Challenges in sustainability Environmental benefits of bioplastics/biocomposites in comparison to their (mainlyfossile-based) conventional counterparts are one of the key drivers for their use andpromotion Companies who intend to use bioplastics for their products are required to providequantification and proof of the environmental benefits in order to avoid false claims andgreenwashing Especially small and medium-sized enterprises are confronted with the challenge ofgenerating this information in an effective, high-quality and low-cost waySource: IfBB Fraunhofer WKI

Sustainability AssessmentEconomicEnvironmentLCSA Life CycleSustainabilityAssessmentLCALife CycleAssessment LCCLife CycleCostingSocial SLCASocial LifeCycleAssessmentSource: IfBB Fraunhofer WKI

SustainabilityScale-upLife Cycle Assessment of thedeveloped materials Screening LCA Hotspot analysis Material balanceEnd of Life(EoL)Secondary andthird generationfeedstockLand useAdditivesLife Cycle Assessment of theexternal partnersSocial aspectsDevelopment of guidelines andmethodologySource: IfBB Fraunhofer WKI

Sustainability in the context of the ongoingprojects InteReSt Project aim: Lightweight structures from biobased polymersand biocomposites for aerospace industry Sustainability task: Development of recycling concept undecological assessment of the developed materials edm aerotec DeFiCoat Project aim: Development of specially coated natural fibers withimproved thermal stability Sustainability task: Life cycle assessment of the developedmaterials Fraunhofer WKI Madina Shamsuyeva SLC Development of a universal sustainable, biobased, small loadlightweight carrier Sustainability task: Life cycle analysis of the developed product Fraunhofer WKI Fraunhofer WKI Hasan Mezdegi

BioMat LCABiobasedplasticsNatural fibersConventional plasticsFillers & additivesConstruction andprocessing of automotive componentsSource: IfBBRecommendationsfor generalized applicationSource: IfBB Fraunhofer WKI

LCA of biobased plasticsRaw material acquisition ronmental impactsValue Chain - Biobased plasticsProcessingBioplasticUseEnd of LifeBioplasticProductRecyclateSource: IfBB Fraunhofer WKI

LCA of biobased plastics VICharacterizationfactorTendency ofbiopolymersBiopolymersConventional polymersEnergy demandDifferent energy demandfor different biopolymersDifferent energy demand fordifferent conventional polymersGlobal-warmingpotentialHigh CO2 storage duringthe plant growthHigh CO2 emission during burningAbiotic resourcedepletionBio-based (renewable)Crude oil-based (finite)Eutrophication potentialConsumption of fertilizersand pesticidesNot necessaryAcidification potentialConsumption of fertilizersand pesticidesNot necessaryLand useAgricultural field necessaryAgricultural field not necessaryWater consumptionProcess water and waterfor irrigationOnly process waterSource: Source: PE INTERNATIONAL/ IfBB 2014 Fraunhofer WKI

Thinkstep & IfBBBioplastics LCA tool For more ecific GaBi database (incl. feedstock, granulates, additives, conversions,auxiliaries, transport, end-of-life) IfBB as scientific development partner for LCA data Base your decisions on consistent, high-quality, up-to-date and reliable background data Comparison of scenarios (products, conversion/compounding processes, transportoptions, end-of-life (recycling, composting, incineration), bioplastics vs. conventionalplastics) Know about the environmental consequences before investing in product and processchanges Easy-to-use interface, instant result calculation and reporting with customized content,tables, diagrams, format and company design Communicate verifiable LCA results created on your own without being an LCA expert The tool covers all stages of the bioplastics supply chain Be prepared to answer questions from your clients and even questions asked to your clientsSource: Thinkstep Fraunhofer WKI

Further information on bioplastics Information on thewidely-varying processing proceduresfor almost 100 bio-based urce:IfBB Procurement-relevant information onproducts made from bioplastics RTechnical material characteristics r.com Fraunhofer WKIhttp://www.hanser.de/buch.asp?isbn 978-3-446-42403-6&area TechnikSource: IfBB, FNR,M-Base

Outlook on future research End-of-Life / New-Life Options Additives / Blending Hybridization Communication (awareness, social responsibility, etc.) Sustainability methods & LCA for bioplastics & biocomposites Quality and availability of LCA data (manufacturers of fibers, biopolymers, etc.) Cascade utilization and ecological assessment Time horizon in LCA Regional and global assessment of sustainable production Competence exchange (material development, global wording, etc.) Assessment of social sustainability Fraunhofer WKI

Organizers of the ofer ProjectCentre for CompositeResearchSource: Google MapsWebinar05. and 26.06.2018 Fraunhofer WKIWorkshop25.-26.10.2018

WKI Workshop in CanadaWhy should I join the workshop in London?25.-26.10.2018 in London (CAN) Competence exchange between scientists and industry Identification of new ideas and topics for collaborative projects Efficient

Driver: Bio-based, non-biodegradable (Bio-PE, Bio-PET 30 etc.)*: 63 % (2016) 82 % (2021) . Bio-hybrid fiber-reinforced polymers Motivation Flexibility regarding mechanical properties Weaving technique, localized reinforcement, etc. Integration of new properties

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