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Anwendungsbereiche und Perspektiven biobasierter Faserverbundwerkstoffe
Johannes Ganster, André Lehmann, Jens Erdmann Fraunhofer Institute for Applied Polymer Research IAP, Potsdam
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AGENDA
Anwendungsbereiche und Perspektiven biobasierter Faserverbundwerkstoffe
© Fraunhofer UMSICHT
1 Fraunhofer IAP
2 WPC and NFC
3 Cellulose Rayon Reinforced Thermoplastics
4 Novel Cellulose Fibers for Reinforcement (Lehmann)
5 Bioplastics (in parenthesis)
6 Bio-based Carbon Fibers (Lehmann, Erdmann)
7 Summary
8 Acknowledgements
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The Fraunhofer-Gesellschaft at a Glance
The Fraunhofer-Gesellschaft undertakes applied research of direct utility to private and public enterprise and of wide benefit to society.
25,527 staff
More than 70% is derived from contracts with industry and from publicly financed research projects.
Almost 30% is contributed by the German federal and Länder Governments.
72 institutes and research units Fin
an
cial
volu
me
2.3 billion
2017
Co
ntr
act
Rese
arc
h
2.0 billion
Major infrastructure capital expenditure and defense research
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Fraunhofer IAP at a Glance
■ 204 employees (Status 12 | 2017)
■ 2017: € 19.3 million institute‘s budget
€ 14.4 million external revenues
■ Research sites: Potsdam-Golm
Hamburg
Schkopau
Schwarzheide
Teltow
Wildau
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WPC and NFC – a market reality Commodities for decking and injection molding
Extrusion – WPC Injection molding – NFC
Always PP as matrix, first attempts at PLA
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Pulp fibers vs. Cellulose spun fiber (viscose, rayon, Lyocell)
Pulp sheets
Fibrillated alcaline cellulose
Cellulosisc spun fiber
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Spinning line at Fraunhofer IAP
drying
spinning pump
nozzle Coagulation bath
fiber
1. drawing
washing
Finishing
2. drawing
storage tank
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Man-made cellulose fiber reinforced thermoplastics – An alternative to glass fiber reinforcement
Faurecia
Müller Wallau
Would be
Stiebel-Eltron
Rayon tire cord yarn: Commercially available man-made cellulose fiber with 20 GPa modulus
Started with PP
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Reduced number and length of pulled-out fibers and cylindrical voids
SEM cryo fracture results
weak
Interphase between Rayon and PLA:
medium strong
Going 100 % bio-based with PLA matrix Successful interphase modification
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Results with 20 % Rayon in PLA
Improved impact strength, strength and stiffness with rayon
PLA
PLA + 20% Rayon + PP-g-MAH
PLA + 20% rayon
PLA + 20% GF (Piolen G20CA67)
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Biopolymers – Promising future circular materials Bio-based and/or biodegradable
Bio-based: from renewable raw materials (starch, sugar, bio ethanol)
Biodegradable: Integration into natural cycles by micro organisms
Degradation
Depolymerisation
Assimilation in mikroorganisms
Mineralisation into water and CO2
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Biopolymers – Promising future circular materials Advantages versus conventional plastics
Based on renewable raw materials
Reduced dependence on oil and gas (political)
Preserving fossil resources
Value stream for bio-refineries
Drop-Ins: chemically identical to conventional plastics (bio-PE)
Relevance for climate/environment
Storage of atmospheric CO2 in material
Biodegradability as additional benefit (if so)
Composting possible (if so)
Contribution to fight (marine) littering
Improved barrier in Polylactide (PLA) films by nano clays (IAP)
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Better man-made cellulosic fibers for reinforcement – What is possible? Specific properties
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Process Polymer Solvent Regeneration Treatment
Lyocell Cellulose NMMOxH2O water
Super 3 Cellulosexanthate NaOHaq H2SO4 + salt decomposition
Bocell* Cellulose 74% P2O5 Acetone Intense washing
DuPont* Cellulosetri-acetate (DS > 2.7)
TFA/CH2Cl2 or formic acid
Methanol (~ -30 °C)
Steam drawing + saponification
Michelin* Celluloseformiate Formic acid/H3PO4
Acetone saponification
Fortisan Celluloseacetate (DS 2.2 – 2.5)
Acetone Hot air Steam drawing + saponification
Bocell: H. Boerstoel, PhD Thesis, University Groningen, 1998 DuPont: EP 0103398 Michelin: WO85/05115 Fortisan: Moncrieff, R.W.; Silk and Rayon Rec.; 27,12,1012 (1953)
Cellulose Man-made fibres – Why so few? Requirements to reach high modulus cellulosic fibers
Shaping conditions can not (not likely to) be industrialized
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IAP results via modified Lyocell route Tuning cellulose super molecular structure by alkalization + kneader technology
Textile-physical properties:
o Strength: 0.9 GPa
o E-Modulus: 47.5 GPa
o Elongation: 7.8 %
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Lyocell or other Technologies
Precursor development 40 to 1000 filaments
round or lobulated cross section
Lignin content > 30%
homogeneous lignin distribution
Patent applications
Stabilization and carbonization stages under development
Bio-based carbon fibers: Precursors from Cellulose-Lignin-Blends Lignin to boost carbon yield
17
Carbon fiber from a tree by Stora Enso
Tree
Wet-
Spinning
to
Precursor
Stabilization Carbonization
Precursor
Carbon
Fiber
Oil Cracking to
Propylene
Ammo-
xidation
to ACN
Wet-
spinning
to
Precursor
Stabilization
Poly-
merization
to PAN
Carbonization
Carbon Fiber is today made from the oil-based raw material polyacrylonitrile (PAN)
Cellulose to viscose, adding lignin
2019-10-31
© Fraunhofer
Summary
WPC and NFC established market products
Improvements in properties can be achieved with cellulose spun fibers
This is proven with cellulose tyre cord (rayon)
Better cellulose reinforcing fibers via Lyocell-route possible/economically feasible
Bio-based carbon fibers with combined cellulose-lignin precursors under way
Finally : CLEANER TECH with bio-based solutions . Who else than cellulose can provide a bio-based (and degradable) reinforcing fiber?
© Fraunhofer
FNR (BMEL), PtJ (BMBF), FhG for funding
Stora Enso for joint development
Cordenka GmbH long standing cooperation
Thank you very much for your attention!
Acknowledgements
Fraunhofer IAP is member of
Contact: Prof. Dr. Johannes Ganster Division director »Biopolymers« Fraunhofer Institute for Applied Polymer Research IAP Geiselbergstraße 69 14476 Potsdam-Golm Telephone +49 (0) 331 568-1706 Mobile +49 (0) 173 3874772 email: johannes.ganster @iap.fraunhofer.de
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Diesen Kasten nicht löschen (ist für die Funktion der Folie wichtig)
Fraunhofer Cluster of Excellence (CoE): Circular Plastics Economy CCPE®
Bundling of competencies and system services Excellence in depth, relevance in critrical mass International thematic leadership
Purpose of a Fraunhofer Cluster?
To research fundamentals, know-how, structures, and system services for a knowledge-based circular plastics economy
To optimize the value chain plastics by circuclar principles To develop products to circular product systems
What does the Cluster Circular Plastics Economy strive to achieve?
Prof. Dr. Eckhard Weidner
Director of the Cluster
Who represents the Fraunhofer Cluster Circular Plastics Economy?
Prof. Dr. Alexander Böker
Prof. Dr. Uwe Clausen Prof. Dr. Tobias Melz
Prof. Dr. Peter Elsner
Structure und research agenda of the cluster
Circular prototypes Circular prototypes
Photos: shutterstock.com