Seminar “BIOPLASTIKA” v okviru projekta PLASTiCE

Celje, 21. marec 2012

Potencial bioplastike in

trendi na področju

Janez Navodnik

GIZ Grozd Plasttehnika

Prehod se bo zgodil že leta 2011

Novi materiali reagirajo na zunanje vplive (kot so T, svetloba, EM- polje, bio- ali

kemijski vplivi) s spreminjanjem oblike, barve ali pa pretvarjajo energijo (e-papir, ki

sveti ali predvaja film, folija, ki proizvaja elektriko, nit, ki se v telesu sama zavozla)

Funkcionalni in inteligentni materiali

2

Polimeri

imajo med

naprednimi

materiali

vodilno vlogo

Funkcionalni in inteligentni materiali

3

Polimeri – postajajo najpomembnejši funkcionalni material

Svet: 202 mio ton

Rast 9% - 60 let

EU: 35 mio ton

130 md €

1,6 mio zaposlenih

37.000 firm

SLO: 330.000 ton + polizd.

1600 firm

18.000 zaposlenih

Več kot jeklo, Al, papir…

+

orodja, stroji

Polimeri + 1% = HT

1% = napredni materiali in tehnologije

ter znanje 4

5

Razvoj bioplastike skozi zgodovino

Razvoj

6

Uporaba bioplastike v Evropi po namenu

uporabe

Trenutno stanje

7

Tržni deleži bioplastike v letu 2011 po namenu

uporabe

Trenutno stanje

8

Razvojni status (v letu 2011) termoplastov iz

bioplastike

Trenutno stanje

BIOPLASTIKA

Trg

9

10

Svetovne proizvodne kapacitete bioplastike

glede na vrsto materiala v 2010

Trenutno stanje

11

Svetovne proizvodne kapacitete bioplastike v

letu 2011 glede na vrsto materiala

Trenutno stanje

12

Proizvodne kapacitete bioplastike po svetu v letu 2011

in prognoza do 2015

Tenutno stanje in trendi

13

Proizvodne kapacitete bioplastike po svetu

do 2015

Trendi

14

Trg za bioplastiko bo ostal niša v prihodnjih

letih kljub skokoviti rasti proizvodnje

(predvidena je 44% letna rast)

Trendi

15

Skupne kmetijske površine in teoretično

potrebne kmetijske površine za proizvodnjo

bioplastike v letu 2015

Trendi

16

Komercialni tržni delež različnih bioplastičnih

materialov v letu 2015

Trendi

BIOPLASTIKA

PRIMERI MATERIALOV

17

18

Primeri bioplastike

Bio-pultruzija (lan)

Solid particles in polyurethan foam mouldings

Hennecke in Bayer MaterialScience

19

Primeri bioplastike

Bio PA + vlakna bambusa

20

Primeri bioplastike

granulat

PE + vlakna soje in PP + vlakna soje

21

Primeri bioplastike

Bio-pultruzija (lan)

BIOPLASTIKA

Lesni kompoziti

22

LESNI KOMPOZITI

Primerjava specifične trdnosti in E/modula različnih materialov

23

Sl. 2: Cene materialov glede na modul

24

LESNI KOMPOZITI

25

LESNI KOMPOZITI

26

0

1

2

3

4

5

6

7

8

0 10 20 30 40 50 60 70 80

Charpy [kJ/m2]

E-m

od

ulu

s [

GP

a]

PLA

NF-PLA

PHB coPHV NF-PHB coPHV

NF-Lignin

NF-Starch

PLA-, PHB-, Starchcompounds

PLA+IM

LESNI KOMPOZITI

Furan-Flax Example Parts

Furan-flax

prepreg tubes

Furan-flax prepreg

ambulance panel

Furan-flax prepreg

sandwich panel

LESNI KOMPOZITI

28

Razvoj poliuretana iz odpadne lesne biomase

BIOPUR: razvoj specialnih

ligninskih kompaundov, kot so

npr. elektroprevodni polimeri,

inženirski plasti in poliuretan.

Input (tons/year)

LIQUEFYING

+

SYNTHESIS

Output

Cellulignin 20.000 Polyurethane - hard

Polyurethane - soft

Polyurethane - foam

64.000 tons/year, h=80 %

Polyhydrig

alcohols

57.000

Catalyst 1.200

Hardeners 1.800

PUR sendviči – lesni odpadki

Izbor WCP profilov

29

WPC – lesni kompoziti

Tržne možnosti lesnih kompozitov WPC

30

WPC – lesni kompoziti

Poraba WPC v vseh panogah

31

WPC – lesni kompoziti

Kdo proizvaja WPC

32

WPC – lesni kompoziti

Proizvodnja po državah

33

WPC – lesni kompoziti

Pri WPC Evropa zaostaja

34

WPC – lesni kompoziti

Važen je visok % lesa

35

WPC – lesni kompoziti

Les ni termično stabilen

36

WPC – lesni kompoziti

Proizvajalci po tipih

37

WPC – lesni kompoziti

Primerjava lastnosti

38

WPC – lesni kompoziti

BIOPLASTIKA

Lastnosti

39

40

Lastnosti bioplastike

Barierne lastnosti bioplastike

41

Lastnosti bioplastike

PLA – mehanske lastnosti

42

Lastnosti bioplastike

PLA – mehanske lastnosti

43

Lastnosti bioplastike

PP + celuloza (Tencel FCP) – mehanske

lastnosti

BIOPLASTIKA

End-of-life

44

45

End-of-life

Skupine

odpadkov po

nemški

zakonodaji

46

End-of-life

Možni načini ravnanja z bioplastiko po koncu

uporabe

47

End-of-life

Bioplastiko je možno tudi reciklirati !

48

Biogoriva

Za vsako ceno!

Idealni zaključen krog?

49

Biogoriva

Delež in rast biogoriv

50

Biogoriva

So vsa bio goriva zelena?

51

Biogoriva

52

Biogoriva

Postopki predelave biomase

Delež gozdnih virov

53

Biogoriva

Napovedi so optimistične

54

Evidence of the growth of biofuel power is underlined by the fact that Ford sold

nearly 250 000 flex fuel vehicles in 2006, while some 37 000 "green" cars -

designed to run on ethanol - were registered in Sweden, serviced by some

600 filling stations. Currently, the US has about 10 000 ethanol fuels stations,

and race cars competing in the 2007 IndyCar Series are now running on 100%

ethanol.

Biogoriva

55

Po državah ogromne

razlike

In 2005 the US revealed plans to

nearly double ethanol production by

2012, while the European Community

(EC) recently announced that biofuels

are projected to meet 10% of its

transportation fuel needs by 2020.

Biogoriva

56

Vplivi na CO2

emisije –

temnejša plat

medalje

Forget biofuels – burn

oil and plant forests

instead.

19:10 16 August 2007

by Catherine Brahic

Biogoriva

57

End-of-life

Količina bioplina pri razgradnji različnih

bioragradljivih plastičnih materialov

58

Zemlja – temnejša plat medalje

Biogoriva

BIOPLASTIKA

Evropski raziskovalno razvojni

projekt

59

60

CENTRAL

EUROPE

Future laboratory for the diffusion and application of innovation in materials

science and engineering FLAME www.flameurope.eu

CENTRAL

EUROPE

Creating framework conditions for enhancing the development of the

biodegradable plastics market in central europe as an innovative test bed for

new product applications in selected industries

PLASTiCE www.plastice.org

CORNET Polylactic acid (PLA ) for new biobased packaging Biobased

packing

CORNET

Development of tools to communicate advanced technologies on active and

intelligent packaging to meet the needs and trends in food processing and

retailing and to improve the knowledge transfer especially for smes

AIP –

COMPETENCE

PLATFORM

www.activepackaging.eu

CORNET Advanced simulation methods for part and process development of complex

injection moulded parts tailored for SMEs

ADVANCED

PartSim

EUREKA Automatic fire extinguisher AFE

EUREKA Development of biopolymers from waste wood biomass BIOPUR

EUREKA Improved product development and post-production controller system iPDS demos.aitiip.com/eureka-ipds

FP6 New classes of composite materials from renewable resources BIOCOMP www.biocomp.eu.com

FP6 New closed loop development guidance system for complex injection

moulded plastic parts and moulds applicable by sme Pro4Plast

FP7 Complex semi-finished structural parts from improved thermoplastic bio-

composites – improved wood plastic composites BIOSTRUCT www.biostructproject.eu

FP7

Development of a new recyclable long life co-injected high barrier packaging

for food applications, with broad design possibilities and reduced

manufacturing costs

COBAPACK www.aimplas.es/proyectos/

cobapack

FP7 Whey protein-coated plastic films to replace expensive polymers and

increase recyclability WHEYLAYER www.wheylayer.eu

FP7 Study of recyclability of painted, printed, metallized or laminated plastic parts

using supercritical CO2 technologies and nanofillers CLIPP

www.clipp-project.eu

Eco-Innovation Marine debris removal and preventing further litter entry MarineClean www.marineclean.eu

IPA SI-AT

Razvoj POLIREGIJE z združitvijo R&R in gospodarskih kapacitet s

poudarkom na MSP-jih na področju polimernih tehnologij, s ciljem

nadgradnje zaloge znanja, infrastrukture ter konkurenčnosti.

PolyRegion

61

Projects

GP is/was involved in the following EU projects about

simulation methods in plastic production:

NEW CLOSED LOOP DEVELOPMENT GUIDANCE

SYSTEM FOR COMPLEX INJECTION MOULDED

PLASTIC PARTS AND MOULDS APPLICABLE BY SME - Pro4Plast

IMPROVED PRODUCT DEVELOPMENT AND POST-

PRODUCTION CONTROLLER SYSTEM - iPDS

ADVANCED SIMULATION METHODS FOR PART AND

PROCESS DEVELOPMENT OF COMPLEX

INJECTION MOULDED PARTS TAILORED FOR SMEs

– ADVANCED PartSim

ended

running

running

EUREKA - iPDS

62

OBJECTIVES

1. Make a new Obligation Book for assemblies or products, not only parts, which consider their

particularities (Interferences, wear, lubrication, overlapping,…)

2. Develop an improved PDS (IPDS) for simplifying the use of this Obligation Book, including a new

“Stage 5” for post-production managing (logistics, quality control, etc…)

3. Embed the Support Tools into the software open code to be used without the Office pack,

improving them in some cases and creating new ones on others.

http://demos.aitiip.com/eureka-ipds/

Improved product development and

post production controller system

CORNET – Advanced PartSim

63

ADVANCED SIMULATION METHODS FOR PART AND PROCESS DEVELOPMENT

OF COMPLEX INJECTION MOULDED PARTS TAILORED FOR SMEs

On the way to virtual prototyping with

• 4 new and highly innovative

• easy-to-use simulation-methods for OEM/SME

• developed on a prototype base

Coming from Pro4Plast Case Studies experience, these

4 methods are the

• most important missing development methods

in Stage 1 and Stage 2

64

COMPLEX SEMI-FINISHED STRUCTURAL

PARTS FROM IMPROVED

THERMOPLASTIC BIO-COMPOSITES –

IMPROVED WOOD PLASTIC COMPOSITES - BIOSTRUCT

As first in the world we

have produced some

wooden products

(loudspeaker) with the

technology of injection

molding of plastics.

NEW CLASSES OF

COMPOSITE MATERIALS

FROM RENEWABLE RESOURCES - BIOCOMP

POLYLACTIC ACID (PLA ) FOR

NEW BIOBASED PACKAGING - Biobased packing

GP is/was involved in the following EU projects about

new plastic materials from renewable resources:

Projects

running

ended

ended

FP6: BIOCOMP

Loudspeaker, 100 % wood

www.biocomp.eu.com

Products

BIO-BASED PACKING

COMPOUNDING

- compounding and adding different

polymers and additives on semi-industrial

compounder

- improvement of mechanical properties,

especially impact strength, thermal

properties and barrier properties

- montmorillonit, CNT, impact modifiers

and n-AG for bactericide

- 32 different compounds

67

WHEY PROTEIN-COATED PLASTIC FILMS TO

REPLACE EXPENSIVE POLYMERS AND INCREASE RECYCLABILITY - WHEYLAYER

DEVELOPMENT OF TOOLS TO COMMUNICATE

ADVANCED TECHNOLOGIES ON ACTIVE AND INTELLIGENT PACKAGING - AiP Competence Platform

STUDY OF RECYCLABILITY OF PAINTED, PRINTED,

METALLIZED OR LAMINATED PLASTIC PARTS USING SUPERCRITICAL C02 AND NANOFILLERS - CLIPP

DEVELOPMENT OF A NEW RECYCLABLE LONG LIFE CO-

INJECTED HIGH BARRIER PACKAGING FOR FOOD

APPLICATIONS, WITH BROAD DESIGN POSSIBILITIES AND REDUCED MANUFACTURING COSTS - COBAPACK

GP is/was involved in the following EU projects about

plastic materials for food packaging:

Projects

running

ended

ended

ended

FP7: COBAPACK

68

Development of a new recyclable long life

co-injected high barrier packaging for food

applications,with broad design possibilities

and reduced manufacturing costs

www.aimplas.es/proyectos/cobapack

OBJECTIVE:

• Reduction in production costs using cheaper inner material

• Developing the manufacture process in just one step (substituting co-extrusion +

thermoforming by co-injection)

• Increasing products range

• Opening new markets for materials from renewable resources

• Increasing the amount of recycled commodity thermoplastics in the market

“Research for the Benefit of SMEs”

Aims of the Project

Develop Whey protein-coated plastic films to replace

expensive polymers and increase recyclability

Investigate a new application for whey, a by-product of

dairy industry

Extend food shelf life by addition of active ingredients

Whey

layer

FP7: WHEYLAYER

www.wheylayer.eu

FP7: CLIPP

70

STUDY OF RECYCLABILITY OF PAINTED, PRINTED,

METALLIZED OR LAMINATED PLASTIC PARTS USING SUPERCRITICAL C02 AND NANOFILLERS - CLIPP

Objective:

to promote a system which allows to use post-industrial wastes coming from scraps, and

reels refused by manufacturers of plastic film for flexible packaging and injected packages.

www.clipp-project.eu

71

Innovative value chain development for

sustainable plastics in Central Europe -

PLASTiCE

GP is involved in the following EU projects:

Projects

running

running

IPA SI-AT: PolyRegion

72

Technology centre Poli-Eko is involved in the following EU

project:

Projects

running

Marine debris removal and preventing

furter litter entry - MarineClean

Marine Clean Grant Agreement ECO/10/277396/SI2.601543

Edible and

biodegradable

food packaging

Smart

fishing

equipment

Marine litter

removing

equipment

www.marineclean.eu

Thank you very

much for your

attention! Contact:

Slovenian Plasttechnics Cluster

Kidriceva 25a, SI-3000 Celje, Slovenia

phone: +386 3 425 84 00

fax: +386 3 425 84 09

e-mail: navodnik@giz-grozd-plasttehnika.si

web: www.giz-grozd-plasttehnika.si