Presentation contents. Overview Synbra group BioFoam project overview; PLA polymerisation; LCA and carbon footprint; Conclusions.

Transcription

1 BioFoam applicatons

2 Presentation contents Overview Synbra group BioFoam project overview; PLA polymerisation; LCA and carbon footprint; Conclusions. 2

3 Synbra Group : 26 production locations in 6 countries Synbra s European coverage About 1.`400 employees; Turnover of about 300 million Producer of EPS polymer Producer of PLA polymer ( only one in EU) Fous on Foam Synbra Technology supplies with EPS beads Local BUs convert the beads into products Local BUs invest in product and application innovations Synbra Technology supports with material innovation 3

4 Megatrends in foamed polymers Sustainable Insulation Systems (SIS) Industrial Products & Solutions (IPS) Trend Opportunity for Synbra (e.g.) Trend Opportunity for Synbra (e.g.) Energy saving Insulation of houses & buildings Energy saving Rapid replacement of warm water, boiler systems, heating systems Reducing weight in automotive by using EPS/EPP/Piocelan foams Sustainability - Biofoam PLA based material Safety Xire Firesafe (insulation) material - Biostyr (water filtration system) Low cost customer - Insulation systems - Pitched roof elements Safety Increased demand for light weight helmets cycling / skiing

5 BioFoam project overview

6 History BioFoam project Formal project started April 2006; R&D with Wageningen University WUR; Starting point: Use Synbra EPS pre-expansion & moulding; Use Polylactic acid (PLA); Best results Blowing with CO 2 ; Shape moulding with proprietary coating; R&D achievements and PPS BioFoam Dutch EOS KTO subsidy 800k PLA plant Sulzer Chemtech and Purac Biochem 2012 BioBest Gelderland Biobased Performance materials: PPS with 52 companies 6

7 BioFoam E-PLA cell structure Structure looks very similar to EPS 7

8 Composting results 5 x 5 x 5 cm 3 BioFoam blocks (various densities) disintegrate completely at 70 C within 4 wks No composting at RT (30 C) No degradation at roof for 2 years, no change of colour nor molecular length 8

9 EPS PLA foaming Impregnation with CO 2 Coating of prefoamed beads Impregnation of coated beads Raw bead production Prefoaming raw beads Maturing of prefoamed beads Moulding of prefoamed beads 9

10 Validation and supporting information 10 Fire test Bean Bags Efectis & Moulded NRW-MPA meets BS 5852 ( sigaret/match) crib 5 meets DIN4102 B1 and B2 Meest Euroclass E fire classification No halogens present Droptesting at Clemson University (South-Carolina); LCA verified by, AkzoNobel Technology & Engineering Sust. Dev.Group; Sweden Peer reviewed by Prof. Martin Patel-Utrecht Uni. Compostability certification EN13432 Passed EN117/118 Termite/pest and fungus tests C2C certified by EPEA; 10

11 BioFoam Moulded Packaging Fish box Pallets LCD buffer Childs seat Kelvin box

12 BioFoam Construction

13 BioFoam Horti Seed trays Soil improvement Aqua culture Permeable covers tree growing

14 Substrate development R&D Biobest Gelderland EOL :Compostable EOL: Incineartion Bio-based C2C certified water rentention Price Perlite BioFoam Open cell BioFoam C in application Mineral Wool

15 Other applications Puncture detector Surf boards BioFoam HR ( grey)

16 C2C Validation 16 C2C since 2010 Upgraded March 2013 Synterra Silver due to GMO free 16

17 BioFoam Awards Winner of the Frost & Sullivan Technology Innovation Of The Year Award 2008 PLA polymerisation process Winner 2009 gold sustainability medal awarded by the Dutch Rubber and Plastics Federation #1 of the 2010 MKB top 100 : Earmarked most innovative company in the Netherlands Third Price in Dutch 2010 packaging De gouden Noot Winner Nederlandse Bouwprijs 2011 at construction exhibition in Utrecht (NL). Winner of the Frost & Sullivan Technology Innovation Of The Year Award 2011 for BioFoam

18 Synterra PLA

19 Stereocomplex-PLA improves Heat Resistance (HDT) PLLA and PDLA sc Fibres Synterra IM PLA fast crystallisation injection moulding ISO 306 Vicat A 1 kg load 160 C Vicat B 5 kg load 100 C 19

20 Environment & Synterra

21 More & more regulations are favorable for the use of bioplastics (f.e. plastic carrier bags BAN in Italy) End-of-life options : chemical recycling to Lactid Acid industrial composting anaerobic digestion incineration to renewable energy Impact on Global Warming Potential & carbon Footprint : development of life-cycle-analysis tool in cooperation with AkzoNobel 21

22 Sustainability PLA most sustainable polymer Bio-PE much less efficient than PLA Source: and Int. Journal Life Cycle assessment, LCA of the manufacture of lactide and PLA... 3 Aug 2010 PLA in 2015 is under development at Purac R&D

23 Comparison cradle-to-gate Func. U. for 1 m2 Rc 2,5 insulation Table: Functional traits of the different insulation materials defining the Functional Unit (F.U.) Material Lambda [mm/m*k] Density [kg/m 3 ] Mass [kg/f.u.] Thickness [cm] E-PLA BioFoam ,65 8,25 EPS ,44 8 Mineral Wool ,6 10,5

24 Crude oil eq. consumption for 1 m2 Rc 2,5 insulation No additional green energy purchased

25 Carbon footprint for 1 m2 Rc 2,5 insulation Conclusions: EPS very good energy efficient insulant BioFoam overall even better

26 Eye opener: Land use per kg Land use for cardboard 3 times higher than BioFoam

27 3th generation PLA almost a fact : production Lactide Gypsum free : Less chemicals Lower environmental impact with better LCA Further developments kg CO2 eq./ton L Improvements in lactic acid and lactide processing 4th generation PLA produced with cellulose based Lactid Acid : Improved sustainability CO2 sink No impact on food chain use waste paper or cellulose kg CO2 eq./ton L Carbon sequestered Sugar production Transport Aux. chem. production Energy need L2 manufaturing Energy cogerantion Total Lactide from w aste; biorefineries, energy from eg. lignines 27

28 Future?: Dutch Grown Biopolymers initaitive Suikerunie, Purac and Synbra are exporing the creation of a 100% Dutch biopolymer production Green deal satsus with Economic affairs Gvmnt will facilitate the development Study no obligation

29 Thank you for your attention Any Questions?