Biokunststoffe Modetrend oder nachhaltige Alternative?

Biokunststoffe Modetrend oder nachhaltige Alternative? Hans-Josef Endres Forum Automobillogistik, 3.-4. Februar 2016 IfBB Institute for Bioplastics and Biocomposites - www.ifbb-hannover.de

Prof. Dr.-Ing. Hans-Josef Endres Studium: Maschinenbau (Ruhr-Universität Bochum) mit Vertiefungsrichtung Werkstofftechnik Berufliche Erfahrungen: Ca. 10 Jahre Industrietätigkeit, zuletzt Bereichsleiter (ca. 230 Mitarbeiter) bei Thyssen-Krupp Berufsbegleitende Promotion Seit 1999 Professur an der Hochschule Hannover Biokunststoffforschung seit 25 Jahren Niedersächsische Wissenschaftspreis in 2012 Forschungsprofessur in 2013 B.A.U.M. Umweltpreis Kategorie Wissenschaft 2015 Gründung/Aufbau Hochschulinstituts IfBB (ca. 30 Mitarbeiter) Fraunhofer Anwendungszentrum HOFZET (15 MA), Holzfaser- und Compositeforschung

Gliederung Wording Bioplastic Market Situation Perspectives

Plastics as essential materials Golf 1 Golf 6 Weight Costs Source: VW, Peter Helmke

Future of petro-based plastics Consumption of crude oil 5.000.000 x higher than its rate of regeneration challenge only to convert energy; the increasing quantity requirements for plastics will become a feedstock problem! Growth of population (Expectation: per head plastic consumption in India and China as high as in Europe) Worldwide production of plastics has to be doubled! Issue for the environment: critical exploitation of oil with increasing ecological impacts and littering through plastics

What are Green Plastics Biobased feedstock Biodegradable Based on biobased CO 2 Petrobased CO 2 but renewable energy Green Plastics Bio- Composites Recycled Plastics Petrobased but renewable energy Petroleum-free plastics Source: H.-J. Endres, A. Siebert, A.-S. Kitzler Biopolymers a discussion on end of life options Bioplastics Magazine 01/08

What are Bioplastics? Based on renewable resources Bio-based Bio-degradable and based on renewable resources Biopolymers Biopolymers Non degradable Conventional plastics Biopolymers Degradable Petro-based Biodegradable Source: Hans-Josef Endres, Andrea Siebert-Raths; Engineering Biopolymers, Carl Hanser-Verlag, Juni 2011

Bioplastics Nondegradable Bio-based 1. Cellulose Acetates Rubber, Casein 5. Bio-PA, Bio-PE Bio-PET, PTT, 2. Polyethylene Polypropylene Polyvinylchloride Bio-based Bio-degradable and biobased 4. Polylactide, Starch blends, Cellulose Hydrates, Polyhydroxyalkanoate 3. Polycaprolactone Polyvinyl alcohols Polyesters (PBAT, PBS,..) Biodegradable Degradable Petro-based Source: Hans-Josef Endres, Andrea Siebert-Raths; Engineering Biopolymers, Carl Hanser-Verlag, Juni 2011

Biodegradability O CH 3 CH O C n Primary degradation Final degradation Hydrolyses HO COOH C H CH 3 Oxidative degradation (CO 2 + H 2 O) + (Biomass) Source: Hans-Josef Endres, Andrea Siebert-Raths; Engineering Biopolymers, Carl Hanser-Verlag, Juni 2011

Certification and labeling of compostability Biodegradable Products Institute (BPI, USA); ASTM D 6400 Jätelaitosyhdistys (Finland); DIN EN 13432 AIB Vinçotte, Belgien; DIN EN 13432 Japan BioPlastics Association (JBPA; Japan) DIN CERTCO, Germany Source: Hans-Josef Endres, Andrea Siebert-Raths; Engineering Biopolymers, Carl Hanser-Verlag, Juni 2011

Degradation Szenarios Landfill Litter Metabolization in organisms Anaerobic digestion ( Bio-methane) Biopolymer product Decomposition in soil Domestic composting Dissolving in (salt) water Industrial Composting Source: H.-J. Endres, A. Siebert, A.-S. Kitzler Biopolymers a discussion on end of life options Bioplastics Magazine 01/08

What is biobased Quelle: H.-J. Endres, A. Siebert-Raths; Engineering Biopolymers, Carl Hanser-Verlag, 2011

Certification and labeling of biobased Carbon (ASTM 6866) DIN CERTCO Vincotte Source: Hans-Josef Endres, Andrea Siebert-Raths; Engineering Biopolymers, Carl Hanser-Verlag, Juni 2011

Biopolymers and Bioplastics Raw Polymer Finishing Material ( ready to use ) Biopolymers Additives, e.g: Stabilizers Plasticizer Processing aid Coloring Filler Reinforcing component Co-, Terpolymers Bioplastics Blending Quelle: H.-J. Endres, A. Siebert-Raths; Technische Biokunststoffe, 2-te Auflage, Carl Hanser-Verlag, 2016

Old and New Economy Bioplastics Bioplastics Old Economy New Economy Rubber Regenerated Cellulose Cellulose Acetates Linoleum etc. Novel PLA PHA PEF Starch Blends etc. Drop-Ins Bio-PA Bio-PE Bio-PET Bio-PP etc. Quelle: H.-J. Endres, A. Siebert-Raths; Technische Biokunststoffe, 2-te Auflage, Carl Hanser-Verlag, 2016

Bioplastics Biobased (partly or fully) Durable (biobased) Novel e.g. PLA, starch, PTT, PBS, PBAT Thermoplastics New Economy BIO- PLASTICS Petro-based (biodegradable) Biodegradable (compostable) Drop-Ins, Biobased e.g. Bio-PE, Bio- PET Thermosets Elastomers,TPE Old Economy e.g. rubber, rayon, linoleum, CA, cellophane IfBB

Gliederung Wording Bioplastic Market Situation Perspectives

The Biopolymer Market (2014) PRODUCTION CAPACITY [t/a] Total biopolymer production capacity: ~1.6 mt/a TPE PA12 P U R P C L > 1,000 PA10.10 PA4.10 PRICES [ /kg] 16 > 10,000 DSB PA6.10 PA11 Cellulose Derivatives CA 5.00-10+ POLYESTER* TSC > 100,000 PE PLA PHA 2.50 5.00 > 1 mil. PET 2.50 CA = cellulose acetate PE = bio polyethylene PHA = polyhydroxyalkanoates DSB = durable starch blends *other biodegradable polyesters (PBAT, PBS) Durable biobased Biodegradable petrobased Market Volume: ~ 5.8 bn PA = bio polyamide PET = bio polyethylene terephthalate PLA = polylactide PUR = bio polyurethane TPE = bio thermoplastic elastomer TSC = thermoplastic starch composites www.downloads.ifbb-hannover.de

New Economy Bioplastics - Production capacities

New Economy Bioplastics - Production capacities Europe s share of the global bioplastics production capacity is shrinking!

New Economy Bioplastics -Applications Packages remain the most important application of bioplastics!

New Economy Bioplastics - Share of material types

New Economy Bioplastics - material utilization

Gliederung Wording Bioplastic Market Situation Perspectives

Methodology of land use calculation Source: www.downloads.ifbb-hannover.de Seite 25

Yields of renewable raw materials 25,0 20,0 [t /(ha*a)] 15,0 10,0 5,0 0,0 Sugarcane Sugar-beet Corn Potato Wheat Rice Palm Jatropha Coconut Castor Rape Sunflower Soya Wood Pulp Wheat straw Hemp Flax Cotton Sugar Starch Vegetable Oils Cellulose(fibers) Source: Hans-Josef Endres, Andrea Siebert-Raths; Engineering Biopolymers, Carl Hanser-Verlag, 2011

New Economy Bioplastics - land use

Land use of New Economy Bioplastics (2019) Annual plastics production in 2012 [10 6 t] Annual bioplastics production in 2018 (projection) [10 6 t] Land use for bioplastics production in 2019 (projection) [km 2 ] Arable land [km 2 ] World 265 6.7 14.000 14 million EU 60 0.5 1.000 1.1 million Germany 20 0.15 300 0.12 million Lake Constance 540 Land use for annual bioplastics production in 2018: < 0,1 % of the global arable land. Full replacement of petro-based plastics in the automotive industry with bioplastics requires < 0,3 % of the global arable land. Full replacement of petro-based plastics in the packaging industry with bioplastics requires < 2% of the global arable land. Full replacement of total petro-based plastics with bioplastics requires ~ 5 % of the global arable land.

Land use of New Economy Bioplastics 2014 1. Global Land use 700.000 ha or 7.000 km 2 This is: - Approximately 0,004% of the global arable land - Less than 0,1% of the land used for trashed food worldwide - About 70% of the land used to produce biogas in Germany 2. Substitution of all plastics by bioplastics < 10% of the trashed land is needed! Additional Bioplastics could deliver CO 2 -neutral energy after utilization (no support like green electricity) Discussions of bioplastics tend to be driven by emotional concerns rather than by real facts!

Biokunststoffe in Verruf 11.04.2012 Pressemitteilung 23.07.2015, 11:59 Uhr Quelle: DUH Danone täuscht Verbraucher weiterhin mit Activia-Joghurtbechern Seit März 2011 verpackt die Danone GmbH ihren Activia-Joghurt in einem Becher aus dem Biokunststoff Polylactid (PLA). Bereits zur Einführung kritisierte die Deutsche Umwelthilfe (DUH), dass den PLA-Bechern nicht nur ein gesamtökologischer Vorteil im Vergleich zu herkömmlichen Plastikbechern fehlte, sondern auch, dass sie als Verpackungsabfall nicht recycelt werden konnten. Die Danone-Geschäftsführung hatte daraufhin Ende 2011 angekündigt, einen bundesweiten Recyclingkreislauf für Verpackungen aus PLA aufzubauen. Vier Jahre nach der Abgabe dieses Versprechens kommt die DUH zu dem Ergebnis, dass es nicht eingehalten wurde. Quelle: DUH

Risk communication

Nachhaltiges Handeln?

Biokunststoffe als Sekundärlösung zur Marin Litter Problematik Marine Litter Problematik Kunststoffe in der marinen Umwelt European Commission; Ferdi Rizklyanto

Konsum so nachhaltig wie möglich

More information on bioplastics http://www.hanser.de/buch.asp?isbn=978-3-446-42403-6&area=technik http://www.hanser.de/buch.asp?isbn=3-446-41683-8&area=technik

Contact Prof. Dr.-Ing. Hans-Josef Endres Head of the Institute for Bioplastics and Biocomposites (IfBB) University of Applied Sciences, Hannover Heisterbergallee 12 D- 30453 Hanover Tel 0049 (0) 5 11 / 9296 22 68 Fax 0049 (0) 5 11 / 9296 99 22 68 Mail info@ifbb-hannover.de Prof. Dr.-Ing. Hans-Josef Endres Head of the Application Center for Wood Fiber Research Fraunhofer-Institut für Holzforschung - Wilhelm-Klauditz-Institut WKI University of Applied Sciences, Hannover Heisterbergallee 12 D- 30453 Hanover Tel 0049 (0) 5 11 / 9296 22 68 Fax 0049 (0) 5 11 / 9296 99 22 68 Mail hans-josef.endres@wki-fraunhofer.de www.ifbb-hannover.de www.wki.fraunhofer.de Seite 36

Backup Seite 37

IfBB Institut für Biokunststoffe und Bioverbundwerkstoffe an der Hochschule Hannover Gründung: 2011 (Konsequenz stetig gewachsener Forschungsaktivitäten) Mitarbeiter: ca. 30 Jahresumsatz ca. 3 Mio. Euro Enge Vernetzung mit der Industrie Arbeitsschwerpunkte im Bereich Biowerkstoffe: Spezifische Materialentwicklung Verarbeitung Recycling und andere End-of-life Optionen Ökologische Bewertungen Informationsbereitstellung (Marktentwicklung, Datenbanken, ) Foto: Ksenia Kuleshova Foto: Ksenia Kuleshova Seite 38

IfBB Institute for Bioplastics and Biocomposites Approx. 30 research staff members as of now Annual turnover approx. 3 million Large-scale research facilities: plastics technology and materials research and testing (technical processing center, laboratories for materials testing) Numerous projects supported by third-party funds or carried out in collaboration with an array of industrial partners in bioplastics and biocomposites photos: David Carreno Hansen Seite 39

Processing routes Non Biodegradable Chemical synthesis of biotechnological raw materials (e.g. Bio-PE, Bio-PA, Bio-PUR) Modification of renewable feedstock (e.g. CA) Biobased Feedstock Chemical synthesis of biotechnological raw materials (e.g. PLA) Modification of renewable feedstock (e.g. Starch) Direct biosynthesis of polymers (e.g. PHAs) Biodegradable Chemical synthesis of petro-chemical feedstock (e.g. PCL, Ecoflex) Petrochemical Feedstock Source: Hans-Josef Endres, Andrea Siebert-Raths; Engineering Biopolymers, Carl Hanser-Verlag, Juni 2011

Processing routes Non Biodegradable Chemical synthesis of biotechnological raw materials (e.g. Bio-PE, Bio-PA, Bio-PUR) Modification of renewable feedstock (e.g. CA) Biobased Feedstock Chemical synthesis of biotechnological raw materials (e.g. PLA) Modification of renewable feedstock (e.g. Starch) Direct biosynthesis of polymers (e.g. PHAs) Biodegradable Chemical synthesis of petro-chemical feedstock (e.g. PCL, Ecoflex) Petrochemical Feedstock Source: Hans-Josef Endres, Andrea Siebert-Raths; Engineering Biopolymers, Carl Hanser-Verlag, Juni 2012

Zertifizierung der Kompostierbarkeit Teilschritte bei der Untersuchung der Kompostierbarkeit nach DIN EN 13432 Allgemeine Informationen Chemische Analyse Laborversuche zur biologischen Abbaubarkeit Analyse der Kompostiereigenschaften unter realitätsnahen Bedingungen Toxizitätsanalyse der Entstehenden Abbauprodukte Source: Hans-Josef Endres, Andrea Siebert-Raths; Technische Biopolymere, Carl Hanser-Verlag, Juni 2009

Degradation principles Source: H.-J. Endres, A. Siebert-Raths; Engineering Bioplymers, Carl Hanser-Verlag, 2011 Source: H.-J. Endres, A. Siebert-Raths; Engineering Bioplymers, Carl Hanser-Verlag, 2011

Biobased - what does it mean? Carbon exists in form of 3 different isotopes: 12 C, 13 C (stabile) and 14 C (radioactive) Half-Life time of 14 C only 5730 years Due to a continuous regeneration of 14 C in atmosphere the 14 C quota is nearly constant Photosynthesis similar relationship of C-isotopes in plants Bio-based Polymers similar relationship of C-isotopes in biopolymers Quelle: Currie, Lloyd A., modifiziert Petrochemical raw materials and plastics contain no young 14 C, they consist out of old 12 C

Biobased Fibres Fiber grades Possible renewable resources Carbon fibers Synthetic organic fibers Natural fibers Ceramic fibers Glass fibers Boron fibers Biobased Carbon PLA Bio-PE Bio-PA Bio-PET, PTT Cellulosics animal plants based on cellulose, lignin, etc. based on corn starch, sugar, etc. based on sugar cane, corn starch, resp. bio-ethanol based on castor-oil e.g. based on sugar cane, corn starch, resp. bio-alcohols based on cellulose silk, wool (= proteins) wood, cotton, hemp, flax, sisal, jute, etc. (= polysaccharides) Quelle: H.-J. Endres, T. Koplin, C. Habermann, Technology and Nature Combined, Kunststoffe International, 2012

Biocomposites Bio-based Matrix Conventional Fibers - Bio-PA + GF - Bio-PP + GF - Bio-Resin + GF - Bio-Resin + CF - - PA + GF - PP + GF - PP + CF - - PLA + NF - Natural rubber + CRF - Bio-PA + CRF - - PE + NF - PP + Wood flour - PA + CRF - PP + CRF - GF: CF: NF: CRF: Bio-based Fibers glass fibre carbon fibre plant fibre rayon Conventional Composites Bio-based Fiber Petrobased Matrix Quelle: H.-J. Endres, T. Koplin, C. Habermann, Technology and Nature Combined, Kunststoffe International, 2012

Biobased Building Blocks

Where to find information Biopolymer database Technical material characteristics e.g. for engineers NawaRo Kommunal Purchase of bioplastic products Biopolymer platform market data, processing routes, feedstock, land use, etc. Marketing, politics, scientists, etc.

Materials Database Comparing Materials and Properties

Materials Database

Land use of New Economy and Old Economy Bioplastics (2012) Global land use in hectare New Economy Biopolymers 1 Pulp 2 Natural rubber

Entropie-Effizienz als Maß für die Nachhaltigkeit Entropie berücksichtigt Down cycling von Energie und Materie Entropie-Effizienz = Nutzen / Entropie Produktion = Nutzen E i= A S i Je höher die Entropie-Effizienz, umso höher ist Nachhaltigkeit Quelle: H.-J. Endres, A. Siebert-Raths; Engineering Biopolymers, Carl Hanser-Verlag, Juni 2011

2) Status quo Ökobilanzierung Biokunststoffe (Cradle to grave) Source: PE INTERNATIONAL/ IfBB 2014 PE INTERNATIONAL/IfBB 2012 and PE INTERNATIONAL 2014 Seite 53

1. Was ist Marine Litter? [EEA13] Seite 54

Handlungsbedarf ( Pull-Seite ) Definition, Regelung und saubere Verwendung von Begrifflichkeiten Biobasiert ( C14?) Kompostierbarkeit versus Oxoabbaubarkeit, Abbau in Salzwasser, Old and New Economy Werkstoffe Drop-Ins ( Recycling) Negativbeispiele: Öko-PET, petroleum free, CO 2 reduzierte Werkstoffe, Allokationsszenarien (Mass Balance), Mischung von green energy and green materials, green composites, Öffentliche Beschaffung biobasierter Produkte Politische Gleichbehandlung (stoffliche und energetische Biomassenutzung) EEG, E10, CO 2 -Zertifikate, THG-Quote, Mehrfachförderung von Nutzungskaskaden und CO 2 -Senken Fakten zur Entemotionlisierung der Diskussionen

Handlungsbedarf ( Push-Seite ) Weitere Forschungsaktivitäten und Materialoptimierungen Biobasierte natürliche und synthetische Fasern, z.b. Pflanzenfasern, Viskose, Bio-Polyamid, Bio-Aramid, Bio-Carbon, ) Faserhalbzeuge (Faseroberflächen, lastpfadoptimierte Strukturen, ) Hybridstrukturen Industrielle Materialanbieterstrukturen Ready to use - Materialien (Compounds, Prepregs, ) Haftung (Liefergarantie, konstante Qualität, ) Lieferantenauswahl, High-End Support Bereitstellung zuverlässiger Materialdaten, insbesondere bzgl. Verarbeitungseigenschaften (z.b. zur Simulation) Gebrauchseigenschaften (z.b. Langzeiteigenschaften) Entsorgungseigenschaften Glaubhafte Nachhaltigkeitsindikatoren