Nattinen Kalle 3593.Tecnaro.arboform

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  • Fully Bio-Based Thermoplastic

    Lignin Composites

    22.5.2013

    Biomaterials - Towards Industrial Applications

    Kalle Nttinen, Antti Ojala, Lisa Wikstrm,

    VTT Technical Research Centre of Finland

  • 223/05/2013

    Content

    VTT and plastics processing

    Materials

    Processing

    Results

    Conclusions

  • 323/05/2013

    Customer sectors

    Biotechnology, pharma-ceutical and food industries

    Chemical industry and environment

    Electronics Energy Forest industry ICT Machine, vehicle and metal

    industries

    Real estate and construction

    Services and logistics

    Focus areas of research

    Applied materials Bio- and chemical

    processes

    Energy Information and

    communication

    technologies

    Industrial systems management

    Microtechnologies and electronics

    Services and the built environment

    Business research

    VTTs operations

    Research and Development Strategic Research Business Solutions Business Development Group Services VTTs companies

    - VTT Expert Services Ltd

    (incl. Labtium Ltd and Enas

    Ltd)

    - VTT Ventures Ltd

    - VTT International Ltd (incl.

    VTT Brasil LTDA)

    - VTT Memsfab Ltd

    VTT Group in brief

    Turnover 316 M (2012) Personnel 3,206 (31.12.2012)

  • 423/05/2013

    Plastics processing

    Micro-scale melt processing

    Small Scale Processing

    Pilot Scale Processing

    Injection Molding

    Extrusion

    Pre- and Post-processing

    Collin(30 x 25D) blown film extruderInjection mouldingThermo-Haake MiniLab

    Micro Compounder

  • 523/05/2013

    Thermoplastic lignin compositesMaterials

    Lignin: Softwood kraft lignin from Metso (LignoBoost)

    Plasticizers: Starch acetate (Ac-starch) and triethyl citrate (TEC)

    Fiber: Softwood TMP

  • 623/05/2013

    Melt processable starch acetate

    Effect of acetylation

    reduces hygroscopicity

    improves thermal processability by lowering Tg

    Plasticisation with triethyl citrate (TEC)

    Iower Tg

    improves ductility

    Tensile performance1

    1K. Nttinen et al., Polym Comp., 2010.

  • 723/05/2013

    Processing stepsWood fiber reinforced thermoplastic lignin composites

    Cellulose

    fibers

    Extraction

    of lignin Plasticization

    Compounding

    with fibers

    Injection molding

    LigninPlasticized

    lignin

    Pellets

  • 823/05/2013

    Thermoplastic lignin compositesProcessing steps in laboratory scale

    Injection molding(Thermo-Haake Mini-

    Jet)

    Plasticization and melt

    compounding (Brabender Plasti-Corder50 cm3 batch)

    Tensile testing(Instron 4505)

  • 923/05/2013

    Thermoplastic lignin compositesProcessing steps in pilot scale

    Twin-screw extruder

    Berstorff ZE 25 x 48 D

    High-speed twin-screw extruder

    KrausMaffei Berstorff Ze25A x 49D UTX

    Compounding

    Engel ES 200/50 HL

    Instron 4505

    Injection molding

    Tensile testing

    Advanced

    materials

  • 1223/05/2013

    Contents of the thermoplastic lignin composites

    0 50 100

    Content / wt%

    SW ligninAc-starchTEC

    30-60% 15-30% 10-20% 0-40%

  • 1523/05/2013

    Ac-starch/TEC plasticised lignin compositesEffect of TMP fiber content

    Fixed lignin/Ac-starch/TEC ratios

    2,5

    3,5

    4,5

    5,5

    0

    5

    10

    15

    20

    25

    30

    35

    0 5 10 15 20 25 30 35

    You

    ng'

    s m

    od

    ulu

    s /

    GP

    a

    Ten

    sile

    str

    en

    gth

    / M

    Pa

    TMP fibre / wt-%

    0 50 100

    Content / wt%

    SW lignin

    Ac-starch

    TEC

    TMP

  • 1623/05/2013

    Effect of processing on TMP fiber lengths

    Finnish Bioeconomy Cluster FIBIC Oy 23.5.20131 FiberLab, R. Korpela, bo Akademie University, 2013. 2 X-ray computed microtomography, A. Miettinen, M. Kataja, University of Jyvskyl, 2012.

    1 9801

    1562

    0

    500

    1000

    1500

    2000

    Native TMP fiber Lignin composite (20% TMP)

    Me

    an f

    ibe

    rle

    ngt

    h /

    m

  • 1723/05/2013

    Fiber-matrix compatibilityTensile fracture surfaces of Ac-starch/TEC

    plasticised composites (SEM)

    Finnish Bioeconomy Cluster FIBIC Oy 23.5.2013

    Good compatibility Uniform dispersion of fibers

  • 1823/05/2013

    Thermoplastic lignin compositesAc-starch/TEC vs PEG plasticisation

    30 wt% TMP fiber content Optimised lignin / plasticiser ratios

    30 29

    4,8 5,9

    0,6 0,51,7

    4,2

    Ac-starch/TEC PEG

    Tensile Strength (MPa)

    Young's modulus (GPa)

    Strain at break (%)

    Impact Strenght (kJ/m2)

  • 1923/05/2013

    Water absorption of thermoplastic lignin compositesAc-starch/TEC vs PEG

    20 wt% TMP reinforcement PEG dissolves from the composites

    0

    10

    20

    30

    40

    50

    0,0 0,5 1,0 1,5 2,0 2,5

    We

    igh

    t ch

    ange

    / %

    Time / weeks

    Ac-starch/TECPEG

  • 2023/05/2013

    Property PP +

    Wood1Lignin + PEG +

    TMP

    Lignin + starch

    acetate + TMP

    Tensile strength

    (MPa)

    37 29 30

    Stiffness (GPa) 3.0 6.5 5.4

    Impact strength

    (kJ/m2)

    15 4.4 2.01Ichazo et al., Compos. Struct., 2001

    Comparison:

    40% Wood fibers + PP

    vs

    30% TMP + lignin + starch acetate + TEC

    vs

    30% TMP + lignin + PEG

  • 2123/05/2013

    FuBio JR2 23.5.2013

    Evaluation of TECNAROsthermoplastic lignin composites

    Arboforms consist ofthermoplastic lignin, natural additives and fibres (flax, hemp etc.)

    Odour of the composites: F45: typical ZE50: low V3: very low

    Application areas: Automotive interiors Electronics Consumer articles Furniture industry etc

    Composition of FUMO 74: Ac-lignin 41% Ac-starch 23% TEC 16% TMP 20%

    The pic and the tensile properties are extracted from the web page:

    http://www.tecnaro.de/english/willkommen.htm?section=we

    18

    29

    61 60

    33

    6,3 4,96,7

    3,65,3

    0,3 0,7 1,34,8

    0,72,05,0

    8,5

    15,0

    2,6

    Arboform F45 Arboform ZE50 Arboform L, V3 PLA 3051D FUMO74

    Tensile strength (MPa) Modulus (GPA)

  • 2223/05/2013

    Conclusions

    Thermoplastic lignin composites based on fully renewable materials have been

    fabricated

    Kraft lignin can be efficiently plasticisedwith Ac-starch-TEC mixtures

    TMP fiber loading improves processability and mechanical performance of the

    composites

    Composites are very rigid yet brittle

    PEG improves ductility of the lignin composites

    Heavy breakage of TMP fibers during processing of the composites

    Northern lights in Tampere, Finland (17.3.2013)

  • 2323/05/2013

    Acknowledgements

    Funding from TEKES and Finnish bioeconomy cluster (FIBIC)

    within FuBio Joint Research 2 (FuBio JR2) project

  • 2423/05/2013

    VTT creates business

    from technology