Bio-renewable materials

Jan E.G. van Dam

Seminar UTM 03 10 2011

Food and Biobased Research at WUR

Marketing and Sensory studies Design and development of foodstuffs based on consumer preferences Functional Ingredients

Structure and Technology

Mild Conservation and Food Safety

Biobased Products

Development of:

industrial processing industrial products

Based on:

renewable plant and animal resources

Green chemistry

Dutch situation

Densely populated Restricted land area for bulk production Specialized high productivity farming
Highly industrialized Logistic organisation Long trading tradition

Bio-economy

.the solution for sustainable developments ...?...

Dutch challenges: Milenium development goals

Reduce oil dependency Imports of biomass Collecting and on site pre-processing systems
Biorefineries analogue to petrochemical refining Exports of value added green chemicals

Dutch Government and Industries & Bioeconomy

Advise for CO2 neutral production Alternative biomass farming

Energy crops / Marine crops / algae / seaweeds

Suitable sources for imports for fuel and chemistry and biobased products Carbon emission trade Development aid and CDM

Bio-economy & Sustainable developments CO2 neutral production Transition process Renewable resources for energy and industries Exploitation of biomass from agro-industrial residues Value addition in materials, and green chemicals

Growing demand for biomass resources

Agricultural crops sugar fats and oils Forestry crops wood

ethanol biodiesel

fuel charcoal

Transition to bio-economy

What are the biomass resources where are those available at what costs
??

Underutilised biomass resources

Agricultural crops residues Agricultural

Food industry wastes

Forestry crops

Forestry residues
Black liquor Waste paper

Animal waste Manure Municipal solid waste Sewage Marine crops

Various Crops and Regions

Soft Wood Wheat Corn Soya Cotton Coconut Sugarcane Soya Hard Wood

Soft Wood Wheat Sugar beet Algae Cacao Cotton

Soft Wood

Rice Cotton Coconut Palm oil Hard Wood

Cassava

Soya
Eucalypt

Eucalypt

Agroresidues of food and non-food crops

Palm oil Rubber Rice Sugar cane Cocoa Coconut Banana Pineapple Etc.

EFB, POME, fibre, shell, trunk, leaves wood / latex residues straw / hull bagasse, molasse shell, residue husk, shell, water raqui, stems tops

Biobased materials
Biomass for energy returns quickly CO2 in the atmosphere

Carbon sequestration can be achieved in durable goods: Bioplastics (PLA, PHA/PHB and other), Cellulose and Starch plastics (CDA, cellophane), Char Composites Building materials (wood and fibre boards)

Whats Happening to Climate and Why

1,000 concentrations CO 2 Years of Carbon Emissions,

Atmospheric Concentrations, and Temperature Change

Human-induced Sources of Heat-trapping Gases

How Climate Change Will Affect Us

Current Population Density

Climate Change Effects on Human Health

An Urgent Need for Climate Policy

Energy Efficiency Programs

Low Carbon Energy Supply

Forests and Agriculture

Building Industries large contribution to CO2

Concrete Steel Aluminum Glass Synthetic polymers (PVC, PUR, PIR, PP)

Sustainable building developments

Energy saving (insulation) Renewable energy (solar / wind) Recycling of materials

recently green building

Green architecture

Cradle to Cradle C2C

W. McDonough M. Braungart

Remaking the way we make things

Eco-efficient / effective design of products Reuse of waste to produce new products

Waste becomes food.. Ever lasting cycles

Ford / NIKE / many industries are following (?)

Bio-based economy and C2C

Green Architecture and building Automotive industries sustainable trade and industry Nutrient Upcyling, Triple-Top-Line, Eco-effectiveness, Industrial design, Technical and biological resources for ..everlasting consumption.. (?)

Green architecture

Ecological building

Adobe

Ecolonia

Wood frame building

(c) Meertens Inst

Agrodme demonstration project Wageningen

Agrodme experimental building project

Materials and building method selection ranking

sustainable produced wood or agro raw material processed wood or agro-products reuse of building materials mineral resources (cement / lime / bricks / stone) metals petrochemical synthetic polymers

Biodegradable building materials

(c) Meertens Inst

Agrodme

Agrodme

Prefab elements, high demands on insulation

Agrodme

Inventory Renewable building materials

Catalogue of products, methods and suppliers Wood products Wood fibre panels and boards Non-wood products Adhesives, coatings and building chemicals

Application of renewable resources

wood - (wood frame construction)
softwood / protected by coatings hardwood / eco-lable

wood based reassembled (glued) products:

fibre boards: HDF / MDF / particle boards multiply veneer panels, OSB cellulose insulation

other non-wood products

Multiply constructions

Application of non-wood building products

Bamboo and bamboo composites Fibre crops (flax, hemp, jute, kenaf, etc) non-woven insulation shives particle boards Wheat, rice straw bales / compressed panels (MDF) Reed / canes /palm fronts for thatched roofs Coir fibre mats and compressed (binderless) board Cork (and other bark residues)

Straw bale building

Fire hazard

Protect against attack of moulds and insects

Application of non-wood building products

sheep wool insulation shell lime mortar whole-shell underfloor moisture barrier silica ash as substitute for cement

Roof insulation with sheep wool

(c) Dosha

Application of non-wood building products

coatings and adhesives
latex based coatings plant oil coatings / alkyl resins starch based adhesives protein coatings and adhesives lignin / furan adhesives (bio-oil)

natural dyes

Application of non-wood building products

biopolymers
rubber thermoplastic starch, cellulose acetate polyesters (PLA/PHA) thermosets (lignin / furan / pyrolysis oil)

composites
fibre reinforcement / filler biopolymer matrix

Application of non-wood building products

paper pulp products
corrugated boards honey comb light weight laminates cylinder / tube pressed massive board (recycled pulp)ing wall paper cover cellulose spray coating

Paper tube constructions

Bamboo structures

Simon Velez

Bamboo traditional constructions

Bamboo plywood construction

Renewable building materials

foundation ground floor outer walls
massive wall wall cavity wall

inside walls
- supporting - partition wall

floors / ceiling roofing material

pitched or flat

Renewable building materials

ground floor
whole shells / expanded clay as damp absorbent (in crawl space) wooden beams sandwich panels prefab concrete extruded slabs (bio-crete)

Renewable building materials

outer walls
wood or wood composites covering

shingles / rabat profiles / boards straw bales / loam recycled bricks fibre insulation (cellulose / flax / wool)

massive wall

cavity wall

Renewable building materials

inner walls
supporting walls

wood frame construction with insulation and finishing concrete (biocrete) slabs particle boards laminate (fibre) boards paper boards

partition walls

Renewable building materials

floors / ceiling
wooden beams multiply

coir / cork insulation

sandwich panels / fibre board prefab concrete extruded slabs (bio-crete)

finishing
marmoleum parquet / bamboo / cork

Renewable building materials roofing material

pitched roof

thatched and fibre board panneling shingles photovoltaic cells green roofing / substrate bitumen substitute cork insulation

flat roof

Biomass from agro-industrial residues

World production capacity coconut husk 15-20 million tons / year

Overview continuous pilot line

Husk storage

Mill

Transport

Dryer

Trimmer

Hot press

Mat former

Building and construction materials

Building system development

New Design and Architecture Supply chain Product diversification

Sustainable building

Renewable materials High performance Competing for quality for comfort for safety

Low cost housing design (URBOX)

Dirk Smets (c)

Modular design (URBIX)

Dirk Smets (c)

Oil Palm (Malaysia, Indonesia)

ca 46 millions tons palm oil per year (2010)

25% of the Worlds vegetable oil production

Extensive global expansion (from 2 to 7 million ha in last 20 years) 80% of the World production on account of Malaysia and Indonesia Palm oil and palm kernel oil are the only products (9% of the produced biomass), the rest is waste

Biomass from agro-industrial residues

palm oil residues ca 40 million tons biomass

720 PJ of (primary) energy

low utilisation rate

Utilisation of Palm oil residues

Lignocellulosic fibres at estate fronts (10.5 tons /ha/yr) trunks (70 tons / ha / 25 yr) Residues at palm oil mill empty fruit bunch (1 ton / ton palm oil) mesocarp fibre (0.6 ton / ton) shells (0.4 ton / ton) effluent (0.4-1.0 ton/ton) partly used as boiler fuel

Options for sustainable residue utilisation

Bio-diesel (residual oil / pressing cakes) Bio-gas, H2 / ABE and ethanol fermentation Bio-polymers (PLA, PHA) Bio-oil pyrolysis Charcoal Fibres for paper, building boards and composites Dissolving cellulose Binderless board (intrinsic lignin) green chemicals (furfural adhesives)

Utilisation efficiency
The palm oil industry is one of those rare industries where very
little attempt is made to save energy Husain et al (2003)
Malaysian methane emission from open of effluent ponds amount to 225.000 tons = 5,17 million tons of CO2. Piling up of waste biomass = CH4 production,eutrophication of surface water, illegal burning (CO2), soil mining of plantation

EFB from Malaysia ( 30 wt% dm)

Empty Fruit Bunches

Left after removal of fruits Regularly collected and discharged at palm oil mills Returned to plantation sites as compost Used to be burnt at the mills; practically banned

EFB cellulose

Low grade

Fuel / ethanol Particle boards Composites Paper and board Viscose / Rayon Cellulose derivatives (CDA, HEC, CMC)

Medium grade (pulp)

High grade (dissolving cellulose)

Conclusions
Application

of renewable building materials is technically feasible labor intensive and more expensive only small scale production

More demonstration projects required for architects, building industries and commissioners Ecological building has broad public interest

Conclusions
Research

needs for development of renewable building

materials
innovative building systems design supply chain indoor climate control functional life time control (protection against moisture,fire and degradation) Building systems fitting in current building practice education product promotion and publicity

Conclusions
By-products utilisation for added value is beneficial to the sustainability of palm oil production

Essential for certifying the sustainability of the palm oil biomass energy and products. Multi-stakeholder involvement needed. Include outsider (food vs non-food) industries involved in energy and fibre products

Conclusion

There is no need for waste when its bio-based