Bio-renewable materials Jan E.G. van Dam Seminar UTM 03 10 2011
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Bio-renewable materials
Jan E.G. van Dam Seminar UTM 03 10 2011
Food and Biobased Research at WUR
Marketing and
Sensory studies
Functional Ingredients
Structure and
Technology
Mild Conservation
and Food Safety
Design and
development of
foodstuffs based
on consumer
preferences
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 ethanol
fats and oils biodiesel
Forestry crops
wood fuel
charcoal
What are the biomass resources
where are those available
at what costs
??
Transition to bio-economy
Underutilised biomass resources
Agricultural crops Agricultural
residues
Food industry wastes
Forestry crops Forestry residues
Black liquor
Waste paper
Animal waste Manure
Municipal solid waste Sewage
Marine crops
Various Crops and Regions
Cotton
Cotton
Corn
Sugarcane Soya
Sugar beet
Palm oil Coconut Coconut
Cassava
Algae
Soft Wood Soft Wood Soft Wood
Cotton
Hard Wood
Hard Wood
Wheat
Soya
Rice
Wheat
Eucalypt Eucalypt
Cacao
Soya
Palm oil EFB, POME, fibre, shell, trunk, leaves
Rubber wood / latex residues
Rice straw / hull
Sugar cane bagasse, molasse
Cocoa shell, residue
Coconut husk, shell, water
Banana raqui, stems
Pineapple tops
Etc.
Agroresidues of food and non-food crops
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)
What’s Happening to Climate and Why
1,000 Years of Carbon Emissions,
Atmospheric Concentrations,
and Temperature Change
CO2 concentrations
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
Agrodôme
demonstration
project
Wageningen
• 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
Agrodôme experimental building project
Biodegradable building materials
(c) Meertens Inst
Agrodôme
Agrodôme
Prefab elements, high demands on insulation
Agrodôme
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 • inside walls
– massive wall - supporting
wall
– cavity wall - 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
• massive wall
• straw bales / loam
• recycled bricks
• cavity wall
• fibre insulation (cellulose / flax / wool)
Renewable building materials
• inner walls
• supporting walls
• wood frame construction with insulation and finishing
• concrete (biocrete) slabs
• partition walls
• particle boards
• laminate (fibre) boards
• paper boards
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
• flat roof • green roofing / substrate
• bitumen substitute
• cork insulation
Biomass from agro-industrial residues
World production capacity coconut husk
15-20
million tons /
year
Husk storage Mill Transport Dryer
Hot press Mat former Trimmer
Overview continuous pilot line
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 World‟s 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
Medium grade (pulp)
Paper and board
High grade (dissolving cellulose)
Viscose / Rayon
Cellulose derivatives (CDA, HEC, CMC)
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 it’s bio-based
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