Dr Sudhakar Muniyasamy at Sustainability Conference 2015, NCPC

1. Contents
DEVELOPMENT OF SUSTAINABLE BIOBASED
COMPOSITE PRODUCTS FROM AGRICULTURAL WASTE
Sudhakar Muniyasamy and Sunshine Blouw
CSIR-MSM, Nonwoven and Composite Research Group
Port Elizabeth 6001
E-mail: sblouw@csir.co.za
Industrial Efficiency Conference 2015, 21&22 July 2015, ICC-Durban

2. 2
INTRODUCTION : World Plastics Production, Consumption and Demands
and its related Environmental problems
SUSTAINABLE BIO-COMPOSITES FROM RENEWABLE RESOURCES:
Opportunities and Challenges in the Next Generation of Materials, Processes
and Products
OBJECTIVES : In Support of Bioeconomy Strategy
RESEARCH AND DEVELOPMENTS: Value Added Industrial Biobased
Composite Materials and Products from Agricultural biomass
SUMMARY
WAY FORWARD
CONTENTS

3. 3
World Plastics Production and their Consumptions
Note: Based on preliminary estimates by European Market Research &
Statistics Working group. Includes thermoplastics, thermosets, adhesives,
coatings and dispersions. Fibers are not included
Source: Plastics Europe 2013, WG Market Research & Statistics
Plastics are a global
success story
 1950: 1.7 Mt
 1976: 47 Mt
 1989: 100 Mt
 2002: 204 Mt
 2007: 257 Mt
 2011: 279 Mt
 2012: 288 Mt
 2013: 299 Mt

4. 4
World Production of Plastic Materials by Regions in 2013
 China Ranks First
 Europe Ranks Second
Source : PlasticsEurope 2014
Does not include other plastics (thermosets, adhesives, coatings and sealants) nor PP-fibres

5. 5
Plastics Demands by Segment and Polymer type in 2013
Source : PlasticsEurope 2014
 Packaging,
building &
construction and
automotive are
the top three
markets for
plastics

6. 6
Environmental Impact of Plastics
• Most of the fossil fuel based plastics takes
more than 100 years to degrade and are not
only to pollute the environment but actually
harm many living organisms.
• Plastics are cheap to produce but very
expensive to clean the environment.
• Future generation will suffer from the pollution
caused by plastic.
www.epa.com 2013

7. 7
Current Situation in South Africa
 SA is leading countries in the worlds
with mechanical recycling.
 SA currently only uses mechanical
recycling and no other energy from
waste plant yet operational.
 280 000 tons produced in 2013.
 220 400 tons were plastics packaging.
 20% all plastics manufactured were
recycled in 2013 with 4.1% increase
from 2012 recycling rate.
 Plastics SA announced Zero Plastics
to Landfill by 2030.
*Mechanical recycling refers recover plastics waste via mechanical pro-
cesses (grinding, washing, separating, drying, re-granulating and
compounding), and converted into new plastics products, often substituting
virgin plastics

8. 8
Agricultural Wastes & Undervalued Biomass for
Developing Green Materials
Lignin
(Paper Industry)
Crude Glycerol
(Biodiesel Industry)
Jute fibre Flax fibre Hemp fibre Prepared kenaf
fibre
Switchgrass
Natural Fibres from Agricultural feed stock
By-products and Co-products from Biofuel industry
Value-added uses: Economic Benefit + Replacement for Petro-based
Products + Reduced GHG Emission
Lignin
(Bioethanol Industry)
Post harvested Agricultural Residues
Sugarcane Bagasse Maize stalks

9. 9
R&D to Support SA Industrial Sectors
Identified as Strategic
IPAP
focused
sector
Aerospace Automotive Rail
transport
Equipment
Renewable
Energy
Agro-
processing
Plastics
Contributio
n to SA
GDP
-
R3.4bn (7%
of GDP)
R44.2
billion
(2.54% of
GDP)
-
R7.7bn (16.
% of GDP)
R50 bn (-
R7bn trade
deficit)
Sector
objective
Substantially
diversify and
deepen the
components
supply
chain.
Substantially
diversify and
deepen the
components
supply
chain.
Metal
fabrication,
capital and
rail transport
equipment
Increase
local content
on
renewable
energy
components
Value
addition of
waste
stream to
increase
beneficiation
Address
environment
al concerns
regarding
plastic
manufacturi
ng and
waste
disposal
Source: IPAP 2014/15

10. 10
10
Why Green composite Materials?
 Limited petroleum resource
 Increasing cost of petroleum
 Reduction in ‘Greenhouse’
gases
 New sustainable materials for
various structural applications
 Made from Renewable resources
 Recyclable
 Biodegradable (end of life)
 Economically viable
 Environmentally acceptable
Benefits
Green Composites : Opportunities and Challanges

11. 11
Non-Renewable Energy Process Product(s) Landfill or Incineration
Conventional
Waste
Fossil Energy
Bioprocess
Biobased
By-product(s)
Bioprocess Bioproduct(s)Renewable Bioresource
Recycle into bioresource
Biomass
Why Green Materials

12. 12
WORLD BIOPLASTICS DEMAND
Global production capacities of bioplastics
by market segment
 1.1 million metric tons in 2013.
 1.4 million metric tons in 2014
 About 6 million metric tons in 2019,
 Annual growth rate (CAGR) of 32.7% for
the five-year period, 2014 to 2019.
Bioplastics Demand
Bioplastic Economic : Strengthening
International competitiveness of bio-
based products

13. 13
Agricultural Biomass for Biobased Products
Biomass
Manufacture
Cellulose
Starch
Hemicellulose
Lignin
Oil
Biobased
Products
Reuse
Intermediates
Additives (Modifier)
Adhesives, Coating,
Microfibrillated cellulose
nanofibres
The Conversion Chain
Biocomposites
Biodegrade Recycle
Disposal Use
Sugarcane bagasse Maize stalk

14. 14
MOTIVATION
• Waste management in South Africa faces numerous challenges due to growing
population and economy, leading to increased volumes of waste generated.
• This puts pressure on waste management facilities, which are already in short supply.
• Farmers also experience major challenges in handling agricultural wastes.
ANTICIPATED BENEFITS:
• Waste management strategy
• Environmental benefits (Low carbon economy)
• Creation of green jobs

15. 15
OBJECTIVES
• IDENTIFY GAPS IN THE PLASTIC MARKET TO MEET THE LOCAL PLASTIC DEMANDS
• TO PERFORM TECHNO-ECONOMIC STUDY IN COLLABORATION WITH CSIR-ECD
(ENTERPRICE CREATION DEVELOPMENT) TO DEVELOP THE MANUFACTURING
INDUSTRY
• TO HAVE IMPACT TO COMMUNITIES
• CREATE GREEN JOBS
• “TO TURN WASTE INTO PROFIT”

16. 16
OVERVIEW OF R&D INITIATIVE
Maize Stalk
Sugarcane Baggasse
Asanda et al 2015(118) Carbohydrate
polymer

17. 17
Extraction of cellulose nanocrystals and
nano fibres from Maize stalk residues
Asanda et al 2015(118) Carbohydrate polymer
Asanda et al 2014 , Composite Part A

18. 18
AFM characterizations of Nanocellulose
A
Cellulose nanofibres (CNFs) Cellulose nanocrystals (CNCs)
Asanda et al 2015(118) Carbohydrate polymer

19. 19
Development of Biodegradable Green Composites based
from Natural Fibre/Bioplastics

20. 20
Optimized biodegradable green composites based from
PLA/cellulose fibres for Packaging Applications
• Targeted optimized composite
made from maize stalk residue.
• Such green composites have the
potential of substituting their
petroleum-based counterparts
such as polypropylene (PP) with
added advantages of
compostibility and low carbon
economy.
0
20
40
60
80
100
120
140
160
180
0 10 20 30
Micro crystaline cellulose fibres (%)
Tensile Strength (Mpa)
Elongation (%)
Neat
Biopolymer
Mechanical properties
Data from CSIR MSM-PE ongoing research activities

21. 21
Preparation of PFA composites
Furfuryl
alcohol (FA)
Acidified FA
Acidified FA-
particle
mixture
P-toluene
sulfonic acid
7 days
1. 50 ⁰C for 5
days
2. 100 ⁰C for 1h
3. 160 ⁰C for 1h
Maize particles
PFA composite
Tensile properties
Data from CSIR MSM-PE ongoing research activities

22. 22
COMPOSTIBILITY AND BIODEGRADATION TESTING
FACILITY
C Substrate
Microbial Transformation
CO2 + H2O + New Microbial Biomass
SA does not have Industrial composting set up.. This facility can support for
testing biodegradable and compostable materials

23. 23
BIODEGRADATION TESTING OF POLYMERIC MATERIALS AND
PLASTICS

24. 24
ISO
Standards
Title Test
Duration
Test Validity
14852:1999 Determination of the ultimate aerobic biodegradability of plastic
materials in an aqueous medium - Method by analysis of evolved carbon
dioxide
6 months At least 60% biodegr.
reference material
14855:1999 Determination of the ultimate aerobic biodegraability and
disintegration of plastic materials under controlled composting
conditions - Method by analysis of evolved carbon dioxide
6 months At least 60% biodegr.
reference material
17556:2003 Plastics - Determination of the ultimate aerobic biodegradability in soil
by measuring the oxygen demand in a respirometer or the amount of
carbon dioxide evolved
6 months
(2 years)
At least 60% biodegr.
reference material
14855:1 Determination of the ultimate aerobic biodegradability and
disintegration of plastic materials under controlled composting
conditions - Method by analysis of evolved carbon dioxide;
Amendment 1: Use of activated vermiculite instead of mature compost
6 months At least 60% biodegr.
reference material
14855:2 Determination of the ultimate aerobic biodegradability and
disintegration of plastic materials under controlled composting
conditions - Part 2: Gravimetric measurement of carbon dioxide
evolved in a laboratory-scale test
6 months At least 60% biodegr.
reference material
20200:2004 Plastics - Determination of the degree of disintegration of plastic
materials under simulated composting conditions in a laboratory-scale
test
List of Standard Biodegradation Tests, Guides and Practices Available at the
CSIR-MSM,PE for Analyzing the Environmental Degradability of Plastic Materials

25. 25
CEN
Standards
Title Test
Duration
Test Validity
EN-ISO
14852:2004
Determination of the ultimate aerobic biodegradability of plastic
materials in an aqueous medium - Method by analysis of evolved carbon
dioxide (ISO 14852:1999)
6 months At least 60%
biodegr. reference
material
EN-ISO
14855:2004
Determination of the ultimate aerobic biodegraability and
disintegration of plastic materials under controlled composting
conditions - Method by analysis of evolved carbon dioxide (ISO
14855:1999)
6 months At least 60%
biodegr. reference
material
EN
14046:2003
Packaging - Evaluation of the ultimate aerobic biodegradability of
packaging materials under controlled composting conditions - Method
by analysis of released carbon dioxide
45 days
(to be
extended)
At least 70%
biodegr. reference
material
EN
14047:2002
Packaging - Determination of the ultimate aerobic biodegradability of
packaging materials in an aqueous medium - Method by analysis of
evolved carbon dioxide
At least 70%
biodegr. reference
material
prCEN/TR
15822
Plastics - Biodegradable plastics in or on soil - Recovery, disposal and
related environmental issues
List of Standard Biodegradation Tests, Guides and Practices Available at the
CSIR-MSM,PE for Analyzing the Environmental Degradability of Plastic Materials

26. 26
ASTM
Standards
Title Test duration Test validity
D6954-04 Standard Guide for Exposing and Testing Plastics that Degrade in the
Environment by a Combination of Oxidation and Biodegradation
D5988-03 Standard Test Method for Determining Aerobic Biodegradation in Soil
of Plastic Materials or Residual Plastic Materials After Composting
1 year At least 70% biodegr.
reference material
D6002-96
(2002)
Standard Guide for Assessing the Compostability of Environmentally
Degradable Plastics
D5338-98
(2003)
Standard Test Method for Determining Aerobic Biodegradation of
Plastic Materials Under Controlled Composting Conditions
45 days (to
be extended)
At least 70% biodegr.
reference material
D6691-01 Standard Test Method for Determining Aerobic Biodegradation of
Plastic Materials in the Marine Environment by a Defined Microbial
Consortium
D5209-92 Standard Test Method for Determining the Aerobic Biodegradation of
Plastic Materials in the Presence of Municipal Sewage Sludge
D5511-02* Standard Test Method for Determining Anaerobic Biodegradation of
Plastic Materials Under High-Solids Anaerobic-Digestion Conditions
4 months At least 70% biodegr.
reference material
D5526-94
(2002)*
Standard Test Method for Determining Anaerobic Biodegradation of
Plastic Materials Under Accelerated Landfill Conditions
4 months At least 70% biodegr.
reference material
D5510-94
(2001)
Standard Practice for Heat Aging of Oxidatively Degradable Plastics
D5272-92
(1999)
Standard Practice for Outdoor Exposure Testing of Photodegradable
Plastics
List of Standard Biodegradation Tests, Guides and Practices Available at the
CSIR-MSM,PE for Analyzing the Environmental Degradability of Plastic Materials

27. 27
BIODEGRADABILITY AND COMPOSTABILITY
OF BIOBASED MATERIALS
SEM Analysis
PLA/tough biopolymer blends PLA/MCC blends

28. 28
BIODEGRADATION STUDIES OF GREEN COMPOSITE
MATERIALS AND ITS CONSTITUENTS UNDER
COMPOSITING CONDITIONS
100
90
80
70
60
50
40
30
20
10
0
Biodegradation(%)
180160140120100806040200
Incubation Time (Days)
Neat Bioplastic
Maize Stalk residues
Bioplastic/Maize stalk Biocomposite
 Biofillers enhances the
biodegradability of
polymer matrix
 Completion of carbon
cycle in short span

29. 29
OVERVIEW OF R&D INITIATIVE
CSIR PATENT: POLYMERIZATION OF FURFURYL ALCOHOL (FA) TO DEVELOP SUSTAINABLE
MATERIALS

30. 30
OVERVIEW OF R&D INITIATIVES: BIOCOMPOSITES FOR PACKAGING
Maize stalk residues have potential of substituting non-biodegradable petroleum
Polypropylene (PP) with added advantage of biodegradable and low carbon economy.
Making the technology adaptable for real-world applications and possible commercialization.
SA exports fruits and paying carbon tax
OUTCOME : IP opportunities
PARTNERSHIP (INDUSTRY)

31. 31
OVERVIEW OF R&D INITIATIVE: BIOCOMPOSITES FOR
GREEN BUILDINGS (4 PROTOTYPES)
BIO-BRICK
ROOF PANELS
THERMAL INSULATION MATERIAL

32. 32
CONCLUSIONS AND ACKNOWLEDGEMENTS
• 4 PROTOTYPES
• 6 RESEARCH PUBLICATIONS
• IP DEVELOPMENT (Opportunities)
• PROPOSAL SUBMITTED FOR MANUFACTURING INDUSTRY
• PARTNERSHIP (INDUSTRY)
BCOC

33. 33
Research Project Team Members:
Research Group Leader:
Dr. Sunshine Blouw, CSIR- Material Science & Manufacturing, Fibre & Textile Competency
Area
Research Scientist
Dr. Sudhakar Muniyasamy (Joined in July 2013)
Dr. Tshwafo Motaung
Ph.D. student
Mr Asanda Mtibe
Mr Osei Ofosu
Undergraduate Research Assistant
Mr Abongile Gada
Ms Sandisiwe Bala
Mr Thuso Tserane
Anelisa Billi
POTENTIAL IMPACT: Human Capital Development

34. 34
ACKNOWLEDGEMENTS
RESEARCHER
• Dr Linda Z. Linganiso (Senior Researcher)
FUNDING
• DEPARTMENT OF ENVIRONMENTAL AFFAIRS, DBSA Green Fund
• DST –BCoC
• CSIR

35. Thank you
Contact Us:
Dr Sunshine Blouw; e-mail: sblouw@csir.co.za