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Renewable resources

Biopolymers

Bild: Siemens
© 2013 Renewable Resources Engeneering / Biopolymers
FH Schmalkalden, Fakultät Maschinenbau 1
Renewable Resources Engineering / Biopolymers
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Index

» Introduction
» Motivation
» Concepts involved
» Biopolymers

 Structure and Production


 Technical properties

» Applications
» Future

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Definition

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Definition

Biopolymers

“[…] polymer material that fulfills at least one of the following


properties:
• Consists of bio-based raw material
• Is in some way biodegradable “
[1]

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Overview

 World Commission on Environment and Development, 1987

Sustainable development

“[…] is development that meets the needs of the present without


compromising the ability of future generations to meet their own
needs“

[2]

» use of new materials in construction


» recycling of reusable materials

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Overview – Spheres of Sustainability

[14]
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Overview – Historical background

[1]
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Overview – Historical background

[9]
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Overview – Historical background

[9]
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Overview – Historical background

[9]
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Overview – Historical background

[9]
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Index

» Introduction
» Motivation
» Concepts involved
» Biopolymers

 Structure and Production


 Technical properties

» Applications
» Future

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Petroleum sector

“[...] Nothing remains forever in the oil sector, and prices are already rising for
quite some time. [...] The oil sector is unstable due to geopolitical and economic
crises. [..] The difference between production capacity and consumption is
increasing. Therefore, sooner or later, there may be a collapse.”
Leonardo Maugeri/ Researcher at Harvard Kennedy School

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Production- Comparison

[9]
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Market size - Comparison

[9]
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Market size - Analyse

[9]
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Index

» Introduction
» Motivation
» Involved concepts
» Biopolymers

 Structure and Production


 Technical properties

» Applications
» Future

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Petrochemical raw materials

5,3 trillion
liters/ year *

Million of years

* Opep - 2013 [27]


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CO2 Closed Cycle

Bio-ethanol  Bio-ethylene
(Bio-PE)  HDPE, LDPE,
PV, PUR’s, PVC, PA’s [1]
[28]
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Life Cycle of Bioplastics

[29]
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“Bio-based X Biodegradable” - polymers

 Are there some differences? – YES!!!

[1]
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Degradability

Degradability

“[…] is ultimately influenced only by the chemical and physical


microstructure of the polymers, and neither by the origin of the raw
materials used nor by the process used for manufacturing these
polymers.”

“[…] they decompose under exposure to microorganisms and/or


enzymes”
[1]

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Degradability

» Primary and final degradation

» Increases fundamentally as the


ratio of heteroatoms (Ex.: O and
N) increases, in the Main chain

Intracellular
Starch /
Degradability

Cellulose

PLA

PCL

PVAL

Ratio: Heteroatom / carbon (in the main chain) [1]


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Degradability

» There are two types of degradable polymers:

 Degradable Petroleum-based

• based on hydrocarbon monomers and oligomer (crude oil, natural gas,…)


• expended for degradability by incorporating various heteroatom into their molecular
structure ( oxygen and nitrogen)

 Degradable Bio-based

• Ex.: starch-based polymers and their blends, polymers based on sugar, vegetables oils

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Degradability - Standards

» Aerobic biodegradation ( aquatic or terrestrial )

» Anaerobic biodegradation

Aerobic biodegradation Aerobic biodegradation Anaerobic


-aquatic- -terrestrial- biodegradation
• Composting
- DIN EN ISO 14851/ JISK 6950 - DIN EN ISO 14855/ JISK 6953 -DIN EN ISO 14853
- DIN EN ISO 14852/ JISK 6951 -ASTM D 5338
- DIN EN ISO 9408 - DIN EN ISO 15985
- DIN EN ISO 10634 • Disintegration
- DIN EN ISO 16929/ JISK 6952 - DIN EN ISO 11734
- DIN EN ISO 20200/ JISK 6954
- DIN EN 14045, DIN EN 14046,
DIN EN 14806

• Soil
- DIN EN ISO 17556/ JISK 6955
•OECD 208 [1]
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Degradability – Tests / Composting

The tests are based:

» measurement of oxygen demand


»amount of carbon dioxide evolved in the process

 Definition of “ Bio-degradable polymers” : DIN EN 13432

Composting

“A material or materials mix and parts produced from it is considered


compostable, when under defined conditions in a composting system,
it is entirely transformed into CO2, H2O, CH4 and biomass within a
specifies length of time, mostly during a composting cycle ranging.”
[1]

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Certification of Compostability

Biodegradable Japan Compostable


Jätelaitosy DIN Avfall
Certification Products AIB Vincotte, BioPlastics Italian
hdistys, CERTCO / Norge,
organizatio Institute (BPI), Belgium Association, Association,
Finland European Norway
n USA Japan Italy
Bioplastics,
Germany

Green Pla
DIN EN EN 13432 DIN EN
Reference ASTM D6400 DIN EN 13432 identification DIN EN 13432
13432 ASTM 13432
standard system
D6400

Logo

[1]
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Principles of polymers production - Polyaddition

» Definition: method where monomers are added one by one to an active site
on the growing chain without by-products. Based on protons transference and
opening the double bond.

» Components:
 molecules with carbon-carbon double bonds or with triple bonds
 molecules containing with bifunctional groups

» Examples: PU, POM, …

[13]
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Principles of polymers production - Polycondensation

» Definition: method where two molecules combine to form a larger molecule,


together with the loss of small molecule. Possible small molecules lost are
water, hydrogen chloride, methanol or acetic acid.

» Components: Monomers containing at least two functional groups (i.e.


hydroxyl, carboxyl and amino groups; -OH; -COOH; -NH2)

» Examples: Nylon, PCs, PEs and PET

[30]
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Principles of polymers production - Polymerisation

» Definition: method monomers react to polymers by breaking the double


bonds. Occur in three steps: initiation, propagation and termination, involving
free radicals (initiators).

» Components:
 unsaturated monomers
 initiators

» Examples: PP, PE, PS, ….

[31] modified
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Index

» Introduction
» Motivation
» Concepts involved
» Biopolymers

 Structure and Production


 Technical properties

» Applications
» Future

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Biopolymer-The most important (next 5 years)

[9]
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Biopolymer- Production and Capacity

[9]
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Biopolymer- Production and Capacity

[9]
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Biopolymers- Potential substitutes

Polymer PVC PEAD PEBD PP PS PMMA PA PET PC

Starch - + + + + - - - -

PLA - + - + + - + + -

PHB - + - ++ + - - - -

PHBHx + ++ ++ ++ + - - + -

++ Total replacement , + Partial replacement, - Not replace

[5]
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Biopolymers- Process production

[1]
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Bio- based polyesters

» PLA
Starch, Bigenic
wast material
Corn

» Characteristics
H2O Hydrolytic Corn-based
Cracking Starch
 Thermoplastic
 Molecular weight: 100000-300000
 High resistant to attack by
microorganisms
 High elastic modulus, rigidity,
transparency
 Good biocompatibility and moldability

» Renewable sources: starch, sugar from


corn, wheat, sugar cane, sugar beet and
potato

[9]
[5]
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Bio- based polyesters

» Applications

 Drug carriers [15]


Automotive
 High potential for packaging
 Module for hemodialysis
 Fibers for textile Interference screws for
fixation of grafts
 Films for agriculture
 Surgical implants
 Fibers for sutures
 Automotive industries

» Commercial producers of PLA Module for hemodialysis Vascular prothesis

[5]
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Bio- based polyesters

» PHA

» Characteristics

 Polymer that is intracellularly deposited by


bacterias
 Biodegradable and Biocompatible
 Best representative of this biopolymers
family: PHB, PHBV
 Disadvantages: relatively high price (3,7- [1]
15 €/kg [1])

» Biotechnological production

 Bacterial fermentation
 Synthesis in genetically modified plants
 Enzymatic catalysis in cell-free systems
[5]

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Bio- based polyesters

[17] [9]
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Bio- based polyesters

» Renewable sources:
recombinant and wild
microorganisms, transgenic plants, sources of glucose
and sucrose (Obs.: can also be produced by in vitro
process)

» Applications

 Packaging industry
 Printing & photographic industry
 Other bulk chemicals
 Medical implant biomaterials
 Medical
 Healthy food additives
 Biofuels or fuel additives

[16]
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Bio- based polyesters

» Commercial producers of PHA

[5]

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Starch-based polymers

» TPA

» Characteristics

 Starch: major source of energy


 Versatile for potential use in polymers
 Low cost
 Biocompatibility
 Biodegradable and by-products non-toxic
(dehydration and depolymerization)
 capable of being modified or blended
(substitution of hydroxyl groups)  improve
the processing conditions and properties
 Polymers blended: chitin, chitosan, pectin,
cellulose, poly (lactic acid) - PLA

» Renewable sources: seeds of cereals


(corn, wheat, and rice), tubers (potato), and
roots (manioc) [9]

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Starch-based polymers

» Applications

 Food industry ( food packaging, edible


films)
 Agriculture (covering of greenhouse,
mulch film and fertilizers con trolled
release materials)
 Medical field ( hydrogel, bone tissue
engineering scaffold)

» Commercial producers of Starch

[5]
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Cellulose based polymers

» Characteristics
Cellulose
 Carbohydrates
 Strong natural polymer
Fibers/cellulose
 Biocompatibility
 Easy to recycle by combustion
 Very hygroscopic (expand as much as 90% in
water) Regenerated Cellulose
 Good mechanical properties: high tensile cellulose derivates
strength and Young’s modulus, low coefficient
of thermal expansion
Cellulose
Fibers
ester
» Classification
Cellulose
• Regenerated cellulose Filmes
ether
• Cellulose derivates
[1] modified

[1]
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Cellulose based polymers – Global production

Regenerated cellulose and cellulose derivates; global


production 4.940.000 t/a - 2011

10%

Cellulose ester
25%
Cellulose ether
Regenerated cellulose
65%

[1] modified
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Cellulose based polymers

» Regenerated cellulose

» Characteristics

 Essentially cellulose that has been


chemically dissolved and reconstituted in
the form or fibers or films
 Different properties are resulted by different
solvents
 Biologically degradable
 High modulus of elasticity and good thermal
stability
 Most important: viscose silk

Scanning electron microscopic image of bamboo viscose (left) compared with


native bamboo fibers (right) [1] [9]
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Cellulose based polymers

» Applications

 Treatment of Chronic Wounds and Burns


 Haemodialysis membranes [20]
 Syringe filters
 Packaging (Ex: Casings)
 Textile industry
 Cellophane films
[19]

[21] [20]

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Cellulose based polymers

» Cellulose derivates

» Classification

 Cellulose ether  Cellulose ester


 generated by etherification with  Complex structure
alcohols

[9]
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Cellulose based polymers

» Applications

 Cellulose ether

Additives to stabilize viscosity or as water binders in


building materials (Ex: wall coatings), glues,
cosmetics, detergents, pigments, drilling fluids, and in
the paper industry [1].

 Cellulose ester

Organic membranes, pharmaceutical applications (Ex: Membrane


drug delivery [22]), film base in photography,
component in some adhesives, and frame material
for eyeglasses; it is also used as a synthetic fiber and
in the manufacture of cigarette filters, as well as a
coating material (in particular the automotive coating)

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Bio-based polyolefins

» Bio-PE

Drop-in-solutions

“[…] represent an attempt to maintain traditional synthesis processes


developed for petrochemical feedstock while completely substituting
petrochemical raw material components with biogenic feedstock. “
[1]

» Characteristics

 “Green PE”- Braskem (2002)


 Non-degradable
 Each ton of green polyethylene  2,5 tons of carbon dioxide (CO2) is removed from the
atmosphere [11]
 Manufactured from bio-ethanol (Raw materials: sugar cane, sugar beet, corn)
 Bio-ethylene have potencial to produce also PS, PVC and also PURs, PAs and polyesters

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Bio-based polyolefins - Production and Land use
requirements

[9]
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Bio-based polyolefins

» Applications

 food packaging
 cosmetics
 personal care
 automotive parts and toys
 Cables and pipes
 Textiles

(Obs.: Just as petrochemical PE [23])

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Bio-based polyurethanes

» Bio-PUR

» Characteristics

 Known since the early 1950s


 Produced by polyaddition (multivalent
alcohols and di-or polyfunctional aromatic
or aliphatic isocyanates)
 Comparing with conventional, are not
microbiologically stable
 Isocyanates  petro-based (Ex: TDI, MDI)

» Renewable sources: biogenic polyols


based on vegetable oils [9]

General formation reaction for polyurethanes [1]


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Bio-based polyurethanes

» Applications

 Insulation for roofs and walls,


appliances and coolers
 Coatings
 Adhesives and sealants
 Shoe soles

» Commercial producers of Bio-


PUR
Metzeler Schaum (Germany), Bayer
MaterialScience (Germany), Dow
Polyurethanes (USA), Mitsui Chemical
(Japan), DuPont (USA), Urethane Soy
System (USA), Vertellus Performance
Materials (USA), Cargill (USA).

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Bio-based polyamides

» Bio-PAs

» Characteristics

 Partial or entire substitution


by biogenic feedstock
 Non-biodegradable
 Properties (some Bio-PAs)

» Renewable sources

 natural dicarbonic acids and


their decomposition products
(castor oil)
[9]
 sources of carbohydrates
(corn, sugar beet and sugar
cane)

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Bio-based polyamides

» Bio-PAs based on caster oil

[3]
Ricinus communis - Castor oil plant

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Bio-based polyamides

» Manufacturing routes:

 Three most importants manufacturing routes:

- Condensation reaction of bio-based


dicarboxylic acids with diamines
- Condensation reaction of amino acids
as bi-functional monomers
- Ring-opening polymerization of
lactams (cyclic amide). Obs.: Penicillin
is a kind of lactam.

 New routes

− Fermentative (Drop-in-solution) - PA 6,
PA 66
− Based on natural material lysine
(animals, vegetable proteins) - PA 5.10
− Butadiene as feedstock based on
bioethanol [9]

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Bio-based polyamides

» Applications

 Automotive
 Offshore pipes
 Consumer goods
 Electronic materials [35]

[36]

[37] [34] [32]


» Commercial producers of Bio-PAs

Arkema (France), BASF (Germany), DuPont


(USA), Toray (Germany), Evonik (Germany) and
Rhodia (France).
[33]
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Others

» Bio-PET

» Characteristics

 Consists of 70% terephthalic acid and 30%


monoethylene glycol (based on renewable
resource)
 100% recyclable
 Advantages: good heat-resistence, durability
performance, shink resistence

» Appications

 Automotive sector (seats and carpeting and


other interior components –Toyota 2015)
 Bottles (Coca-Cola – 30%; PepisiCo- 100%
biobased)

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Index

» Introduction
» Motivation
» Concepts involved
» Biopolymers

 Structure and Production


 Technical properties

» Applications
» Future

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Biopolymers vs. Conventional: Price

[1]
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Biopolymers vs. Conventional: Density

[1]
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Biopolymers vs. Conventional: Modulus of
elasticity

[1]
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Biopolymers vs. Conventional: Tensile strength

[1]
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Biopolymers vs. Conventional: Charpy impact
strength

[1]
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Biopolymers vs. Conventional: Hardness

[1]
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Biopolymers vs. Conventional: Glass transition
temperature

[1]
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Biopolymers vs. Conventional: Melting range
temperature

[1]
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Biopolymers vs. Conventional: Tm vsTg

[1]
© 2013 Renewable Resources Engeneering / Biopolymers
FH Schmalkalden, Fakultät Maschinenbau 70
Renewable Resources Engineering / Biopolymers
Ruben Schlutter
Biopolymers vs. Conventional: Shrinkage

[1]
© 2013 Renewable Resources Engeneering / Biopolymers
FH Schmalkalden, Fakultät Maschinenbau 71
Renewable Resources Engineering / Biopolymers
Ruben Schlutter
Index

» Introduction
» Motivation
» Concepts involved
» Biopolymers

 Structure and Production


 Technical properties

» Applications
» Future

© 2013 Renewable Resources Engeneering / Biopolymers


FH Schmalkalden, Fakultät Maschinenbau 72
Renewable Resources Engineering / Biopolymers
Ruben Schlutter
Applications - Overview

[9]
© 2013 Renewable Resources Engeneering / Biopolymers
FH Schmalkalden, Fakultät Maschinenbau 73
Renewable Resources Engineering / Biopolymers
Ruben Schlutter
Applications - Overview

[9]
© 2013 Renewable Resources Engeneering / Biopolymers
FH Schmalkalden, Fakultät Maschinenbau 74
Renewable Resources Engineering / Biopolymers
Ruben Schlutter
Index

» Introduction
» Motivation
» Concepts involved
» Biopolymers

 Structure and Production


 Technical properties

» Applications
» Future

© 2013 Renewable Resources Engeneering / Biopolymers


FH Schmalkalden, Fakultät Maschinenbau 75
Renewable Resources Engineering / Biopolymers
Ruben Schlutter
Acreage: Food vs. Polymeric materials

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© 2013 Renewable Resources Engeneering / Biopolymers
FH Schmalkalden, Fakultät Maschinenbau 76
Renewable Resources Engineering / Biopolymers
Ruben Schlutter
Theoretical minimum and maximum yields per
acreage of Biopolymers

[9] modified
© 2013 Renewable Resources Engeneering / Biopolymers
FH Schmalkalden, Fakultät Maschinenbau 77
Renewable Resources Engineering / Biopolymers
Ruben Schlutter
Land use of Biopolymers

Necessary land use for


Annual polymers Annual biopolymer biopolymer production in
Arable land
production production in 2015 2015
[km2]
[106t] [106t] ( assumption 0,34 kt BP/km2)
[km2]

World 250 1.7 5000 15 million


EU 65 0.5 900 1.8 million
Germany 20 0.25 450 0.17 million
Lake
540
Constance

Full replacement of Full replacement of Full replacement of


Land used for the annual petrochemical based petrochemical based total petrochemical
biopolymer production in plastics in the plastics in the based plastics with
automotive industry with packaging industry with
2015: 0,03% of the world- biopolymers requires
biopolymers requires biopolymers requires
wide available land 4-5% of world-wide
0,3% of world-wide 2% of world-wide available arable land
available arable land available arable land

[9]
© 2013 Renewable Resources Engeneering / Biopolymers
FH Schmalkalden, Fakultät Maschinenbau 78
Renewable Resources Engineering / Biopolymers
Ruben Schlutter
Future

[9]
© 2013 Renewable Resources Engeneering / Biopolymers
FH Schmalkalden, Fakultät Maschinenbau 79
Renewable Resources Engineering / Biopolymers
Ruben Schlutter
Future – 3rd Generation

Biopolymers

I. Modifications (Blends, Additives)


II. Drop-in-solutions
(similar chem. Structure)
[9] modified
© 2013 Renewable Resources Engeneering / Biopolymers
FH Schmalkalden, Fakultät Maschinenbau 80
Renewable Resources Engineering / Biopolymers
Ruben Schlutter
References
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© 2013 Renewable Resources Engeneering / Biopolymers
FH Schmalkalden, Fakultät Maschinenbau 81
Renewable Resources Engineering / Biopolymers
Ruben Schlutter
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© 2013 Renewable Resources Engeneering / Biopolymers
FH Schmalkalden, Fakultät Maschinenbau 82
Renewable Resources Engineering / Biopolymers
Ruben Schlutter
References
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© 2013 Renewable Resources Engeneering / Biopolymers


FH Schmalkalden, Fakultät Maschinenbau 83
Renewable Resources Engineering / Biopolymers
Ruben Schlutter

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