1. Composites from renewable resources
25/04/2017
Composites from renewable resources
Natural fibre reinforcement
Biobased thermosets matrix
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2. Life cycle for fossil materials
CO2
Combustion
0 to 10 years
Plants
Renewable
resources
Fuels
Plastics
years
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Crude oil

3. Life cycle for biobased materials
Combustion
CO2
0 to 100 years
0 to 10 years
Plants
Renewable
resources
Fuels
Plastics
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4. CARBON NEUTRAL
A material which has no impact on total atmospheric CO2 levels
The CO2 released due to incineration or decomposition is compensated by an equal amount of CO2 absorbed during photosynthesis for generating the biomass
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5. Historical development
Conducting
polymerers
High-temp
polymers
Bio-
polymers
NATURAL ORIGIN MATERIALS
Polyesters PE PP
Nylon
Epoxy-
resins
Carbon fibres
PVC
Bakelit
Wood
Skin
Fibers
Straw-brick
Paper
Natural rubber PS
Glass fibres
Fishbone glue
Linoleum
Celluloid
Linseed oil paints
SYNTHETIC
MAN MADE MATERIALS bC
1800
1900
1950
2000
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6. Ref: www.ars.usda.gov/is/pr/1998/980209.htm
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7. ENERGY CONSUMPTION DURING COMPOSITE PRODUCT LIFE-TIME
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8. Environmental impact of composites
99 % of all product related energy is consumed during use, only 0.5 % during production
The environmental impact for composites is reduced by their durability, low weight, and energy efficient processing
Composites are by ¨defintion¨ environmentally friendly materials!
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9. Wood – a biobased composite
Matrix: Lignin and extractives
Reinforcement: Cellulose
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10. Wood – a anisotropic compositeX Y
No delamination in Y direction
Delamination in X direction
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11. Natural fibres – possible reinforcements for composites
25/04/2017
Natural fibres – possible reinforcements for composites
Cellulose fibrous polymers
No new idea!
Textiles, ropes, canvas and paper have been made from natural fibres since centuries
Wool, flax and silk have a long tradition in textiles
Crude oil bases fibres replaced natural fibres
India and Brazil continued their use
DDR’s Trabant
contained natural fibres
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12. Why natural fibers? Renewable Abundant Cheap Light weight
Biodegradable
Non-abrasive to processing equipment
CO2 neutral when incinerated
Flexible and though
Can be incinerated with energy recovery
Good mechanical stiffness
Good acoustic and thermal insulating properties
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13. In nature occurring fibers:
25/04/2017
In nature occurring fibers:
Plant fibers
Flax
Hemp
Kenaf
Jute
Ramie
Sisal
Banana
Coconut
Animal fibers
Chicken feathers
Hair
1000 plants can be used for manufacturing industrially usable fibers…..
Kenaf: drought-resistant relative to hibiscus, which grows without extensive use of herbicides or pesticides up to 4.2 m/7 months.
Hemp: non-narcotic form are used
Flax: Cargill’s Durafibre and Durafill
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14. 25/04/2017
Use of natural fibres in composites in the German automotive production
Market study by nova-Institut, Germany
tons of plant fibre NFCs
tons of wood fibre NFCs
tons of cotton fibre NFCs
Totally tons composites of which tons natural fibres
About 16 kg natural fibres used per car in Germany
Plant fibre market volume 15 million euro in automotive
65 % thermoplastic and 35 % thermoset matrices
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15. Use of natural fibres North America 2000
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Use of natural fibres North America 2000
Totally
ton
(7 % of reinforcement and filler market volumes)
ton 2005
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16. Fiber properties Fiber E-modulus (Gpa) Strength (Mpa) Strain (%)
Length (mm)
Diam. (m)
Density (g/cm3)
Glass 72
Cont. 10
2.56
Ramie
128
1.2-4
60-250
10-80
Flax
45-100
13-70
10-30
1.37
Sisal
19-32
1-8
10-40
1.45
Hemp 35
400
5-55
10-50
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17. Production of plant fibers
Fibre
Price comp. to glass (%)
Production
(1000 t)
Jute 18
3600
E-glass
100
1200
Flax
130
800
Sisal 21
500
Banana 40
Data from 1993
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18. Composition of different cellulose based natural fibers
Cotton
Jute
Flax
Ramie
Sisal
Cellulose
82.7
64.4
64.1
68.6
65.8
Hemi-cellulose
5.7
12.0
16.7
13.1
Pectin
0.2
1.8
1.9
0.8
Lignin -
11.8
2.0
0.6
9.9
Water sol. Subst.
1.0
1.1
3.9
5.5
1.2
Wax
0.5
1.5
0.3
Water
10.0
10.06
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Ref.: Bledzki, Prog. Polym. Sci. 24 (1999) 221

19. Properties for natural fibres
25/04/2017
Properties for natural fibres
Mechanical properties:
Large variations among species, dependence on environment and geographical cultivation location, climate and age
Chemical properties:
Inhomogeneous and large variations, hydrophilic
Physical structure:
Complex and heterogeneous, different properties on different size levels
Surface properties:
Heterogeneous, hydrophilic, must be modified before processing
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20. The cellulose polymer
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21. Cellulose OH up OH down Cellobiose repeating unit (-D-glucose)
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OH up
Cellulose
OH down
Cellobiose repeating unit (-D-glucose)
The combination of -D-glucose make it possible to form long straight chains
DP –
MW = –
5 - 7 m linear length in wood
Hydrogen bonds
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22. Compatibilization by maleic anhydride modified polymers
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Compatibilization by maleic anhydride modified polymers
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23. Flax (Linum usitatissimum)
- a slender stemmed plant with branches and flowers near the top
- the stem is around 3 mm thick, and the plant can be up to 1 m high
- flax is a bast fibre, with the fibers in bundles between the outer bark and the central, woody portion of the stem
- the fiber bundles are as high as the plant is high
A bast fibre
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24. Flax fibres can be made into non-wovens
30 % lighter than same stiffness glass fiber
Traditionally used in textiles
Industrial use as insulating material, and in automotive composites
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25. World-wide cultivation area for flax fibres
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World-wide cultivation area for flax fibres
Total area: ha
China: ha
France: ha
Belarus: ha
Russia: ha
the Netherlands: ha
Belgium: ha
Ukraine: ha
Lithuania: ha
Flax fiber output/ha depends largely on geographic location:
in western Europe it is possible to get 1800 kg fiber/ha, while in China and Russia it can be as low as 500 kg/ha
<this corresponds to 1-2 % of annual worldwide volumes
MSK
Data from FAOSTAT 2000

26. Flax cultivation output kg/ha:
kg/ha local variation
Raw flax  860 – 10 510
Rippled flax  560 – 8 480
Seeds – 985
Long fiber  310 – 1 930
Short fiber – 420
Total fiber – 2 360
Data from Belgium cultivation tests 2002
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27. Flax - from plant to fabric
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Flax - from plant to fabric
A step-wise
process:
harvesting
seed rippling
drying
retting
scutching
hackling
carding
drawing
spinning
weaving
fabric treatment
Seed rippling – traditional method
Field retting
Carding
Spinning
Weaving
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28. Flax fibre processing cycle Air-laid insulation Scutching
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Air-laid insulation
Scutching
Scutched fibre bundles
Short fibre tow
Flax fibre
processing cycle
Hackling
Spun yarns
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Carding
Long fibre line yarn
Spinning

29. Biotechnical retting process Developed by Finflax Ltd, Finland
Characteristics:
Bioreactor retting vessel
Closed system with recirculation and regeneration of retting liquor
Pectinase and hemicellulose enzymes
Easy to control (pH, temperature, O2)
hours processing time
Benefits:
Shorter retting time
Better fibre yield
Better fibre strength
Environmentally friendly process
Well-controlled and reproducible method
Efficient method
Reduction of processing costs
A satisfactory batch-wise enzymatic-retting process shall be simple, fast, cheap, reproducible and easily adaptable to existing equipment. The main principles of Arctic Flax retting process are to fulfil these criteria as controlled as possible at industrial scale.
Therefore, the retting liqueur consists of selected pattern of industrial pectinase enzymes either commercial or produced at FinFlax bioprocess department. This retting process is easily to be expanded, enables production automation having low operational costs. The whole process is closed minimizing unwanted microbial effects. It is easily controlled (pH, temperature, oxygen, organic acids, enzymatic activities etc.). The retting time can easily vary ( hours) depending on the type of fibers to be retted or the quality of fibers needed in different technical applications.
 Retting liquor consists of industrial enzymes and selected microbes producing enzymes
 Main enzymes are pectinases and hemicelluloses
 Bioreactor type of retting vessel with modular structure
 Closed system; no unwanted microbial (enzymatic effects)
 Recirculation and regeneration of retting liquor; removal of solids and other inhibitory materials
 Controlled; pH, temperature, oxygen, organic acids, enzymatic activities
Tailoring; retting process depending on raw material or requirements of fiber type and quality
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Photo: FinFlax Ltd

30. SEM surface analysis of enzyme and field retted flax fibres
Field retted fibre, 1000X
Enzyme retted fibre, 1000X
Technical fibre, 50 – 100 m
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31. Kenaf (Hibiscus cannabis)
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Kenaf (Hibiscus cannabis)
Grows 4 m in 7 months
Packaging materials, paper, oil-absorbents
Kenaf: drought-resistant relative to hibiscus, which grows without extensive use of herbicides or pesticides up to 4.2 m/7 months.
Hemp: non-narcotic form are used
Flax: Cargill’s Durafibre and Durafill
MSK

32. Jute (Corchorus casularis)
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Jute (Corchorus casularis)
Short, inelastic fibres
Carpet backing, sacks, wall coverings, floor coverings
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33. SISAL PLANTAGE
Photo by Kristiina Oksman
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34. Wood fibre reinforced thermoplastics
25/04/2017
Wood fibre reinforced thermoplastics
Wood polymer composites (WPC)
Wood fibres are used as a filler or reinforcement
Compounding by extrusion
Processing as thermoplastics
10 – 70 w-% fibre content
PP, PE, PS, ABS, recycled thermoplastics
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35. Palltruder® Production of wood plastic omposites
25/04/2017
Palltruder® Production of wood plastic omposites
K2004 Exhibition, Düsseldorf
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36. Extrusion line for wood polymer composite profiles
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Extrusion line for wood polymer composite profiles
K2004 Exhibition, Düsseldorf
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37. Construction materials
25/04/2017
Construction materials
50 % growth in the US
Easy maintenance
Compared to impregnated wood less toxic
Processed as wood
A wood-like surface finish
Can be colored with pigments
¨A plastic¨ surface feeling and out-look
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38. Car parts from natural fibres
25/04/2017
Mainly non-structural components for interior
Flax, hemp, kenaf
Reinforcement in non-woven form or chopped short fibres
Processing by compression moulding
EU directive End-of-Life Vehicle (ELV) demands that 85 % of car weight must be recycled, 10 % can be incinerated and only 5 % can be land-filled
Plant fibres are % of lower weight than glass fibres
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39. TEXFLAX European project
Flax fabrics
Flax yarn
Flax fibre
Flax cultivation
Composite laminates
Composite product
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40. TEXFLAX Demonstrator prototypes
Sandwich
panel
Bicycle helmet
Flower pot
Vacuum infused lid
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Water tank

41. Design and biocomposites
25/04/2017
Design and biocomposites
OLD CONCEPTS – NO DESIGN!
NEW CONCEPTS – WITH DESIGN!
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42. Kareline Ltd, Finland Wood composite compounds
25/04/2017
Kareline Ltd, Finland Wood composite compounds
Window frame by Allplast
Bleached softwood pulp + polypropylene
50 wt-% fibre content
Injection molding and extrusion molding
Design aspects considered
Electic guitar by Flaxwood
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43. Necessary developments:
25/04/2017
Necessary developments:
Fibre processing techniques into usable forms
Dust and microorganism in plants can be health hazards
Hydrophilicity of natural fibers causes water sensitivity (rotting and swelling)
Matrix incompatibility causes poor mechanical properties
Seasonal variability in plant properties
Better understanding about mechanical properties and structure
Temperature stability (processability and recycling)
Burning smell and odours while processing at high temperatures
Cellulose degrades at 300 C, which is near the processing at C.
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44. Natural fibre reinforcements
The environmental impact of the natural fibre reinforcements must be evaluated, and all steps must be considered
Cultivation: pesticides, fertilizers, erosion, farming equipment,…
Processing: fibre extraction, spinning and weaving
Disposal: end-of-life treatment
During use: durability in the composite
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