Polymerisation
| Technology | |
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| Technology details | |
| Name: | Polymerisation |
| Category: | Conversion (Chemical processes and technologies) |
| Feedstock: | Single molecules, monomers |
| Product: | Polymers (polyolefins, polycondensates) |
Polymerisation (polymerization in American English) is the process of reaction smaller molecules, i.e. monomers, together into a chain or network, i.e. a polymer. There are many forms of polymerisation reactions. A common distinction is between homopolymers, where one type of monomer forms the polymer, and co-polymers, where multiple different monomers make up the polymer. A well-known application of polymers is in plastics. However, polymerisations can also lead to smaller chains, known as oligomers, which are for example used as plasticisers and lubricants.
Feedstock
Origin and composition
Several bio-based feedstock options have been explored for the production of bio-based polymers. Lignin can be depolymerised and the obtained products can be used as monomers. Ethanol from sugar fermentations can be processed to produce ethylene, a common feedstock for polymerisations to different polymers. Fatty acids can be used in long-chain linear aliphatic polymers. Other biomass feedstock includes CO2, terpenes, and furfural.[1]
Pre-treatment
The pre-treatment of the feedstock for polymerisation is depending on the specific process and feedstock used. In principal, the feedstock is converted to a building block like ethylene, propylene, styrene or others in a first step and then polymerised in a catalytic process. High purity of the feedstock is crucial for successful polymerisation reactions, which are highly susceptible to pollutants, often leading to lower polymerisation grades or smaller polymerisation chains.
Process and technologies
There has been signifcant effort to produce polymers from biomass rest streams. The key challenge lies in producing materials that have comparable or improved properties to their fossil-based counterparts. The right processing, which is often neglected by chemists, plays a crucial role in enhancing the material properties.[1] The specific technologies are depending on the types of polymer, but normally do not differ from conventional polymerisation processes in case of drop-in polymers like bio-based PE, PP, PET and others.
- Some examples for polymerisation of (bio-based) monomers
- Ethylene --> Polyethylene
- Propylene --> Polypropylene
- Lactic acid --> Polylactic acid (PLA)
- Laurinlactam --> Polyamid PA12
Product
Three critical processes to obtain sustainable bio-based polymers are the conversion of lignin monomers to polymers, the production of bio-based polyolefins, for example from ethylene via the ethanol route, and the production of long-chain aliphatic polycondensates, which can be obtained from fatty acids.[1]
Post-treatment
Normally the resulting polymers are compounded to plastics with different kinds of additives like plasticizers or others or post-processed to reach their aimed properties. In case of plastics the material normally is melted and extruded to pellets for the further processing.
Technology providers
| Company name | Country | Technology subcategory | Technology name | TRL | Capacity [kg/h] | Catalyst | Residence time [h] | Temperature [°C] | Feedstock: Food waste | Feedstock: Garden & park waste |
|---|---|---|---|---|---|---|---|---|---|---|
| B4Plastics | Belgium | - | Polymerisation | 4-5 | 1 | - | - | - | ||
| Vertimass | USA | - | CADO (Consolidated alcohol dehydration and oligomerization) | 9 | - | - | - | - |
B4Plastics
| General information | |||
| Company: | B4Plastics | 
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| Country: | Belgium | ||
| Contact: | [email protected]
+32(08)9231131 | ||
| Webpage: | https://b4plastics.com | ||
| Technology and process details | |||
| Technology name: | Polymerisation | Technology category: | Conversion (Chemical processes and technologies) |
| TRL: | 4-5 | Capacity: | Gram to ton scale. Lab scale: 10g – 1kg. Pilot equipment: multi-kg scale. Multipurpose plant: ton scale production as of 2023. Between 1-100 kg/h kg·h-1 |
| Catalyst: | not relevant | Residence time: | not relevant min |
| Temperature: | not relevant °C | Other: | Service: Biomaterial R&D excellence center. Polymer Architects, Production Center, Licencing House |
| Feedstock and product details | |||
| Feedstock: | bio-based building blocks | Product: | FORTAN® (strong sustainable alternatives for PAs), RUBRAN® (sustainable elastomers to substitute TPEs) |
B4Plastics is a Polymer Architecture company, catalyzing the introduction of novel biomaterials, and growing them from niche to bulk applications. As an architect creates your dream house, we create your dream plastic. For your application, we design the dream material. Striking the best balance between functionality, ecology and cost. We prototype fast; we hit accurately. Your new polymer ambitions are in the hands of a team of biobased materials masters and experts – uniquely educated to create new material value chains, from the field to your product, and back. Our solutions did not yet exist. We create with you, and for you. And for this world.
Senbis
| General information | |||
| Company: | Senbis | 
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| Country: | The Netherlands | ||
| Contact: | [email protected] | ||
| Webpage: | https://www.senbis.com/ | ||
| Technology and process details | |||
| Technology name: | Polymerization | Technology category: | Conversion (Chemical processes and technologies) |
| TRL: | 6-9 | Capacity: | - Lab autoclave: <1 kg
- Pilot plant autoclave <50 kg - Polymerization factory 60.000 mt/year kg·h-1 |
| Catalyst: | not relevant | Residence time: | not relevant min |
| Temperature: | not relevant °C | Other: | not relevant |
| Feedstock and product details | |||
| Feedstock: | Chemicals – polymer monomers & buildings blocks including bio-based | Product: | Polyesters, Polyamides, Bioplastics |
Senbis has two company activities, namely providing third party research to the plastic industry and producing and selling our own developed sustainable products. Our own products are made out of biodegradable plastics made for applications that have a high likelihood of ending up in nature, where they cause lasting harm to our environment. Senbis is the continuation of the former R&D department of Akzo Nobel. The combination of decades of experience in fiber and yarn development, the flexibility of a start-up, and extensive modernized lab and pilot plant facilities give us unique innovation potential. We expect to grow our business in the coming years. The public discussion around the plastic soup is becoming more intense and so will the legislation around the sustainable use of plastics. We have a proven track record of developing high performance biobased & biodegradable solutions for the horticulture, sports, marine, textile, agriculture & greenery sector.
Vertimass
| General information | |||
| Company: | Vertimass |
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| Country: | USA | ||
| Contact: | |||
| Webpage: | https://www.vertimass.com/ | ||
| Technology and process details | |||
| Technology name: | CADO (Consolidated alcohol dehydration and oligomerization) | Technology category: | Conversion (Chemical processes and technologies) |
| TRL: | 9 | Capacity: | kg·h-1 |
| Catalyst: | Residence time: | min | |
| Temperature: | °C | Other: | |
| Feedstock and product details | |||
| Feedstock: | 'Wet' ethanol | Product: | Jet fuel, biodiesel |
Open access pilot and demo facility providers
Patents
Currently no patents have been identified.
References
- Polymerization in Wikipedia
- ↑ a b c Zhongkai Wang, Mitra S. Ganewatta, Chuanbing Tang, 2020-02-01: Sustainable polymers from biomass: Bridging chemistry with materials and processing. Progress in Polymer Science, Vol. 101, 101197. doi: https://doi.org/10.1016/j.progpolymsci.2019.101197