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DRYBIOMAT

Development of dry processing methods to manufacture low environmental-footprint bio-based materials
Funder: French National Research Agency (ANR)Project code: ANR-23-CE43-0002
Funder Contribution: 242,136 EUR

DRYBIOMAT

Description

Plastic products are present everywhere in daily life with 370 million metric tons produced in 2020. Raising concerns about oil depletion, end-of-life management, microplastics effects on life and land have led institutions to take severe measures to avoid their use such as Europe’s directive on SUP from 2018. Today, the necessity to find more sustainable solutions for everyday life materials and the recent advances in our comprehension of cellulosic biomass opens up new challenges in materials science and manufacturing. In particular, one possible direction is to explore more sustainable processes to produce materials using biomass that could substitute plastic products. In this context, DRYBIOMAT proposes to evaluate the potential of dry processing methods to manufacture bio-based materials with reduced environmental impact. The main purpose is to succeed in processing bio-materials that are energy and cost-efficient, sustainable, economically competitive and up-scalable. The dry processes identified are ultrasonic compression molding (UCM) and thermocompression. UCM is a derivative of the ultrasonic welding and inspired from sintering processes. It consists in forming materials through the welding of compressed bio-elements induced by local heating resulting from inter-particle friction and viscous dissipation. Dry-processing methods have not been much considered so far to manufacture bio-based materials. Nevertheless, the topic is highly innovative and responds in many ways to the challenges of tomorrow. Historically, pulp, papers or cardboards are obtained through wet-processes which consume energy (2.9 MWh/ton of paper) and water (15-25 m3/ton) thus increasing their environmental footprint. Only a few recent studies have started to focus on the obtention of binderless boards and all-cellulose composites through thermocompression. UCM has only been used to process 100% bio-composites from a starch powder and wood pulp fibers by researchers involved in this project. Resulting properties were found to be quite close to conventional polymers and even suitable for structural applications. However, some obstacles remain preventing further development of these solutions. The technical barriers are associated to the lack of information regarding (i) the actual conditions (temperature, humidity, stress, strain, structure) within the material during dry-processing, (ii) the influence of elements size, shape, structural properties, and stress/strain states on heat generation, propagation, and dissipation in UCM, and (iii) the overall energetic efficiency of ultrasonic processes. These phenomena are of prime concern because they drive the establishment of adhesion between elements that result in the formation of bulk materials. The objective of DRYBIOMAT is to lift these technical barriers through four research axes. The 1st one will concern the development of UCM and thermocompression at lab-scale adapted to biomass specificities. The 2nd axis will evaluate the capability of bio-resources and by-products to form materials using dry-processing methods. The 3rd one will investigate on the understanding of adhesion mechanisms leading to the formation of materials and associate them to the changes in properties during the process. At last, the 4th axis will focus on the characterization of dry-processed materials and analyze their performances in respect of the associated environmental footprint. The development of dry-processed methods could lead to the obtention 100% bio-based and bio-degradable materials with properties similar to plastics and composites. The direct use of agriculture and wood by-products could lead to bio-materials with significantly reduced environmental footprints while promoting circularity. It would prove the existence of alternative methods to process biomass into materials and accelerate the development of sustainable solutions in materials science and engineering.

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