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Today, bioplastics are recognized as one of the key sustainable elements of 21st century. They offer an improved balance between the environmental benefits and the environmental impact of plastics.<\/p>\n
Among them, one bio-based polymer which has gained immense popularity in the past few years is: PEF – Polyethylene Furanoate!<\/p>\n
This next-gen polymer offers a great potential to replace oil-based polymers. It is renewable, non-toxic and a recyclable alternate with similar properties. However, there are still several aspects that need consideration for efficient production of PEF at commercial scale.<\/p>\n
Explore more about this polymer in detail! Get information about its properties, applications, growth aspects… And, understand what makes PEF a bio-based polymer of future for packaging applications and more.
\nBy SpecialChem<\/p>\n
Key Properties and Benefits of PEF – Polyethylene Furanoate
\nWhat is PEF – Polyethylene Furanoate?<\/p>\n
Polyethylene Furanoate or PEF is a 100% recyclable, bio-based polymer produced using renewable raw materials (sugars) derived from plants.<\/p>\n
PEF is referred as the next generation polyester which exhibits great potential to replace polyethylene terephthalate (PET), a durable polymer derived from conventional synthetic resources.<\/p>\n
As compared to PET, PEF offers numerous benefits such as:
\nSuperior barrier performance as well as mechanical and thermal properties
\nHigh glass transition temperature and lower melting point
\nRecyclable and hence reduced carbon footprint
\nCost competitive at industrial scale<\/p>\n
At the same time, it improves packaging sustainability since PEF produced from FDCA is 100% biobased when biobased monoethylene glycol (MEG) is used.<\/p>\n
PEF is produced when furandicarboxylic acid (FDCA) is polymerized in presence of ethylene glycol. At the level of its manufacture, the synthetic route is similar to that of PET, the terephthalic acid being substituted by 2,5 furan dicarboxylic acid (FDCA).
\nFuranics: World is Behind \u2018Sleeping Giants\u2019 for Next Gen Polyester<\/p>\n
5-hydroxymethylfurfural (5-HMF), 2,5-Furandicarboxylic acid (FDCA) and 2,5-dimethylfuran (2,5-DMF) are the main representatives of the furanics (furan derivatives) family. Furans have been referred as \u201cSleeping Giants\u201d of renewable intermediate chemicals because of their enormous market potential.<\/p>\n
C6 Sugars (Carbohydrates) are found to be excellent source for the production of furanics monomer. HMF and FDCA are identified as high potential starting materials (precursors) for PEF.<\/p>\n
FDCA (Furandicarboxylic acid or 2,5-Furan Dicarboxylic Acid) (C6H6O3; MW = 126.11) is a bio-based building block for resins and polymers. It holds potential and used to produce high value products such as:<\/p>\n
Polyesters
\nPolyamides
\nCopolymers
\nSolvents
\nCoating resins and plasticizers<\/p>\n
It is formed by an oxidative dehydration of hexose. The conversion can also be carried out by oxidation of 5-hydroxymethylfurfural (HMF).<\/p>\n
FDCA has a large potential as a replacement of terephthalic acid (PTA). PTA is widely used conventional synthetic component used to produce polyesters such as polyethylene terephthalate (PET) and polybutylene terephthalate (PBT).<\/p>\n
While, FDCA is used to produce relatively news class of polymer called polyethylene furanoate (PEF) which exhibits enormous potential to produce bio-based plastics bottles.
\nFew methods used to produce FDCA include:<\/p>\n
Dehydration of hexose derivatives,
\nOxidation of 2,5-disubstituted furans, and
\nCatalytic conversion of furan derivatives<\/p>\n
Further the versatility of FDCA is also seen in the number of derivatives available via relatively simple chemical transformations. Selective reduction can lead to:<\/p>\n
Partially hydrogenated products, such as 2,5-dihydroxymethylfuran, and
\nFully hydrogenated materials, such as 2,5-bis(hydroxymethyl)tetrahydrofuran<\/p>\n
Both of these materials can be used as alcohol components to produce new polyester. As well as their combination with FDCA would lead to a new family of completely biomass-derived products.<\/p>\n
However, there are some technical barriers associated with production and use of FDCA.<\/p>\n
High process as well as its production is further limited by availability of the intermediate hydroxymethylfurfural (5-HMF)<\/p>\n
Development of effective and selective dehydration processes for sugars
\nSugar dehydration could leading to a wide range of additional, inexpensive building blocks. Currently, dehydration processes are generally non-selective, unless the unstable intermediate products can be transformed to more stable materials as soon as it is formed. Necessary R&D will include development of selective dehydration systems and catalysts.<\/p>\n
Development and control of FDCA esterification reactions as well as control reactivity of the FDCA monomer
\nIntense knowledge of chemistry occurring between acid and alcohol during polymer formulation and the properties of final polymer is an important aspect to understand this technology further and use it for commercial production.
\nBenefits of PEF Over PET<\/p>\n
PEF has very good barrier properties (hard to achieve with most bio-based polymers)O2 barrier \u2013 6 times greater than PET
\nCO2 barrier \u2013 3 times better than PET
\nH2O barrier \u2013 2 times better than PET<\/p>\n
PEF also has interesting mechanical properties compared to PET.Higher Tg (glass transition temperature)
\nLower Tm (melting point)
\nHigher modulus<\/p>\n
Better tensile strength
\nPEF requires less additives than PET
\nPEF can be recycled and incorporated into the PET recycle streams at up to 5% PEF with no effect on the recycled PET performance
\nPermits greater light weighting and superior thermal stability without heat-setting (can be hot filled at about 200\u00b0 F)
\nPEF holds potential to demonstrate cost efficiency as compared to PET<\/p>\n
Polyethylene Furanoate – Key Applications<\/p>\n
PEF\u2019s excellent barrier properties and its calculated cost price indicate that it can compete with traditional, multi-million-ton, packaging products such as aluminum cans, multilayer packaging and small size multilayer PET bottles, on price and performance when produced at large scale.<\/p>\n
PEF offers unique opportunities in packaging:
\nEnabling for safe and recyclable small-size rigid packaging
\nProviding simplicity and renewability to flexible packaging
\nPEF Bottles – Water bottle, beverage bottle etc. The polymer completely meets the growing trends in packaging such as sustainability, cost reduction etc. as a 100% biobased, fully transparent and recyclable alternative to PET. PEF is lightweight, thermally, stable, transparent and offers prolonged shelf life in bottles.<\/p>\n
PEF Films \u2013 It opens new opportunities in flexible packaging. As compared to BOPET-based packaging, PEF has equal thermo-mechanical and surface properties. Even SiOx\/AlOx coated or metalized BOPEF can offer superior barrier to conventional substrate films. PEF films are recyclable with suitable other layers or compatible with clean energy recovery at reduced GHG emissions<\/p>\n
PEF Fibers – Its main applications include apparels, carpets, home furnishing, disposables commodities, fabrics, diapers, filters and industrial fibres
\nRecycling of Polyethylene Furanoate<\/p>\n
Products made of PEF can easily be recycled or converted back to atmospheric CO2 by incineration. Eventually, that CO2 will be taken up by grass, weeds and other plants, which can then be used to make more PEF.<\/p>\n
PEF to PEF recycling is similar to PET recycling<\/p>\n
PEF can be separated from PET by IR sorting and recycled to \u2018rPEF\u2019 using the same steps as PET (mechanical or chemical recycling using same steps as PET)
\nPEF significantly less impact on rPET then Nylon or PLA<\/p>\n
PEF reduces the need for multi-material functionality in packaging. However there are still some steps to be taken in packaging re-design and waste management.<\/p>\n
Polyethylene Furanoate is the next step towards circular economy<\/p>\n
Growth Prospects of PEF – Industrial Scale Developments<\/p>\n
The utility of FDCA as a PET\/PBT analog offers an important opportunity to address a high volume, high value chemical market. To achieve this opportunity, R&D to develop selective oxidation and dehydration technology is being carried out.<\/p>\n
As discussed above, 2,5-Furandicarboxylic acid (FDCA) is an important chemical intermediate for PEF production and several chemical companies are currently working on manufacturing it.<\/p>\n
AVA-CO2 offers a patented conversion process of 5-HMF to FDCA
\nWageningen UR has successfully prepared FDCA semi-aromatic polyesters
\nAvantium, along with BASF is working towards making FDCA and PEF a commercial reality
\nCorbion is also working on manufacture of FDCA for PEF
\nETH Zurich develops new method that could finally make the PEF marketable<\/p>\n
Out of these Synvina (BASF + Avantium JV) and Corbion are focusing their energies on FDCA for PEF.<\/p>\n
Avantium developed and patented YXY technology platform aimed at manufacturing bio fuels, bio-based plastics and bio chemicals. The JV between Avantium and BASF established strategic partnership with Danone, Coca-Cola and ALPLA for developing and commercializing bio-based polymers derived from PEF.<\/p>\n
In 2014, Avantium, Danone, Swire Pacific and Coca-Cola signed a consortium of USD 50 million investments aimed at developing and commercializing the alternative to PET for packaging applications.<\/p>\n
In 2014, Avantium demonstrated the application of PEF for manufacturing of fibers to make 100% bio-based t-shirts for textile manufacturers.<\/p>\n
However, commercial production and launch of FDCA and PEF is expected to be operation by 2024.<\/p>\n
Watch Now!
\nInterview with Patrick Schiffers, Synvina.
\nAt the European Bioplastics Conference in Berlin November 2017<\/p>\n
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