Periodic Reporting for period 1 - BIORING (Engineering high performance biocoatings from renewable reactive building blocks)
Reporting period: 2023-06-01 to 2024-11-30
UV curable polyurethane (PU) coatings play a major role in a wide range of industries, due to their versatility, excellent performance, energy-efficient production and application, and 100% reactive components (no VOCs). However, they still largely depend on fossil-based raw materials.
Biobased coatings are a small (5% in sales and 1 % in volume in the coatings business) but emerging market, thanks to sustainable targets of companies, increasing awareness of end-users and customers, and sustainability goals from policies. There is a growing push to increase opportunities for biobased systems, in line with the EU bioeconomy strategy and the global transition to a circular economy.
Moreover, biocoatings applications are largely influenced by the technical demand of the final product. Thus, there is a need for new formulations for high-demanding sectors (industry, marine, automotive, wood…) that combine high- performance and sustainability.
BIORING develops biobased building blocks that allow the formulation of novel high-performance biocoatings with enhanced thermomechanical performance, providing a viable alternative to existing fossil-based ones. Their recycling and biodegradability are tested in view of end-of-life (EoL) real scenarios.
We provide a versatile, robust and scalable solution of biobased coatings based on biomass-derived photoreactive molecules, validated on a semi-industrial scale on rigid substances like paper and plastic.
Our solution is structured as a modular platform which will allow the integration of new and different building blocks in the future, to adapt to a variety of applications and industries.
We have 5 specific objectives:
1. Provide a platform of renewable building blocks and oligomers from biomass as suitable constituents of tailor-made high-performance biobased UV curing coatings.
2. Develop 2 novel 95% biobased formulations based on BIORING’s platform constituents for biobased coatings.
3. Provide results as a proof of improved performance, health, safety profile and end-of-life.
4. Develop a process modelling framework that aligns the decisions to be taken in the process design and predict of the coating properties based on their formulation.
5. Demonstrate the market and economic feasibility of new coatings by developing proofs of concept for two sectors (automotive and construction) and identifying broader market applications for BIORING’s platform.
Biobased coatings are a small (5% in sales and 1 % in volume in the coatings business) but emerging market, thanks to sustainable targets of companies, increasing awareness of end-users and customers, and sustainability goals from policies. There is a growing push to increase opportunities for biobased systems, in line with the EU bioeconomy strategy and the global transition to a circular economy.
Moreover, biocoatings applications are largely influenced by the technical demand of the final product. Thus, there is a need for new formulations for high-demanding sectors (industry, marine, automotive, wood…) that combine high- performance and sustainability.
BIORING develops biobased building blocks that allow the formulation of novel high-performance biocoatings with enhanced thermomechanical performance, providing a viable alternative to existing fossil-based ones. Their recycling and biodegradability are tested in view of end-of-life (EoL) real scenarios.
We provide a versatile, robust and scalable solution of biobased coatings based on biomass-derived photoreactive molecules, validated on a semi-industrial scale on rigid substances like paper and plastic.
Our solution is structured as a modular platform which will allow the integration of new and different building blocks in the future, to adapt to a variety of applications and industries.
We have 5 specific objectives:
1. Provide a platform of renewable building blocks and oligomers from biomass as suitable constituents of tailor-made high-performance biobased UV curing coatings.
2. Develop 2 novel 95% biobased formulations based on BIORING’s platform constituents for biobased coatings.
3. Provide results as a proof of improved performance, health, safety profile and end-of-life.
4. Develop a process modelling framework that aligns the decisions to be taken in the process design and predict of the coating properties based on their formulation.
5. Demonstrate the market and economic feasibility of new coatings by developing proofs of concept for two sectors (automotive and construction) and identifying broader market applications for BIORING’s platform.
During the first half of BIORING, one main aim has been to develop chemical technologies to produce high-grade biobased monomers to formulate UV-curable polyurethane coatings. This also included the development of suitable purification methods to guarantee the required quality of the compounds. We have successfully synthesised biobased polyols, as well as various UV-reactive monomers needed for cross-linking. So far, we have demonstrated the technical viability of the production of these monomers on the scale required for the production of PU resins.
Another key activity has focussed on the application of the novel biobased monomers for the development of renewable oligomers/resins as major components for biobased UV coatings. We have progressed in optimising strategies to functionalise different PU structures with each of BIORING’s renewable UV-reactive monomers. Simultaneously, photoreactivity and physicochemical properties of these polymers are evaluated. This has allowed us to create various new resins, able to crosslink under UV radiation for further formulation of coatings.
To prepare for the case studies, we have gathered information concerning the tests and specifications which a coating has to overcome to be suitable for applications on plastic for the automotive and on paper for construction sector.
Furthermore, we have performed a benchmarking analysis on commercial bio-based UV-curable coatings for the automotive and/or construction sectors. Currently, there are no bio-based UV curable coatings this application on the market, which underlines the need for further developments. However, our analysis has provided a wide view of how the sector of industrial coatings is trying to face eco sustainability. We will use benchmarks for fossil-based UV curable automotive coatings for assessment of the BIORING products.
We have developed a conceptual process design of the BIORING technology, including a detailed technoeconomic assessment. This provided insights into the current bottlenecks of the BIORING manufacturing process.
Another key activity has focussed on the application of the novel biobased monomers for the development of renewable oligomers/resins as major components for biobased UV coatings. We have progressed in optimising strategies to functionalise different PU structures with each of BIORING’s renewable UV-reactive monomers. Simultaneously, photoreactivity and physicochemical properties of these polymers are evaluated. This has allowed us to create various new resins, able to crosslink under UV radiation for further formulation of coatings.
To prepare for the case studies, we have gathered information concerning the tests and specifications which a coating has to overcome to be suitable for applications on plastic for the automotive and on paper for construction sector.
Furthermore, we have performed a benchmarking analysis on commercial bio-based UV-curable coatings for the automotive and/or construction sectors. Currently, there are no bio-based UV curable coatings this application on the market, which underlines the need for further developments. However, our analysis has provided a wide view of how the sector of industrial coatings is trying to face eco sustainability. We will use benchmarks for fossil-based UV curable automotive coatings for assessment of the BIORING products.
We have developed a conceptual process design of the BIORING technology, including a detailed technoeconomic assessment. This provided insights into the current bottlenecks of the BIORING manufacturing process.
The research conducted for the synthesis of the biobased monomers has, in several cases, resulted in the identification of new routes or new catalysts for their production. These results beyond the state of the art have a potential impact on the sustainability and economic viability of the synthesis processes for biobased building blocks for bio-coatings and other polymer applications. We are currently performing thorough SSbD and LCA assessments, which, in case of a positive outcome, will help foster industrial interest and future uptake of these results.
Several initial approaches towards the formulation of biobased coatings, using the monomers synthesized within BIORING, have shown potential for cross-linking by UV-curing. During the further course of the project, we will carry out real-life application of the complete formulation of the final coatings. Future impact of our products will be defined by the functional characteristics demonstrated in these applications and the biobased content of the coatings.
Several initial approaches towards the formulation of biobased coatings, using the monomers synthesized within BIORING, have shown potential for cross-linking by UV-curing. During the further course of the project, we will carry out real-life application of the complete formulation of the final coatings. Future impact of our products will be defined by the functional characteristics demonstrated in these applications and the biobased content of the coatings.