MULTIFUNCTIONAL BIOPHENOLS FOR SAFE AND RECYCLABLE MATERIALS

Project Information

BioPhenom

Grant agreement ID: 101135107

DOI

10.3030/101135107

EC signature date 2 May 2024

Start date 1 June 2024

End date 31 May 2028

Funded under

• Food, Bioeconomy Natural Resources, Agriculture and Environment

Total cost

€ 3 677 680,25

EU contribution

€ 3 677 680,25

Coordinated by

TEKNOLOGIAN TUTKIMUSKESKUS VTT OY
Finland

Periodic Reporting for period 1 - BioPhenom (MULTIFUNCTIONAL BIOPHENOLS FOR SAFE AND RECYCLABLE MATERIALS)

Reporting period: 2024-06-01 to 2025-11-30

Summary of the context and overall objectives of the project

Common materials and products used in our daily life are often formulated with unsustainable petrochemicals, many of which are substances of very high concern (SVHC) due to their harmful effects on the environment and human health. In addition to safety concerns, the recyclability of materials containing harmful substances is very challenging, and around 50% of the 100 M tons of hazardous waste generated annually in the EU is still landfilled or incinerated, perpetuating the pollution of our ecosystems.
The main objective of BioPhenom is to explore the utilization of biophenols extracted from industrial biomass sidestreams as replacement of SVHC for development of safe, sustainable, and recyclable materials. By upgrading selected biomass sidestreams, the project will produce bio-based, flame-retardant, and recyclable materials, including wood products, carbon fibres, thermoset composites, and thermoplastics for various industrial applications. This will be achieved through a series of specific objectives including:
• Scoping opportunities and challenges for exploiting underutilized industrial biomass sidestreams as sources of biophenols.
• Isolation of biophenols from selected biomass sidestreams using liquid extraction or fast pyrolysis technologies.
• Testing the isolated biophenols in the development of Safe and Sustainable by Design (SSbD) wood products, carbon fibres, epoxy resins, and thermoplastic materials.
• Assess and benchmark the functionality and recyclability of selected product demonstrators.
• Integrate and develop SSbD framework for assessing the safety and sustainability of the biomaterials throughout the entire development process.
• Contribute high-quality data generated along targeted value chains through effective and efficient dissemination, communication, and exploitation activities.
The results from BioPhenom will contribute to the Zero Pollution ambition of the European Green Deal and to the application of the SSbD framework in the development of bio-based solutions, thus promoting reduction of waste and the transition towards a circular bioeconomy.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The main activities performed during this reporting period (M1-M18) were related to the scoping and collection of biomass sidestreams, isolation of biophenols from selected sidestreams by liquid extraction and fast pyrolysis, chemical functionalization of isolated biophenols to produce bio-based flame retardants, testing of biophenols in several material formulations, and implementation of the SSbD methodology to guide and support the technical developments.
Ten different sidestreams from forest, agro, and food industries were scoped as potential sources of biophenols based on criteria such as availability in the EU, biophenol content, logistic aspects, and competition with existing uses. The selected streams were collected, analysed, and further subjected to liquid extractions and/or fast pyrolysis for isolation and characterization of the biophenols. Liquid extractions were conducted under water-only or alkaline conditions, and the use of catalysts in fast pyrolysis processes was evaluated.
Biophenols obtained by fast pyrolysis of logging residues and alkaline extraction of bark, as well as commercial lignin and tannins, were initially investigated in the development of wood impregnation processes, synthesis of bio-based epoxy resin precursors, electro-spinning to subsequently produce carbon fibres, and production of PLA-based thermoplastic composites. In addition to biophenols, biochar obtained from fast pyrolysis was also tested as potential flame retardant in epoxy resin systems and in thermoplastic composites. The biophenols were also used in different chemical functionalization routes aimed to convert them into bio-based intumescent flame retardants.
The different processes developed in BioPhenom and their system boundaries were established for implementation of the SSbD methodology, which was tailored to the project needs. Data collection and the first iterations of the assessment (safety and environmental sustainability) were performed, with analyses of hotspots based on safety and sustainability profiles.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The sidestreams tree bark, logging residues, olive stones, and grape stalks were selected as the most potential sources of biophenol, based on their combination of large availability in the EU, high biophenol content, minimum processing required for logistics, and low value. Tree bark and grape stalks are rich in tannins, while lignin is the main biophenol in logging residues and olive stones. A preliminary LCA showed that tree bark, especially from softwoods, has the best overall environmental performance.
Catalytic fast pyrolysis of selected sidestreams demonstrated that calcined dolomite is an effective catalyst for producing phenol-rich bio-oils, and that temperature and catalyst loading could be controlled to provide the best balance between deoxygenation and cracking reactions. On the other hand, hot water extraction provided satisfactory biophenol (tannins) yields for tree bark but not for olive stones or logging residues. Fast pyrolysis of tree bark and olive stones and alkaline extraction of bark were successfully upscaled to produce biophenols in kg scale, and nitrogen-modified biophenols were successfully prepared via four synthesis methods which are being upscaled to evaluate their flame-retardant properties.
Impregnation of wood with pyrolysis lignin from logging residues provided antifungal properties, and novel coatings applied to the impregnated wood to prevent leaching maintained a stable surface after six weeks of artificial weathering. Glycidylation of pyrolysis lignin to prepare bio-based epoxy resins was validated on lab scale, followed by optimization of the purification after glycidylation to increase epoxy stability. Electro-spinning commercial lignin, tannin, and lignin/tannin blends were demonstrated, and oxidation and carbonisation processes to produce bio-based carbon fibres were developed. PLA-based composites containing biochar showed a good particle–matrix adhesion and structural integrity up to 30% wt. filler loading. Continuous PLA melt-processing was also demonstrated. The technical solutions in BioPhenom are built upon state-of-the-art SSbD assessments and any new developments with relevance to the project work are continuously monitored.