Periodic Reporting for period 3 - CHAMPION (Circular High-performance Aza-Michael Polymers as Innovative materials Originating from Nature)
Reporting period: 2023-04-01 to 2024-05-31
Polymers are used in many areas of modern life, including kitchen surface and car textile coatings, laundry detergent and glues that fix wind turbine parts together. However, many of these polymers are made from non-renewable (fossil-derived) components and have a range of environmental issues, both during production and once they reach the end of their useful life.
Society cannot rely on non-renewable polymers in the long term, and the avoidance of harmful production processes is necessary for the many workers in these industries. As demonstrated in the drive to reduce single-use plastics, it is essential to consider what will happen to the polymers once they are no longer in use, and design them so that effective recycling and/or biodegradability is possible. CHAMPION aimed to replace the conventional polymers with new, high-performing and safer bio-based ones, with improved end-of-life options via recycling or biodegradation.
The key achievements against the objectives of the project:
• 180 novel materials were prepared, in addition to the monomers and pre-polymers.
• Key knowledge was acquired on polymerisation processes for production of unsaturated polyesters for implementing and optimization at larger pilot scale. Databases were generated of the chemical processes for production of unsaturated polyesters with suitable molecular weights for targeted applications of the aza-Michael materials.
• An innovative, cost-effective testing strategy was established to rapidly evaluate toxicological safety issues of candidate products.
• Seven bio-based polymer candidates were produced at a scale suitable for application testing in a relevant industrial setting.
• The project completed initial performance tests on 60 polymer candidates, well exceeding the 10-40 that was originally planned. The three candidates which met all the necessary criteria proceeded to advanced testing as homecare formulation additives, coatings and automotive interior surfaces during the final year of the project.
• Biodegradation was improved compared to conventional materials but it was not possible to achieve complete biodegradation in soil or water within a reasonable time frame.
• Communication with key audiences and stakeholders along the entire value chain was achieved via newsletters, webinars, workshops, and comics.
Society cannot rely on non-renewable polymers in the long term, and the avoidance of harmful production processes is necessary for the many workers in these industries. As demonstrated in the drive to reduce single-use plastics, it is essential to consider what will happen to the polymers once they are no longer in use, and design them so that effective recycling and/or biodegradability is possible. CHAMPION aimed to replace the conventional polymers with new, high-performing and safer bio-based ones, with improved end-of-life options via recycling or biodegradation.
The key achievements against the objectives of the project:
• 180 novel materials were prepared, in addition to the monomers and pre-polymers.
• Key knowledge was acquired on polymerisation processes for production of unsaturated polyesters for implementing and optimization at larger pilot scale. Databases were generated of the chemical processes for production of unsaturated polyesters with suitable molecular weights for targeted applications of the aza-Michael materials.
• An innovative, cost-effective testing strategy was established to rapidly evaluate toxicological safety issues of candidate products.
• Seven bio-based polymer candidates were produced at a scale suitable for application testing in a relevant industrial setting.
• The project completed initial performance tests on 60 polymer candidates, well exceeding the 10-40 that was originally planned. The three candidates which met all the necessary criteria proceeded to advanced testing as homecare formulation additives, coatings and automotive interior surfaces during the final year of the project.
• Biodegradation was improved compared to conventional materials but it was not possible to achieve complete biodegradation in soil or water within a reasonable time frame.
• Communication with key audiences and stakeholders along the entire value chain was achieved via newsletters, webinars, workshops, and comics.
The work completed during the CHAMPION project includes:
• Implementation and use of management processes to support delivery of the project and management of project data. In particular, the successful integration of results across all work areas in order to find the best candidates for advanced testing.
• Establishing the External Advisory Board and holding three annual meetings to present results and obtain feedback.
• Computational modelling of over 100 potential polymers to inform experimental work.
• The elucidation of the aza-Michael reaction mechanism between bio-based Michael acceptors and amines, permitting more efficient syntheses.
• Synthesis of novel materials for use in CHAMPION polymer preparation, up to kilogram scales.
• Making polymers suitable for use in the target applications using the novel and commercially available bio-derivable materials.
• Validation of high-throughput toxicity screening methods to test novel materials including polymer candidates. Completion of migration studies and analysis of any Volatile Organic Compounds (VOCs) for the relevant applications.
• Screening of polymer properties for their suitability in the target applications. Initial testing of the performance of the polymers in industry settings to direct further synthesis with the best candidates proceeding to advanced testing.
• Biodegradation testing of the currently used materials to set the baseline against which the CHAMPION materials can be judged. The results from biodegradation testing of CHAMPION candidates was used to guide further development. Other end-of-life options for recyclable polymers was also explored.
• Gathering life cycle inventory data for relevant biomass derived building blocks and conducting cradle-to-gate life cycle assessment (LCA) where it was found that up to a 47% reduction in greenhouse gas emissions could be achieved.
• Delivery of preliminary process designs, cost evaluations and LCA for starting materials. Process costs are dominated by the price of the bio-based components. Alternative synthetic routes were identified to overcome feasibility, cost, or environmental limitations.
• Defining a strategy for a broader sustainability/circularity evaluation of CHAMPION products. Recommendations were produced to guide futher development and commercialisation.
• Development of the brand identity of the project and launch of the website and social media accounts. Making regular updates of the website and social media, including the launch of a YouTube channel.
• Communication with stakeholders through a combination of webinars, website updates, project newsletters, presentations and publications. Creation of a learning section on the website to explain the methodologies used in CHAMPION for different audiences.
• Evaluation of the current relevant EU policy relating to the circular economy and identifying where CHAMPION can support these aims.
• Conducting a market study to identify needs and preferences of market actors. The analysis conducted includes literature study, expert interviews and focus group meetings.
• Implementation and use of management processes to support delivery of the project and management of project data. In particular, the successful integration of results across all work areas in order to find the best candidates for advanced testing.
• Establishing the External Advisory Board and holding three annual meetings to present results and obtain feedback.
• Computational modelling of over 100 potential polymers to inform experimental work.
• The elucidation of the aza-Michael reaction mechanism between bio-based Michael acceptors and amines, permitting more efficient syntheses.
• Synthesis of novel materials for use in CHAMPION polymer preparation, up to kilogram scales.
• Making polymers suitable for use in the target applications using the novel and commercially available bio-derivable materials.
• Validation of high-throughput toxicity screening methods to test novel materials including polymer candidates. Completion of migration studies and analysis of any Volatile Organic Compounds (VOCs) for the relevant applications.
• Screening of polymer properties for their suitability in the target applications. Initial testing of the performance of the polymers in industry settings to direct further synthesis with the best candidates proceeding to advanced testing.
• Biodegradation testing of the currently used materials to set the baseline against which the CHAMPION materials can be judged. The results from biodegradation testing of CHAMPION candidates was used to guide further development. Other end-of-life options for recyclable polymers was also explored.
• Gathering life cycle inventory data for relevant biomass derived building blocks and conducting cradle-to-gate life cycle assessment (LCA) where it was found that up to a 47% reduction in greenhouse gas emissions could be achieved.
• Delivery of preliminary process designs, cost evaluations and LCA for starting materials. Process costs are dominated by the price of the bio-based components. Alternative synthetic routes were identified to overcome feasibility, cost, or environmental limitations.
• Defining a strategy for a broader sustainability/circularity evaluation of CHAMPION products. Recommendations were produced to guide futher development and commercialisation.
• Development of the brand identity of the project and launch of the website and social media accounts. Making regular updates of the website and social media, including the launch of a YouTube channel.
• Communication with stakeholders through a combination of webinars, website updates, project newsletters, presentations and publications. Creation of a learning section on the website to explain the methodologies used in CHAMPION for different audiences.
• Evaluation of the current relevant EU policy relating to the circular economy and identifying where CHAMPION can support these aims.
• Conducting a market study to identify needs and preferences of market actors. The analysis conducted includes literature study, expert interviews and focus group meetings.
Replacements to contemporary polymers is required due to their reliance on fossil-based starting materials, hazardous production processes and the lack of suitable end-of-life options. To support the transition to a circular economy, CHAMPION aimed to provide replacement polymers that not only addressed the shortcomings of the existing materials but also delivered equal or improved performance across four target applications. Towards this aim, an external advisory board was established, which extended the potential production chains in the project and also provided useful insight into the ambitions of other sectors.
The substitution of current materials with the safer, renewable CHAMPION polymers would deliver both health and environmental benefits. However, it was always clear that technologies at the early stages of development would have major challenges to meet, especially in terms of production costs. The project tried to anticipate these challenges and take them into account in the design and selection of monomers and polymers. Working on establishing an environmentally and socially sustainable production chain is also a key factor that was central to the project achieving its ambitions. In pursuing these aims, we have created a library of bio-based materials up to the kilogram scale with a variety of properties and studied environmental and techno-economic characteristics. Advanced testing was conducted in R&D facilities and product development is continuing.
The substitution of current materials with the safer, renewable CHAMPION polymers would deliver both health and environmental benefits. However, it was always clear that technologies at the early stages of development would have major challenges to meet, especially in terms of production costs. The project tried to anticipate these challenges and take them into account in the design and selection of monomers and polymers. Working on establishing an environmentally and socially sustainable production chain is also a key factor that was central to the project achieving its ambitions. In pursuing these aims, we have created a library of bio-based materials up to the kilogram scale with a variety of properties and studied environmental and techno-economic characteristics. Advanced testing was conducted in R&D facilities and product development is continuing.