SBIR Phase I: Development of lignin-based biodegradable plastic alloys via solvent free reactive extrusion

这个小型企业创新研究第一阶段项目将展示从农业和林业废液中生产出一系列新的生物基和可生物降解聚合物的能力，这些聚合物有可能缓解农业作业中普遍存在的垃圾填埋场和一次性塑料。在传统的农业作业中，农民使用塑料地膜来阻止杂草并保持土壤中的水分，最终提高作物产量。不幸的是，使用的不可降解塑料必须在收获后移走并送往垃圾填埋场，因为它们由于受到土壤和杀虫剂的污染而无法回收，导致大量劳动力和处置成本，并增加环境负担。在本项目中，木质素聚合物合金作为一种创新的可生物降解塑料平台进行了研究，可以作为传统材料的替代品，这些材料是不可回收的。农业电影代表着一个25亿美元的全球市场。其他有吸引力的市场机会包括农业容器(50亿美元)、垃圾袋(100亿美元)和包装(1150亿美元)。木质素作为一种可再生原料，是低成本、可生物降解塑料的极佳候选者。成功地演示木质素的商业规模使用对新兴的生物炼油业至关重要，也是确保美国未来能源和材料安全的首要任务。该项目的智力优势解决了低成本、生物基塑料取代石油衍生材料的需求，同时确保了不会因废物积累而产生财务和环境负担的闭环生命周期。到目前为止，由于需要广泛的溶剂型改性和分离工艺，基于木质素的聚合物价格昂贵得令人望而却步。本研究项目的目的是证明：1)通过无溶剂、高剪切熔体加工，生产出木质素含量为50%或更高的木质素聚合物合金；2)提高材料的界面表面积；3)机械性能接近或超过低密度聚乙烯；4)在环境土壤和高温堆肥条件下的生物降解性。预期的技术成果将是生产出至少1种最优配方，满足上述确定的适用于农业地膜应用的条件。如果以上4项都能实现，那么在随后的第二阶段奖励中进行的进一步研究将能够展示这种新型可持续生物材料的规模化生产，并有可能在美国制造出第一批商业上可行的木质素基塑料，用于农业塑料应用和其他领域。

This Small Business Innovation Research Phase I project will demonstrate the ability to create a new family of biobased and biodegradable polymers produced from agricultural and forestry waste streams that have the potential to mitigate landfill-bound, single-use plastics prevalent in agricultural operations. In conventional agricultural operations, farmers use plastic mulch films to block weeds and retain moisture in the soil, ultimately increasing crop yields. Unfortunately, the non-degradable plastics that are used must be removed after harvest and sent to a landfill as they are not recyclable due to contamination by soil and pesticides, leading to significant labor and disposal costs and increasing environmental burden. In this project, lignin polymer alloys are investigated as an innovative biodegradable plastic platform which can be used as an alternative to conventional materials that are not recyclable. Agriculture films represent a global market of $2.5 billion. Other attractive market opportunities include agricultural containers ($5 billion), garbage bags ($10 billion), and packaging ($115 billion). Lignin as a renewable feedstock is an excellent candidate for low cost, biodegradable plastics. Successful demonstration of commercial-scale uses for lignin is vital for the emerging biorefinery industry, and a primary task to secure the energy and materials future for the US.The intellectual merit of this project addresses the need for low-cost, biobased plastics to replace petroleum derived materials, while ensuring a closed-loop lifecycle that does not generate financial and environmental burden due to waste accumulation. To date, lignin-based polymers have been prohibitively expensive due to the need for extensive solvent-based modification and separations processes. The objective of this research project is to demonstrate the production of lignin-polymer alloys with: 1) unmodified lignin contents of 50% or higher through solvent-free, high shear melt processing; 2) enhanced interfacial surface area for material durability; 3) mechanical properties near or exceeding that of low-density polyethylene; and 4) biodegradability under both ambient soil and thermophilic composting conditions. The expected technical results will be production of at least 1 optimal formulation meeting the above conditions identified as suitable for use in agricultural mulch film applications. If all 4 of these are achieved, further research in a subsequent Phase II award will allow for demonstration of scaled manufacturing of this new family of sustainable biomaterials and has the potential to lead to some of the first commercially viable lignin-based plastics in the US for use in agricultural plastic applications and beyond.