Polymerisation

Technology
Technology details
Name:	Polymerisation
Category:	Conversion (Chemical processes and technologies)
Feedstock:	Single molecules, monomers
Product:	Polymers (polyolefins, polycondensates)

Polymerisation (polymerization in American English) is the process of reaction smaller molecules, i.e. monomers, together into a chain or network, i.e. a polymer. There are many forms of polymerisation reactions. A common distinction is between homopolymers, where one type of monomer forms the polymer, and co-polymers, where multiple different monomers make up the polymer. A well-known application of polymers is in plastics. However, polymerisations can also lead to smaller chains, known as oligomers, which are for example used as plasticisers and lubricants.

Feedstock

Origin and composition

Several bio-based feedstock options have been explored for the production of bio-based polymers. Lignin can be depolymerised and the obtained products can be used as monomers. Ethanol from sugar fermentations can be processed to produce ethylene, a common feedstock for polymerisations to different polymers. Fatty acids can be used in long-chain linear aliphatic polymers. Other biomass feedstock includes CO₂, terpenes, and furfural.

Pre-treatment

The pre-treatment of the feedstock for polymerisation is depending on the specific process and feedstock used. In principal, the feedstock is converted to a building block like ethylene, propylene, styrene or others in a first step and then polymerised in a catalytic process. High purity of the feedstock is crucial for successful polymerisation reactions, which are highly susceptible to pollutants, often leading to lower polymerisation grades or smaller polymerisation chains.

Process and technologies

An example of alkene polymerization, in which each styrene monomer's double bond reforms as a single bond plus a bond to another styrene monomer. The product is polystyrene.

There has been signifcant effort to produce polymers from biomass rest streams. The key challenge lies in producing materials that have comparable or improved properties to their fossil-based counterparts. The right processing, which is often neglected by chemists, plays a crucial role in enhancing the material properties. The specific technologies are depending on the types of polymer, but normally do not differ from conventional polymerisation processes in case of drop-in polymers like bio-based PE, PP, PET and others.

Two main routes from lactic acid to PLA

Some examples for polymerisation of (bio-based) monomers

• Ethylene --> Polyethylene
• Propylene --> Polypropylene
• Lactic acid --> Polylactic acid (PLA)
• Laurinlactam --> Polyamid PA12

Product

Confectionery packaging made of PLA-blend bio-flex

Bottles made from cellulose acetate biograde

Three critical processes to obtain sustainable bio-based polymers are the conversion of lignin monomers to polymers, the production of bio-based polyolefins, for example from ethylene via the ethanol route, and the production of long-chain aliphatic polycondensates, which can be obtained from fatty acids.

Post-treatment

Normally the resulting polymers are compounded to plastics with different kinds of additives like plasticizers or others or post-processed to reach their aimed properties. In case of plastics the material normally is melted and extruded to pellets for the further processing.

Technology providers

Technology comparison

Company name	Country	Technology category	Technology name	TRL	Capacity [kg/h]	Catalyst	Residence time [h]	Temperature [°C]	Feedstock: Food waste	Feedstock: Garden & park waste
B4Plastics	Belgium	-	Polymerisation	4-5	1	-	-	-
Vertimass	USA	-	CADO (Consolidated alcohol dehydration and oligomerization)	9	-	-	-	-

B4Plastics

Polymerisation provider

General information
Company:	B4Plastics
Country:	Belgium
Contact:	contact@b4plastics.com +32(08)9231131
Webpage:	https://b4plastics.com
Technology and process details
Technology name:	Polymerisation	Technology category:	Conversion (Chemical processes and technologies)
TRL:	4-5	Capacity:	Gram to ton scale. Lab scale: 10g – 1kg. Pilot equipment: multi-kg scale. Multipurpose plant: ton scale production as of 2023. Between 1-100 kg/h kg·h-1
Catalyst:	not relevant	Residence time:	not relevant min
Temperature:	not relevant °C	Other:	Service: Biomaterial R&D excellence center. Polymer Architects, that design …
Feedstock and product details
Feedstock:	bio-based building blocks	Product:	Fortan (strong sustainable alternatives for PAs), Rubran (sustainable elastomers to substitute TPEs)

B4Plastics is a Polymer Architecture company, catalyzing the introduction of novel biomaterials, and growing them from niche to bulk applications. As an architect creates your dream house, we create your dream plastic. For your application, we design the dream material. Striking the best balance between functionality, ecology and cost. We prototype fast; we hit accurately. Your new polymer ambitions are in the hands of a team of biobased materials masters and experts – uniquely educated to create new material value chains, from the field to your product, and back. Our solutions did not yet exist. We create with you, and for you. And for this world.

Vertimass

Polymerisation provider

General information
Company:	Vertimass
Country:	USA
Contact:
Webpage:	https://www.vertimass.com/
Technology and process details
Technology name:	CADO (Consolidated alcohol dehydration and oligomerization)	Technology category:	Conversion (Chemical processes and technologies)
TRL:	9	Capacity:	kg·h-1
Catalyst:		Residence time:	min
Temperature:	°C	Other:
Feedstock and product details
Feedstock:	'Wet' ethanol	Product:	Jet fuel, biodiesel

Open access pilot and demo facility providers

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Patents

Currently no patents have been identified.

References

• Polymerization in Wikipedia