Development of CO2-optimized biomass carbonized compounds as a recyclable materials solution for plastic components

Project description

BIOCHARPP focuses on the holistic development of technologies for the production of CO2-optimized and recyclable NET compounds and their continuous data collection and linking for technical and ecological evaluations. Key development elements include the production of optimized biomass carbonates from biogenic residues using thermochemical conversion processes (patented TCR® process, Fraunhofer UMSICHT), their functionalization for embedding in plastics (Fraunhofer ISE), subsequent compounding into PP-based NET compounds (Fraunhofer ICT), and recycling of the materials obtained (Fraunhofer UMSICHT, Fraunhofer ICT). Closely linked to this technical work is an analysis of the potential environmental impacts, a life cycle assessment (LCA) at Fraunhofer ISE, and an evaluation of the technical application potential. Parallel to the technical processes and characterizations, a continuous documentation process is being established to evaluate the materials for future virtual product development processes and integration into CAE chains (Computer Aided Engineering, CAE) (Fraunhofer IWM). To this end, a comprehensive and permanently traceable data process in the sense of digital materials will be established among all partners, from the pyrolysis process to the demonstrator and from the LCA to the technical evaluation and economic aspects.

The result is Fraunhofer technologies for technically high-quality NET compounds, from biomass carbonate production, functionalization, incorporation into a PP matrix, and further processing into a housing cover, to data and methods for the complete accounting and digitalization of development chains and materials. The biomass carbonates developed represent alternatives to mineral fillers such as talc due to their at least 20% reduction in GWPs and offer additional lightweight construction potential due to their lower density. The optimization of the processes enables a high degree of flexibility in the biogenic residues to be processed and also yields liquid or gaseous by-products that can in turn be used for plastics production or energy generation.