Today's KNOWLEDGE Share :MANUFACTURING OF Polyethylene Furanoate (PEF)

Today's KNOWLEDGE Share

Manufacturing of PEF:

PEF is produced from the two monomers: (mono)ethylene glycol (MEG) and 2,5- furandicarboxylic acid. Both monomers are possible to produce from biomass, meaning that PEF can be 100% biobased. Bio-MEG is commercially available and is the same monomer used also for bio-PET.

PEF synthesis is a stepwise polymerization and can be produced via two routes: polycondensation of MEG with FDCA or transesterification using dimethyl-2,5- furandicarboxylate (DMF) (Guigo, Forestier and Sbirrazzuoli, 2019). The first PEF synthesis was patented already in 1946 (Drewitt and Lincoln, 1947), who used melt polymerization. The transesterification pathway has been studied by e.g., (Khrouf et al., 1998) and is more efficient.

Polymerization to PEF

The polymerization reactions to produce PEF are analogous to PET-polymerization, but with FDCA instead of TPA (Louw, 2024). The reaction temperatures for FDCA and MEG is lower, and the reaction times are somewhat shorter compared to TPA and MEG, which could imply a lower production cost. Polymerization of PEF is performed in two steps, i.e. esterification (into bis(2-hydroxyethyl)-2,5- furandicarboxylate (BHEF)) and polycondensation. Polycondensation is typically conducted in two phases; melt phase polymerization (MPP) followed by solid-state polymerization (SSP) to increase the molecular weight of the polymer. During polycondensation, MEG and water is continuously released and removed using vacuum.

A summary of syntheses based on FDCA and thermal properties of a variety of furanoate-based polyesters, including PEF were reported by (Papageorgiou et al., 2016). The paper covers different melt polycondensation methods as well as solution methods, and apart from PEF, other polyesters, such as poly(propylene 2,5- furandicarboxylate) (PPF), poly(butylene 2,5-furandicarboxylate) (PBF) and poly(hexylene 2,5-furandicarboxylate) (PHF) are described and considered as viable candidates for the next generation of novel bio-based coatings, toners, binders, glues, bottles and wrapping materials. In a study by Stanley et al. comparison of using FDCA versus the derivative dimethyl 2,5-furan dicarboxylate (DMFD) for producing PEF showed that FDCA was more effective in generating PEF of high molecular weight. As an alternative to polycondensation, ring-opening polymerisation (ROP) has also been proposed to avoid potential degradation and discoloration reactions and long reaction times (Rosenboom et al., 2018). The ROP process starts from cyclic PEF oligomers and by initiation in the presence of a high boiling and inert liquid plasticiser, the self-plasticising effect of the forming polymer can be exploited to form PEF with high molecular weight.

ROP has shown to deliver bottle-grade PEF in relatively short reaction times and a preliminary comparison of the energy requirements shows that ROP resulted in similar values as polycondensation .

source:Chalmers Industriteknik

Today's KNOWLEDGE Share : A new method to evaluate carbon fibre microstructure

Today's KNOWLEDGE Share

China’s Institute of Coal Chemistry establishes a new method to evaluate carbon fibre microstructure.

The team led by Zhang Shouchun, a researcher at the Institute of Coal Chemistry, Chinese Academy of Sciences, has made progress in the field of carbon fibre microstructure research, and published a paper titled “Assessing the radial microstructural heterogeneity of polyacrylonitrile (PAN)-based carbon fibres using nanoindentation” in the Journal of Materials Research and Technology.

The paper proposed a new method based on nanoindentation technology to characterise the radial structural heterogeneity of carbon fibres and the orientation of graphite crystallites, providing a new technical approach for the study of carbon fibre microstructure with simple sample preparation, reliability and high efficiency.

Challenges in characterising radial heterogeneity of carbon fibre

Carbon fibre is a typical structural heterogeneous material. The microstructural analysis and precise control of the radial heterogeneity of carbon fibre are of great significance for breaking through the technical bottleneck of the next generation of high-strength and high-modulus carbon fibre.

With the advancements in micro-area characterisation technology, the radial heterogeneous structural characteristics of carbon fibre have gradually been revealed, such as selected electron diffraction (SEAD), microbeam X-ray diffraction (microbeam-XRD), etc. However, the sample preparation of such high-resolution analysis technology is extremely difficult. The sample needs to ensure strict dimensional accuracy and surface flatness, and its complex pretreatment process significantly increases the difficulty of the experiment.

In addition, there are few reports on the radial distribution of micromechanical properties of carbon fibre. It is very necessary to find a simple characterisation technology in a different way.

Filling the gap in detection methods:

Nanoindentation detection technology is like a “geologist” in the microscopic world. It taps the surface of the material with a nanoprobe and deciphers the hardness and toughness codes hidden between atoms from the tiny dents and ripples.

Nanoindentation technology is a key means of modern micromechanical characterisation and has been widely used in the field of carbon fibre and its composite materials, such as the study of the interface properties of carbon fibre composite materials, the determination of carbon fibre elastic constants, etc. It has the core advantage of nanoscale displacement control accuracy. The research team used nanoindentation technology to systematically evaluate the radial distribution of micromechanical properties (elastic modulus and hardness) of several commercial PAN-based carbon fibres in the axial and transverse directions.

The results show that T300 and T700S grade carbon fibres with lower strength grades exhibit severe radial micromechanical property heterogeneity. In contrast, T800H, T800S and T1000G grade carbon fibres exhibit excellent radial micromechanical uniformity. The ratio R can reflect the orientation of graphite crystallites to a certain extent. The larger R is, the better the orientation of graphite crystallites. It is inferred that the orientation degree of different regions within a single fibre is from high to low: transition layer, cortex, and core layer.

Nanoindentation advances carbon fibre microstructure analysis

Nanoindentation technology has shown significant advantages in evaluating the radial heterogeneity of carbon fibre, including simple sample preparation, reliable results and high detection efficiency.

This study innovatively proposed a new method for characterising the microstructure of carbon fibre based on nanoindentation technology, which fills the gap in the study of radial distribution of micromechanical properties of carbon fibre.

source: english.sxicc.cas.cn /jeccomposites.com

Over 3 GW of photovoltaic module shipments with frames using Covestro PU composites

Covestro is pleased to announce today that shipments of photovoltaic (PV) modules using frames made with its polyurethane (PU) composites technology have surpassed 3 gigawatts—a major milestone for this cost-effective, low-carbon alternative to aluminum, pioneered in China by the materials manufacturer. This volume is equivalent to about 5 million standard solar panels, covering more than 1,100 soccer fields—underscoring growing market acceptance.

Made with Covestro’s Baydur® PU composites, the frames offer high strength, corrosion resistance, and insulation properties - thereby enhancing solar module performance and longevity. As the second-most costly PV module component after the solar cells themselves, aluminum frames typically account for 10–15 percent of total module costs. PU composites provide a stable, cost-effective alternative amid aluminum price volatility. The PU composite also enables up to 85 percent lower cradle-to-gate carbon emissions compared to aluminum in frames1, due to its less energy-intensive production process.

“Through more than a decade of innovation and continuous refinement, we have pioneered new ways for the PV industry to reduce costs and improve efficiency, while driving sustainable development,” said Akhil Singhania, Global Head of PU Specialties in Covestro’s Tailored Urethanes Business Entity. “Achieving this milestone of over 3 GW of photovoltaic module shipments with frames using our material in just over two years validates the transformation of an innovative concept into a crucial component that enhances competitiveness of the solar modules.

Strong demand

As the world’s largest producer of PV modules, China has been at the forefront of adopting composite frames. In 2023, when the PV industry faced mounting cost pressure, manufacturers seeking cost-effective components began adopting composite frames—leading to a breakthrough in their application. With outstanding properties and certifications from both TÜV Rheinland and TÜV SÜD, Baydur® rapidly gained industry-wide recognition.

The Baydur® composite technology reached a pivotal milestone in 2024 as major Chinese solar manufacturers integrated this technology into their mass production lines. This advancement comes at a crucial time in the renewable energy landscape. According to the International Energy Agency’s Renewables 2024 report, the global renewables capacity is set to expand by 5,520 GW by 2030, with solar PV installations accounting for 80 percent of the growth. The timing of PU composite frames’ market entry therefore positions this sustainable solution to meet the industry’s unprecedented expansion.

Materials enabling the energy transition:

Beyond PU composite frames, Covestro also supplies Desmodur® ultra N 31890 BA—a new, fast-curing aliphatic hardener developed in China for PV backsheet coatings. It dries nearly three times faster than standard hardeners, boosting production efficiency while supporting energy savings and carbon emissions reduction. It also offers superior UV and hydrolysis resistance for long-term backsheet durability.

Additionally, Covestro’s polycarbonate solutions combine lightweight with excellent mechanical performance to protect PV modules, energy storage systems, charging stations and other new energy equipment, ensuring reliable outdoor performance. The materials also support advanced designs that integrate lighting, haptic feedback, displays and electronic circuits—ideal for next-generation solar energy, storage and charging systems. Available in low-carbon versions and backed by stable global supply, they help customers advance sustainable innovation and strengthen their international competitiveness.

Covestro is announcing this 3 GW milestone ahead of SNEC PV Power & ES Expo, the world’s largest solar energy trade fair. Covestro will showcase its latest PU composite frames and other high-performance materials supporting the clean energy transition at Booth B260, Hall 8.2, National Exhibition and Convention Center (Shanghai), June 11-13.

source: Covestro

Today's KNOWLEDGE Share : Michelin Shifts Gears With Biobased Innovations

Today's KNOWLEDGE Share

Michelin to construct EUR60 mn demo plant for bio-based 5-HMF (Hydroxymethylfurfural) in France

Michelin announces the construction of an initial industrial demonstration unit for the 5-HMF molecule. This bio-sourced and non-toxic molecule can replace ingredients derived from fossil fuels in a wide variety of industrial fields. This unit, which will be located on the Osiris platform in Péage en Roussillon, France, will have an annual production capacity of 3,000 metric tons, making this site the largest production site in the world for this molecule. This project represents a total investment of EUR 60 million, partly subsidized by the ADEME in France and the CBE JU1 at European level. It will allow for the creation of approximately 30 direct jobs and should begin its activities during 2026.

A molecule with extremely promising properties:

5-HMF, also known as 5-Hydroxymethylfurfural, is a platform molecule with multiple possible derivatives. It is bio-sourced and non-toxic, allowing it to replace ingredients sourced from oil or those of concern. It is known as the “Sleeping Giant” due to its versatility and its ability to replace a wide range of conventional molecules. This molecule is obtained from fructose that has been transformed using green chemistry processes.

5-HMF will therefore be one of the rare monomers that meet the following characteristics: bio-sourced, non-toxic, available on an industrial scale in thousands of metric tons, and produced in Europe using European raw materials.

 

A potential market of over 40,000 metric tons by 2030

This project, entitled CERISEA, was developed within the framework of a partnership bringing together multiple industrial, institutional, and academic stakeholders.

Supported by the ADEME3, it forms part of the France 2030 program, which aims to support industrial innovation and the ecological transition. It also benefits from support from the CBE JU1 at European level.

The European 5-HMF market is still emerging, as the molecule is produced solely in Asia, in very small quantities, and it remains prohibitive for industrial uses.

Already used in the manufacture of non-toxic adhesive resins developed by Michelin ResiCare, this molecule allows these resins to reduce operator and consumer exposure to harmful products. The production of this initial industrial scale unit will allow for safeguarding Michelin ResiCare’s supply and for lowering costs. It also paves the way for the marketing of new materials in a variety of sectors, such as cosmetics, agriculture, industry, construction, transport, aeronautics, or electronics, as well as in many other fields of application. The projects launched demonstrate a potential market of over 40,000 metric tons by 2030.

Provision has been made for 20,000-metric ton units to be duplicated via a license system, in order to develop a production network for this bio-sourced molecule, in conjunction with the project’s industrial partners.

 

source:Michelin

Today's KNOWLEDGE Share : Breaking a plastic part

Today's KNOWLEDGE Share

Have you ever asked yourself if breaking a plastic part (or tensile bar) always means you are breaking polymer chains ?

It is not a trivial question and it is actually quite an important aspect to address if we want to better understand a polymer performance.

As it turns out it has a lot to do with the polymer chain entanglement density of the polymer of interest (and the temperature).

In a loosely entangled polymer, like Polystyrene, the lower ability to delocalize stress inside the network will allow an easier reach of the carbon-carbon bond strength limit, allowing thus significant chain scission when breaking a PS sample.

On the other side, highly entangled polymers like PC or PSU/PES/PPSU will spread the stress around the much denser entangled network, making carbon-carbon bonds way more unlikely to fail. The result is that failure will be dominated by disentanglement.

This has been proven by observing the significant appearance of free radicals (testifying chain scissions) on the PS fracture surface, contrary to the lack of free radicals for a PC fractured sample.

Of course, at very low temperatures, plasticity is almost totally suppressed, leaving chain scission as the only failure mechanism for all polymers, regardless of their entanglement density.

The Physics at play is not so different from what we observe in GF filled grades. Classical short GF (150-250 micron long) are too short to develop a stress higher than the glass stress at break, so fibers will be pulled out when breaking a sample.

LGF (long glass fibers, say longer than 1 mm) will typically break because the fibers are beyond the “critical length”, allowing the maximum stress in the fiber to reach the strength of glass.

source : Vito leo

Today's KNOWLEDGE Share : Panacol unveils moisture-resistant cyanoacrylate adhesive for medical devices

Today's KNOWLEDGE Share

New Water-Resistant, Biocompatible Cyanoacrylate Adhesive

Panacol presents its latest moisture- and water-resistant cyanoacrylate adhesive Cyanolit® 290 WR. This acrylate-based instant adhesive impresses with its fast curing time and high adhesive strength on metals and thermoplastics such as ABS and PVC.

The Cyanolit® 290 WR instant adhesive is a solvent-free 1-component adhesive that cures within seconds utilizing atmospheric humidity. After just a few minutes, the adhesive strengths lead to substrate fractures on plastics and achieve tensile shear strengths of up to 16 MPa on metals.

 

The main feature of Cyanolit® 290 WR is its reliable adhesion after several hundred hours in an ageing test at 85°C and 85% humidity. Here, the latest cyanoacrylate from Panacol still achieves more than 50% of its initial performance. Cyanolit® 290 WR exhibits extreme media resistance, especially after storage in pure engine oil, isopropyl alcohol or water. Even after 500-1000 hours, no loss of tensile shear strength can be determined. This extreme chemical resistance in particular makes Cyanolit® 290 WR an ideal adhesive for fast, reliable bonding between plastics and metals that may also be exposed to media.

This newly developed Cyanolit® 290 WR adhesive has also been tested in accordance with DIN ISO 10993-5 and is therefore also suitable for use in medical devices or articles and wearables.

source: Panacol

Avantium secures EU funding to advance production of biobased HMF

Avantium N.V. has been awarded a €200,000 grant by the EU Horizon Europe program to participate in a consortium for the large-scale production of the biobased chemical 5-Hydroxymethylfurfural (5-HMF).

The consortium, consisting of 12 European partners and led by Michelin Engineered Polymers, aims to construct and operate an HMF Flagship Plant to demonstrate the wide range of applications for HMF. The project also plans to assess synergies with Avantium’s FDCA Flagship Plant.

Linking HMF and FDCA for circular chemical value chain:

HMF is a biobased chemical derived from sugars, such as fructose. Due to its versatility and ability to replace a broad range of conventionally produced building blocks, HMF serves as a key intermediate between biomass and biochemicals.

Despite its significant potential, there are currently no large-scale industrial processes to produce HMF. Michelin Engineered Polymers, specialized in developing advanced polymer materials, plans to engineer and construct an industrial-scale HMF plant under the grant program.

The grant consortium will also explore a wide range of bio-based sustainable applications for HMF. HMF can for example be used as an intermediate in the production of FDCA. This creates a direct link between Michelin's planned HMF plant and Avantium’s FDCA Technology. The foreseen synergies will help to create an integrated and sustainable European production ecosystem that reduces environmental impact and strengthens the economic resilience of the European chemical industry.

The consortium, known under the name CERISEA, has received a €20 million EU Horizon Europe grant in total. Michelin Engineered Polymers will lead the consortium, which includes Avantium and 10 other industry and academic organizations: IFP Energies Nouvelles, ADM Bazancourt SASU, Arkema, Kraton Chemical B.V., Université de Technologie de Compiègne (UTC), Centre National de la Recherche Scientifique (CNRS), IFEU - Institut für Energie- und Umweltforschung Heidelberg, Instituto Tecnológico del Embalaje, Transporte y Logística, Energieinstitut an der Johannes Kepler Universität Linz Verein, and Bioeconomy for Change.

CERISEA stands for “Competitive production of HMF and derivatives for an Eco-designed and Resilient Industry towards Sustainable European Autonomy.

source: Avantium/polymer-additives.specialchem.com