identification and review of downstream options for the ... · •the “bast”produces long...
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Identification and review of downstream options for the recovery of value from fibre-producing plants: Hemp, Kenaf, Bamboo
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Production stages
Conversion
Lead product
Cultivation HarvestPre-
treatmentProduct
recovery
Conversion
Plant
biomass
Fibrous-
Part
By-products
SeedWater
Non-Fibrous-
part
(twigs, leaves,
seeds etc)
Fibrous-
Part
Additional
product(s )
Conversion
Processing Manufacturing
Manufacturing
Biorefinery
Biorefinery
High-end
by-products
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Bast fibre plants Hemp Kenaf
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Bark (epidermis)
Bast fibre
Hurd (woody core)
Hollow core
Bast fibre plants
• The “bast” produces long fibres (70-90% of the bast) and short fibres (10-30% of the bast).
• The hurd or woody core is the inner woody tissue which accounts forabout 60-75% of the stem.
• Different bast plants have a different ratio of bast to woody core - Kenafbast fibre is about 35% of the stem and hemp bast fibre is about 30%.
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Bast fibre plant e.g. hemp
Seeds
Stem
Bast plant productsWhole plant
Stem
Seeds
Energy (e.g. bioethanol, biogas)
Bast Fibre
Woody tissue/core fibre
Whole seed
Chemicalextracts
Shives (animal bedding etc)
Insulation boards
Oil
Protein
Food
Long fibre
Short fibre
Paper pulp
Leaves
Edible oil (e.g. hemp seed oil)Personal productsPaint/varnish
Animal Fodder
Conventional textiles
Construction composites
CordagePaper pulp
Biocomposite textiles/ concreteBioplastics
Bioethanol/biobutanol
Human food
or
&
&
or
&
Part of plant Intermediates End-products
&
Medicine
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Main process stagesConventional textiles
• Hemp and kenaf fabrics are breathable, warm, moisture-wicking,antibacterial and biodegradable.
• Bast fibres can be easily blended with other fibres such as cotton to makelightweight softer fabrics.
Hemp fabric Blended fabrics
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Main process stagesPlant fibre reinforced composites
• Fibre composites are made by embedding plant fibres in synthetic orbiodegradable resins.
• PFRCs are being incorporated into thermoplastic matrix composites and aregaining traction in the automotive and aerospace industries.
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Main process stagesConstruction materials
• Hemp and kenaf construction products range from insulating panels, non-woven felts for acoustic damping or levelling from woody tissue/hurds tofibre reinforced polymers for façade panels and concrete.
• The most commonly applied product in the building and constructionsector is hempcrete.
Insulation mats
Insulation matting Fibre boards Concrete (hempcrete)
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Main process stagesPaper products
• Paper pulp can be made either from short bast fibre or woody tissue.
• Paper made from kenaf bast fibre is reported to be comparable to paperfrom some softwoods and most hardwoods
• Paper from core fibre or woody tissue (hurd) is not as strong, but is easier tomanufacture as well as softer, adsorbent and more suitable for hygienicproducts.
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Main process stagesSeed oils
• Hemp and kenaf seeds can either be used as a whole or crushed andpressed to produce oil and a residual seed cake.
• Hemp seeds contain 30% oil by weight, whereas kenaf seeds contain 20%oil.
• The residual seed cake has been proven to be a protein-rich feed forlivestock.
Hemp seed oil Kenaf seed oil
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Main process stagesBast fibre processing
• Stems are pre-treated to soften them through retting or degumming, whichcan be chemical, mechanical or high-pressure/temperature processes.
• Bast fibre is separated from woody tissue, into long & short fibre through aprocess known as decortication.
Harvest Retting Decortication
Conversion
Plant biomass
By-products
Leaves &
Seeds
Fibre products
Woody tissue
StemConversion
Woody
productsConversion
FibreStem
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Main process stagesBast fibre processing
• Different retting pre-treatments result in different fibre length, colour,quality and strength. Water or dew retting are commonly used.
• Bast fibre processing is fairly standard via decortication – though there areslight variations depending on desired end-products (high-end vs low-endproducts).
• Various products can be produced at different stages of processing topotentially form a multi-product flow sheet.
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Breaking Scutching HacklingFibre
Long & short
fibre
Fibre
Woody tissue
Woody tissue (or
shives)
WasteShort fibre
Woody
Products
Long-fibre
products
Short fibre
Shives
Short fibreShives
Short-
fibre
products
Short fibre
Cultivation Harvest Retting
Soil Water
Drying
MillingScutching
Shives
Long & short
Fibre
Dust
Extraction
Short fibre
Short-
fibre
products
Long-fibre
products Woody
products
StemPlant
Water
Water
Fibre
Woody tissue
Dust from process
Dust
Seeds
LeavesSeeds
Leaves
By-
products
By-
products
Seed
Waste (leaves, seeds, dust)
Fibre
*high tech
Bast fibre multi-product process flow sheet
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Bamboo
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Bamboo products
Whole plant
Culm
Leaves
Energy; biofuels
Strips
Poles
Food
Pulp
Chemical extracts
Fodder (Manure)
Branches Sticks
Medicine
Textiles
Construction materials
Flooring
Furniture/decor
Shoots
Part of plantRaw products End-products
Polymer composites
Whole leaves
or
&
&
&
and/or
or
Paper & cardboard
Rayon fibres
Natural fibres
HandicraftsWoven products
Engineered “wood-based” composites
and/or
Sporting equipment
Mats, blinds, chopsticks
Intermediate products
Culm
Node
Internode
Rhizome
Shoot
Twigs
Leaves
Roots
Bamboo plant
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Uses of the parts of a bamboo plant
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Main process stagesWood-based products
• Bamboo has many applications in the construction and building industriesdue to its woody nature and similar properties to timber.
• The culm is either used whole as poles or split into strips to make wovenproducts or engineered bamboo wood-composites.
Bamboo poles
Woven bamboo strips
Plybamboo boards Strand woven boards
Particle boardsBamboo mat boards
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Main process stagesFibre-based products - textiles
• There are two types of bamboo textiles – bamboo linen (also called“natural bamboo fibre”) extracted by mechanical or microbial processes.
• Bamboo rayon made through chemical treatments similar to themanufacturing of rayon viscose.
Natural bamboo fibre Bamboo rayon
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Main process stagesFibre reinforced composites
• Similar to bast fibre composites, bamboo fibres can be used to reinforcenatural or synthetic polymer matrices.
• Bamboo-fibre reinforced plastic (BFRP) composites’ tensile strength iscomparative to mild steel and have a lower density, making them ideal forstructural applications.
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Main process stagesEnergy based products
• Bamboo has a number of desirable characteristics as a fuel for combustion,such as a low ash content and alkali index compared to other bioenergyfeedstocks.
• Bamboo culm can be processed into pellet form or other forms of fuels,such as biogas, bioethanol and charcoal.
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Main process stagesBamboo processing
• Each product type requires a separate treatment or processes.
• Bamboo processing is more intensive and extensive than bast fibreprocessing
Harvest Splitting Fibre recoveryPlantCulm
By-products
Leaves
Shoots
Branches
Strips
ConversionWood-based
products
Strips
Treatment Poles
Conversion
Energy-based products
Whole
plant
Conversion
Fibre-based products
Pulping/
ConversionPaper products
Conversion
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Bamboo multi-product flowsheet scenarios
Harvestplant
Plybamboo/
Burning
Pulping
Energy
Board making
Splitting
Option 1a
Low quality stems/wastes from options 1 and 2
Whole plant (100%)
Top of culm
Culm (80%)High-end
products
Strand woven boards
Bamboo mats
Particle board Low-End or bulk
products
Fibre recovery
Weaving
Board-making
High quality stems
Option 1b
Option 2a
Board making
Natural fibre
Option 2bMDF boards/
Poles
Medium quality stemsPre-treatment
Bamboo mat boards
Paper pulp Option 3a
Option 3b
Option 3c
Medium-value
products
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Potential metal recovery
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Potential integrated metal recovery process options
ConversionWaste
Leadproducts
Cultivation HarvestPre-
treatmentFibre-
recovery
Ashing
Plant Fibrous-
Part
Bio-ore
SoilWater
Non-Fibrous-part
(twigs, leaves, roots etc)
Metals
FibreFibrous-
Part
Additional
products
Conversion
Metals
Leachate
(metals)
Hydrometallurgical
/pyrometallurgical
extraction Metals
(metals)
**Alternatively use hyperaccumulators to recover metals/remove contaminants prior to growing fibres
Plant-
synthesised
nano-
catalysts
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Main process stagesSummary
• All the fibre-producing plants can generate multiple products however, therange of products and targeted markets differ for the different plant types .
• The selection of product recovery and treatment processes is highlydependent on desired product types and output of low-end vs high-endproducts.
• Therefore the exploitation of fibre-based plants will depend on the following;
❖ The considered selection of lead and additional products and by-products
❖ The relationship between the biomass properties, processing methods and desiredquality of the intermediate and final products
❖ Socio-economic drivers and environmental impacts
• Currently few holistic and systemic studies to inform decision-making on theselection of fibre-producing plants, products and processing methods
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Minerals to Metals project team
Acknowledgements