natural fibres and the environment – - namateco fibers and the environm… · natural fibres and...
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Natural Fibres and the Environment Natural Fibres and the Environment ––
environmental benefits of environmental benefits of
natural fibre production and usenatural fibre production and use
Rome, Rome, 20 10 0820 10 08
Jan E.G van DamJan E.G van Dam
Div Div BiobasedBiobased ProductsProducts
Wageningen URWageningen UR
BioBio""basedbased economyeconomy
…….the solution for .the solution for sustainable developments sustainable developments
...?......?...
Natural Natural fibresfibres
…….the solution for .the solution for environmental environmental
improvement ...?...improvement ...?...
Natural Natural fibresfibres
•• Vegetable Vegetable fibresfibres (cellulose)(cellulose)–– Seed hairs: Seed hairs: Cotton, Kapok Cotton, Kapok
–– BastBast fibresfibres:: Jute, Jute, KenafKenaf, Flax, Hemp, Ramie, Flax, Hemp, Ramie
–– Leaf Leaf fibresfibres:: Sisal, HenequenSisal, Henequen
–– Leaf sheath:Leaf sheath: Abaca, banana Abaca, banana
–– Fruit Fruit fibresfibres:: CoirCoir
•• Animal Animal fibresfibres (protein)(protein)–– Wool:Wool: Sheep, Camel, Goat, LlamaSheep, Camel, Goat, Llama
–– Silk:Silk: SilkwormSilkworm
VariousVarious CropsCrops and and RegionsRegions
Cotton
Cotton
Flax
Kenaf
CoconutCoconutSisal
HempBamboo
Cotton
Ramie
Abaca
Sisal
Jute
Coconut
CoconutHenequen
Cotton
Wool
Silk
Natural Natural fibresfibres ??
•• Mineral Mineral fibresfibres–– Asbestos Asbestos
–– Stone wool Stone wool
–– Glass Glass fibrefibre
•• Man made Man made fibresfibres–– Viscose / rayon or regenerated celluloseViscose / rayon or regenerated cellulose
–– Regenerated protein Regenerated protein fibrefibre (soybean, casein)(soybean, casein)
–– Polymer Polymer fibrefibre (polyester)(polyester)
–– ChitosanChitosan (from chitin)(from chitin)
Natural Natural fibresfibres ……??
•• Dietary Dietary fibresfibres
•• Food supplements (Food supplements (prebioticsprebiotics) and health ) and health productsproducts
Natural Natural fibresfibres end useend use
•• Textiles, yarns and woven fabricsTextiles, yarns and woven fabrics
•• Ropes, twines, cordage, netsRopes, twines, cordage, nets
•• NonNon77woven fabrics, tissueswoven fabrics, tissues
•• CompositesComposites
•• Paper and boardPaper and board
•• FibreFibre boards and insulationboards and insulation
•• BioBio77ethanolethanol value additionvalue addition
•• Mulch and compostMulch and compost
€
3000
2000
1000
0
€ / Mg
Agriculturalproduction
Fibre production
Textile fibre
Cellulose
Non-woven
Pulp
GeotextilesFourageAnimal BeddingEnergyCompost
Fibre crops
Agro residues
Waste biomass
Energy crops
Market
Productioncosts
Addedvalue
Conversion steps
Value addition in fibre conversion
Hemp / flax fibre quality chain
€primary processing
spinning
weaving
consumer
marketing &design
agricultureagricultural production
Natural Natural fibresfibres production chain
AAgricultural production
BFibreExtractionProcess
C1Textile fibreprocessing
C2Non7textilefibreprocessing
D1Textilemanufacturing
D2Paper / composites / nonwovenmanufacturing
EConsumeruse
FDisposal
CO2
seeds
leaves
dust
seeds
water/irrigation
fertiliser
pesticides
energy
A " Agricultural Production
sowing
weeding, thinning
harvesting
drying / defoliation
transport storage
Natural Natural fibresfibres production steps A
B
B shives
short fibretow
waste water
energy
water
B " Fibre extractionprocess
retting / degumming
fibre extraction / decortication / scutching
fibre cleaning / washing
drying
Natural Natural fibresfibres production steps B
C1
C2
A
transport storage
Natural Natural fibresfibres production steps C1
D1
B
shives
short fibretow
waste water
lubricants
energy
waterbleachingchemicalsdyes
C1 " Fibre processing
softening / lubricatinghackling / carding /
drawing
spinningweaving
finishing / dyeing / bleaching
C2
transport storage
Natural Natural fibresfibres production steps C2
C1
B
shives
short fibretow
waste water
D2
black liquor
chemicals
waste water
C2 " Fibre processing
pulping/
compounding /
web formation/
blending
chemicals/
resins
polymers
transport storage
NonNon""wood pulpingwood pulping
100% (< 7% total pulp)100% (< 7% total pulp)21.321.3Total WorldTotal World
90%90%19.219.21010"" Country TotalCountry Total
71%71%9%9%1%1%1%1%1%1%1%1%1%1%1%1%1%1%1%1%
15.215.22.02.00.30.30.30.30.30.30.30.30.20.20.20.20.20.20.20.2
ChinaChinaIndiaIndiaMexicoMexicoPeruPeruPhilippinesPhilippinesIndonesiaIndonesiaUSAUSAThailandThailandColombiaColombiaBrazilBrazil
% of total% of totalCapacity (Million tons)Capacity (Million tons)CountryCountry
Non"wood pulp fibres
• Cotton linter Abaca Banknote and security paper
Tea bags, filtersFlax sausage casingHemp cigarette paperKenaf electrolyte condensor paper
• Straw • sugar cane bagasse paper board / wrapping paper• Bamboo
Natural Natural fibresfibres production steps D"F
E
D1 " End"product manufacturing
yarnsapparel fabrics
household textilesfurnishings and wall covering
upholstrysacking
D2 " End"product manufacturing
paper & boardnon7wovenpackaging
fibre boards and panelsinsulation
horticultural productsgeotextiles
composites
energy
recycling raw materials
E " Consumer useF
disposal
transport storage
transport storage
Life cycle assessment framework
Goal and scope definition
Inventoryanalysis
Impact assessment
Interpretation
Product Developmentand improvement
Stategic Planning
Public Policy making
Marketing
Other
Quantitative environmental impact LCA
•• Criteria .. Criteria .. Standards ISOStandards ISO771404014040774343–– Whole life cycle of a product including its byWhole life cycle of a product including its by77productsproducts
–– Raw material acquisition to product disposalRaw material acquisition to product disposal
•• Comparison between diverse environmental Comparison between diverse environmental impact factorsimpact factors–– Emissions and consumption of resourcesEmissions and consumption of resources
•• EcoEco77indicators indicators –– weighing / classification factors weighing / classification factors
•• Interpretation Interpretation
Weighing factors (Eco7indicator)
•• Green house effect Green house effect COCO22 2.52.5
•• Ozone layer depletionOzone layer depletion CFKCFK 100100
•• AcidificationAcidification (Sulfur)(Sulfur) 1010
•• EutrophicationEutrophication (Phosphate)(Phosphate) 55
•• SmogSmog (Methane)(Methane) 2.52.57755
•• PesticidesPesticides 2525
•• Heavy metalsHeavy metals (Lead)(Lead) 55
World fibre production
World fibre production 1920-2006 (kton)
0
5,000
10,000
15,000
20,000
25,000
30,000
35,000
40,000
1915 1925 1935 1945 1955 1965 1975 1985 1995 2005
Cotton
Synthetic (petro-based)
Man-made cellulose fibres *
Cotton vs polyester LCA
•• Cotton requires less fossil resources Cotton requires less fossil resources
(energy, fertilizer), but higher demand for water(energy, fertilizer), but higher demand for water–– Organic cotton (agrochemicals) Organic cotton (agrochemicals) vsvs GMOGMO
No dramatic differences inNo dramatic differences in
•• Textile processing (dyeing and bleaching) Textile processing (dyeing and bleaching)
•• Longer functional lifetime for blended fabricsLonger functional lifetime for blended fabrics
•• Lower energy requirement in laundering for Lower energy requirement in laundering for synthetic textiles synthetic textiles
Agrofibre reinforced composites
•• AgrofibreAgrofibre compounds for compounds for injection moulding injection moulding implementation at implementation at commercial scalecommercial scale
•• Strength of the Strength of the elementary fibre is elementary fibre is important not that of the important not that of the fibre bundlefibre bundle Injection moulded products from
natural" fibre/plastic granules
Technology for natural fibre reinforced plastics
Injection moulding
Raw materials agrofibre
PP
Granules
Extrusion
Fibre composites in automotive
• Applied as nonwoven mats combined with plastic sheets
• LCA advantage in weight reduction
Natural fibres vs synthetic / glass fibre
•• In the production phase the score of In the production phase the score of
fibrefibre crops on COcrops on CO22 and greenhouse gas emission and greenhouse gas emission levels, fossil energy consumption and resources levels, fossil energy consumption and resources is much betteris much better
•• In composites, blended textiles or nonIn composites, blended textiles or non77wovenswovens the the impact of synthetic resins on the LCA is largeimpact of synthetic resins on the LCA is large
Natural Natural fibresfibres vsvs synthetic / glass synthetic / glass fibrefibre
•• The The utilisationutilisation phase phase
contributes most to the impactcontributes most to the impact
•• Weight reduction in composites in automotive Weight reduction in composites in automotive applications contributes to fuel savings applications contributes to fuel savings
•• For the same mechanical performance heavier For the same mechanical performance heavier constructive elements with natural constructive elements with natural fibrefibre is requiredis required
Cradle to Cradle Cradle to Cradle C2CC2C
•• W. McDonough M. W. McDonough M. BraungartBraungart–– Remaking the way we make thingsRemaking the way we make things
•• EcoEco77efficient / effective design of productsefficient / effective design of products
•• Reuse of waste to make new products Reuse of waste to make new products –– Waste becomes food.. Ever lasting cyclesWaste becomes food.. Ever lasting cycles
•• Ford / NIKE / Ford / NIKE / ……many companies followmany companies follow
BioBio77based economybased economy and and C2CC2C
•• Green Architecture and building Green Architecture and building
•• Automotive industries Automotive industries …… sustainable commercesustainable commerce
•• Nutrient Nutrient UpcylingUpcyling, Triple, Triple77TopTop77Line, Line,
EcoEco77effectiveness, Industrial design, effectiveness, Industrial design,
•• Technical and biological nutrients for Technical and biological nutrients for
..everlasting consumption.. (?)..everlasting consumption.. (?)
Ecological footprintEcological footprint
Land area required per person to maintain his lifestyleLand area required per person to maintain his lifestyle
(incl. food, energy, water, housing, clothing, travel, etc.)(incl. food, energy, water, housing, clothing, travel, etc.)
BioBio77based economybased economy and Sustainable developmentsand Sustainable developments
•• KYOTOKYOTO and COand CO22 neutral productionneutral production
•• Transition processTransition process
•• Renewable resources for Renewable resources for energyenergy and and productsproducts
•• Exploitation of biomass from agroExploitation of biomass from agro77industrial residuesindustrial residues
•• Value addition in materials, and Value addition in materials, and ‘‘greengreen’’ chemicalschemicals
Competing claimsCompeting claims for biomass resourcesfor biomass resources
Sustainableustainable productionproduction
foodfood supplysupply securitysecurity
land land useuse
deforestationdeforestation
ruralrural developmentdevelopment
RapidRapid expansionexpansion of of demanddemand forfor energyenergy purposespurposes
DEVELOPMENT OF BIOREFINERYDEVELOPMENT OF BIOREFINERY
R&D activities & sustainable developmentR&D activities & sustainable development
•• renewable energy from biomass residuesrenewable energy from biomass residues
•• building materials, recyclingbuilding materials, recycling
•• ‘‘greengreen’’ chemicals & polymeric productschemicals & polymeric products
•• alternative technologies and sources for cellulose alternative technologies and sources for cellulose textile production (bamboo)textile production (bamboo)
•• horticultural substrates & biodegradable erosion horticultural substrates & biodegradable erosion control materialscontrol materials
and many otherand many other
•• AgroresiduesAgroresidues of food and nonof food and non77food cropsfood crops–– cotton stalks cotton stalks
–– rice straw / hull rice straw / hull
–– sugar cane sugar cane bagassebagasse
–– corn cobscorn cobs
–– coconut huskcoconut husk
–– jute sticksjute sticks
–– palm oil residuespalm oil residues
–– eucalypt barkeucalypt bark
–– verge grasses, etcverge grasses, etc
Renewable raw materialsRenewable raw materials
OptionsOptions forfor sustainablesustainable residueresidue utilisationutilisation
BioBio77dieseldiesel ((residualresidual oiloil / / pressingpressing cakes)cakes)
BioBio77gasgas, H, H22 / ABE and ethanol / ABE and ethanol fermentationfermentation
BioBio77polymerspolymers (PLA, PHA)(PLA, PHA)
BioBio77oiloil pyrolysispyrolysis / / CharcoalCharcoal
FibresFibres forfor paper, building boards and paper, building boards and compositescomposites
DissolvingDissolving cellulosecellulose
““greengreen”” chemicalschemicals ((ligninlignin and and furfuralfurfural adhesivesadhesives))
precipitation Coatings Biopolymersextract
sugars Alcohol / H2
effluentdryingchoppingpelletising
residue
Feedgassifycombustion
Energy
waste compost
compostingdisposal
silica
fermentation
tar
ash
Protein, lipids
Biomass
fuel
extraction modification
refining fibre pulp Paper / boardadhesives
Biorefinery (cascading) of biomass
Biomass from agroBiomass from agro77industrial residuesindustrial residues
World production capacity coconut husk
15720
million tons /
year
Husk preparation (CFC/ FAO project)Husk preparation (CFC/ FAO project)
Coconut husk
Opening Milling
Coconut
Building and construction materialsBuilding and construction materials
BinderlessBinderless boardsboards
First production lineBatangas Phillipines
• Multi daylight
press
15 tons/d capacity
Market: Japan
Heavy duty packaging
(pallets wood subsitute)
Economical evaluation
• Production: – 10,000 tonnes board/year
– 400,000 boards 4 ft*8 ft* 0.25 inch� 1,333 boards/day
• Raw material– 77,650,000 husks/year
� 260,000 husks/day
• Investment estimate– 650,000 US$
Blue print business plan
• Capital investment plan – Production scale 10,000 tonnes board/year
– Location / site
• Marketing plans– Eco7labeling (FSC) / Fair trade / quality certification
– CDM / carbon credits
• Social development plans– Education plan
– NGO involvement
• Product development plan
Business roll out plan
• Demonstration industrial production – Production units 10,000 tonnes board/year
– Integrated whole nut utilisation (oil, press cake, shell, husk)
– N. Sulawesi, Indonesia / Mindanao, Philippines
– Franchising (?)
• Common marketing strategy – Trade mark / brand retail
– Niche products (packaging / furniture) value addition
• Social development strategy– Village level involvement (housing / labour / schooling..)
Non7technical aspects of implementation plans
Financing structures and commercial developments
Clean development mechanism (CDM) and carbon trading
Common sales, common market, fair trade / ecolabeling
Socio7economic aspects – food vs fuel (biodiesel)
Political implications
Sustainability criteria
• Ecological .. Wood substitute products
to prevent deforestation
• Carbon credits / CDM
• Socio7economic – labour, income and housing
• Addressing poverty by supporting the incomes and livelihoods of commodity producers
• Fair trade and quality certification
•• The Project seems more than feasibleThe Project seems more than feasible
•• Prospects to apply for external funding are Prospects to apply for external funding are very goodvery good
•• This kind of project is exactly what is needed This kind of project is exactly what is needed as a pilot/example for other regions and as a pilot/example for other regions and countriescountries
Conclusions fibres and the environmentConclusions fibres and the environment
Ecological impact assessments are complex
and use incomparable weighing factors
The impact of primary agricultural production of fibre crops on the LCA is marginal
Restricted information available from industrial fibre production chains
Conclusions fibres and the environmentConclusions fibres and the environment
The environment has become a The environment has become a major drivermajor driver
for industries and governmentsfor industries and governments
Natural fibres are a major renewable (CONatural fibres are a major renewable (CO22 neutral) neutral) resource for bioresource for bio77based economical developmentsbased economical developments
Overall ecological performance of a crop improves when Overall ecological performance of a crop improves when residues and byresidues and by77products are better usedproducts are better used
Conclusions fibres and the environment Conclusions fibres and the environment
Certification Certification of the sustainability of of the sustainability of
the fibre production chains for biomass energy and the fibre production chains for biomass energy and products is needed products is needed
MultiMulti77stakeholder involvement needed: stakeholder involvement needed:
Include outsider (food Include outsider (food vsvs nonnon77food) industries food) industries involved in energy and fibre productsinvolved in energy and fibre products
Now is the moment for active participation! Now is the moment for active participation!