Accelerated Industrialization of Lignin-based Elastomers

Traditional elastomers have relied on easy availability of petrochemicals and nearly a century of optimization processes until today, they are crucial for the smooth functioning of modern society. Several tens of millions of tons of elastomers are produced annually. Unsurprisingly, it is very challenging to replace such a highly optimized material, with new experimental bio-based alternatives. Even after successful lab-scale trials, catching up with nearly a century of head-start in optimization and mixing industrially relevant formulations is a big challenge. 

Growth opportunity for bio-based alternatives

Several tens of millions of tons of elastomers are used globally, with an estimated market size that is well over 100 million USD by 2030. During the same time, the projected size of bio-based elastomer market is a mere 2 million USD. This difference shows the scale of opportunity for viable bio-based alternatives. Lignin-based alternatives enjoy other advantages such as pre-existing supply-chain from forest to factories and the ready availability of tens of millions of tons within a industrial set-up.

Fast-tracking the industrialization of lignin-based alternatives

In this project, we built upon our existing knowhow on producing lignin-based elastomers and optimize several parameters and formulations, such as different lignin-types, pre-processing, crosslinking, additives, etc. After the initial laboratory work to set up synthesis, formulation, curing and testing SOPs, we robotized the process flow to accelerate the optimization process. This way, we could go through a large number of optimization experiments automatically. 

Industrially relevant screening and pilot trials

Trelleborg Group, with their decades of experience in the traditional rubber industry, is a very valuable partner in the research area. Their insights continue to be invaluable in selecting industrially relevant properties for optimization and compatible feedstocks. We explored industrially relevant lignin feedstocks provided by our supplier team of Lixea and MetGen. In addition, BASF supported us with input on industrially relevant chemical-building blocks and additives in the material optimization. After robotized screening, promising candidates were shortlisted for in-depth verification in lab and industrial pilot scales. Here the pilot facilities at Trelleborg Group was made available to evaluate process compatibility with the production and mixing facilities in the rubber industry.

Outlook

In addition to accelerated development of lignin-based rubbers, this novel project methodology allows the interesting possibility of incorporating advanced digital tools and machine learning algorithms to suggest new formulations for specific applications. Therefore, this project could have a wide-reaching impact in the general area of bio-based substitution by fast-tracking the material optimization stage with advanced digitalization tools such as robots and possibly even artificial intelligence reinforced material discovery process.