Improving the sustainability of resins and films with natural lignin derived from biomass residues

Challenge

Lignin is a material obtained from woody biomass, such as forestry waste, that has specific chemical and physical properties which make it suitable for a range of applications including cosmetics, fragrances, resins, adhesives, and composites. However, lignin is rarely a ‘drop-in’ replacement for fossil fuel-based chemicals.

Sonichem produces lignin through its novel, sustainable ultrasonic process to fractionate woody biomass. They wanted to investigate the feasibility of using their natural lignin in the production of advanced, bio-based and sustainable films and resins in packaging and composite manufacturing. They had two routes to market but wanted to investigate various chemical conversions to make their lignin suitable for use in a range of end applications, including resins, coatings, films, and foams.

Solution

With support from IBioIC through our Feasibility Fund, Sonichem worked with Professor Dave Adams at the University of Glasgow on this project.

Sonichem isolated their lignin through various production methods and provided University of Glasgow with samples for characterisation and analysis.

Professor Adams’ team fully characterised the Sonichem lignin, and compared it with traditional ‘Kraft’ type lignin to understand the physical and chemical property benefits. Chemical intermediates derived from Sonichem lignin were prepared that have the potential to be used in a wide range of applications and end products. Synthetic methods were assessed for their sustainability and where it was identified that they were likely to have a detrimental impact on the environmental impact of the product, alternative methods were explored. This work is still ongoing.

The details of the modified lignin intermediates were passed to potential customers of Sonichem to gauge their interest. Internally, the company has also made a preliminary assessment of the sustainability of these products.

Outcome

As a result of this project, Professor Adams was able to publish a new paper and develop a bid for follow-on funding to support a postdoc and is also exploring funding for a PhD.

A great deal of new knowledge was achieved around the chemical modification of Sonichem lignin. The results will enable Sonichem to build up its future customer base by sharing non-confidential results from this project to demonstrate how their lignin can be used to replace unsustainable, petrochemically-derived, alternatives.

The project is likely to indirectly support the creation of new jobs once Sonichem build their first commercial plant, which is planned in Scotland for 2027.

There is huge market potential for a bio-derived starting material and the results of this project will support investment, company growth, and Sonichem’s route to commercialisation.