The use of isosorbide (IS), a still a low market volume bio-based chemical but with a high Cumulative Annual Growing Rate of 10.9%, in the manufacturing of intermediate building blocks and high volume polymers, such as polycarbonates, has some drawbacks that could be overcome by using isosorbide bis(methyl carbonate) (IBMC), a barely explored IS secondary building block which is proposed to enhance IS value chain. VIPRISCAR main objectives are: 1) To validate at pilot scale in an industrially relevant environment (TRL 5) a sustainable IBMC production process from IS; 2) To show a proof of principle for the added value IBMC brings to the market by demonstrating the usefulness of polymers derived thereof in three high-volume market sectors: industrial coatings, hot-melt adhesives, and biomedicine (antithrombotic-antimicrobial catheters). Results expected are: 1) A validated highly-efficient IBMC production process (TRL 5) able to be up-scaled and produce, under suitable market conditions, IBMC at a similar price to that of current oil-based monomers used in polycarbonates and polyurethanes; 2) at least 1 IBMC-derived coating for automotive and furniture; 3) at least 1 IBMC-derived hot-melt adhesive; 4) 1 antithrombotic-antimicrobial IBMC-derived catheter. Exploitation encompasses patent licensing, collaborative research for further development to high TRLs and direct production-commercialization (industrial partners). The 3-years project is divided in 4 phases consisting of 8 WPs: 1) IBMC manufacturing process improvement to move from the current TRL of 3 (TEC granted patent) to 4 (WP2); 2) IBMC up-scaling to TRL 5 (WP3); 3) Proof of principle of IBMC applications (WP4-Coatings, WP5-Adhesives, WP6-Catheters); 4) Horizontal issues: Management (WP1); techno-economic analysis, LCA, REACH, health-safety, barriers and standards (WP7); market analysis, business models-financial impacts, IPR and exploitation, risk management, communication and dissemination strategy (WP8).

Polyurethane (PUR) products, which include foams for building, construction, automotive and furniture and bedding, are petroleum-based and usually lack important properties. The need for sustainability in these industries leads to the development of cost-efficient processes and sustainable added-value products from low carbon footprint materials. The main objective of BIOMAT is to establish an Open Innovation Test Bed (TB) for the benefit of industries and SMEs, aiming to facilitate the cross-border partnership and accelerate innovation in nano-enabled bio-based insulation materials for these industries. Through the creation of a Single-Entry Point (SEP), SMEs and other industrial parties will have open access at a competitive price to physical facilities (pilot production lines) and services (characterisation, nanosafety, standardisation/regulation, business/marketing plans as well as technological and business-oriented mentoring) which will be focused on manufacturing and testing of nanoparticle-enabled functional PUR-based foams for the above mentioned industrial sectors. The SEP will follow all EC guidelines related to the establishment of new entities providing services through different testbeds across Europe. BIOMAT ecosystem will cover the entire Value Chain (VC) from fundamental biomaterials and functional nanoparticles to the final products and their proof of concept in an industrial environment, thus accelerating the market uptake of the new nano-enabled sustainable bio-based products. BIOMAT will, therefore, fill the existing gaps in the VC of these industrial sectors, by providing new services and support at different levels the use of such materials in these key industries.

New lightweight High-Performance Composite (HPC) materials and efficient sustainable processing technologies will have an enormous environmental and performance benefit in all sectors of application. However, current sustainable HPC application is limited to large sectors due to their limitations in terms of long processing times, high prices and low recyclability. To overcome these limitations, r-LightBioCom propose a paradigm shift in the way HPC are manufactured and recycled, unlocking sustainable-by-design production of lightweight HPC. Therefore, the project will enable new circular value chains towards r-LightBioCom results, contributing to environmental-related EU goals and reducing the HPC waste generation and the use of non-sustainable fossil resources. To this end, a sustainable catalogue of new advanced biobased and recycled HPC materials will be initially developed with inherent recyclability properties (at least 3 new types of bio-resins, 4 new biomass-derived nanofillers and additives, and 3 families of sustainable fibre-based textile products). To reduce current associated manufacturing costs and high energy consumptions and emissions, efficient processing techniques will be developed (2 new fast curing techniques) combined with recycling technologies for the new catalogue of materials to reduce waste generation and induce circularity. A new open method and related tools (Coupled Ecological Optimisation framework) will promote and standardise holistic sustainable HPC design, modelling and systematic optimisation, leading to continuous sustainable catalogue growth and inclusion of new families of biobased, recyclable lightweight HPC at competitive cost. All results will be validated in 3 use cases at automotive, infrastructure and aeronautic industries with specific business cases, contributing to establishing new resilient, sustainable and innovative value chains in the EU HPC industry, promoting a change of paradigm from linear to circular ones.

Building on successful projects and relevant assets from partners and an interdisciplinary approach, BioSPRINT applies process intensification in the context of biorefining operations, so as to improve the efficiency of the purification and conversion of sugars from the hemicelluloses fraction of lignocellulosic biomass and to enable their transformation into new bio-based resins for substituting fossil based polymers in a range of applications. The ultimate objective is to lead to a reduction in operation costs, feedstock and energy resources, greenhouse gas emissions and higher yields, while increasing operation safety, by concentrating on technologies which can intensify processing methods and create an integrated biorefinery concept. Of particular interest in BioSPRINT is the valorisation of hemicelluloses streams derived from hard wood and straw, from processes employed in the production of paper pulp or biofuels. Such streams are readily available from the pilot or production processes of the project’s research and industrial partners (Fraunhofer and UPM). A case study using a stream from Clariant will also be carried out. With regards to processing technologies, BioSPRINT will focus on 4 activity areas (a) Upstream purification; (b) Catalytic conversion; (c) Downstream purification and (d) Polymerisation. The project will develop and validate an intensified and integrated purification strategy leveraging innovative anti-solvent precipitation and membrane separation methods, novel intensified and integrated catalytic processes for dehydration of C5 and C6 hemicelluloses sugars into monomers, extractive-reaction methods to isolate the reaction products from the reaction medium in situ, heterogeneous catalysts and an intensified polymerisation process for furan-based derivatives. Cross-cutting activities will cover process simulation and optimisation, an integrated Lifecycle sustainability assessment, standardisation, dissemination and exploitation activities

SmartLi aims at developing technologies for using technical lignins as raw materials for biomaterials and demonstrating their industrial feasibility. The technical lignins included in the study are kraft lignins, lignosulphonates and bleaching effluents, representing all types of abundant lignin sources. The raw materials are obtained from industrial partners. The technical lignins are not directly applicable for the production of biomaterials with acceptable product specifications. Therefore, pretreatments will be developed to reduce their sulphur content and odour and provide constant quality. Thermal pretreatments are also expected to improve the material properties of lignin to be used as reinforcing filler in composites, while fractionating pretreatments will provide streams that will be tested as plasticizers. Lignin is expected to add value to composites also by improving their flame retardancy. The development of composite applications is led by an industrial partner. Base catalysed degradation will be studied as means to yield reactive oligomeric lignin fractions for resin applications. The degradation will be followed by downstream processing and potentially by further chemical modification aiming at a polyol replacement in PU resins. Also PF type resins for gluing and laminate impregnation, and epoxy resins will be among the target products. Full LCA, including a dynamic process, will support the study. The outcome of the research will be communicated with stakeholders related to legislation and standardisation.