A method for producing a biodegradable material from lignocellulosic biomass and a biodegradable material therefrom

Abstract

A method for the production of biodegradable material from lignocellulosic biomass is disclosed The method involves several steps: first, lignocellulosic biomass is treated with a mild alkali solution at a temperature of 100 degrees Celsius for 30 minutes, resulting in the extraction of lignin and other valuable extractives. Next, the solid and liquid components of the treated biomass are separated through filtration. The resulting liquid is then mixed with polyvinyl alcohol (PVA) while heated and continuously stirred. Calcium chloride (CaCl2) is added as a filler, and glycerol serves as a plasticizer in the mixture. Finally, the mixture is dried to produce the biodegradable material. Optionally, colorants can be added to the material, and its thickness and properties can be adjusted by varying the amounts of PVA, fillers, and plasticizers. The obtained biodegradable material is a thin film characterized by having tensile strength of 9.87 MPa, and is used to produce items such as bags, wallets, chappals (sandals), or car seat covers.

Description

A method for producing a biodegradable material from lignocellulosic biomass and a biodegradable material therefrom.TECHNICAL FIELD OF THE INVENTION

[0001] The present subject matter relates to a method for producing a biodegradable material from lignocellulosic biomass and a biodegradable material therefrom. Furthermore, the present invention pertains to the eco-friendly production of the biodegradable material selected from a plastic-like and a leather-like materials from the lignocellulosic biomass, offering sustainable alternatives to traditional petroleum-derived plastics and animal-based leather.BACKGROUND OF THE INVENTION

[0002] Traditional petroleum-based plastics are ubiquitous in modern society, finding applications in various industries, including packaging, textiles, and automotive manufacturing. However, their long-lasting nature poses a significant environmental problem. These plastics can persist in landfills and oceans for centuries, contributing to pollution and harming ecosystems. Furthermore, the recycling of traditional plastics often generates hazardous byproducts and consumes energy, making it an imperfect solution. The dependence on petroleum for plastic production is not sustainable, as it depletes the finite resources and contributes to the carbon emissions.

[0003] On the other hand, the production of animal leather involves resource-intensive and often ethically contentious practices. Particularly, the traditional leather industry involves the slaughter of animals and often raises ethical concerns related to animal rights and welfare.

[0004] US11046840B2 discloses a method for degrading articles made from certain types of plastics (polyethylene, polypropylene, or polystyrene) using a specific approach involving the blending of these plastics with carbohydrate -based polymericmaterials that include a plasticizer.

[0005] CN102268491A pertains to a biodegradable leather degreaser primarily composed of ingredients such as fatty alcohol polyethenoxy ether, coconut oil fatty acid diethanolamine, sodium ethoxylated alkyl sulfate, alkyl benzene sulfonate, sodiumhydroxide, solvent, and water.

[0006] US11198767B2 discloses a method for enhancing the polyester degrading capability of biological entities within a plastic composition containing at least one polyester chosen from polylactic acid (PLA), polycaprolactone (PCL), polybutylene adipate terephthalate (PBAT), polyhydroxyalkanoate (PHAs), and polybutylene succinate(PBS), along with an anti-acid filler and biological entities.

[0007] Most of the solutions available in the state-of-the-art focus on the degradation process for plastic and leather materials. However, none of them disclose durable alternatives for such plastic and leather materials. Therefore, there is a need for a sustainable and eco-friendly method for producing biodegradable plastic-like and leather- like materials from more sustainable sources such as lignocellulosic biomass.OBJECT OF THE INVENTION

[0008] The primary objective of the present invention is to provide a sustainable and environmentally friendly alternative to traditional petroleum-derived plastics. By utilizing lignocellulosic biomass and creating a biodegradable material, the invention aims to reduce plastic pollution, minimize the burden on landfills, and mitigate the harmful effects of plastic waste on ecosystems.

[0009] To address ethical concerns associated with animal leather production, the invention seeks to offer a cruelty-free and sustainable alternative. By eliminating the need for animal-derived materials, it promotes animal welfare and ethical practices in the fashionand leather industries.

[0010] It is another objective of the present invention to reduce dependence on fossil fuels, such as petroleum, by utilizing renewable lignocellulosic biomass resources. This help conserve finite resources and reduces carbon emissions, contributing to a more sustainableand resource-efficient future.

[0011] By implementing a zero-waste production process, the invention minimizes environmental impact. Both the liquid and solid residues from biomass processing areutilized, aligning with circular economy principles, and reducing overall waste generation.

[0012] To meet the diverse needs of various industries, the invention seeks to provide versatile materials suitable for applications such as packaging, textiles, automotive components, and construction materials. Its adaptability to different applicationscontributes to its overall utility and market appeal.

[0013] Another object of the present invention is to create materials that are fully biodegradable ensuring that they break down naturally when disposed of, thereby reducing long-term environmental harm caused by non-biodegradable plastics and waste.

[0014] By making use of agricultural and forestry residues that are often underutilized or discarded, the invention contributes to the efficient utilization of biomass resources, promoting sustainability in agriculture and forestry practices.SUMMARY OF THE INVENTION

[0015] In light of the disadvantages mentioned in the previous section, the following summary is provided to facilitate an understanding of some of the innovative features unique to the present invention and is not intended to be a full description. A full appreciation of the various aspects of the invention can be gained by taking the entire specification and drawings as a whole. Embodimentsdescribed herein provide a sustainable solution by utilizing lignocellulosic biomass, such as agricultural and forestry residues, to create biodegradable plastic-like and leather-like materials.

[0016] According to an embodiment of the present invention, a method for producing a biodegradable material from lignocellulosic biomass is disclosed. The method comprises of treating lignocellulosic biomass with a mild alkali solution at a temperature of 100 degrees Celsius for 30 minutes to extract lignin and other extractives. Next, separating the solid and liquid components of the treated lignocellulosic biomass through filtration and mixing the resulting liquid portion with polyvinyl alcohol (PVA) while hot and continuously stirring. Further, adding calcium chloride (CaC12) as a filler and glycerol as a plasticizer to the mixture. Finally, drying the mixture to form the biodegradable material.

[0017] According to an embodiment of the present invention, optionally colorants are added to the obtained biodegradable material and modifying the thickness and properties of the biodegradable material by adjusting the amounts of PVA, fillers and the plasticizers.

[0018] According to an embodiment of the present invention, the lignocellulosic biomass comprises at least one of sawdust, rice straw, wheat straw, bamboo waste, sugarcane plantresidue, coconut plant residue (including coconut leaf and coir), chilli plant residue, pineapple leaf, maple leaf, wood residue, paper mill waste, and lignincontaining materials.

[0019] According to an embodiment of the present invention, the mild alkali solution comprises a 10% sodium hydroxide (NaOH) solution.

[0020] According to an embodiment of the present invention, the PVA is added in the range of 1% to 10% by weight of the liquid portion.

[0021] According to an embodiment of the present invention, the calcium chloride (CaC12) is added in the range of 1% to 10% by weight of the liquid portion.

[0022] According to an embodiment of the present invention, the glycerol is added in the range of 1% to 5% by weight of the liquid portion.

[0023] According to an embodiment of the present invention, the drying is performed in a hot air oven set at 60 degrees Celsius.

[0024] According to an embodiment of the present invention, the obtained biodegradable material completely biodegrades when immersed in soil, with complete biodegradation occurring within 30 days.

[0025] According to an embodiment of the present invention, the solid residue left after solid-liquid separation is mixed with cassava pith waste and / or starch, chitin or any other bio-based or non-biobased binders in the range of 1 to 10% with moisture up to 50% and heat-compressed at 150 degrees Celsius to produce a compressed woodlike material suitable for small furniture items or window frames.

[0026] According to an embodiment of the present invention, the biodegradable material is a thin film characterized by having tensile strength of 9.87 MPa. The thickness of the thin film is in the range of 0.1 mm to 0.3 mm.

[0027] According to an embodiment of the present invention, the use of the biodegradable material is for crafting the grow bags for plants. The grow bags have stability for the time period in the range of 1 to 13 months.

[0028] According to an embodiment of the present invention, the use of the biodegradable material is for manufacturing articles selected from bags, wallets, footwears, and seat covers. The biodegradable material is polished for a leather like appearance.BRIEF DESCRIPTION OF ACCOMPANYING DRAWING

[0029] The detailed description is provided with reference to the accompanying figures. These and other features and advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detaileddescription when considered in connection with the accompanying drawings wherein:

[0030] Fig. 1 is a flowchart illustrating a method for producing biodegradable material from lignocellulosic biomass in accordance with an embodiment of the present invention.

[0031] Fig. 2 is a schematic representation of the method for producing biodegradable material from lignocellulosic biomass in accordance to an embodiment of the present invention.

[0032] Fig. 3 is a schematic representation of thin-film extraction of the biodegradable material in accordance with an embodiment of the present invention.

[0033] Fig. 4 is a schematic representation of a leather-like material obtained from the biodegradable material in accordance with an embodiment of the present invention.

[0034] Fig. 5a-d is a schematic representation of grow bags obtained from thebiodegradable material in accordance with an embodiment of the present invention.

[0035] Fig. 6 is a schematic representation of a bag obtained from the biodegradablematerial in accordance with an embodiment of the present invention.

[0036] Fig. 7 is a schematic representation of footwear obtained from the biodegradablematerial in accordance with an embodiment of the present invention.

[0037] Fig. 8 is a schematic representation of leather-like material obtained from the biodegradable material in accordance with an embodiment of the present invention.

[0038] Fig. 9 is a schematic representation of thick leather-like material obtained from the biodegradable material in accordance with an embodiment of the present invention.

[0039] Fig. 10 is a schematic representation of a compressed wood-like material inaccordance with an embodiment of the present invention.DETAILED DESCRIPTION

[0040] For the purpose of promoting an understanding of the principles of the disclosure,reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure.

[0041] The terms "comprise", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.

[0042] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.

[0043] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.

[0044] Embodiments of the present invention discloses a method for producing biodegradable material from lignocellulosic biomass.

[0045] Fig. 1 is a flowchart illustrating the method for producing biodegradable material from lignocellulosic biomass in accordance with an embodiment of the present invention. Fig. 2 is a schematic representation of method for producing biodegradable material from lignocellulosic biomass in accordance with an embodiment of the present invention. As used herein, “Eignocellulosic biomass” refers to a type of biomass material primarily composed of three main components: lignin, cellulose, and hemicellulose. It is commonly found in plant cell walls and is a key structural element in various types of plants, including wood, grasses, agricultural residues (such as crop stalks and straw), and forestrybyproducts.

[0046] According to an embodiment of the present invention, a method for producing biodegradable material from lignocellulosic biomass is disclosed. The method comprises of treating lignocellulosic biomass with a mild alkali solution at a temperature of 100 degrees Celsius for 30 minutes to extract lignin and other extractives at step 102. Next, separating the solid and liquid components of the treated lignocellulosic biomass through filtration at step 104 and mixing the resulting liquid portion with polyvinyl alcohol (PVA) while hot and continuously stirring at step 106. Further, adding calcium chloride (CaC12) as a filler and glycerol as a plasticizer to the mixture at step 108. Finally, drying the mixture to form the biodegradable material at step 110.

[0047] Fig. 3 is a schematic representation of thin-film extraction of the biodegradable material in accordance with an embodiment of the present invention. Fig. 4 is a schematic representation of a leather-like material obtained from the biodegradable material in accordance with an embodiment of the present invention.

[0048] According to an embodiment of the present invention, optionally colorants are added to the obtained biodegradable material and modifying the thickness and properties of the biodegradable material by adjusting the amounts of PVA, fillers and the plasticizers.

[0049] According to an embodiment of the present invention, the lignocellulosic biomass comprises at least one of sawdust, rice straw, wheat straw, bamboo waste, sugarcane plant residue, coconut plant residue (including coconut leaf and coir), chilli plant residue, pineapple leaf, maple leaf, wood residue, paper mill waste, and lignin-containing materials.

[0050] According to an embodiment of the present invention, the mild alkali solution comprises a 10% sodium hydroxide (NaOH) solution.

[0051] According to an embodiment of the present invention, the PVA is added in the range of 1% to 10% by weight of the liquid portion.

[0052]

[0049] According to an embodiment of the present invention, the calcium chloride (CaC12) is added in the range of 1% to 10% by weight of the liquid portion.

[0053] According to an embodiment of the present invention, the glycerol is added in the range of 1% to 5% by weight of the liquid portion.

[0054] According to an embodiment of the present invention, the drying is performed in a hot air oven set at 60 degrees Celsius.

[0055] According to an embodiment of the present invention, the obtained biodegradable material completely biodegrades when immersed in soil, with complete biodegradation occurring within 30 days.

[0056] According to an embodiment of the present invention, the solid residue left after solidliquid separation is mixed with cassava pith waste in the range of 1 to 10% with moisture up to 50% and heat-compressed at 150 degrees Celsius to produce a compressed wood-like material suitable for small furniture items or window frames.

[0057] Fig. 7 is a schematic representation of footwear obtained from the biodegradable material in accordance with an embodiment of the present invention.WORKING EXAMPLESExample 1Production of Biodegradable Material from Sawdust

[0058] Fig. 8 is a schematic representation of a biodegradable material as a leather-like material obtained from the method of obtaining a ttdgsdtfe material in accordance with an embodiment of the present invention.Step 1: Biomass Treatment

[0059] Begin with 100g of sawdust, a readily available lignocellulosic biomass. In a 3000ml beaker, combine the sawdust with 1500ml of a 10% sodium hydroxide (NaOH) solution. Heat the mixture to 100 degrees Celsius while maintaining continuous stirring forprecisely 30 minutes. This process extracts lignin and other extractives from the sawdust.Step 2: Filtration and Separation

[0060] After the thermal treatment, separate the solid and liquid components of the treatedsawdustthrough a sieve or filtration system. Collect the hot liquid extract, which is rich inlignin and extractives, for further processing.Step 3: Material Formation

[0061] The hot liquid extract is now the primary material for biodegradable products. Begin by adding 2g of polyvinyl alcohol (PVA) to the liquid while it is still hot, ensuring thorough dissolution with continuous stirring. This step provides the material's basestructure.Step 4: Customization

[0062] To tailor the material's properties, introduce calcium chloride (CaC12) as a filler (1% by weight of the liquid portion) and glycerol as a plasticizer (1% by weight of the liquid portion) into the mixture. Adjust the amounts of PVA, fillers, and plasticizers to achieve the desired thickness and properties for specific applications. The thickness of the b i o d e g r ad ab l e material is in the range of 0.1 mm to 1.5 mm.Step 5: Drying Process

[0063] The customized mixture is poured into a tray and placed in a hot air oven set at 60degrees Celsius. Allow the material to dry completely, forming the biodegradable productwith the desired characteristics.Step 6: Application Testing

[0064] The resulting biodegradable material can be utilized in various applications, including bags, wallets, chappals (sandals), car seat covers, or grow bags for plants, depending on the adjusted properties. It can also be painted with leather / acrylic paint or polished with leather polish for fashion and decorative items.

[0065] Experimental Result - Table 1 shows the results of the tensile strength of the leather-like biodegradable material obtained by the present invention.Step 7: Biodegradability Assessment

[0066] To confirm its environmental friendliness, immerse a sample of the material in soil. Observe complete biodegradation within 30 days, verifying its eco-friendliness and minimal environmental impact.Example 2

[0067] Fig. 9 is a schematic representation of thick leather-like material obtained from method of obtaining the biodegradable material in accordance with an embodiment of the present invention. As mentioned in Example 1, the properties of the material can be altered by adjusting the concentration of PVA and NaOH. Initially, 100g of sawdust was placed in a 3000ml beaker, followed by the addition of 1500ml of water and 10g of NaOH.The mixture was thoroughly mixed and heated in a magnetic stirrer set at 100 degrees Celsius with continuous stirring. After 30 minutes, solid and liquid components were separated throughfiltration using a sieve. Subsequently, the hot liquid was returned to the magnetic stirrer setat 100 degrees Celsius, and 5g of PVA was added. Once complete dissolution of the PVA was achieved, 1% CaC12 and 1% glycerol were introduced. After thorough mixing of CaC12 and glycerol, the entire mixture was transferred to a tray and placed in a hot air ovenset at 60 degrees Celsius. This process resulted in the production of a thicker material, as per the desired specifications.Example 3

[0068] As explained in Example 1 , following the removal of the material from the tray, it can be further enhanced with leather / acrylic paint for coloring. Additionally, the material is amenable to polishing with leather polish, improving its aesthetic appeal. This sheet of leather-like material can be easily stitched using a sewing machine, facilitating the creation of wallets and bags.Example 4

[0069] Fig. 6 is a schematic representation of a bag obtained from the biodegradable material in accordance with an embodiment of the present invention. As illustrated in bothExample 1 and 3, the material can be skillfully stitched to craft grow bags designed for planting small plants and facilitating their growth. These grow bags exhibit remarkable stability, enduring various weather conditions effectively for durations spanning from 3 to 12 months.Example 5

[0070] Fig. 5a-d is a schematic representation of grow bags obtained from the biodegradable material in accordance with an embodiment of the present invention. As detailed in Example 4, when the material is submerged in soil, it undergoes complete degradation, with the entire biodegradation process occurring within just 30 daysExample 6

[0071] Fig. 10 is a schematic representation of compressed wood- like material in accordance with an embodiment of the present invention. As outlined in Example 1, the solid residue remaining after the solid-liquid separation process can be repurposed effectively for crafting packing materials and creating compressed wood-like materials. To prepare the latter, 50g of the solid residue was combined with 5g of cassava pith waste and subjected to heat compression at 150 degrees Celsius. The resulting compressed material proves suitable for use as treated wood, finding applications in small furniture items, window frames, and more.

[0072] The present invention offers a multitude of advantages that collectively contribute to itssignificance and potential impact. Firstly, it addresses pressing environmental concerns by providing a sustainable alternative to traditional petroleum-derived plastics, thereby reducing plastic pollution, and lessening the burden on landfills and ecosystems. Secondly, the invention promotes ethical practices by offering cruelty-free, non-animal- based leather alternatives, mitigating the ethical concerns surrounding animal leather production. Thirdly, it conserves valuable resources by reducing reliance on finite fossil fuels and optimizing the utilization of lignocellulosic biomass, often underutilized, or discarded. Furthermore, its zero-waste approach, utilizing both liquid and solid residues, aligns with circular economy principles and minimizes waste generation. The resulting materials are versatile, fully biodegradable, and adaptable for a wide range of applications, meeting the growing market demand for eco-friendly materials in various industries. Overall, this invention represents a holistic and sustainable approach to materials production, addressing environmental, ethical, and resource efficiency challenges while fostering a more responsible and eco-conscious future.

[0073] Examples described herein can also be used in various other scenarios and for various purposes. It may be noted that the above-described examples of the present solutionare for the purpose of illustration only. Although the solution has been described in conjunction with a specific embodiment thereof, numerous modifications may be possible without materially departing from the instructions and advantages of the subject matter described herein. Other substitutions, modifications, and changes may be made without departing from the spirit of the present solution. All of the features disclosed in this specification (including any accompanying claims, abstract, and drawings), and / or all of the steps of any method or process so disclosed, may be combined in any arrangement, except combinations where at least some of such features and / or steps are mutually exclusive.

[0074] The present description has been shown and described with reference to theforegoing examples. It is understood, however, that other forms, details, and examples canbe made without departing from the spirit and scope of the present subject matter.

Claims

We Claim:

1. A method for producing a biodegradable material from lignocellulosic biomass, comprising: a. treating the lignocellulosic biomass with mild alkali solution at a temperature of 100 degrees Celsius for 30 minutes to extract lignin in a liquid portion and the other extractives; b. separating the liquid portion from the solid residue of the treated lignocellulosic biomass through filtration; c. mixing the resulting liquid portion with polyvinyl alcohol (PVA) while hot under continuously stirring to obtain a mixture; d. adding calcium chloride (CaC12) as a filler; and glycerol as a plasticizer to the mixture to obtain a solution; and e. drying the solution to form the sheets of the biodegradable material.

2. The method as claimed in claim 1, wherein colorants are added optionally to the obtained colored biodegradable material; and wherein the sheet of the biodegradable material is having a thickness and the properties of the biodegradable material are adjusted by modifying the amounts of PVA, filler and the plasticizer by weight of the liquid portion.

3. The method as claimed in claim 1, wherein the lignocellulosic biomass comprises at least one selected from sawdust, rice straw, wheat straw, bamboo waste, sugarcane plant residue, coconut plant residue selected from coconut leaf and coir, chilli plant residue, pineapple leaf, maple leaf, wood residue, paper mill waste.

4. The method as claimed in claim 1 , wherein the mild alkali solution comprises a 10% sodium hydroxide (NaOH) solution.

5. The method as claimed in claim 1, wherein the PVA is added in the range of 1% to 10% by weight of the liquid portion.

6. The method as claimed in claim 1 , wherein the calcium chloride (CaC12) is added in the range of 1% to 10% by weight of the liquid portion.

7. The method as claimed in claim 1, wherein the glycerol is added in the range of 1% to 5% by weight of the liquid portion.

8. The method as claimed in claim 1, wherein the drying is performed in a hot air oven set at a temperature of 60 degrees Celsius.

9. The method as claimed in claim 1, wherein the biodegradable material completely biodegrades when immersed in soil, wherein the complete biodegradation occurs within 30 days.

10. The method as claimed in claim 1, wherein the solid residue left after the solidliquid portion separation is mixed with the materials at least one selected from cassava pith waste, starch, chitin, and any other bio-based and non-biobased binders in the range of 1 to 10% with moisture up to 50%; and is heat-compressed at a temperature of 150 degrees Celsius to produce a compressed wood-like material suitable for small furniture items and window frames.

11. The method as claimed in 1 , wherein the colorants are the colors like acrylic or leather colorant or bio- colorant; and are incorporated at any stages of the producing the biodegradable material.

12. A biodegradable material obtained from the process as claimed in 1, is recycled by putting it inhot water with continuous stirring; wherein the dissolved material is again molded back, followed by drying into any other forms.

13. The biodegradable material as claimed in claim 12 is a thin film characterized by having tensile strength of 9.87 MPa, wherein the thickness of the thin film is in the range of 0.1 mm to 0.3 mm.

14. Use of the biodegradable material as claimed in claim 1 to 13 for crafting the grow bags for plants, wherein the grow bags have stability for the time period in the range of 1 to 13 months.

15. Use of the biodegradable material as claimed in claim 1 to 13 for manufacturing articles selected from bags, wallets, footwears, and seat covers, wherein the biodegradable material is polished for a leather like appearance.

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