A composition, preparation process, and product

Abstract

The invention relates to an composition, and a preparation process thereof. The composition comprises biomass and one or more binders comprising synthetic polymer, biopolymer, terpenoid, or any combination thereof, and optionally one or more additives, wherein the biomass is incorporated into a matrix of the one or more binders and the optional one or more additives. The invention further relates to products comprising said composition.

Description

[0001] A composition, preparation process, and product

[0002] Technical field

[0003] The invention relates to an composition and a preparation process thereof. The composition comprises biomass and one or more binders comprising synthetic polymer, biopolymer, terpenoid, or any combination thereof, and optionally one or more additives. The biomass is incorporated into a matrix of the one or more binders and the optional one or more additives. The invention further relates to products comprising said composition.

[0004] Background

[0005] Plastic pollution, i.e. , the accumulation of plastic objects and particles in the environment, is a growing problem that impacts both humans, wildlife and their habitats. Plastic pollution in the oceans has raised particular concern.

[0006] Conventional plastics are environmentally inert and resistant to natural degradation. They may break into micro-sized particles, i.e., microplastics, that may persist for centuries, contaminating ecosystems and entering the food chain as well as human bodies. The effects of microplastics in living organisms has not yet been extensively studied, and especially the long-term effects are not yet known. However, harmful effects on, e.g., inflammation, DNA damage, and increased cancer risk are already known.

[0007] Additionally, the reduced supplies of fossil raw materials as well as climate concerns shift industries towards using renewable raw materials and circular economy. This is reflected in, e.g., legislation where the requirement of renewable material sources increases all the time.

[0008] Biodegradable polymer composite materials have been studied. However, novel materials are needed to meet the environmental requirements and to reduce the plastic pollution globally. Summary

[0009] An object of the invention is to reduce or overcome the drawbacks in the prior art.

[0010] Particularly, an object of the invention is to provide a material that meets the environmental standards regarding plastic pollution while still maintaining characteristics required from high-quality plastic materials in, e.g., household plastic products, sports, handheld tools, or composite structures for construction, such as composite board.

[0011] The invention is defined by what is recited in the independent claims. Embodiments of the invention are presented in the dependent claims.

[0012] The features recited in the dependent claims and the embodiments in the description are mutually freely combinable unless otherwise explicitly stated.

[0013] The exemplary embodiments presented in this text and their advantages relate by applicable parts to all aspects of the invention, namely, to the composition, to the process, and to the product, even though this is not always explicitly mentioned.

[0014] Any embodiments or examples of the invention presented herein that are specified with the open term ‘comprise’ may be further limited with a closed term ‘consisting of’.

[0015] A composition is provided. The composition comprises biomass and one or more binders. The one or more binders may comprise a synthetic polymer. The one or more binders may comprise a biopolymer, such as lignin or lignin derivative, polysaccharide, natural latex, fatty acid polyester, or any combination thereof. The one or more binders may comprise a terpenoid. The one or more binders may comprise any combination of the synthetic polymer, the biopolymer, and the terpenoid. The composition may optionally comprise one or more additives. In the composition, the biomass is incorporated into a matrix of the one or more binders and the optional one or more additives. The term ‘biopolymer’ refers to natural polymers produced by the cells of living organisms. Typical examples of biopolymers include polynucleotides, polypeptides, polysaccharides, natural latex, i.e., natural rubber, suberin, and lignin. The IIIPAC defines biopolymers as “macromolecules (including proteins, nucleic acids and polysaccharides) formed by living organisms”.

[0016] The term ‘synthetic polymer’ should be understood as a polymer produced in a facility. Synthetic polymers do not occur in nature. The term 'synthetic polymer' may be used interchangeably with the term ‘artificial polymer’, defined by IIIPAC as “Man-made polymer that is not a biopolymer.” Regenerated biopolymers should in the course of this application be classified together with biopolymers, not with synthetic polymers.

[0017] Further, a process for preparing a composition is provided. The process comprises incorporating the biomass into a matrix of one or more binders and optionally one or more additives.

[0018] The presented composition may be compostable. Compostability refers in the course of this specification to industrial compostability according to the European standard EN 14995:2007. Industrial compostability can be defined as the controlled biological decomposition of organic waste under managed conditions that are predominantly aerobic (i.e. in the presence of oxygen) and that allow the development of thermophilic conditions as a result of biologically produced heat. Thermophilic conditions refer to temperatures of 50-65 °C or higher.

[0019] The presented composition may additionally be home compostable. Home compostability refers to aerobic breakdown of organic material or waste in psychrophilic (0-20°C) to mesophilic (20-45°C) conditions. Volumes treated in home composting are considerably smaller than in industrial composting and the compost is usually used in private gardens. Home compostability is considered a more strict requirement for a given material, such as the composition, than industrial compostability. The presented composition may have a compostability similar to packaging materials compliant with the European standard EN 17427:2022. Compostability, whether industrial or home compostability, provides an advantage of reducing the environmental impact of the composition. Compostability of the product ensures that the composition does not release microplastic material to the soil or marine environment. The compostability also makes the composition compatible with the concept of circular economy.

[0020] The presented composition may be antistatic. In the course of this specification, the term antistatic should be understood as a property of an object capable of reducing, removing, or preventing the buildup of static electricity. Some electrical conductivity is typically required to make the composition antistatic.

[0021] The presented composition may be elastic. An elastic material is defined as a material able to stretch and be returned to its original shape or size. In other words, an elastic material is a material capable of recovering size and shape after a deformation.

[0022] The presented composition may be protected against ultraviolet radiation, whereby the composition and products utilizing said composition may have an increased lifespan compared to conventional products.

[0023] Brief description of the drawings

[0024] Figure 1 presents processes according to embodiments of the invention.

[0025] Figure 2 presents an artificial turf comprising a composition according to embodiments of the invention.

[0026] Detailed description

[0027] The presented composition comprises biomass. Biomass is a renewable material source, whereby compositions may be provided in an environmentally sustainable manner. The composition may comprise the biomass in an amount of 5-95 wt-%, preferably in an amount of 20-60 wt-% of the total weight of the composition.

[0028] The biomass may originate from a source that would otherwise be considered as waste. For example, the biomass may originate from cutting or mowing unwanted plantation from, e.g., waterways, such as lakes, rivers and sea. The unwanted plantation, such as reed and sedge, may eutrophicate lakes and rivers, which may lead to increased biomass of phytoplankton, changes in macrophyte species composition and biomass, dissolved oxygen depletion, increased incidences of fish kills, and loss of desirable fish species. Removing eutrophicating biomass from waterways improves the water quality in said waterways.

[0029] The biomass may originate from agriculture. Thus, the biomass may comprise agricultural waste biomass. Agricultural waste biomass refers herein to vegetation-based waste biomass, such as cork, coconut, hemp, grass, cellulose, hay, straw, and any combination thereof.

[0030] The invention provides possibilities to reduce biomass waste by utilizing agricultural waste biomass or biomass removed from waterways in the presented composition. The use of biomass in the present invention reduces the need for waste management, whereby the invention is compatible with the concept of circular economy.

[0031] The biomass may be selected from the group comprising reed, sedge, cork, coconut, hemp, grass, cellulose, reed, hay, straw, and any combination thereof. Preferably, the biomass comprises or consists essentially of reed, sedge, cork, coconut, hemp, grass, cellulose, reed, hay, straw, and any combination thereof.

[0032] The expression “consists essentially of” should in the course of this application be understood such that no further components are added to the biomass (e.g., reed, sedge, cork, coconut, hemp, grass, cellulose, reed, hay, straw, or the combination thereof) when forming the composition. Since the biomass is a natural product, there may be other species, such as plant species, arthropods (e.g., insects, arachnids), and / or micro-organisms among a certain biomass source that are not removed when harvesting the biomass and when forming the composition. The term “consists essentially of” therefore means that nothing, other than the one or more binders and the optional one or more additives, is specifically added to the biomass when forming the composition but the biomass may naturally contain other species due to not having been removed upon harvesting of the biomass. The biomass may comprise or consist essentially of sedge plants selected from the Cyperaceae family, such as wood clubrush, papyrus sedge, hare's- tail cottongrass, fingered sedge, acute sedge, water sedge, common sedge, or any combination thereof.

[0033] The biomass may comprise reed. The reed may be selected from the Phragmites genus, such as common reed (Phragmites australis), Phragmites japonicus, Phragmites karka, or Phragmites mauritianus. Preferably, the biomass comprises or consists essentially of common reed. Reed is abundant in waterways, causing eutrophication and aesthetic inconvenience. Thus, it is advantageous to remove reed from the waterways to prevent said negative effects. The abundance of reed available makes it a well-suited candidate for the presented composition.

[0034] In the presented composition, the biomass is incorporated into a matrix of the one or more binders and the optional one or more additives. Being incorporated in a matrix should be understood as the biomass and the one or more binders and the optional one or more additives are arranged in a stable, non-separable arrangement. During the lifespan of the composition when used in a product, the biomass should not be separable from the one or more binders and the optional one or more additives.

[0035] The presented composition comprises one or more binders. The one or more binders may comprise synthetic polymer; biopolymer such as lignin or lignin derivative, polysaccharide, natural latex, or fatty acid polyester; terpenoid; or any combination thereof. The one or more binders may provide the composition with advantages such as improved elasticity, processability, compostability, hydrophobicity or water repellence, durability, and / or protection from ultraviolet radiation, together with increased weight.

[0036] The composition may comprise the synthetic polymer in an amount of 0-95 wt-%, preferably in an amount of 5-95 wt-%, more preferably in an amount of 20-80 wt-% of the total weight of the composition. The composition may comprise the biopolymer in an amount of 0-95 wt-%, preferably in an amount of 5-95 wt-%, more preferably in an amount of 20-80 wt-% of the total weight of the composition. The one or more binders may comprise a synthetic polymer or a combination of synthetic polymers. The synthetic polymers may be individually selected from the group comprising poly(lactic acid) (PLA), polyhydroxyalkanoate (PHA), polybutylene succinate (PBS), polyhydroxybutyrate (PHB), polycaprolactone (PCL), poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV), polyacrylates, polyurethanes, thermoplastic elastomers (TPE), ethylene propylene diene monomer rubber (EPDM), and any combination thereof.

[0037] Preferably, the synthetic polymer is biodegradable to such an extent that the composition may be industrially compostable according to the European standard EN 14995:2007. The polymer may provide the composition with improved elasticity, processability, compostability, hydrophobicity or water repellence, and / or durability, together with increased weight.

[0038] The synthetic polymer may comprise poly(lactic acid) (PLA). PLA is a thermoplastic polymer having the backbone formula (CsH4O2)n or [- C(CH3)HC(=O)O-]n. PLA is formally obtained by condensation of lactic acid C(CH3)(OH)HCOOH with loss of water. It can also be prepared by ring-opening polymerization of lactide [-C(CH3)HC(=O)O-]2, the cyclic dimer of the basic repeating unit. PLA may be particularly suitable for compostable compositions because PLA may be biodegradable. PLA may be particularly suitable for the presented composition when combined with one or more other binders.

[0039] The synthetic polymer may comprise a thermoplastic elastomer (TPE) originating from recycled materials. Thermoplastic elastomers are often composed of ethylene, butadiene, and styrene copolymers. Even though TPEs are commonly made from virgin raw materials, they can be produced also using recycled raw materials. Using recycled starting materials to construct the TPE may render the TPE material suitable for the present invention.

[0040] The synthetic polymer may comprise ethylene propylene diene monomer (EDPM) rubber originating from recycled materials. EPDM rubbers are synthetic vulcanized rubber polymers made from ethylene, propylene, and a diene comonomer that enables crosslinking via sulfur vulcanization. Crosslinking provides EPDM rubber the functional rubbery properties. Typically used dienes in the manufacture of EPDM rubbers are ethylidene norbornene (ENB), dicyclopentadiene (DCPD), and vinyl norbornene (VNB). Even though EPDM rubber is commonly produced from virgin raw materials, it can also be generated from recycled rubber.

[0041] The one or more binders may comprise a biopolymer or a combination of biopolymers. The biopolymer may be individually selected from the group comprising polysaccharides, lignin or lignin derivatives, natural latex, fatty acid polyesters, or any combinations thereof.

[0042] The one or more binders may comprise a polysaccharide. In other words, the biopolymer may comprise a polysaccharide. The polysaccharide may be individually selected from the group comprising starch, chitosan, pectin, and any combination thereof. The polysaccharide may comprise starch, such as potato starch. Using starch as a binder may provide the composition with, e.g., improved elasticity, processability, compostability, durability, and increased weight.

[0043] The one or more binders may comprise lignin, lignin derivatives, or any combinations thereof. In other words, the biopolymer may comprise lignin, lignin derivatives, or any combinations thereof.

[0044] Lignin is a class of complex organic polymers that form key structural materials in the support tissues of most plants. Chemically, lignins are polymers made by cross-linking phenolic precursors. Lignin is naturally hydrophobic, whereby it may provide the infill composition with hydrophobicity or water repellent properties. Lignin may further provide the composition with protection from ultraviolet radiation. Thanks to its conjugated aromatic structure, lignin blocks irradiation from medium wave ultraviolet rays (range of 290-320 nm) and thus is a natural macromolecular UV blocker. Protection from UV radiation may increase the lifespan of the composition.

[0045] The biopolymer may comprise a lignin derivative. The lignin derivative is preferably selected from lignosulfonate, sulfonated lignin, lignin subjected to hydrothermal carbonization treatment (HTC lignin), and a combination thereof. The biopolymer may comprise lignosulfonates, sulfonated lignin, or a combination thereof. Lignosulfonates (LS) are water-soluble anionic polyelectrolyte polymers: they are byproducts from the production of wood pulp using sulfite pulping. Most delignification in sulfite pulping involves acidic cleavage of ether bonds, which connect many of the constituents of lignin. Sulfonated lignin (SL) refers to other forms of lignin by-product, such as those derived from the much more popular Kraft process, that have been processed to add sulfonic acid groups. The two have similar uses, and may be used as a binder in the presented composition. Lignosulfonates and sulfonated lignin may both appear as free-flowing powders. Lignosulfonates and sulfonated lignin may both be dissolved in water, facilitating incorporating the biomass into the binder. Upon drying and / or compression, the lignosulfonates and / or sulfonated lignin may gain their biomass-binding properties.

[0046] Lignosulfonates may have very broad ranges of molecular mass. A range of from 1000 to 140000 Da, i.e., 1000-140000 g / mol, has been reported for softwood lignosulfonates with lower values reported for hardwoods. Sulfonated lignin tends to have smaller molecules having a molecular mass in the range of 2000-3000 Da (2000-3000 g / mol). Both lignosulfonates and sulfonated lignin are non-toxic, non-corrosive, and biodegradable, whereby they may be well suited for the presented composition.

[0047] The biopolymer may comprise lignin subjected to hydrothermal carbonization treatment (HTC), i.e., HTC lignin. The hydrothermal carbonization treatment of lignin refers to a thermochemical conversion process of lignin-containing material in an aqueous suspension. Hydrothermal carbonization treatment of lignin produces lignin derivatives having high carbon content and functional groups.

[0048] The lignin may be derived from any suitable source. The lignin may be derived from e.g. wood, such as hardwood, softwood, broadleaf wood, or their combination, or from any other biomass such as sugarcane. The wood may originate from e.g. pine, poplar, beech, aspen, spruce, eucalyptus, ash, or birch. The wood may also be any combination or mixture of these.

[0049] The one or more binders bay comprise natural latex. In other words, the biopolymer may comprise natural latex. In the course of this application, the terms ‘natural latex’, ‘natural rubber’, ‘latex rubber’, and ‘natural latex rubber’ are used interchangeably. Natural latex consists of polymers of isoprene, with minor impurities of other organic compounds. Types of polyisoprene that are used as natural rubbers are classified as elastomers. Rubber is primarily harvested from the rubber tree Hevea brasiliensis. Latex is a sticky, milky and white colloid drawn off by making incisions in the bark and collecting the fluid in vessels in a process called tapping. The raw latex is then refined into latex rubber that may also be vulcanized. Natural latex may be biodegradable. Particularly, vulcanized natural latex may be susceptible to degradation by a wide range of bacteria such as Streptomyces coelicolor, Pseudomonas citronellolis, and Nocardia spp.

[0050] The one or more binders may comprise fatty acid polyesters. In other words, the biopolymer may comprise fatty acid polyesters. Preferably, the biopolymer may comprise suberin. Suberin is a naturally occurring complex polyester mainly composed of poly-functional long chain fatty acids, also called suberin acids, and glycerol. Suberin may serve as protective barrier, preventing water loss, microbial attacks, and physical damage. Suberin may provide the composition with both elasticity and hydrophobicity, possibly also with antistaticity.

[0051] The suberin may originate from birch bark.

[0052] Birch bark consists of brown inner bark (approx. 75 wt-%) and white outer bark (approx. 25 wt-%). The inner bark consists mainly of wood-like material such as lignin, pentosans and hexosans. The outer bark may comprise, by dry weight, up to 40 wt-% fats, fatty acids, resins and triterpenes, in particular betulin, at up to 30 wt-%. In addition, the outer bark may comprise up to 35 wt- % suberin (by dry weight).

[0053] Birch bark, particularly the outer bark, may be processed to extract betulin. Betulin, lup-20(29)-ene-3[3,28-diol, is a triterpenoid of lupane structure. It has a pentacyclic ring structure, and hydroxyl groups in positions C3 and C28. Betulin provides the protective white colour of birch tree. Betulin is lipophilic and well-known for its crystalline structure. Birch bark powder may be subjected to a liquid-solid extraction to recover suberin and / or co-hydroxy fatty acids. Suberin may be extracted from birch bark powder prior to or after extracting betulin.

[0054] The extracted betulin may be used in the composition as a binder. In other words, the terpenoid may be betulin.

[0055] The suberin may further be processed to obtain regenerated suberin. In other words, the biopolymer may comprise regenerated suberin. Regenerated suberin is an elastomeric material obtainable by a method of polymerizing suberin monomers. The suberin monomers may be obtained from powdered birch bark by removing extractives to obtain suberin. The suberin may undergo an alkaline hydrolysis, breaking down the suberin to suberin monomers, i.e. , suberic acids and glycerol. The suberin monomers may acidified, extracted, and melted, followed by polymerizing the melted monomers to obtain a crosslinked regenerated suberin.

[0056] The one or more binders may comprise any combination of any of the synthetic polymers, the biopolymers, and the terpenoids (such as betulin).

[0057] Particularly, the one or more binders may comprise birch bark, preferably the outer birch bark. As noted above, the outer bark may comprise, by dry weight, up to 40 wt-% fats, fatty acids, resins and triterpenes, in particular betulin, at up to 30 wt-%. In addition, the outer bark may comprise up to 35 wt-% suberin (by dry weight). The outer bark may be in powder form, i.e., powdered birch bark.

[0058] The one or more binders may comprise cork. Cork is composed of suberin (approx. 40 wt-%), lignin (approx. 20 wt-%), cellulose and hemicellulose (approx.18 wt-%), extractives (approx.15 -wt%), and other materials, the weight percentages calculated from the total weight. Cork is a lightweight material, viscoelastic and impermeable to liquids or gases, good thermal, acoustic and electrical insulator, sound and vibration insulator and exhibits a near-zero Poisson coefficient.

[0059] The one or more binders may comprise a combination of a synthetic polymer and one or more biopolymers. For example, the one or more binders may comprise poly(lactic acid) (PLA) combined with lignin or lignin derivative, polysaccharide, natural latex, fatty acid polyester, and / or terpenoid, including betulin, suberin, regenerated suberin, cork, and / or powdered birch bark.

[0060] The presented composition may optionally comprise one or more additives. The additives may provide the composition with improved mechanical properties and processability, as well as improved compostability, hydrophobicity, and flame-retardancy. The one or more additives may individually be selected from the group comprising plasticizers, coupling agents, processability agents, compatibility enhancers, stiffeners, flameretardants, and any combinations thereof. The composition may comprise the one or more additives in an amount of 0-30 wt-%, preferably in an amount of 0-10 wt-% of the total weight of the composition. More preferably, the composition may comprise the one or more additives in an amount of 1-8 wt- % of the total weight of the composition.

[0061] The composition may comprise one or more plasticizers as an additive. The one or more plasticizers may be individually selected from the group comprising glycerol, polyethylene glycol, and any combination thereof. Plasticizers may provide the composition with improved mechanical properties, such as increased flexibility and elasticity.

[0062] The composition may comprise one or more coupling agents and / or compatibility enhancers. The one or more coupling agents and / or compatibility enhancers may be individually selected from the group comprising maleic anhydride, silane, titanate, zirconate, and any combination thereof. Coupling agents may improve binding and miscibility between the biomass and the matrix of the one or more binders and the optional one or more additives.

[0063] The composition may comprise one or more stiffeners and / or flame-retardants as an additive. Particularly, the composition may comprise inorganic salts, such as calcium carbonate (Ca CO3), as an additive. Calcium carbonate may provide the composition with improved mechanical properties (e.g., improved stiffness). Calcium carbonate may further improve the fire-protection or flameretardant properties of the composition. Calcium carbonate may further improve the hydrophobicity and compostability of the composition. The calcium carbonate may originate from natural or synthetic sources. Preferably, the calcium carbonate originates from natural sources, such as eggshells, snail shells or seashells. The eggshells, snail shells or seashells may conveniently be crushed or powdered prior to using in the presented composition. In other words, the composition may comprise crushed eggshells, crushed snail shells or crushed seashells as an additive, preferably crushed eggshells.

[0064] The composition may have a density of > 1000 kg / m3In other words, the composition may have a density exceeding the density of water. The high density of the composition may provide the composition with the advantage of not floating in water.

[0065] The presented composition may be hydrophobic. In other words, the presented composition may lack affinity for water. Thus, the composition may be insoluble in water or immiscible with water. Hydrophobicity of the composition ensures that water originating from, e.g., rain, does not infiltrate into the structure of the composition. Thus, water, e.g., rain water, cannot alter the characteristics of the composition.

[0066] The composition may be non-flammable and / or non-combustible. The composition may be fire-resistant or at least fire-retardant.

[0067] The biomass may be arranged in the form of pellets in the presented composition. The composition may comprise the biomass pellets encapsulated in the matrix of the one or more binders and the optional one or more additives.

[0068] Alternatively or in addition, the composition may be arranged as a biocomposite, wherein the biocomposite comprises the biomass and the one or more binders, and optionally the one or more additives, in the form of a homogeneous mass.

[0069] The composition may even comprise the biomass in the form of pellets encapsulated in a matrix of a biocomposite comprising biomass and one or more binders, and optionally one or more additives. In other words, the composition may comprise biomass both in the form of pellets and in the matrix encapsulating the biomass pellets. The presented composition may be arranged in the form of non-spherical granules. The granules preferably have size in the range of 0.5-5 mm, more preferably in the range of 1-5 mm, even more preferably in the range of 1 .5- 4 mm. The size if the granules is defined as a largest linear dimension of an individual granule. The granules may take, e.g., ellipsoidal, pulvinated, cuboidal, cylindrical, tetrahedral, triangular prism-like, or non-symmetric shapes.

[0070] A process for preparing a composition is presented. The process comprises incorporating the biomass into a matrix of one or more binders and optionally one or more additives. The process is schematically presented in Figure 1 .

[0071] The incorporating the biomass into the matrix may comprise encapsulating the biomass by a mixture of the one or more binders and optionally the one or more additives. Alternatively or in addition, the incorporating the biomass into the matrix may comprise comprises mixing the biomass with a mixture of the one or more binders and optionally the one or more additives into a homogeneous mass, thus providing the composition in the form of a biocomposite.

[0072] The incorporating the biomass into the matrix may comprise encapsulating the biomass by a mixture of the one or more binders and optionally the one or more additives. The encapsulating may comprise depositing the mixture of the one or more binders and optionally the one or more additives onto the biomass. Alternatively or in addition, the encapsulating may comprise submerging the biomass into the mixture of the one or more binders and optionally the one or more additives.

[0073] Depositing the mixture of the one or more binders and optionally the one or more additives onto the biomass may comprise, e.g., spraying, brushing, rolling, screen printing, stamping or sponging.

[0074] The one or more binders and optionally the one or more additives may be premixed to provide the mixture prior to encapsulating the biomass by said mixture. The process may further comprise drying the mixture of the one or more binders and optionally the one or more additives with the encapsulated biomass to provide the composition.

[0075] The process may alternatively or in addition comprise forming a biocomposite. In other words, the incorporating the biomass into the matrix may comprise mixing the biomass with a mixture of the one or more binders and optionally the one or more additives into a homogeneous mass, thus providing the composition in the form of a biocomposite.

[0076] The process may comprise both encapsulating the biomass and the forming of the biocomposite. In other words, the process may comprise forming a biocomposite mixing the biomass with a mixture of the one or more binders and optionally the one or more additives into a homogeneous mass, followed by encapsulating biomass by said biocomposite.

[0077] The process may further comprise pre-treating the biomass prior to the forming the biocomposite or the encapsulating. The pre-treating may comprise one or more selected from cutting, chopping, pelletizing, defibrating, and any combination thereof.

[0078] The process may comprise pre-treating the biomass prior to the encapsulating. For example, biomass may be cut, chopped or pelletized prior to the encapsulating. The cut, chopped or pelletized biomass may then be encapsulated by the mixture of the one or more binders and optionally the one or more additives.

[0079] Alternatively, the biomass may be encapsulated by the mixture of the one or more binders and optionally the one or more additives without the pre-treating. The encapsulated biomass may further be granulated into non-spherical granules if desired, as described below.

[0080] The process may comprise pre-treating the biomass prior to the forming the biocomposite. For example, the biomass may be cut, chopped, and / or defibrated prior to mixing the biomass with a mixture of the one or more binders and optionally the one or more additives into a homogeneous mass. The homogeneous mass of the biocomposite may be granulated into non-spherical granules as described below.

[0081] The process may further comprise granulating the composition into granules, such as non-spherical granules. Preferably, the granules have size in the range of 0.5-5 mm. More preferably, the granules have size in the range of 1- 5 mm, even more preferably in the range of 1 .5-4 mm. The size of the granules may be defined as a largest linear dimension of an individual granule. The granulating may comprise one or more of wet laying, air laying, foam laying, extrusion, injection molding, cutting, chopping, pelletizing, and any combination thereof.

[0082] Granulating the composition into granules may be performed in different stages of the process for different process options.

[0083] For biomass encapsulated by the mixture of the one or more binders and optionally the one or more additives, the granulating may comprise one or more of wet laying, air laying, foam laying, and any combination thereof. Alternatively or in addition, the granulating for the encapsulated biomass may comprise one or more of cutting, chopping, pelletizing, and any combination thereof. If the biomass is cut, chopped or pelletized prior to the encapsulation, the granulating may comprise one or more of wet laying, air laying, foam laying, and any combination thereof. If the biomass is encapsulated without the pretreating, the granulating may comprise one or more of wet laying, air laying, foam laying, cutting, chopping, pelletizing, and any combination thereof.

[0084] For the biocomposite, the granulating may comprise one or more of wet laying, air laying, foam laying, extrusion, injection molding, cutting, chopping, pelletizing, and any combination thereof. For example, the biocomposite may directly be extruded or injection molded into the non-spherical granules. Alternatively, the biocomposite may be wet laid, air laid, foam laid, injection molded, or extruded into a mat, followed by drying and cutting or chopping the mat into the non-spherical granules.

[0085] Wet laying refers to a process where a suspension of water and the material to be granulated, i.e., the biomass encapsulated by the mixture of the one or more binders and optionally the one or more additives, or the biocomposite, is deposited on a forming wire. The water is sucked off, leaving the material to be granulated on the forming wire as a mat, followed by drying and cutting or chopping the mat into the non-spherical granules.

[0086] Foam-laying is a variation of the wet laying process wet process where the aqueous foam instead of water is used to deposite the material to be granulated on the forming wire. In foam-laying, a surfactant is needed to foam up the suspension of the water and the material to be granulated.

[0087] Air laying refers to a process where the material to be granulated, i.e., the biomass encapsulated by the mixture of the one or more binders and optionally the one or more additives, or the biocomposite, is fed into a fast-moving air stream, followed by condensing the material onto a forming wire by means of pressure or vacuum. The condensing step in the air laying process may be followed by drying and cutting or chopping the mat into the non-spherical granules.

[0088] Injection molding refers to a process where molten material is injected into a mold, where it cools and hardens to take the shape of the mold.

[0089] Extrusion refers to a process where a thermoplastic material is heated, homogenized and compressed within an extruder. The mass is fed through a nozzle by an extruder screw, thus providing the final shape of the granule.

[0090] The presented composition may be suitable for use in any application where polymer biocomposites can be used. The presented composition may be suitable for both indoor and outdoor use depending on the selected use. The presented composition may find uses in household plastic products, packaging, sports, handheld tools, construction, electronics, casings or protective covers for electronic devices, toys and games, clothing accessories, vehicle interiors, interior fixtures, such as bathroom fixtures, among others.

[0091] The presented composition may be particularly suitable for use as an infill material in artificial turf surfaces.

[0092] There is an increasing need for high-quality playing surfaces for, e.g., football. Natural grass has been conventionally used for decades. However, natural grass has a poor wear resistance, and the playing surface is easily damaged upon use. Furthermore, natural grass surfaces may be difficult to grow and to maintain, especially in cold climates.

[0093] Along with natural grass surfaces, artificial turf surfaces have gained an increased interest in the recent years. Artificial or synthetic turf refer to surfaces made of synthetic materials that replicate the look and feel of natural grass. Typically, artificial turf is constructed from a substrate, artificial grass fibers and a granular infill material located between the fibers. The artificial grass fibers are most conveniently attached to the substrate.

[0094] Safety and playing performance of artificial turf surfaces have increased from the first artificial turfs, such as the AstroTurf, TartanTurf and PolyTurf installed in the Northern America in the 1960s and 1970s. Artificial turf surfaces enable the playing field to be used more frequently without the need for fixing or regrowing the grass. They generally require less maintenance compared to natural grass surfaces. Artificial turf systems are not dependent on photosynthesis, whereby they can be used also in cold climates having a small heat summation value. Artificial turf is also highly suitable for indoor playing fields.

[0095] A granular infill material is typically used in artificial turf to support the artificial grass fibers, to add weight to the artificial turf, and to increase elasticity of the artificial turf. The increased elasticity adds safety in, e.g., falling incidents.

[0096] Sand (silica) and polymeric or elastomeric infill materials are widely used in artificial turf systems, possibly also in combinations. Polymeric materials are well-suited for infill materials due to their hydrophobicity and elasticity. However, due to the increasing environmental concern with respect to plastic pollution and marine litter, new infill materials are required.

[0097] The use of biomass as infill composition has been investigated. However, using biomass alone as the infill composition is not desired, because biomass granules are hard and brittle. Biomass granules would thus break apart easily under wear. Furthermore, the hardness of plain biomass granules may increase the seventy of injuries when slipping or falling over. The presented composition may provide a material that meets the environmental standards regarding plastic pollution while still maintaining the characteristics required for high-quality artificial turf surfaces.

[0098] The presented product may be an artificial turf. The artificial turf comprises the presented composition, or an composition obtainable by the presented process as an infill material, termed also an infill layer, or shortly, infill. The infill layer may consist of the presented composition.

[0099] Referring to Figure 2, the artificial turf may comprise a substrate 201 , to which artificial grass fibers 202 are attached. The presented composition, the form of granules 203, may be arranged between the artificial grass fibers. The granules 203 are preferably arranged between the artificial grass fibers 203 as a loosely packed layer. A loosely packed layer refers to a layer of the granules of the composition, wherein void spaces are formed between the individual granules 203. The loosely packed layer of the granules of the presented composition may thus constitute the infill layer or infill material of the artificial turf surface.

[0100] The presented composition may suitable for use as an artificial turf infill in both indoor and outdoor playing fields.

[0101] Antistaticity of the composition may provide benefits in artificial turf applications. Antistaticity of the composition may increase the safety of the artificial turf surfaces by reducing the electric shock hazard for the users of an artificial turf playing field utilizing the presented composition as an infill.

[0102] Elasticity of the composition may provide benefits in artificial turf applications utilizing the presented composition as an infill. Elasticity of the composition may increase the user safety of artificial turf surfaces by diminishing the risk of injuries in, e.g., falling incidents.

[0103] The high density of the composition may provide the composition with the advantage of not floating in water. This may be particularly advantageous in artificial turf infill use. Thanks to the high density of the composition, rain falling on the playing field may remain above the infill layer comprising the presented composition on the artificial turf surface. Therefore, the infill layer comprising or consisting of the presented composition may remain in the bottom part of the artificial turf surface even during heavy rain. Thus, the density of the composition may be selected such that the composition does not escape from between the artificial grass fibers even during rain. Compositions with a density of > 1000 kg / m3may be especially suitable for use in outdoor playing fields. There is nothing, however, that would limit the use of compositions with a density of > 1000 kg / m3in indoor playing fields.

[0104] Hydrophobic compositions may be especially suitable for use in outdoor playing fields, since water, such as rain water, cannot infiltrate into the structure of the composition that might cause altering the characteristics of the composition. The life period of an artificial turf comprising the presented composition as an infill may thus be improved compared to infill materials with a higher affinity for water. There is nothing, however, that would limit the use of hydrophobic compositions in indoor playing fields.

[0105] Non-flammability and / or non-combustibility of the composition may provide advantages in artificial turf applications, as fire-resistant or at least fire- retardant artificial turf surfaces may be produced by using the presented composition as an infill. The non-flammability and / or non-combustibility of the presented composition and artificial turf increase the fire safety of artificial turf playing fields. Non-flammable and / or non-combustible compositions may be especially suitable for use in indoor playing fields. There is nothing, however, that would limit the use of non-flammable and / or non-combustible compositions in outdoor playing fields.

[0106] Non-spherical shape of the granules may provide the composition with several advantages in artificial turf applications. The non-spherical shape of the granules may prevent the granules from packing too densely when used as an infill in an artificial turf structure. The non-spherical shape of the granules ensures that void spaces are formed between individual granules in an infill layer. The void spaces may improve the penetrability of water through the infill layer, thus improving the water permeability of the entire artificial turf structure. Water permeability of the artificial turf structure may be advantageous during, e.g., rain, because rain water may be more efficiently and rapidly lead away from the artificial turf surface. The non-spherical shape of the granules may further provide the composition and the artificial turf with increased friction, leading to reduced risk of slipping and falling over. Thus, the non-spherical shape of the granules may provide the composition and the artificial turf with increased user safety.

[0107] Examples

[0108] Example 1. Encapsulated biomass pellets

[0109] Common reed was used as a raw material. The reed material was chopped and pelletized into cylindrical pellets with ca. 3 mm length. The reed pellets were coated with a mixture of lignin, PBS and additives. The encapsulated reed pellets were dried by air laying, and the resulting mat was cut into granules. The resulting composition contains 35 wt-% reed, 20 wt-% lignin, 40 wt-% PBS, and 5 wt-% additives.

[0110] Example 2. Biocomposite

[0111] Common reed was used as a raw material. Polybutylene succinate (PBS) and lignin were used as binders. The reed material was chopped into fibers and mixed with PBS, lignin and additives. The resulting composition contains 33 wt-% reed, 13 wt-% lignin, 50 wt-% PBS, and 4 wt-% additives.

[0112] Example 3.

[0113] Different compositions were containing varying amounts of biomass (common reed), natural latex, cork, eggshell, and lignin were tested. Table 1 presents the contents of each material in the composition in wt-% of the total weight of the composition. Example 4. Water adsorption test

[0114] Samples 2 and 6 of Example 3 were tested for water adsorption. The samples were immersed in water for 3 hours. The samples were weighed before the water immersion, after 1 h immersion time, and after 3 h immersion time. The weight of the samples did not change within the measurement accuracy of the used setup. It was noted that the samples did not float in water.

Claims

Claims:

1. A composition comprising biomass and one or more binders comprising synthetic polymer, biopolymer, terpenoid, or any combination thereof, and optionally one or more additives, wherein the biomass is incorporated into a matrix of the one or more binders and the optional one or more additives.

2. The composition according to claim 1 , wherein the biomass is selected from the group comprising reed, sedge, cork, coconut, hemp, grass, cellulose, reed, hay, straw, and any combination thereof.

3. The composition according to claim 1 or 2, wherein the synthetic polymer is selected from the group comprising poly(lactic acid) (PLA), polyhydroxyalkanoate (PHA), polybutylene succinate (PBS), polyhydroxybutyrate (PHB), polycaprolactone (PCL), poly(3-hydroxybutyrate- co-3-hydroxyvalerate) (PHBV), polyacrylates, polyurethanes, and any combination thereof.

4. The composition according to any of the preceding claims, wherein the biopolymer is lignin or lignin derivative, preferably wherein the biopolymer is lignin derivative selected from lignosulfonate, sulfonated lignin, lignin subjected to hydrothermal carbonization treatment, i.e., HTC lignin, and a combination thereof.

5. The composition according to any of the preceding claims, wherein the biopolymer is a polysaccharide selected from the group comprising starch, chitosan, pectin, and any combination thereof; or wherein the biopolymer is natural latex.

6. The composition according to any of the preceding claims, wherein the biopolymer is a fatty acid polyester, preferably suberin.

7. The composition according to any of the preceding claims, wherein the terpenoid is betulin.

8. The composition according to any of the preceding claims, further comprising one or more additives, the one or more additives being selectedfrom the group comprising plasticizers, coupling agents, processability agents, compatibility enhancers, stiffeners, flame-retardants, and any combinations thereof; and / or wherein the one or more additives comprise eggshells, snail shells or seashells.

9. The composition according to claim 8, wherein the plasticizer is selected from the group comprising glycerol, polyethylene glycol, and any combination thereof.

10. The composition according to any of the preceding claims, wherein the coupling agent and / or compatibility enhancer are individually selected from the group comprising maleic anhydride, silane, titanate, zirconate, and any combination thereof.

11. The composition according to any of the preceding claims, wherein the composition has a density of > 1000 kg / m312. The composition according to any of the preceding claims, wherein the biomass is arranged in the form of pellets, whereby the composition comprises the biomass pellets encapsulated in the matrix of the one or more binders and the optional one or more additives.

13. The composition according to any of the preceding claims, wherein the composition is arranged as a biocomposite, wherein the biocomposite comprises biomass and the one or more binders, and optionally the one or more additives, in the form of a homogeneous mass.

14. The composition according to any of the preceding claims, wherein the composition is arranged in the form of granules, preferably non-spherical granules, wherein the granules have size in the range of 0.5-5 mm, more preferably in the range of 1-5 mm, even more preferably in the range of 1 .5- 4 mm, the size defined as a largest linear dimension of an individual granule.

15. The composition according to any of the preceding claims, wherein the composition is compostable, preferably industrially compostable according to the European standard EN 14995:2007.

16. The composition according to any of the preceding claims, wherein the composition comprises the biomass in an amount of 5-95 wt-%, preferably in an amount of 20-60 wt-%, the synthetic polymer in an amount of 0-95 wt-%, preferably in an amount of 5-95 wt-%, more preferably in an amount of 20-80 wt-%, the biopolymer in an amount of 0-95 wt-%, preferably in an amount of 5-95 wt-%, more preferably in an amount of 20-80 wt-%, and optionally the additive in an amount of 0-30 wt-%, preferably in an amount of 0-10 wt-%, more preferably in an amount of 1-8 wt-% of the total weight of the composition.

17. A process for preparing a composition according to any of claims 1 to 16, the process comprising incorporating the biomass into a matrix of one or more binders and optionally one or more additives.

18. The process according to claim 17, wherein the incorporating the biomass into the matrix comprises encapsulating the biomass by a mixture of the one or more binders and optionally the one or more additives.

19. The process according to claim 18, wherein the encapsulating comprises- depositing the mixture of the one or more binders and optionally the one or more additives onto the biomass; or- submerging the biomass into the mixture of the one or more binders and optionally the one or more additives, and wherein the process further comprises drying the mixture of the one or more binders and optionally the one or more additives with the encapsulated biomass to provide the composition.

20. The process according to any of claims 17 to 19, wherein the incorporating the biomass into the matrix comprises forming a biocomposite by mixing the biomass with a mixture of the one or more binders and optionally the one or more additives into a homogeneous mass.

21. The process according to any of claims 17 to 20, wherein the process further comprises pre-treating the biomass prior to the forming the biocomposite or the encapsulating, the pre-treating comprising one or more selected from cutting, chopping, pelletizing, defibrating, and any combination thereof.

22. The process according to any of claims 17 to 21 , wherein the process further comprises granulating the composition into granules, preferably non- spherical granules, wherein the granules have size in the range of 0.5-5 mm, more preferably in the range of 1-5 mm, even more preferably in the range of 1.5-4 mm, the size defined as a largest linear dimension of an individual granule, wherein the granulating comprises one or more of wet laying, air laying, foam laying, extrusion, injection molding, cutting, chopping, pelletizing, and any combination thereof.

23. A product comprising the composition according to any of claims 1 to 16, or a composition obtained by the process of any of claims 17 to 22.

24. The product according to claim 23, wherein the product is an artificial turf, preferably wherein the artificial turf comprises a substrate (201 ), to which artificial grass fibers (202) are attached, and the presented composition in the form of granules (203) arranged between the artificial grass fibers as an infill.

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