research & development roadmap bio-based polymers jochen michels dechema e.v. 17 march, 2015
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Research & Development RoadmapBio-Based Polymers
Jochen MichelsDECHEMA e.V.17 March, 2015
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Biodegradable and/or compostable bio-based polymers(e.g. PLA and PHAs)
Non-biodegradable bio-based polymers(e.g. bio-based PE, partially bio-based PET and PTT)
Non-biodegradable thermosets(e.g. partially bio-based polyurethanes and epoxies)
Bio-based plastics are a heterogeneous group:
Roadmapfocus
Research & Development Roadmap
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Biodegradable and/or compostable bio-based polymers(e.g. PLA and PHAs)
Non-biodegradable bio-based polymers(e.g. bio-based PE, partially bio-based PET and PTT)
Non-biodegradable thermosets(e.g. partially bio-based polyurethanes and epoxies)
Bio-based plastics are a heterogeneous group:
Roadmapfocus
Research & Development Roadmap
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PLA is produced by chemical polymerisation of lactic acid, which is a anaerobic fermentation product
Fermentation leads to either optically pure L-(+)- or D-(-)-lactic acid, which are the desired sources for the polymerisation
Impurities by its counterpart enantiomer lead to more amorphic polymers with different properties, which are relevant for processing and use
Polylactic acid (PLA)
Research & Development Roadmap
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PHAs are a group of biodegradable biobased linear polyesters which are produced directly by microbes in an aerobic fermentation process
PHA are intracellular storage substances (as granules)
The most common type of PHA is the homopolymer of 3-hydroxybutyrate (PHB), which became available in the 1980s
Polyhydroxyalkanoates (PHA)
Research & Development Roadmap
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Systematic of Hurdles & Solutions
Research & Development Roadmap
Hurdles & Solutions General(horizontal)
Specificfor PLA
Specificfor PHA
Feedstock supply
Bioconversion
Downstream processing
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Systematic of Hurdles & Solutions
Research & Development Roadmap
Hurdles & Solutions General(horizontal)
Specificfor PLA
Specificfor PHA
Feedstock supply
Bioconversion
Downstream processing
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Main Hurdles and Solutions (general)
Supply of sufficient amounts of feedstock*
1. Integrate feedstock production and bioconversionto minimize transportation costs and post-harvest losses
2. Certification of feedstock productionagainst fluctuating feedstock quality (incl. waste)
3. New (non-food) feedstocks
4. Develop Biorefinery conceptsto valorize the biomass as much as possible
*that compete on price with fossil derived feedstocks
Research & Development Roadmap
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Main Hurdles and Solutions (specific for PLA & PAH)
Supply of sufficient amounts of feedstock*
1. Waste streams & by-productslike residues from agricultural materials or glycerol from biodiesel production
2. 2nd generation lignocellulosic feedstockslike wood or straw (C6 & C5 conversion)
3. C1-compoundsSyngas-fermentation (CO, CO2, H2)
4. Complex nitrogen sourceslike grass press juice
*that compete on price with fossil derived feedstocks
Research & Development Roadmap
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Main Hurdles and Solutions (general)
Poor performance and efficiency of bioconversion
1. Novel microbial production routes for• tolerance to cheap feedstocks and• resistance to by-products and target products• anaerobic fermentation
2. New enzymes for improved biocatalysis• more active and robust enzymes• engineered bioproduction systems for enzymes
3. New water management systems
Research & Development Roadmap
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Main Hurdles and Solutions (specific for PLA)
1. New production strains• higher yield• tolerance against by-products of hydrolysis of
2nd generation feedstocks
2. Lactate solely fermentation from alt. C-sources without by-products (like acetate)
3. Optical pure L(+)- or D(-)-lactate fermentationby genetic engineering
4. Lower pH-Optimum of fermentationminimizes salt and gypsum production
Poor performance and efficiency of bioconversion
Research & Development Roadmap
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Main Hurdles and Solutions (specific for PAH)
1. Anaerobic fermentation processE. coli for anaerobic fermentation
2. Unsterile, anaerobic fermentation processS. cerevisiae for anaerobic fermentation
3. Mixed culture fermentationMulti phase biological synthesis of PHA
4. Transgenic plant cells
Poor performance and efficiency of bioconversion
Research & Development Roadmap
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Main Hurdles and Solutions (general)
High level of im-purities and low product conc. hampers down-stream processing
1. Modeling of the entire processfor maximum product (and space-time) yield
2. New more efficient bio-catalytic systems(see: bioconversion)
3. Integrating Bioconversion with DSPalso includes chemical conversion
4. New water management systems• Improved product recovery from water• Minimising water usage
5. Separation technologies to improve product recovery, contaminant removal and water re-use
Research & Development Roadmap
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Main Hurdles and Solutions (specific for PLA)
High level of im-purities and low product conc. hampers down-stream processing
(Reference to the presentation of Dr. Schulze, TKIS)
Research & Development Roadmap
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Main Hurdles and Solutions (specific for PAH)
Environmentally friendly & cost-effective PHA granule recovery steps are needed e.g. sodium hypochlorite extraction
Expensive PHA extraction step*
Research & Development Roadmap
* Not applicable are: • solvent based extraction (chloroform)• enzyme based biomass digestion• mechanical disruption
Non-technological RoadmapBio-Based Polymers
Dirk CarrezClever Consult bvba17 March, 2015
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Main hurdles and bottlenecks (as identified by the stakeholders)
Feedstock related barriers
Logistics: securing large quantities of biomass all year round
Seasonability of biomass cropping versus need of continuous feedstock supply
Inefficient transport and distribution of biomass Inefficient recovery systems for (bio)waste
Feedstock at affordable prices
Costs of feedstock produced in Europe are too high compared to other regions
Varying feedstock prices (High) import costs for certain types of feedstock No commonly accepted “sustainability” certification
system
Investment barriers and financial hurdles
Capital requirements
Limited availability of public R&D funding Limited public support for scale-up activities Limited access to finance for spin-offs and start-ups Limited access to finance for SMEs Limited financial support for new production facilities
IB perceived as sector with high investment risk Too long “return of investment” time Lack of visible tangible products and blockbusters Lack of investors’ confidence
Public perception and communication
Poor public perception and awareness of IB and Biobased products
Advantages of biobased products are not visible enough Negative messages in the media on GMO and biofuels
influence perception of IB
Demand side policy barriers
Absence of incentives or efficient policies
No framework to promote biobased products Lack of a “green public procurement” policy promoting
biobased products Wide variety of ecolabels and no uniform standard
present for sustainable and Biobased products
Non-technological Roadmap
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HURDLE SOLUTIONS
New biobased plastics are often more expensive than the conventional ones
Funding for innovations in order to reduce production costs (e.g. conversion technologies and down-stream processing)
Explain better the benefits of bioplastics, so consumers accept to pay a (bio-)premium
New value chains still have to be developed to obtain critical mass
Develop infrastructure for effective composting or recycling Development of policy tools to stimulate demand
Need for clear standards and a regulatory framework promoting market uptake
Defining in a transparent way the characteristics:‘green’, “bio-degradable”, “biobased”, “bioplastics”, etc
Develop clear standards Improve communication and education Developing a good programme to stimulate market uptake in
Europe (e.g. public procurement)
Lack of financial incentives Implementing a tax and/or subsidies for certain applications to
close the price gap between biobased and fossil based plastics
Biobased plastics (e.g. PLA, PHA)
Main hurdles and solutions
Non-technological Roadmap
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