research & development roadmap bio-based polymers jochen michels dechema e.v. 17 march, 2015

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


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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)


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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)


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Systematic of Hurdles & Solutions


Hurdles & Solutions General(horizontal)

Specificfor PLA

Specificfor PHA

Feedstock supply

Bioconversion

Downstream processing

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Systematic of Hurdles & Solutions


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


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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


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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


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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



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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



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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


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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)


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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*


* 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

research & development roadmap bio-based polymers jochen michels dechema e.v. 17 march, 2015

Documents

biobased pet

biobased polyurethanes

epoxies biobased plastics

main hurdles

solutions specific

new enzymes

amorphic polymers

new nonfood feedstocks