Final Report Summary - BISIGODOS (High value-added chemicals and BIoreSIns from alGae biorefineries produced from CO2 provided by industrial emissions)
Executive Summary:
BISIGODOS is a 42-month project that aims at the production of high value-added algae derived chemicals and bio-resins for flexible packaging, coatings, printing, food and hair care applications.
The starting raw material is cost-effective and renewable algae biomass, which is directly cultivated from the CO2 from industrial emissions (cement, steel factory, thermal power plants, etc.).
The work carried out during was related to the cultivation of the algae strains based on the requirements of the cases of study and optimal growth conditions (WP2), mathematical modelling of the process and its implementation in a software program process, integration, energetic and mass balance evaluation and improvement (WP3), extraction of the lipid fraction and the transesterification of fatty acids and the production of diols and diisocyanates for producing polyurethane adhesives (WP4)
Moreover, in WP5 and WP6, some of the compounds were separated and processed further for aminoacids, conductive polymers, surfactants and ink production. The scaling up of each selected fine chemical substance and bio-resins was studied and carried out in WP7
In WP8 the regulatory, economic and environmental viability study of each selected fine chemical substance and bio-resins was carried out. Dissemination and exploitation activities was achieved along the project development in WP9 as well as Project Management (WP10).
Project Context and Objectives:
BISIGODOS aims to address the production of valuable algae derived chemicals, amino acids and high added-value bio-resins for flexible packaging, coatings, printing, food and hair care applications, starting from algae biomass fed directly with CO2 from industrial emissions (cement, steel factory, thermal power plants, etc.) as raw material that is cost-effective and renewable. The process is assisted by solar radiation, nutrients and sea water microalgae. In order to develop such technology, several innovative approaches were proposed:
-New algae strains production optimization and CO2 energetic balance improvement.
-Optimization of photo-bioreactors by means of the implementation of a software program process.
-Selection and adaptation of separation of algae components based on hybrid technologies.
-Production of algae derived chemicals for hair care, flexible packaging, coatings and food applications
-Production of bio-based chemicals from algae based fatty acids such as diols and diisocyanates.
-Real knowledge achieved of the algae derived products in the industrial-market atmosphere from the techno-economical, environmental and regulatory point of view:
Analysis of the possibilities that the microalgae technologies offer and contributing to define the roadmap of the technology.
See table with objectives in the attachment
Project Results:
The main scientific and technological results achieved are the following presented in WP basis. Partners description can be found in the project website: http://www.bisigodos.eu/
WP1 Proposed substances to recovery and the pathway definition
Leader: CRODA
Participant partners: ALL
Objectives
Definition of the needs and requirements of the producers and end users of the algae derived products to be obtained. To perform a preliminary economic, environmental and energetic review in order to help in the selection of the most promising substances. To define the best pathway to concentrate, purify or/and recover the substances of interest.
Risk management: to carry out a continuous (ongoing) assessment of the progress of the project. To review the progress of the work in relation to the defined success measures and to report on this progress. Where appropriate, contingency plans are identified and implemented
Work Plan
Task 1.1 Definition, compilation and summary of the needs and requirements of the end users.
Task 1.2 Market and trend analysis of the substances case of study
Task 1.3 Undertake analysis of legislation and identify key compounds of commercial interest.
Task 1.4 Definition of separation and purification technologies requirements
Task 1.5. Risk indicators definition and risk management
Results
-End-user requirements for selected case studied defined
-Separation and purification technologies requirements outlined
-Market, standards and legislation requirements defined
-WP risk indicators identified
WP2 Algae production optimization
Leader: PHYCOSOURCE
Participant partners: AIMPLAS, PDC, BFS, BANGOR
Objectives
To optimize and enhance the algae route production process in terms selection of the suitable algae strains in order to achieve a suitable yield in obtaining the substances of interest previously defined in WP1. To control the growing conditions and select alternative algae strains to maximize the production of proposed high added value substances.
Work Plan
Task 2.1 Selection, characterization and optimization of the most suitable algae strains
Task 2.2 Evaluation of the optimal growth conditions achievement
Task 2.3 Final microalgae composition determination and optimization
Results
- Improvements in the procedure of growing algae strains: cultivation and scaling up
- 3 algae strains selected: Nannochloropsis, Porphyridium and Dunaliella salina
WP3 Photo-bioreactors optimization
Leader: BFS
Participant partners: AIMPLAS, PHYCOSOURCE, CASPEO, VTT, BANGOR, WARWICK
Objectives
To optimize the bio-reactors and enhance the algae route production process in terms of yield, energy balance,and improvement of the process parameters to facilitate process scale-up, control and integration. To improve current CO2 energy balance, by reducing in at least 20% of the consumption of energy in the whole process (photo-bioreactors and thermo-chemical process)
Work Plan
Task 3.1 Evaluation and optimization of the bio-reactor design
Task 3.2 Process control
Task 3.3 Process integration, energetic and mass balance evaluation and improvement
Results
-Mathematical modelling of the process and the photo-bioreactors and its implementation in a software program: assessment of the energy required to maintain the culture temperature in its optimal range throughout the year; prediction of the evolution of culture temperature with time on an hourly basis; simulation of the action of temperature regulation systems; size heating/cooling equipment; optimization of the design of the PBR (geometrical parameters, materials); comparison of various geographical locations; estimation of the monthly average microalgae production
-Improvement of the heat transfer modelling
WP4 Bio-polyurethane adhesives development
Leader: CUSA
Participant partners: AIMPLAS, 3VTECH, PDC, GBR.AT VTT, WARWICK
Objectives
The main objectives of WP4are to convert non-food unsaturated methyl acid esters (extracted and transesterificated in free fatty acids) into diols using a tungsten-based catalyst system and subsequently convert these diols into polyurethanes using commercially available diisocyanates. In a second stage, we have also transformed the fatty acids into diisocyanates and as a result produce 100% bio-derived polyurethanes (PU) by reacting them with the diols from the first stage.
Work Plan
Task 4.1 Environmental friendly Lipid extraction technologies from algae biomass
Task 4.2 Solid catalysed transesterification from triglycerides to methyl ester fatty acid
Task 4.3 Diol synthesis
Task 4.4 Diisocyanate synthesis
Task 4.5 PU synthesis from diols and diisocyanates
Task 4.6 PU adhesives validation
Results
- Novel separation systems for algae HTL products
- Robust catalyst selected for algae oil transesterification
- Improvements in the process of breaking the cells
- Controlled ring opening of epoxidised fatty acids to produce oligomeric diols
- Industrially-viable route to diisocyanates from lipids
- Diols & Diisocyanates production for bio-PU adhesives
WP5 Separation technologies. Conductive polymers for anticorrosive paints and
bio-based surfactants
Leader: BANGOR
Participant partners: AIMPLAS, 3VTECH, PDC, BECKER, CRODA, VTT, BANGOR, BFS
Objectives
The main objective of WP5 is to study and achieve low energy and cost-effective separation procedures that would allow producing anti corrosion coatings and biobased gemini surfactants chemicals using as a raw material the phenol and pyrrolidones fraction. To produce high value drop-in biofuel, which ultimate properties as an aviation fuel would be obtained via blending/additivation.
Work Plan
Task 5.1. Optimisation of hydrothermal process variables
Task 5.2 Separation of high value chemicals.
Task 5.3 Modelling of separation process
Task 5.4. Upgrading of BFS Hydrothermal Bio-fuel as Drop-In Biofuel and bio-solvents
Task 5.5 Production of the biosurfactants
Task 5.6 Production of conductive polymer
Task 5.7 Production and evaluation of anticorrosive pigment
Results
-Improvements in the extract purification
-Hybrid thermal separation system
-Thermo-chemical process implemented
-Production of conductive polymer coated chromate free pigments for use in pre-coated metal
-Production of furan dicarboxylic acid based polyesters to replace phthalate based polyesters in primers for pre-coated metal
WP6 Bio-based inks binders and aminoacids
Leader: GBR.AT
Participant partners: AIMPLAS, 3VTECH, SUNCHEM, BANGOR
Objectives
The main objectives of WP6 are to produce a bio-based resin which performance would allow substituting a percentage of existing petroleum based resins used in standard flexographic inks formulations. These bio-based resins are based in a new range of acrylic and vinyl-lactam (styrene like) analogues and their copolymers from biomass feedstocks derived from the thermal processing of microalgae that are fractioned in WP5. Produce a bio-based resin which performance would allow substituting 10-20% existing petroleum based resins presently used in flexographic inks manufacturing and 30% in current HybridTM for compostable plastic. To formulate and develop a new range of bio-based binder systems for water based printing and coating applications that are replicated the current technology which consists of 60% styrene and 40% acrylic functionalities, but would provide products environmentally friendly. Final properties of water ink binder may be at least 75% in comparison with current binder formulated from petrol based monomers. To produce a new range of acrylic and vinyl lactam (styrene like) analogues and their copolymers from biomass feedstocks derived from the thermal processing of microalgae that are cheaper feedstocks than existing higher sugar content materials with food used. To obtain a broad range of amino acids and protein products with a crude protein higher than 60% using an adapted FrALs technology as described in the state-of-the-art.
Work Plan
Task 6.1 Binder for water based printing inks and coatings development
Task 6.2 Evaluation in ink applications
Task 6.3 Amino acids and proteins production
Results
-Extraction and production of amino acids from defatted algae biomass.
-Acrylic styrene bio-based analogues to be applied in the flexible packaging market, as a sustainable supplement to existing petrochemical based materials.
WP7 Scale-up and validation of industrial products
Leader: BECKER
Participant partners: ALL
Objectives
WP 7 translated substances development from WP2-6 to industrial prototype scale. The main objective is the development of semi-industrial routes at DEMO stage for obtaining algae derived chemicals, amino acids, proteins and valuable bio-resins, to study the easiness of scaling up the processes, to test the substances and technologies in real world test and applications and to demonstrate the potential of the
innovative production of valuable substances starting from algae biomass (CO2 indirectly) using CO2 from industrial emissions. The substances are then produced, finished and assessed against existing traditional production routes used for each application (described below). A ‘Guide to best practice for production of algae derived chemicals, amino acids and bio-resins using the microalgae biomass are produced, to contribute to the technology transfer and dissemination.
Work Plan
Task 7.1 Scaling-up the production of alternative algae strains selected in WP2 in the new optimized BFS’s photo-bio-reactors
Task 7.2. Scaling-up algae bio-based PU adhesives for flexible packaging applications
Task 7.3 Scaling-up bio-based conductive polymer for anticorrosive paints and coatings
Task 7.4 Scaling-up Gemini surfactants for hair care products applications
Task 7.5 Scaling-up binders for water-based printing inks
Task 7.6 Scaling-up Amino acids for food applications
Task 7.7 To elaborate a “Guide to produce algae derived chemicals and bio-resins from algae biomass using CO2 from industrial fumes as raw material”
Results
- Scaling-up new algae strains and photo-bioreactors optimization
- Scaling-up the bio-based polyurethane adhesives
- Scaling-up the bio-based conductive polymer
- Scaling-up amino acids
- Guide to produce algae derived chemicals and bio-resins from algae biomass using CO2 from industrial fumes as raw materials
WP8 Economic, logistic, environmental and health evaluation
Leader: AIMPLAS
Participant partners: ALL
Objectives
The aim of this WP is to conduct an environmental, logistic and economic impact study of the new substances obtained throughout each stage of development from microalgae culture production to application in the selected industry sectors (hair care products, inks, paints, food and adhesives) to ensure compliance with legislation and to maximise market acceptance. For each defined end user product, we have:
• Analysed the CO2 energy balance.
• Studied the environmental suitability of the algae derived chemicals, amino acids, protein and high added-value bio-resins production by a Life Cycle Assessment (LCA) study
• Assessed the economic viability of the processes, and ensured that the obtained substances fulfil related legal requirements.
• Health and safety issues related to final products, proposed chemical routes and separation technologies. In summary, WP8 provided:
i) Decision tools to WP2 to WP7 based on technical, economic and environmental assessment to help the design of process development strategies;
ii) A data-set of indicators for each substance obtained in order to assess the feasibility and sustainability of large-scale commercial operation.
Work Plan
Task 8.1. Economic analysis
Task 8.2. Environmental study
Task 8.3. CO2 energy balance for selected products produced from industrial CO2 fumes
Task 8.4 Regulatory analysis and safety issues
Results
-Cost Calculation
- LCA studies for the selected products
-Techno-economical evaluation of the processes and products involved to achieved algae-derived chemicals and resins
-Continuous assessment and analysis of the regulatory and safety aspects
-Report on CO2 energy final balance
Potential Impact:
Potential impact
Exploitation was carefully planned and managed from an early stage in the project to ensure maximum exploitation impact after the project
-The use of environmentally and low toxicity routes to produce bio-polyurethanes, conductive polymers, aminoacids and inks produces a positive environmental impact. In addition, the results of using non-food renewable biomass and green chemistry routes in comparison with current technologies boosts the societal implications: Meeting the market needs without compromising the needs of future generations.
-Eco-efficiency is achieved by the delivery of economically competitive goods and services that satisfy their customers’ needs and brings quality of life, while progressively reducing ecological impact and resource intensity throughout the lifecycle.
- The innovative algae derived chemicals and bio-resins from microalgae biomass biorefineries using CO2 as raw material will be successful on the market and have improved participants’ skills and portfolio, EU food, inks, bio-surfactants, polyurethane adhesives and anticorrosive coating industry competitiveness and companies’ creation opportunities.
Exploitation of results
Potential Key Exploitation Results
Type of exploitable foreground Description Owner(s)
Commercial exploitation of R&D results Improvement on vacuum thermal purification 3VTECH
General advancement of knowledge Hybrid thermal separation system 3VTECH
Commercial exploitation of R&D results Continuous dehydration system 3VTECH
Technology transfer. R&D activities and consultancy services. Knowledge in algae derived chemicals and bio-resins synthesis and validation for further AIMPLAS
General advancement of knowledge Developing knowledge on separation technologies BANGOR
General advancement of knowledge Improved understanding of end user applications BANGOR
Commercial exploitation of R&D results Conductive polymer coated chromate free pigments for use in pre-coated metal BECKERS/BANGOR
Commercial exploitation of R&D results Furan dicarboxylic acid based polyesters to replace phthalate based polyesters in primers for pre-coated metal BECKERS/BANGOR
General advancement of knowledge Improvements in the photo-bioreactor design for the selected algae BFS
General advancement of knowledge Improvements in the procedure of growing BFS
General advancement of knowledge Improvements in the biomass mechanical separation process BFS
Commercial exploitation of R&D results Improvements in the biomass mechanical separation process BFS
Commercial exploitation of R&D results Improvements in the biomass dehydration process BFS
Commercial exploitation of R&D results Improvements in the process of breaking the cells BFS
Commercial exploitation of R&D results Mathematical modelling of the process and its implementation in a software program CASPEO
Commercial exploitation of R&D results Improvement of heat transfer modelling CASPEO
General advancement of knowledge Development of novel high-performance surfactants and emulsifiers CRODA
Exploitation of R&D results via standards Diols & diisocyanates for bio-PU adhesive CUSA
General advancement of knowledge Application of developed technology to extract amino acids from defatted algae biomass. GBR.AT
General advancement of knowledge Process concept: Technical evaluation of polyurethanes production by different routes PDC
General advancement of knowledge Process concept: Technical evaluation of conductive polymer production PDC
General advancement of knowledge Process concept: Technical evaluation of trans esterification and hydrolysis of algae oil PDC
General advancement of knowledge Process concept: Technical evaluation of lipid extraction from algae (solvent selection, products purification, ...) PDC
General advancement of knowledge Improvement in production models of algae strains PHYCOSOURCE
General advancement of knowledge Acrylic styrene bio-based analogues business to be applied in packaging market, as a sustainable supplement to existing petrochemical based materials. SUNCHEM
General advancement of knowledge. R&D activities Novel separation systems for algae HTL products VTT
General advancement of knowledge. R&D activities Robust catalyst for algae oil transesterification VTT
Technology transfer. R&D activities Improvements in the extract purification VTT
General advancement of knowledge Controlled ring opening of epoxidised fatty acids to produce oligomeric diols WARWICK
General advancement of knowledge Industrially-viable route to diisocyanates from lipids WARWICK
General advancement of knowledge Development of bio-polyurethane adhesives WARWICK
Dissemination activities
The project information has been disseminated via three channels:
a) By partners, within their organizations and with their clients/contacts (e.g. companies, website, newsletter, meetings, training courses, etc)
b) By partners during external events (e.g. fairs, conferences, exhibitions, workshops. etc)
c) By partners, using media across Europe (e.g. press release, Internet, specialized/ sectorial magazines, etc)
It is essential to highlight that a considerable number of dissemination activities have been completed during the development of BISIGODOS project. The use of various channels and methods (written, face to face & online) assured an optimal contribution of coverage, visibility and most important- setting up the scene for better market acceptance in the near future.
The activities in the Dissemination Plan covers different audiences and channels depending on the type of information to be disseminated in order to assure the success of the project from the strategic, environmental, technologic and economic direction based on BISIGODOS approach.
Dissemination tools and activities were divided in two main groups:
-Industrial level: active work of all partners and through their close relation with their own countries’ industry, particularly Industrial partners. Attendance to main international fairs and events as, Bio-Europe convention, the European Coatings Show, K-Show, Interpack, Achema, Algae Europe, etc.
-Non-commercial level: The RTD and HE participants are more focused on these kinds of activities. These organizations are members of international networks in their own fields and collaborate closely with industrial Associations at National and EU level. The HE/RS Partners have strong links with their own sectors (microalgae biomass, separation technologies, algae derived chemicals and bio-resins) in EU and indeed world-wide. Information of the projects results were published via Internet on their individual web sites. They use these networks as well as trade and technical journals with industrial focus to publish the work of the consortium. Opportunities to deliver papers to specialised conferences (the ECCA conferences, International Conference on Bioinspired and Biobased Chemistry & Materials, Conference on Green Chemistry, Congress on Catalysis (ICC), International Symposia on Chemical Reaction Engineering (ISCRE) were taken. To guarantee the dissemination at technological level, RTD performers participate in specialised forums (congresses, seminars, etc.). Based on these two dissemination levels, the dissemination routes have included: publications, articles, technical papers for scientific journals, audio and video recordings, web and CD ROM based training schemes, presentations at suitable events and conferences, workshops, training days, targeted dissemination campaigns to identified companies and organizations, and selected articles targeting the links between science and society. Furthermore, a project web-site was designed in the early steps of the project. During the development of the project this web was used as a partners’ forum and for internal information flow. After the end of the research the web-site is used as a useful diffusion tool, for the project results
List of Websites:
AIMPLAS - Instituto Tecnológico del Plástico
C/ Gustave Eiffel, 4 (València Parc Tecnològic)
46980 - PATERNA (Valencia) – SPAIN
Tlf. (+34) 96 136 60 40
Email: proyectos@aimplas.es
BISIGODOS is a 42-month project that aims at the production of high value-added algae derived chemicals and bio-resins for flexible packaging, coatings, printing, food and hair care applications.
The starting raw material is cost-effective and renewable algae biomass, which is directly cultivated from the CO2 from industrial emissions (cement, steel factory, thermal power plants, etc.).
The work carried out during was related to the cultivation of the algae strains based on the requirements of the cases of study and optimal growth conditions (WP2), mathematical modelling of the process and its implementation in a software program process, integration, energetic and mass balance evaluation and improvement (WP3), extraction of the lipid fraction and the transesterification of fatty acids and the production of diols and diisocyanates for producing polyurethane adhesives (WP4)
Moreover, in WP5 and WP6, some of the compounds were separated and processed further for aminoacids, conductive polymers, surfactants and ink production. The scaling up of each selected fine chemical substance and bio-resins was studied and carried out in WP7
In WP8 the regulatory, economic and environmental viability study of each selected fine chemical substance and bio-resins was carried out. Dissemination and exploitation activities was achieved along the project development in WP9 as well as Project Management (WP10).
Project Context and Objectives:
BISIGODOS aims to address the production of valuable algae derived chemicals, amino acids and high added-value bio-resins for flexible packaging, coatings, printing, food and hair care applications, starting from algae biomass fed directly with CO2 from industrial emissions (cement, steel factory, thermal power plants, etc.) as raw material that is cost-effective and renewable. The process is assisted by solar radiation, nutrients and sea water microalgae. In order to develop such technology, several innovative approaches were proposed:
-New algae strains production optimization and CO2 energetic balance improvement.
-Optimization of photo-bioreactors by means of the implementation of a software program process.
-Selection and adaptation of separation of algae components based on hybrid technologies.
-Production of algae derived chemicals for hair care, flexible packaging, coatings and food applications
-Production of bio-based chemicals from algae based fatty acids such as diols and diisocyanates.
-Real knowledge achieved of the algae derived products in the industrial-market atmosphere from the techno-economical, environmental and regulatory point of view:
Analysis of the possibilities that the microalgae technologies offer and contributing to define the roadmap of the technology.
See table with objectives in the attachment
Project Results:
The main scientific and technological results achieved are the following presented in WP basis. Partners description can be found in the project website: http://www.bisigodos.eu/
WP1 Proposed substances to recovery and the pathway definition
Leader: CRODA
Participant partners: ALL
Objectives
Definition of the needs and requirements of the producers and end users of the algae derived products to be obtained. To perform a preliminary economic, environmental and energetic review in order to help in the selection of the most promising substances. To define the best pathway to concentrate, purify or/and recover the substances of interest.
Risk management: to carry out a continuous (ongoing) assessment of the progress of the project. To review the progress of the work in relation to the defined success measures and to report on this progress. Where appropriate, contingency plans are identified and implemented
Work Plan
Task 1.1 Definition, compilation and summary of the needs and requirements of the end users.
Task 1.2 Market and trend analysis of the substances case of study
Task 1.3 Undertake analysis of legislation and identify key compounds of commercial interest.
Task 1.4 Definition of separation and purification technologies requirements
Task 1.5. Risk indicators definition and risk management
Results
-End-user requirements for selected case studied defined
-Separation and purification technologies requirements outlined
-Market, standards and legislation requirements defined
-WP risk indicators identified
WP2 Algae production optimization
Leader: PHYCOSOURCE
Participant partners: AIMPLAS, PDC, BFS, BANGOR
Objectives
To optimize and enhance the algae route production process in terms selection of the suitable algae strains in order to achieve a suitable yield in obtaining the substances of interest previously defined in WP1. To control the growing conditions and select alternative algae strains to maximize the production of proposed high added value substances.
Work Plan
Task 2.1 Selection, characterization and optimization of the most suitable algae strains
Task 2.2 Evaluation of the optimal growth conditions achievement
Task 2.3 Final microalgae composition determination and optimization
Results
- Improvements in the procedure of growing algae strains: cultivation and scaling up
- 3 algae strains selected: Nannochloropsis, Porphyridium and Dunaliella salina
WP3 Photo-bioreactors optimization
Leader: BFS
Participant partners: AIMPLAS, PHYCOSOURCE, CASPEO, VTT, BANGOR, WARWICK
Objectives
To optimize the bio-reactors and enhance the algae route production process in terms of yield, energy balance,and improvement of the process parameters to facilitate process scale-up, control and integration. To improve current CO2 energy balance, by reducing in at least 20% of the consumption of energy in the whole process (photo-bioreactors and thermo-chemical process)
Work Plan
Task 3.1 Evaluation and optimization of the bio-reactor design
Task 3.2 Process control
Task 3.3 Process integration, energetic and mass balance evaluation and improvement
Results
-Mathematical modelling of the process and the photo-bioreactors and its implementation in a software program: assessment of the energy required to maintain the culture temperature in its optimal range throughout the year; prediction of the evolution of culture temperature with time on an hourly basis; simulation of the action of temperature regulation systems; size heating/cooling equipment; optimization of the design of the PBR (geometrical parameters, materials); comparison of various geographical locations; estimation of the monthly average microalgae production
-Improvement of the heat transfer modelling
WP4 Bio-polyurethane adhesives development
Leader: CUSA
Participant partners: AIMPLAS, 3VTECH, PDC, GBR.AT VTT, WARWICK
Objectives
The main objectives of WP4are to convert non-food unsaturated methyl acid esters (extracted and transesterificated in free fatty acids) into diols using a tungsten-based catalyst system and subsequently convert these diols into polyurethanes using commercially available diisocyanates. In a second stage, we have also transformed the fatty acids into diisocyanates and as a result produce 100% bio-derived polyurethanes (PU) by reacting them with the diols from the first stage.
Work Plan
Task 4.1 Environmental friendly Lipid extraction technologies from algae biomass
Task 4.2 Solid catalysed transesterification from triglycerides to methyl ester fatty acid
Task 4.3 Diol synthesis
Task 4.4 Diisocyanate synthesis
Task 4.5 PU synthesis from diols and diisocyanates
Task 4.6 PU adhesives validation
Results
- Novel separation systems for algae HTL products
- Robust catalyst selected for algae oil transesterification
- Improvements in the process of breaking the cells
- Controlled ring opening of epoxidised fatty acids to produce oligomeric diols
- Industrially-viable route to diisocyanates from lipids
- Diols & Diisocyanates production for bio-PU adhesives
WP5 Separation technologies. Conductive polymers for anticorrosive paints and
bio-based surfactants
Leader: BANGOR
Participant partners: AIMPLAS, 3VTECH, PDC, BECKER, CRODA, VTT, BANGOR, BFS
Objectives
The main objective of WP5 is to study and achieve low energy and cost-effective separation procedures that would allow producing anti corrosion coatings and biobased gemini surfactants chemicals using as a raw material the phenol and pyrrolidones fraction. To produce high value drop-in biofuel, which ultimate properties as an aviation fuel would be obtained via blending/additivation.
Work Plan
Task 5.1. Optimisation of hydrothermal process variables
Task 5.2 Separation of high value chemicals.
Task 5.3 Modelling of separation process
Task 5.4. Upgrading of BFS Hydrothermal Bio-fuel as Drop-In Biofuel and bio-solvents
Task 5.5 Production of the biosurfactants
Task 5.6 Production of conductive polymer
Task 5.7 Production and evaluation of anticorrosive pigment
Results
-Improvements in the extract purification
-Hybrid thermal separation system
-Thermo-chemical process implemented
-Production of conductive polymer coated chromate free pigments for use in pre-coated metal
-Production of furan dicarboxylic acid based polyesters to replace phthalate based polyesters in primers for pre-coated metal
WP6 Bio-based inks binders and aminoacids
Leader: GBR.AT
Participant partners: AIMPLAS, 3VTECH, SUNCHEM, BANGOR
Objectives
The main objectives of WP6 are to produce a bio-based resin which performance would allow substituting a percentage of existing petroleum based resins used in standard flexographic inks formulations. These bio-based resins are based in a new range of acrylic and vinyl-lactam (styrene like) analogues and their copolymers from biomass feedstocks derived from the thermal processing of microalgae that are fractioned in WP5. Produce a bio-based resin which performance would allow substituting 10-20% existing petroleum based resins presently used in flexographic inks manufacturing and 30% in current HybridTM for compostable plastic. To formulate and develop a new range of bio-based binder systems for water based printing and coating applications that are replicated the current technology which consists of 60% styrene and 40% acrylic functionalities, but would provide products environmentally friendly. Final properties of water ink binder may be at least 75% in comparison with current binder formulated from petrol based monomers. To produce a new range of acrylic and vinyl lactam (styrene like) analogues and their copolymers from biomass feedstocks derived from the thermal processing of microalgae that are cheaper feedstocks than existing higher sugar content materials with food used. To obtain a broad range of amino acids and protein products with a crude protein higher than 60% using an adapted FrALs technology as described in the state-of-the-art.
Work Plan
Task 6.1 Binder for water based printing inks and coatings development
Task 6.2 Evaluation in ink applications
Task 6.3 Amino acids and proteins production
Results
-Extraction and production of amino acids from defatted algae biomass.
-Acrylic styrene bio-based analogues to be applied in the flexible packaging market, as a sustainable supplement to existing petrochemical based materials.
WP7 Scale-up and validation of industrial products
Leader: BECKER
Participant partners: ALL
Objectives
WP 7 translated substances development from WP2-6 to industrial prototype scale. The main objective is the development of semi-industrial routes at DEMO stage for obtaining algae derived chemicals, amino acids, proteins and valuable bio-resins, to study the easiness of scaling up the processes, to test the substances and technologies in real world test and applications and to demonstrate the potential of the
innovative production of valuable substances starting from algae biomass (CO2 indirectly) using CO2 from industrial emissions. The substances are then produced, finished and assessed against existing traditional production routes used for each application (described below). A ‘Guide to best practice for production of algae derived chemicals, amino acids and bio-resins using the microalgae biomass are produced, to contribute to the technology transfer and dissemination.
Work Plan
Task 7.1 Scaling-up the production of alternative algae strains selected in WP2 in the new optimized BFS’s photo-bio-reactors
Task 7.2. Scaling-up algae bio-based PU adhesives for flexible packaging applications
Task 7.3 Scaling-up bio-based conductive polymer for anticorrosive paints and coatings
Task 7.4 Scaling-up Gemini surfactants for hair care products applications
Task 7.5 Scaling-up binders for water-based printing inks
Task 7.6 Scaling-up Amino acids for food applications
Task 7.7 To elaborate a “Guide to produce algae derived chemicals and bio-resins from algae biomass using CO2 from industrial fumes as raw material”
Results
- Scaling-up new algae strains and photo-bioreactors optimization
- Scaling-up the bio-based polyurethane adhesives
- Scaling-up the bio-based conductive polymer
- Scaling-up amino acids
- Guide to produce algae derived chemicals and bio-resins from algae biomass using CO2 from industrial fumes as raw materials
WP8 Economic, logistic, environmental and health evaluation
Leader: AIMPLAS
Participant partners: ALL
Objectives
The aim of this WP is to conduct an environmental, logistic and economic impact study of the new substances obtained throughout each stage of development from microalgae culture production to application in the selected industry sectors (hair care products, inks, paints, food and adhesives) to ensure compliance with legislation and to maximise market acceptance. For each defined end user product, we have:
• Analysed the CO2 energy balance.
• Studied the environmental suitability of the algae derived chemicals, amino acids, protein and high added-value bio-resins production by a Life Cycle Assessment (LCA) study
• Assessed the economic viability of the processes, and ensured that the obtained substances fulfil related legal requirements.
• Health and safety issues related to final products, proposed chemical routes and separation technologies. In summary, WP8 provided:
i) Decision tools to WP2 to WP7 based on technical, economic and environmental assessment to help the design of process development strategies;
ii) A data-set of indicators for each substance obtained in order to assess the feasibility and sustainability of large-scale commercial operation.
Work Plan
Task 8.1. Economic analysis
Task 8.2. Environmental study
Task 8.3. CO2 energy balance for selected products produced from industrial CO2 fumes
Task 8.4 Regulatory analysis and safety issues
Results
-Cost Calculation
- LCA studies for the selected products
-Techno-economical evaluation of the processes and products involved to achieved algae-derived chemicals and resins
-Continuous assessment and analysis of the regulatory and safety aspects
-Report on CO2 energy final balance
Potential Impact:
Potential impact
Exploitation was carefully planned and managed from an early stage in the project to ensure maximum exploitation impact after the project
-The use of environmentally and low toxicity routes to produce bio-polyurethanes, conductive polymers, aminoacids and inks produces a positive environmental impact. In addition, the results of using non-food renewable biomass and green chemistry routes in comparison with current technologies boosts the societal implications: Meeting the market needs without compromising the needs of future generations.
-Eco-efficiency is achieved by the delivery of economically competitive goods and services that satisfy their customers’ needs and brings quality of life, while progressively reducing ecological impact and resource intensity throughout the lifecycle.
- The innovative algae derived chemicals and bio-resins from microalgae biomass biorefineries using CO2 as raw material will be successful on the market and have improved participants’ skills and portfolio, EU food, inks, bio-surfactants, polyurethane adhesives and anticorrosive coating industry competitiveness and companies’ creation opportunities.
Exploitation of results
Potential Key Exploitation Results
Type of exploitable foreground Description Owner(s)
Commercial exploitation of R&D results Improvement on vacuum thermal purification 3VTECH
General advancement of knowledge Hybrid thermal separation system 3VTECH
Commercial exploitation of R&D results Continuous dehydration system 3VTECH
Technology transfer. R&D activities and consultancy services. Knowledge in algae derived chemicals and bio-resins synthesis and validation for further AIMPLAS
General advancement of knowledge Developing knowledge on separation technologies BANGOR
General advancement of knowledge Improved understanding of end user applications BANGOR
Commercial exploitation of R&D results Conductive polymer coated chromate free pigments for use in pre-coated metal BECKERS/BANGOR
Commercial exploitation of R&D results Furan dicarboxylic acid based polyesters to replace phthalate based polyesters in primers for pre-coated metal BECKERS/BANGOR
General advancement of knowledge Improvements in the photo-bioreactor design for the selected algae BFS
General advancement of knowledge Improvements in the procedure of growing BFS
General advancement of knowledge Improvements in the biomass mechanical separation process BFS
Commercial exploitation of R&D results Improvements in the biomass mechanical separation process BFS
Commercial exploitation of R&D results Improvements in the biomass dehydration process BFS
Commercial exploitation of R&D results Improvements in the process of breaking the cells BFS
Commercial exploitation of R&D results Mathematical modelling of the process and its implementation in a software program CASPEO
Commercial exploitation of R&D results Improvement of heat transfer modelling CASPEO
General advancement of knowledge Development of novel high-performance surfactants and emulsifiers CRODA
Exploitation of R&D results via standards Diols & diisocyanates for bio-PU adhesive CUSA
General advancement of knowledge Application of developed technology to extract amino acids from defatted algae biomass. GBR.AT
General advancement of knowledge Process concept: Technical evaluation of polyurethanes production by different routes PDC
General advancement of knowledge Process concept: Technical evaluation of conductive polymer production PDC
General advancement of knowledge Process concept: Technical evaluation of trans esterification and hydrolysis of algae oil PDC
General advancement of knowledge Process concept: Technical evaluation of lipid extraction from algae (solvent selection, products purification, ...) PDC
General advancement of knowledge Improvement in production models of algae strains PHYCOSOURCE
General advancement of knowledge Acrylic styrene bio-based analogues business to be applied in packaging market, as a sustainable supplement to existing petrochemical based materials. SUNCHEM
General advancement of knowledge. R&D activities Novel separation systems for algae HTL products VTT
General advancement of knowledge. R&D activities Robust catalyst for algae oil transesterification VTT
Technology transfer. R&D activities Improvements in the extract purification VTT
General advancement of knowledge Controlled ring opening of epoxidised fatty acids to produce oligomeric diols WARWICK
General advancement of knowledge Industrially-viable route to diisocyanates from lipids WARWICK
General advancement of knowledge Development of bio-polyurethane adhesives WARWICK
Dissemination activities
The project information has been disseminated via three channels:
a) By partners, within their organizations and with their clients/contacts (e.g. companies, website, newsletter, meetings, training courses, etc)
b) By partners during external events (e.g. fairs, conferences, exhibitions, workshops. etc)
c) By partners, using media across Europe (e.g. press release, Internet, specialized/ sectorial magazines, etc)
It is essential to highlight that a considerable number of dissemination activities have been completed during the development of BISIGODOS project. The use of various channels and methods (written, face to face & online) assured an optimal contribution of coverage, visibility and most important- setting up the scene for better market acceptance in the near future.
The activities in the Dissemination Plan covers different audiences and channels depending on the type of information to be disseminated in order to assure the success of the project from the strategic, environmental, technologic and economic direction based on BISIGODOS approach.
Dissemination tools and activities were divided in two main groups:
-Industrial level: active work of all partners and through their close relation with their own countries’ industry, particularly Industrial partners. Attendance to main international fairs and events as, Bio-Europe convention, the European Coatings Show, K-Show, Interpack, Achema, Algae Europe, etc.
-Non-commercial level: The RTD and HE participants are more focused on these kinds of activities. These organizations are members of international networks in their own fields and collaborate closely with industrial Associations at National and EU level. The HE/RS Partners have strong links with their own sectors (microalgae biomass, separation technologies, algae derived chemicals and bio-resins) in EU and indeed world-wide. Information of the projects results were published via Internet on their individual web sites. They use these networks as well as trade and technical journals with industrial focus to publish the work of the consortium. Opportunities to deliver papers to specialised conferences (the ECCA conferences, International Conference on Bioinspired and Biobased Chemistry & Materials, Conference on Green Chemistry, Congress on Catalysis (ICC), International Symposia on Chemical Reaction Engineering (ISCRE) were taken. To guarantee the dissemination at technological level, RTD performers participate in specialised forums (congresses, seminars, etc.). Based on these two dissemination levels, the dissemination routes have included: publications, articles, technical papers for scientific journals, audio and video recordings, web and CD ROM based training schemes, presentations at suitable events and conferences, workshops, training days, targeted dissemination campaigns to identified companies and organizations, and selected articles targeting the links between science and society. Furthermore, a project web-site was designed in the early steps of the project. During the development of the project this web was used as a partners’ forum and for internal information flow. After the end of the research the web-site is used as a useful diffusion tool, for the project results
List of Websites:
AIMPLAS - Instituto Tecnológico del Plástico
C/ Gustave Eiffel, 4 (València Parc Tecnològic)
46980 - PATERNA (Valencia) – SPAIN
Tlf. (+34) 96 136 60 40
Email: proyectos@aimplas.es
