Periodic Reporting for period 2 - NENU2PHAR (For a sustainable and european value chain of PHA-based materials for high-volume consumer products)
Reporting period: 2022-03-01 to 2023-02-28
Polyhydroxyalkanoates (PHAs) are biodegradable and bio-based polymers. It is expected that PHAs could gradually substitute conventional plastics since they have similar physicochemical, thermal, and mechanical properties. The fact that PHAs can be obtained by a purely biotechnological route makes them particularly attractive. In addition, PHA has been reported to spontaneously degrade in aquatic environments representing a promising biodegradable substitutes for a number of high-volume consumer products. NENU2PHAR project will focus on the development of a PHAs stream to initiate a competitive value chain of bioplastic material for high-volume consumer product. The goal of NENU2PHAR is to set up a new European value chain of PHA-based bio-plastic products from a sustainable bio-source with an acceptable End of Life. NENU2PHAR will develop a PHAs stream integrated in a circular economy concept, from the production to the biodegradability or recyclability of plastic product to new compounds in order to maximise the valorisation of material and reduce energy consumption. To reach such ambitious target the NENU2PHAR project will have 5 main objectives: 1) Develop competitive bio-source of PHAs polymers, 2) Formulate and functionalise polymer for masterbatch and compounding, 3) Identify processes of PHA-material to reach defined functional properties of bioplastic better than fossil-fuel counterparts, 4) Develop eco-designed PHA-biobased products for high volume consumer products, 5) Demonstrate the circular economy and sustainability of the NENU2PHAR value chain and 6) Increase stakeholders and consumer awareness of new bio-plastic products
During the second period of NENU2PHAR, relevant technical progress has been achieved. The NENU2PHAR value chain from the CO2 fixation by microalgae biomass until this carbon feedstock becomes PHA bioplastic is completed. The starch-rich microalgae biomass from the species Chlorella vulgaris was produced at during two years at semi-industrial scale. The fermentation of bacteria to generate PHA has been developed on glucose hydrolysed from microalgae biomass. The method for PHB extraction at lab-scale based on the green-solvent has been optimised to ensure the processability at a higher scale. NENU2PHAR has developed the formulation, functionalization and compounding of the PHA biopolymer. The evaluated formulations have been used to develop 8 different demonstrators (covering 10 different product applications). Best formulations for flexible films are with low PHB content and for rigid films from low to medium PHB content, the injection of moulded standard samples was quite reproducible with general good characteristics. The thermoforming processing of PHA bioplastic sheets was successfully evaluated at pilot scale. The best processing conditions for rigid food packaging trays or plastic cups have been elaborated and it was possible to obtain thermoformed prototypes. Three potential blends for fibre development have been selected with good and stable processing into textile intermediates. The surface nanostructuration of PHA pieces significantly increased the hydrophobicity and enhanced the antimicrobial properties. Demonstrators were produced at lab and pilot scale for almost each product and hundreds of kilos of PHA-based formulations have been compounded. Extrusion scaling-up trials were successful and flexible films were distributed. At least 8 different samples of films generated. Prototypes of pouches have been successfully hand-made, proving that the films are sealable and hermetic. Thermal resistance is the most critical parameter for biodegradable and compostable thermoformed cup. Good formulations have been found for plastic bottles produced through extrusion blow molding. For the agrotextile products two different blends of PHB/PLA and PHB/PBS have been extruded successfully in larger amounts for a first demonstrator. A step-by-step procedure was followed to systematically implement the ecodesign of the products. All the materials tested are biodegradable under industrial conditions and some of them show promising results under domestic conditions. All samples presented degradation in marine environment. Concerning the sorting of plastic material it has been possible to avoid the contamination of classical plastic waste by updating the library of the sorting equipment. The addition of markers did not impact the mechanical properties of formulations. The recyclability of materials was validated.The life cycle environmental and economic assessment of the current scenario has been performed for the target products. There is very low nano-safety risk derived from possible release of and exposure to nano-objects NENU2PHAR processes. The formulations selected for food packaging prototypes in the project are food contact compliant after an assessment performed using migration modelling software and specific migration tests.
NENU2PHAR will contribute to the creation of new cross-sector interconnection in the bio-based economy by means of the interconnection between the aquatic biomass production sector and the plastic production sector. This cross-sector interconnection has been established as the core concept of NENU2PHAR, the production of PHA biopolymer based on microalgae biomass achieved. The NENU2PHAR value chain addresses new (or optimised) bio-based value chains, the PHA-based bioplastic products from a biological source have been transformed into plastic compounds, the End of Life of these products is promising in terms of biodegradation. The value chain is being structured. The PHA biopolymer products under development in NENU2PHAR have addressed new bio-based materials, at this point the different formulations developed allow the production of the 2 first prototypes of 3D printing and plastic tray products. The TRL gain is being progressively addressed. Progresses have been done on the technical steps of the value chain, carbon feedstock from microalgae biomass is already running in semi-industrial pilot scale. Cell disruption pre-treatments for microalgae and bacteria have been identified and are developped at lab-scale, PHA extraction methods and protocols have been identified and implemented in lab context for PHA polymler. Functionalisation of PHA are being improved by developing blends based on biodegradable polymers and using the compounding process. Compounding of PHAs has been achieved using different plastic transformation technologies like the injection moulding process, a flexible or rigid film extrusion, the filament extrusion, or the surface texturization by injection moulding. PHA formulating and textile extrusion has moved forward by means of the blending of PHA with other polymers and, finally, the end of life by biodegradation of these bioplastic is being demonstrated. These products will increase the environmental sustainability of materials for high-volume consumer products, It is expected that the progress of NENU2PHAR will foster the future market uptake of the bio-based materials for high-volume consumer products and will increase the income and business opportunities for stakeholders and actors (including primary producers) in the bio-based sectors. NENU2PHAR results can create new job opportunities in the bio-based sector, particularly the rural, coastal and/or urban areas at the same time that bioplastic production capacities in Europe are enhanced.