WP 3: Flagship Program on Biopolymers
Transkript
WP 3: Flagship Program on Biopolymers
Flagship Biopolymers WP 3: Flagship Program on Biopolymers Jan van Beilen Yves Poirier Bill Orts Wageningen, May 22, 2006 Jan van Beilen,Yves Poirier 1 Flagship Biopolymers Plastics in EU (15) Bioplastics (EU15, 2003) 40,000,000 T/Y 40,000 T/Y (0.1%) Current market share of bioplastics is very small Potential for growth is very large Substitution of 10% 30% 4,000,000 T/Y 12,000,000 T/Y 50 million hectares of agricultural land in EU (25) are set aside and not required for food production 1 hectare = 2 tons bioplastic Wageningen, May 22, 2006 Jan van Beilen,Yves Poirier 2 Flagship Biopolymers Global mineral oil used for energy Mineral oil used by chemical industry Polymers 4’000 MT 300 MT 150 MT Biopolymers can have a positive impact on dependence on mineral oil and GHG emission Biopolymers as the main product or as a secondary product of biofuels or chemicals from biorefineries Wageningen, May 22, 2006 Jan van Beilen,Yves Poirier 3 Flagship Biopolymers Which biopolymers? • • • • • Polyisoprenoids Starch-based Protein-based Polyhydroxyalkanoates Other plant biopolymers • Cellulose, hemicellulose, lignin: Cell wall • Polyols based on plant oils: Plant oil • Bioplastics produced by fermentation or chemical synthesis: PLA, PHAs, PCL, Sorona: SusChem project Wageningen, May 22, 2006 Jan van Beilen,Yves Poirier 4 Flagship Biopolymers General issues • Biodegradability used as a marketing tool, but GHG emission and renewability may become important drivers • Applications: mostly (potentially) low cost, high volume • Limitations: cost, properties, supplychain • GMO issues, acceptance • Fermentation vs in planta Wageningen, May 22, 2006 QuickTime™ and a TIFF (Uncompressed) decompressor are needed to see this picture. Jan van Beilen,Yves Poirier 5 Flagship Biopolymers Synthetic and natural rubber Synthetic: Plant based: Polystyrene-butadiene (SBR) € 1.30 / kg 2’400’000 T/A Poly-cis-isoprene (natural rubber) € 1.80 / kg 7’000’000 T/A 99% from Hevea brasiliensis Poly-butadiene (BR) Poly-chloropropene (CR) Poly-acrylonitrile-butadiene Polyisoprene Many others Total 10’500’000 T/A Wageningen, May 22, 2006 QuickTime™ and a TIFF (Uncompressed) decompressor are needed to see this picture. Poly-trans-isoprene (gutta percha, balata) and mixtures (chicle) $ 50-100 / kg > 3’000 T/A Jan van Beilen,Yves Poirier 6 Flagship Biopolymers Natural rubber • Produced as in 1910 – Labor intensive – Smallholders and plantations • Strategic importance QuickTime™ and a TIFF (Uncompressed) decompressor are needed to see this picture. Wageningen, May 22, 2006 - Largely produced in SE-Asia - No substitute available (tires) - Rubber plantations are being replaced by palm oil plantations - Could be destroyed by South american leaf blight (SALB) - Limited R&D efforts on SALB and rubber synthesis enzymes Jan van Beilen,Yves Poirier 7 Flagship Biopolymers Natural rubber: to do Hevea brasiliensis – Resistance to South American Leaf Blight – Reduce allergenic proteins … or find alternatives Wageningen, May 22, 2006 Jan van Beilen,Yves Poirier 8 Flagship Biopolymers Natural rubber: to do Alternative sources – Guayule: could be grown in southern USA, perhaps in mediterranean countries – Russian dandelion: could be grown in Europe – Goldenrod and other potential NR sources – Tropical trees other than H. brasiliensis Wageningen, May 22, 2006 QuickTime™ and a TIFF (Uncompressed) decompressor are needed to see this picture. Jan van Beilen,Yves Poirier 9 Flagship Biopolymers Natural rubber: to do Alternative sources – Guayule: could be grown in southern USA, perhaps in mediterranean countries – Russian dandelion: could be grown in Europe – Goldenrod and other potential NR sources – Tropical trees other than H. brasiliensis Wageningen, May 22, 2006 QuickTime™ and a TIFF (Uncompressed) decompressor are needed to see this picture. Jan van Beilen,Yves Poirier 10 Flagship Biopolymers Natural rubber: to do Alternative sources – Guayule: could be grown in southern USA, perhaps in mediterranean countries – Russian dandelion: could be grown in Europe – Goldenrod and other potential NR sources – Tropical trees other than H. brasiliensis Wageningen, May 22, 2006 Jan van Beilen,Yves Poirier 11 Flagship Biopolymers Starch • 57’000’000 T/A, € 0.30 per kg • 20-30% amylose, 70-80% amylopectin • Corn, wheat, potato, cassava, rice • Many variants: high amylose, no amylose, high phosphate, low MW, “starch-enhanced” • Chemical, mechanical, thermal, blending treatments Wageningen, May 22, 2006 Jan van Beilen,Yves Poirier 12 Flagship Biopolymers Starch-based bioplastics Production capacity • • • • Novamont: 20’000 T/A Rodenburg Biopolymers: 36’000 T/A National Starch Company: 20’000 T/A BIOP: 10’000 T/A Biotec: 2’000 T/A • • Sales 25’000 T/A (2001) € 1.00 to € 5.00 / kg • Wageningen, May 22, 2006 QuickTime™ and a TIFF (Uncompressed) decompressor are needed to see this picture. Jan van Beilen,Yves Poirier 13 Flagship Biopolymers Starch-based plastics: issues • Thermoplastic materials resulting from the processing of native starch – Thermal: gelatinization, destructurization – Chemical: esters, ethers, crosslinking, depolymerization – Mechanical: extrusion with fillers, additives, plasticisers (glycerol, polyvinylalcohol, ethyleneglycol) – Blending: polycaprolactone, PHA, cellulose acetate • “Everything has been tried” (and patented)! • But, new renewable polymers available for blending, new plasticisers, new starch variants Wageningen, May 22, 2006 Jan van Beilen,Yves Poirier 14 Flagship Biopolymers Protein biopolymers • Agricultural bulk protein streams – Zein (4% of corn dw): Vicara (2’200 T/A, 1954) – Soy protein (38-45% of soy dw): 1930’s, 40’s – Wheat gluten (cheap) • Repetitive-unit proteins – Silk, elastin, adhesin, synthetic sequences • Non-ribosomally produced polypeptides: – Polyasparate, polylysine Wageningen, May 22, 2006 Jan van Beilen,Yves Poirier 15 Flagship Biopolymers Protein biopolymers: issues • Potentially huge amounts of protein coproducts from biofuels production (zein, soy and potato protein, gluten) • Heterologous production of silk, adhesin, synthetic sequences, cyanophycin: Plants vs fermentation ? • In GMO plants: high level, effects on hosts, post-harvest stability, extraction, processing - need R&D Wageningen, May 22, 2006 Jan van Beilen,Yves Poirier 16 Flagship Biopolymers Polyhydroxyalkanoates • • • • PHB: poly-β-hydroxybutyrate (C4) PHBV: PHB-co-valerate (C4-C5) PHBH: PHB-co-hexanoate (C4-C6) mclPHA: β-hydroxyalkanoates (C6-C16) • Production by fermentation – – – – – Up to 85 % of cell dry weight Control over composition Continuous production Established down-stream processing Projected cost: € 2 / kg Wageningen, May 22, 2006 QuickTime™ and a TIFF (Uncompressed) decompressor are needed to see this picture. Jan van Beilen,Yves Poirier 17 Flagship Biopolymers Polyhydroxyalkanoates: issues • Production in recombinant plants – Potentially cheaper, better CO2-balance – Great effort required to get to significant levels – Down-stream processing – Stability of polyester after harvest • Current status – 40% PHB in leaf tissue (but only 8-10% without effects on growth) – Metabolix develops production in Switchgrass Wageningen, May 22, 2006 Jan van Beilen,Yves Poirier 18 Flagship Biopolymers Biopolymers: fermentation & chemical • Polylactic acid (PLA) – 150’000 T/A capacity (mainly Cargill, many small-scale producers) • Polyhydroxyalkanoates – 50’000 T/A planned by Metabolix / ADM – Nodax, P&G, Kaneka • Polyesters – – – – Eastar: butanediol / succinate / terephthalate copolymers Sorona: propanediol / terephthalate copolymer Bionolle: butanediol / succinate / adipate copolymers Ecoflex: butanediol / adipate / terephthalate copolymers All indirectly (partially) made from sugars or oils Wageningen, May 22, 2006 Jan van Beilen,Yves Poirier 19 Flagship Biopolymers Questions What is the role of agriculture and plant biotechnology in… • Ensuring constant supply of high quality natural rubber, one of the most important biopolymer produced from plants • Make better use of starch as a source of valuable biopolymer • Taking advantage of protein co-product streams (gluten, zein, soy protein, recombinant?) that will become much more important with biofuels • Production of PHAs, specialty proteins and other polymers that can also be produced by fermentation technology Wageningen, May 22, 2006 Jan van Beilen,Yves Poirier 20 Flagship Biopolymers Breakout group on bipolymer flagship Room Dorskampzaal I Wageningen, May 22, 2006 Jan van Beilen,Yves Poirier 21 Flagship Biopolymers More issues • Economics of GMOs: does it pay to create and introduce GMO plants for bioplastics • Selling points: biodegradability and GMO don’t mix well • Disposal: burning may be the best solution, but doesn’t appeal to customers Wageningen, May 22, 2006 QuickTime™ and a TIFF (Uncompressed) decompressor are needed to see this picture. QuickTime™ and a TIFF (Uncompressed) decompressor are needed to see this picture. Jan van Beilen,Yves Poirier 22 Flagship Biopolymers Wageningen, May 22, 2006 Jan van Beilen,Yves Poirier 23 Flagship Biopolymers Starch-based plastics: issues • Thermoplastic materials resulting from the processing of native starch – Thermal: gelatinization, destructurization – Chemical: esters, ethers, crosslinking, depolymerization – Mechanical: extrusion with fillers, additives, plasticisers (glycerol, polyvinylalcohol, ethyleneglycol) – Blending: with polycaprolactone, PHA, cellulose acetate QuickTime™ and a TIFF (Uncompressed) decompressor are needed to see this picture. Wageningen, May 22, 2006 Jan van Beilen,Yves Poirier 24