WP 3: Flagship Program on Biopolymers

Transkript

Flagship Biopolymers
WP 3: Flagship Program on
Biopolymers
Jan van Beilen
Yves Poirier
Bill Orts
Wageningen, May 22, 2006
Jan van Beilen,Yves Poirier
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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
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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
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Which biopolymers?
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•
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•
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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
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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
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are needed to see this picture.
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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
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Poly-trans-isoprene (gutta percha,
balata) and mixtures (chicle)
$ 50-100 / kg
> 3’000 T/A
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Natural rubber
• Produced as in 1910
– Labor intensive
– Smallholders and plantations
• Strategic importance
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- 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
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Natural rubber: to do
Hevea brasiliensis
– Resistance to South American
Leaf Blight
– Reduce allergenic proteins
… or find alternatives
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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
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Alternative sources
grown in Europe
NR sources
brasiliensis
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Alternative sources
grown in Europe
NR sources
brasiliensis
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Starch
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57’000’000 T/A, € 0.30 per kg
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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
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Starch-based bioplastics
Production capacity
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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
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Sales 25’000 T/A (2001)
€ 1.00 to € 5.00 / kg
•
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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
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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
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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
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Polyhydroxyalkanoates
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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
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Up to 85 % of cell dry weight
Control over composition
Continuous production
Established down-stream processing
Projected cost: € 2 / kg
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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
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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
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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
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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
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Breakout group on bipolymer flagship
Room Dorskampzaal I
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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
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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
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WP 3: Flagship Program on Biopolymers

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