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Bioplastics from Biogas - A View of Current Capabilities
1.
© 2015 Pack2Sustain,
LLC Page 1 Trending: Energy from Waste In the larger context of growing global interest in sustainable energy generation, anaerobic digestion (AD) technologies have experienced strong growth in Europe and Asia, and are emerging in Africa and North America. Part of what makes AD compelling is that it addresses not only the renewable energy challenge but also the significant issue of food waste by using this waste as a system input. The value of the global market for anaerobic digesters and landfill gas equipment is estimated at nearly $4.5 billion for 2013. The market is projected to reach $7 billion by 2018, growing at a compound annual growth rate (CAGR) of 9.4% over the five-year period from 2013 to 2018[1] . The food waste that can serve as an input for AD processes is often comingled with packaging waste. As discussed in the first white paper in this series – Anaerobic Digestion: Food & Packaging Waste Are Resources – exciting opportunity exists to explore packaging material designs that facilitate disposal via AD so as to simplify diversion of both food and packaging wastes from landfill. Added to this is the underdeveloped approach of using the very biogas generated by the AD process as feedstock for the manufacture of new packaging materials. Bioplastics From Biogas Understanding the feasibility of generating bioplastic resin from AD-produced biogas is a stated research objective of the biogas industry. Besides the existing uses for biogas – ranging from power generation to transportation fuel – use of biogas as a feedstock for the production of bioplastics has the potential to: Expand the market for biogas improve payback for AD installations Close the resource loop for relevant packaging materials that are or could be purchased by current AD customers Decrease AD customers’ spend on packaging items for which biogas can be used as production feedstock Bioplastics from Biogas – A View of Current Capabilities Jay Edwards, Pack2Sustain February 2015
2.
© 2015 Pack2Sustain,
LLC Page 2 An illustration of the closed resource loop is given here. In addition to material conservation and potential financial efficiencies, adopters of this approach would be able to communicate a very compelling message to consumers about use of packaging made from both reclaimed food and reclaimed packaging: Craig S. Criddle et. al. have indicated the technical feasibility of this approach in U.S. patent application US 20130071890 A1. The methods they describe for the production of bioplastic using biogas are particularly attractive given that: Purification of the biogas produced in an AD process is not necessary prior to introduction into the fermenting / bioplastic production process Use of food scraps & food processing wastes as raw materials are explicitly discussed There is the potential to run the process independently, without additional energy inputs o It would seem that diversion of biogas from the feedstock stream to power the process would naturally affect yield, however The diagram below is part of the published patent application, and provides an overview of the process, its inputs and its products. Following the diagram is a written description of the process as given in the patent application. Food Packaging Anaerobic Digestion w/ Food Waste Biogas ProdutionBioresin Generation Conversion to Packaging Components
3.
© 2015 Pack2Sustain,
LLC Page 3 “Production of bioplastic from biogas requires a biogas feed system, a primary fermenter for growth of aerobic methanotrophic bacteria capable of biopolymer production and a secondary fermenter in which bioplastic production is induced in the presence of methane. In the primary fermenter, biogas methane, oxygen, and all of the required nutrients for growth are provided to enable rapid cell division. In the secondary fermentation, methane and oxygen are provided, but one or more of the remaining nutrients needed for growth are removed to induce bioplastic production. Bioplastic accumulates as granules inside the cells. The bioplastic-rich biomass is sent to a thickening device (belt press, dissolved air flotation device, etc.) to remove most of the water. Bioplastic production is followed by lysis of the cells to release the bioplastic granules from the cells. In the preferred embodiment, lysis is achieved without use of solvents or surfactants. Heating, sonic or electrical pulses, enzymes, or phage may be used to break the cells and release the granules from the cells. In the case of osmophilic methanotrophs, differences in osmotic pressure may be used to break the cells. The bioplastic is then separated from the remaining biomass and purified using one of several methods, including centrifugation to recover a biopolymer pellet, solvent extraction with solvent distillation and reuse, supercritical fluid extraction, and selective dissolution of residual biomass with sodium hypochlorite solutions. The biomass residuals are returned to the anaerobic digester for conversion into biogas.”[2]
4.
© 2015 Pack2Sustain,
LLC Page 4 Current Application, Future Opportunities Fortunately, production of bioplastics from biogas has progressed from demonstration to implementation. San Francisco start-up Mango Materials was founded in 2010 with the mission of “produc[ing] biodegradable plastics from waste biogas (methane) that are economically competitive with conventional oil-based plastics.”[3] Mango Materials currently sources its biomass from a wastewater treatment plant. Concerning their pricing claim, production cost challenges have long been a hurdle to more sustainably- sourced plastics, but Mango seems to have directional support in the study Bacterially Produced Polyhydroxyalkanoate (PHA): Converting Renewable Resources into Bioplastics, which in part explores some of the economic context of PHA production. Specifically: “Each year, a large amount of waste materials are discharged from agricultural and food processing industries and these wastes represent a potential renewable feedstock for PHA production. Utilizing these waste materials as carbon sources for PHA production not only reduces the substrate cost, but also saves the cost of waste disposal.” [4] The application of bioplastics in the field – compostable or digestible – would naturally require development work to match the packaging material to the product; namely to the food products relevant to the current discussion. Pack2Sustain’s Custom Technology Scoping work is an opportunity for resource-constrained organizations to assess packaging options using a firm with decades of commercialization experience. As our network of industry leaders continues to grow, this service becomes all the more powerful. Particularly in the foodservice environment, anaerobic digestion presents a significant opportunity to manage food and packaging wastes in a way that generates the multi-use resource of biogas. To the crucial advantage of landfill diversion of these wastes, AD’s generation of biogas adds renewable energy and renewable- material-sourcing benefits. To discuss this topic further, connect with Pack2Sustain today. [4] Yu J. Microbial production of bioplastics from renewable resources. In: S. T. Yang editor. Bioprocessing for value-added products from renewable resources; 2007 Acknowledgement: A special thanks to John Baldus at Bioferm Energy Systems, Viessmann Group for his assistance in the preparation of this paper Pack2Sustain is a technical services firm that brings two decades of CPG, Packaging R&D and sustainability expertise to packaging industry clients. With practical experience in environmental engineering, packaging R&D and sustainability modeling, we bring powerful perspectives to your projects, with support for environmental-messaging and LCA initiatives.
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