Large Scale Production of Polyhydroxyalkanoates (PHAs) from Wastewater: A Study of Techno-Economics, Energy Use and Greenhouse Gas Emissions

Authors: Cora Fernandez Dacosta, John A. Posada, Andrea Ramirez

Abstract:

The biodegradable family of polymers polyhydroxyalkanoates is an interesting substitute for convectional fossil-based plastics. However, the manufacturing and environmental impacts associated with their production via intracellular bacterial fermentation are strongly dependent on the raw material used and on energy consumption during the extraction process, limiting their potential for commercialization. Industrial wastewater is studied in this paper as a promising alternative feedstock for waste valorization. Based on results from laboratory and pilot-scale experiments, a conceptual process design, techno-economic analysis and life cycle assessment are developed for the large-scale production of the most common type of polyhydroxyalkanoate, polyhydroxbutyrate. Intracellular polyhydroxybutyrate is obtained via fermentation of microbial community present in industrial wastewater and the downstream processing is based on chemical digestion with surfactant and hypochlorite. The economic potential and environmental performance results help identifying bottlenecks and best opportunities to scale-up the process prior to industrial implementation. The outcome of this research indicates that the fermentation of wastewater towards PHB presents advantages compared to traditional PHAs production from sugars because the null environmental burdens and financial costs of the raw material in the bioplastic production process. Nevertheless, process optimization is still required to compete with the petrochemicals counterparts.

Keywords: Circular economy, life cycle assessment, polyhydroxyalkanoates, waste valorization.

Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1100587

References:

[1] M. Carus, “Production capacities for bio-based polymers in Europe - status quo and trends towards 2020,” Nova-Institute for Ecology and Innovation. Press release. July 2013.
[2] R. J. Van Wegen, Y. Ling, and A. P. J Middelberg, “Industrial production of polyhydroxyalkanoates using Escherichia coli: An economic analysis,” Chemical Engineering Research and Design, vol. 76, pp. 417-426, March 1998.
[3] C. S. K., Reddy, R. Ghai, Rashmi, and V. C. Kalia, “Polyhydroxyalkanoates: an overview,” Bioresource Technology, vol. 87, pp. 137-146, April 2003.
[4] R. A. J Verlinden, D. J. Hill, M. A. Kenward, C. D. Williams, and I. Radecka, “Bacterial synthesis of biodegradable polyhydroxyalkanoates,” Journal of Applied Microbiology, vol. 102, pp. 1437–1449, June 2007.
[5] L. L. Madison, and G.W. Huisman, “Metabolic engineering of poly(3- hydroxyalkanoates): from DNA to plastic,” Microbiology and Molecular Biology Reviews, vol. 63, pp. 21-53, March 1999.
[6] H. Salehizadeh, and M. C. M. Van Loosdrecht, “Production of polyhydroxyalkanoates by mixed culture: recent trends and biotechnological importance,” Biotechnology Advances, vol. 22, pp. 261-279, January 2004.
[7] Y. Jiang, L. Marang, J. Tamis, M. C. M. van Loosdrecht, H. Dijkman, and R. Kleerebezem, “Waste to resource: Converting paper mill wastewater to bioplastic,” Water Research, vol. 46, pp. 5517-5530, November 2012.
[8] J. Tamis, L. Katlin, Y. Jiang, M. C. M. van Loosdrecht, and R. Kleerebezem, “Enrichment of Plasticicumulans acidivorans at pilot-scale for PHA production on industrial wastewater,” Journal of Biotechnology, to be published.
[9] N. Jacquel, C.-W. Lo, Y.-H. Wei, H.-S. Wu, and S. S. Wang, “Isolation and purification of bacterial poly(3-hydroxyalkanoates),” Biochemical Engineering Journal, vol. 39, pp. 15–27, April 2008.
[10] L. A. Smith, K. J. Roberts, D. Machin, and G. McLeod, “An examination of the solution phase and nucleation properties of sodium, potassium and rubidium dodecyl sulphates,” Journal of Crystal Growth, vol. 226, pp. 158–167, June 2001.
[11] R. Smith, Chemical process design and integration, pp. 17-31, Chichester: John Wiley & Sons, 2005.
[12] R. K. Sinnott, Coulson & Richardson's chemical engineering. Volume 6: chemical engineering design, fourth ed., pp. 246-279, Oxford: Elsevier, 2005.
[13] G. D. Ulrich, and P. T. Vasudevan, “How to estimate utility costs,” Chemical Engineering, vol. 4, pp. 66-69, April 2006.
[14] International Standards Organization (ISO), ISO 14040:2006, “Environmental management. Life cycle assessment. Principles and framework,” 2006a.
[15] International Standards Organization (ISO), ISO 14044:2006, “Environmental management. Life cycle assessment. Requirements and guidelines,” 2006b.
[16] U.S. Environmental Protection Agency, “Accounting framework for biogenic CO2 emissions from stationary sources,” Office of Atmospheric Programs, Climate Change Division, Washington, DC, 2011.
[17] P. Pawelzik, M. Carus, J. Hotchkiss, R. Narayan, S. Selke, M. Wellisch, M. Weiss, B. Wicke, and M. K. Patel, “Critical aspects in the life cycle assessment (LCA) of bio-based materials–Reviewing methodologies and deriving recommendations,” Resources, Conservation and Recycling, vol. 73, pp. 211–228, April 2013.
[18] Y. Jiang, G. Mikova, R. Kleerebezem, L. A. M. van der Wielen, and M.C. Cuellar, “Feasibility study of an alkaline-based chemical treatment for polyhydroxyalkanoates purification from mixed enriched culture,” unpublished.
[19] D. Michael, “Biodegradable polymer supply chains: implications and opportunities for agriculture,” Wondu Holdings, Sydney, 2004.
[20] J. Choi, and S. Y. Lee, “Process analysis and economic evaluation for Poly(3-hydroxybutyrate) production by fermentation,” Bioprocess Engineering, vol. 17, pp. 335-342, November 1997.
[21] M. Akiyama, T. Tsugea, and Y. Doia, “Environmental life cycle comparison of polyhydroxyalkanoates produced from renewable carbon resources by bacterial fermentation,” Polymer Degradation and Stability, vol. 80, pp. 183–194, February 2003.
[22] S. Y. Lee, and J. Choi, “Effect of fermentation performance on the economics of poly(3-hydroxybutyrate) production by Alcaligenes latus,” Polymer Degradation and Stability, vol. 59, pp. 387-393, January 1998.
[23] J. A. Posada, J. M. Naranjo, J. A. López, J. C. Higuita, and C. A. Cardona, “Design and analysis of poly-3-hydroxybutyrate production processes from crude glycerol,” Process Biochemistry, vol. 46, pp. 310– 317, January 2011.
[24] N. Gurieff, and P. Lant, “Comparative life cycle assessment and financial analysis of mixed culture polyhydroxyalkanoate production,” Bioresource Technology, vol. 98, pp. 3393–3403, July 2007.
[25] J. M. Naranjo, J. A. Posada, J. C. Higuita, and C. A Cardona, “Valorization of glycerol through the production of biopolymers: The PHB case using Bacillus megaterium,” Bioresource Technology, vol. 133, pp.38–44, April 2013.
[26] T. Mumtaz, N. A. Yahaya, S.Abd-Aziz, N. A. Rahman, P. L. Yee, Y. Shirai, and M. A. Hassan, “Turning waste to wealth-biodegradable plastics polyhydroxyalkanoates from palm oil mill effluent - a Malaysian perspective,” Journal of Cleaner Production, vol. 18, pp. 393-1402, June 2010.
[27] ICIS Pricing. http://www.icis.com/
[28] M. Patel, C. Bastioli, L. Marini, and E. Würdinger, “Life cycle assessment of bio-based polymers and natural fibres composites,” Biopolymers online, vol.10, January 2005.
[29] R. Briones, L. Tai, E. Daoud, and J. Hart, “Life Cycle Assessment. Identifying process improvement opportunities and assessing alternatives,” California environmental protection agency department of toxic substances control, DTSC, Plastics Hazards Reduction Unit, June 2011.
[30] A. Liebich, and J. Giegrich, “Eco-profiles of the European plastics industry. Polyethylene terephthalate (PET). Bottle grade,” Plastics Europe, Heidelberg, April 2010.