Research & Development Roadmap Bio-Based Polymers Jochen Michels DECHEMA e.V. 17 March, 2015

Research & Development Roadmap Bio-based plastics are a heterogeneous group: Roadmap focus Biodegradable and/or compostable bio-based polymers (e.g. PLA and PHAs) Non-biodegradable bio-based polymers (e.g. bio-based PE, partially bio-based PET and PTT) Non-biodegradable thermosets (e.g. partially bio-based polyurethanes and epoxies) Today, bio-based plastics have an established market and are rapidly growing both in Europe and on a global scale. Between 2008 and 2013, bio-based plastics showed a compound annual growth rate (CAGR) of 20 % in the EU. In 2013, Europe was both the largest bio-based plastics consumer and producer, supplying one third of the global bio-based plastics output. Concerns about plastic waste problems, GHG emissions and oil price fluctuation are pushing public sectors, businesses, as well as households towards more sustainable alternatives to conventional plastics. Bio-based plastics are a heterogeneous group consisting of:

Research & Development Roadmap Bio-based plastics are a heterogeneous group: Roadmap focus Biodegradable and/or compostable bio-based polymers (e.g. PLA and PHAs) Non-biodegradable bio-based polymers (e.g. bio-based PE, partially bio-based PET and PTT) Non-biodegradable thermosets (e.g. partially bio-based polyurethanes and epoxies)

Research & Development Roadmap Polylactic acid (PLA) PLA is produced by chemical polymerisation of lactic acid, which is a anaerobic fermentation product Fermentation leads to either optically pure L-(+)- or D-(-)-lactic acid, which are the desired sources for the polymerisation Impurities by its counterpart enantiomer lead to more amorphic polymers with different properties, which are relevant for processing and use

Research & Development Roadmap Polyhydroxyalkanoates (PHA) PHAs are a group of biodegradable biobased linear polyesters which are produced directly by microbes in an aerobic fermentation process PHA are intracellular storage substances (as granules) The most common type of PHA is the homopolymer of 3-hydroxybutyrate (PHB), which became available in the 1980s

Research & Development Roadmap Systematic of Hurdles & Solutions Hurdles & Solutions General (horizontal) Specific for PLA Specific for PHA Feedstock supply Bioconversion Downstream processing

Research & Development Roadmap Systematic of Hurdles & Solutions Hurdles & Solutions General (horizontal) Specific for PLA Specific for PHA Feedstock supply Bioconversion Downstream processing

Research & Development Roadmap Main Hurdles and Solutions (general) Integrate feedstock production and bioconversion to minimize transportation costs and post-harvest losses Certification of feedstock production against fluctuating feedstock quality (incl. waste) New (non-food) feedstocks Develop Biorefinery concepts to valorize the biomass as much as possible Supply of sufficient amounts of feedstock* *that compete on price with fossil derived feedstocks

Research & Development Roadmap Main Hurdles and Solutions (specific for PLA & PAH) Waste streams & by-products like residues from agricultural materials or glycerol from biodiesel production 2nd generation lignocellulosic feedstocks like wood or straw (C6 & C5 conversion) C1-compounds Syngas-fermentation (CO, CO2, H2) Complex nitrogen sources like grass press juice Supply of sufficient amounts of feedstock* *that compete on price with fossil derived feedstocks

Research & Development Roadmap Main Hurdles and Solutions (general) Novel microbial production routes for tolerance to cheap feedstocks and resistance to by-products and target products anaerobic fermentation New enzymes for improved biocatalysis more active and robust enzymes engineered bioproduction systems for enzymes New water management systems Poor performance and efficiency of bioconversion

Research & Development Roadmap Main Hurdles and Solutions (specific for PLA) New production strains higher yield tolerance against by-products of hydrolysis of 2nd generation feedstocks Lactate solely fermentation from alt. C-sources without by-products (like acetate) Optical pure L(+)- or D(-)-lactate fermentation by genetic engineering Lower pH-Optimum of fermentation minimizes salt and gypsum production Poor performance and efficiency of bioconversion 3) delete either the D- or L- lactate dehydrogenase genes of the organisms.

Research & Development Roadmap Main Hurdles and Solutions (specific for PAH) Anaerobic fermentation process E. coli for anaerobic fermentation Unsterile, anaerobic fermentation process S. cerevisiae for anaerobic fermentation Mixed culture fermentation Multi phase biological synthesis of PHA Transgenic plant cells Poor performance and efficiency of bioconversion Without by products

Research & Development Roadmap Main Hurdles and Solutions (general) Modeling of the entire process for maximum product (and space-time) yield New more efficient bio-catalytic systems (see: bioconversion) Integrating Bioconversion with DSP also includes chemical conversion New water management systems Improved product recovery from water Minimising water usage Separation technologies to improve product recovery, contaminant removal and water re-use High level of im-purities and low product conc. hampers down-stream processing

Research & Development Roadmap Main Hurdles and Solutions (specific for PLA) High level of im-purities and low product conc. hampers down-stream processing (Reference to the presentation of Dr. Schulze, TKIS)

Research & Development Roadmap Main Hurdles and Solutions (specific for PAH) Expensive PHA extraction step* Environmentally friendly & cost-effective PHA granule recovery steps are needed e.g. sodium hypochlorite extraction * Not applicable are: solvent based extraction (chloroform) enzyme based biomass digestion mechanical disruption

Non-technological Roadmap Bio-Based Polymers Dirk Carrez Clever Consult bvba 17 March, 2015

Non-technological Roadmap Main hurdles and bottlenecks (as identified by the stakeholders) Feedstock related barriers Logistics: securing large quantities of biomass all year round Seasonability of biomass cropping versus need of continuous feedstock supply Inefficient transport and distribution of biomass Inefficient recovery systems for (bio)waste Feedstock at affordable prices Costs of feedstock produced in Europe are too high compared to other regions Varying feedstock prices (High) import costs for certain types of feedstock No commonly accepted “sustainability” certification system Investment barriers and financial hurdles Capital requirements Limited availability of public R&D funding Limited public support for scale-up activities Limited access to finance for spin-offs and start-ups Limited access to finance for SMEs Limited financial support for new production facilities IB perceived as sector with high investment risk Too long “return of investment” time Lack of visible tangible products and blockbusters Lack of investors’ confidence Public perception and communication Poor public perception and awareness of IB and Biobased products Advantages of biobased products are not visible enough Negative messages in the media on GMO and biofuels influence perception of IB Demand side policy barriers Absence of incentives or efficient policies No framework to promote biobased products Lack of a “green public procurement” policy promoting biobased products Wide variety of ecolabels and no uniform standard present for sustainable and Biobased products

Non-technological Roadmap Main hurdles and solutions Biobased plastics (e.g. PLA, PHA) HURDLE SOLUTIONS New biobased plastics are often more expensive than the conventional ones Funding for innovations in order to reduce production costs (e.g. conversion technologies and down-stream processing) Explain better the benefits of bioplastics, so consumers accept to pay a (bio-)premium New value chains still have to be developed to obtain critical mass Develop infrastructure for effective composting or recycling Development of policy tools to stimulate demand Need for clear standards and a regulatory framework promoting market uptake Defining in a transparent way the characteristics: ‘green’, “bio-degradable”, “biobased”, “bioplastics”, etc Develop clear standards Improve communication and education Developing a good programme to stimulate market uptake in Europe (e.g. public procurement) Lack of financial incentives Implementing a tax and/or subsidies for certain applications to close the price gap between biobased and fossil based plastics