Transcript Slide 1

Project 3.4:
PRODUCTION OF
POLYHYDROXYALKANOATES (BIO-PLASTICS)
FROM SUGAR CANE TRASH AND VINASSE
Mauritius Sugarcane Industry Research Institute
Mid-term Review - 2 October 2012
Background

What?
Bioplastics are plastics in which all carbon is
derived from renewable feedstocks.
Polyhydroxyalkanoates (PHAs) are a group of
bioplastics that are completely synthesized by
microorganisms

Why?
Background
Produced from renewable resources v/s petroleum-based
Reduced fossil-fuel use & CO2 emission: reduced
environmental impact.
Biodegradability
Concerns about human health
Potential for sustainable industrial production
Wide application (packaging material, agriculture,
biomedical etc.)

Why not?
Background
High production cost in comparison to petroleumbased plastics :
the high raw material cost
high recovery cost
low PHA yield
2005: Project proposal first formulated
emphasis was on use of sugarcane bagasse as
feedstock
Mar 2011: Amended project proposal was
presented to the SAG
sugarcane trash and vinasse were included as
likely feedstock
SAG recommendations: To revisit Project
Desktop study
Aug 2011: Desktop study completed
Revised Project proposal submitted
Desktop study:
Current use and composition profile of vinasse.
Vinasse as a potential feedstock for production of PHA.
Sugarcane trash as potential feedstock for the
production of PHA.
Pre-treatment and hydrolysis of the lignocellulosic
biomass from sugarcane.
Theoretical PHA yield from sugarcane biomass and
vinasse.
Recommendations
Key findings from desktop study:
 low PHA production potential of vinasse - its use
in a stand-alone PHA production plant unlikely to be
feasible.
 As much PHA may potentially be obtained from
sugarcane trash on a per hectare basis as from
bagasse.
 Vinasse may be considered as part of a process
integrated into a trash-based PHA production plant.
Efficient conversion of the cellulose / hemicelluloses
in the sugarcane trash/vinasse into simple sugars
Isolation, identification and selection of PHAproducing bacteria
Optimization of media and conditions for maximum
bacterial growth and then maximum PHA
production
Optimization of extraction procedures and efficiency
of PHA recovery
Proposed scheme for PHA production using vinasse and
sugarcane trash as feedstock
Lignocellulosic
Biomass (trash)
Optimization
is required
Vinasse
Sugars, VFA’s
Prehydrolysate
Separation
Pre-treatment
Production of
PHA-rich
microbial biomass
Separation
Extraction &
Purification of
PHA
Hydrolysis
Effluent &
residual
biomass
Hydrolysate
Separation
PHA polymer
SOLIDS
Fuel
Fertilizer
SOLIDS
ACTIVITIES PLANNED FOR 2011-2012
1. Purchase of equipment:
January 2012 : International Open Tender published in for the
purchase of
1 liquid chromatograph-mass spectrometer
1 gas chromatograph-mass spectrometer, and
1 gel permeation chromatograph.
June 2012 : Evaluation of tenders received completed
Award of contract awaiting release of funds
Order of 12 items of smaller equipment for Microbiology laboratory by
Negotiated Procedure awaiting release of funds
ACTIVITIES PLANNED FOR 2011-2012
Recruitment and training of scientists
February 2012 : Two graduates recruited on contractual basis.
In-house training on microbiology and chemistry aspects.
Delay in acquisition of new equipment has delayed training
23 November to 3 December 2011: Two scientists from MSIRI
visited the Department of Bioprocess Technology, University Putra
Malaysia (UPM) and the Ecobiomaterials Research Laboratory,
University of Science Malaysia (USM)
ACTIVITIES PLANNED FOR 2011-2012
Isolation, identification and selection of PHA-producing
bacteria:
Bacterial isolates (46) collected and purified from different
niches (vinasse, sugarcane trash, soil, refinery mud) as well as
reference isolates known to produce bioplastics (e.g. Ralstonia
eutropha, Azospirillum brasilense, Rhizobium sp, Bacillus sp)
are being evaluated for their ability to produce bioplastics
Optimization of bacterial growth and of PHA biosynthesis :
Different nutrient media are being evaluated in shake-flask culture
and under different conditions of shaking and incubation
temperature so as to optimize the bulking of bacterial cells.
ACTIVITIES PLANNED FOR 2011-2012
Optimization of PHA recovery and purification:
The evaluation of different PHA extraction protocols for recovery of
PHA from bacterial cells, including the use solvents, non-solvents
and mechanical means, has been initiated.
Characterization of sugarcane trash, vinassse:
Sugarcane trash and vinasse have only partially been characterized
for a number of simple parameters but the quantification of convertible
sugars, volatile fatty acids and other microbially-assimilable
substances is awaiting the acquisition of new equipment (HPLC
system)
ACTIVITIES PLANNED FOR 2011-2012
Pre-treatment and hydrolysis of biomass , Characterization of
hyrolysates:
This activity will be performed once the necessary equipment are
received.
Plan of activities
Activity
2012
Purchase of various equipment and
consumables
X
Visits of MSIRI scientists to
biopolymer laboratories
√
Recruitment of scientists (2) on
contractual basis.
Training on use of equipment and
laboratory techniques
Isolation, identification and selection of
PHA-producing bacteria
√
Partial
√
2013
2014
Plan of activities
Activity
2012
Characterization of sugarcane trash, Partial
vinassse, refinery mud
Pre-treatment and hydrolysis of
biomass/vinasse; Characterization of
hyrolysates
X
Optimization of bacterial growth and of
PHA biosynthesis
√
Optimization of PHA recovery and
purification
√
2013
2014
Plan of activities
Activity
Characterization of PHAs produced
Scaling up of production from 1L to
10L and further optimization of
fermentation process
Further optimization of PHA synthesis
and recovery
Evaluation of biodegradability of PHA
Economic analysis to determine the
feasibility of large-scale adoption of
technology.
Final Report and dissemination of
results
2012
X
2013
2014
Expected outcome
To set the basis for establishment of a future bioplastic
production facility based on unused/cheap sources of
carbon from sugarcane.
Capacity building; acquisition of state-of the-art
equipment.
Beneficiaries
All sugar producing countries looking for a diversification
of the sugar industry.
Acknowledgements
Thank you for your attention
Theoretical PHA yield from
biomass and vinasse.
Production
(kg t-1 cane)
Estimated PHA
yield (kg ha-1)
150 (d.m.)
2000
Bagasse
310 @ 50%
moisture
2090
Vinasse
84 L
45
Sucrose
100
2640
Feedstock
Sugarcane
trash