Vetzuren in de Papierindustrie Van Zuiveren naar Produceren. René Rozendal Papier en PHA; a match made in heaven? 8 Mei 2014, Arnhem

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1 Vetzuren in de Papierindustrie Van Zuiveren naar Produceren René Rozendal Papier en PHA; a match made in heaven? 8 Mei 2014, Arnhem

2 About Paques Innovative biological applications for wastewater and gas Family owned business Founded in 1960 Number of employees : 400 Worldwide presence through network of 20 partners Number of Business Units: 4 (Europe, China, South America & India)

3 Revitalizing Resources Application of microorganisms from nature in our high rate reactors 3

4 Anaerobic Treatment World leader in anaerobic wastewater treatment Removal of organic contaminants Biogas production 1000 Biopaq references in more than 60 countries 4

5 Paques & paper industry Active for more than 30 years More than half of all anaerobic treatment systems in the paper industry were built by Paques. >250 references Chemical pulp, mechanical pulp & recycle paper UASBs and Internal Circulation (IC) reactors Smurfit Kappa Roermond Papier (1983) 5

6 6 UASB reactor IC reactor

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8 Wide range BIOPAQ reactors up to 5000 m 3 (15 m diameter and 28 m height) Capacity: ~100 ton COD/day ~50,000 m 3 biogas/day Equivalent to: ~15 MW th or ~5 MW e (~10,000 households) 8

9 9 Products from Volatile Fatty Acids: An opportunity for the Paper Industry

10 Product values Biogas (without subsidy) Biogas (incl. subsidy NL) Acetic acid Ethyl acetate Medium Chain Fatty Acids Bioplastic (PHA) Product value ( /kg COD) 10

11 Complex Organic Matter/Particulates Hydrolysis Monomers (sugars, proteins) Acidogenesis Acetogenesis Methanogenesis Volatile Fatty Acids, Ketones, Alcohols, H 2 Acetic acid, H 2 Volatile Fatty Acids (C 2 /C 3 /C 4 ) V F A P L A T F O R M BIOBASED PRODUCTS (E.g., Bioplastic) 11 Biogas

12 Poly-b-hydroxyalkanoate (PHA) Common and widespread storage material in microorganisms (>90 genera of archaea and eubacteria) Storage up to 90 wt% in granules Biodegradable Made from renewable resources CURRENTLY VERY EXPENSIVE! 12

13 13 Nieuw proces ontwikkeld!

14 Nieuwe proces Eigenschappen Aeroob proces Open cultures, dus gewone afvalwaterzuivering Geen genetisch gemodificeerde micro-organismen! Geen sterilisatie noodzakelijk! Vetzuren uit afvalwater als grondstof Geen hoogwaardige grondstoffen nodig! Hoge omzettingssnelheden Hoge efficiëntie Hoge percentages aan PHA in cellen t.b.v. : Lagere kosten voor downstream processing Mogelijkheden tot directe verwerking Bereikt door Microbial community engineering 14

15 Microbial Community Engineering Explore the metabolic diversity available in nature By imposing selective pressure on a natural ecosystem To develop processes for treatment of wastewater and the production of chemicals and energy

16 Why microorganisms make PHA? = hoarding weeks

17 Ecological role of bioplastics PHA = Microbial Fat Feed supply Time Pulse feeding of substrate favors growth of bioplastic producing microorganisms: feast famine regime

18 Microbial selection Substrate PHA storing bacteria not PHA storing bacteria 18

19 Amount [(C)mmol] Fraction PHB [Cmol/Cmol] 60 1, ,4 1,2 1,0 30 0, ,6 0,4 0,2 0 0, Time [min]

20 PHB [%] 100 Evolution based system improvement April July 2007 Feb Time [h]

21 21 5/8/

22 Comparision Origin Traditional TU Delft / Paques Biomass GMO E. coli Open mixed culture Substrate Glucose, propionate Wastewater Operation Sterilisation No sterilisation Process Batch (semi)continuous Product yield/time 80-90% / ~ 40 h 80-90% / < 10 h 22

23 STW W2R PHA Twee 4 jarige STW projecten PhD studenten and 2 Post-docs 4 Universiteiten Delft, Eindhoven, Wageningen, Utrecht 11 bedrijven Attero, Avebe, Bioclear, DSM, Indaver, Kiemkracht, Mars, NNZ, Paques, Purac, Eska Graphic Board 23

24 Process development polymer organic acid rich wastewater treated water DSP PHA USP Pilot plant Biomass/PHA cell debris chemical conversion Waste treatment Industrial production Overall process

25 PHA Pilot Plant 25 Mars productie plant Veghel, Nederland Capaciteit : 1 kg/day

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27 PHA pilot : Resultaten 74 % PHA 27

28 STW W2R PHA Overige resultaten Tot 99 % zuiverheid in downstream processing Inzicht in effect van verschillende downstream processing methodes op de uiteindelijke kwaliteit van het product Eerste films gemaakt en extrudertesten uitgevoerd Ook verwerking zonder downstream processing mogelijk Proces ook succesvol getest op papierafvalwater 28

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30 The real world: Paper Mill Wastewater (Yang et al, submitted for publication) 1 Acidification: Production of VFA Waste water CSTR 2 Cultivation: selection of PHA producing enrichment Accumulation: maximizing 3 the cellular PHA content Sequencing batch reactor Fed batch reactor PHA Biomass Eska Graphic Board wastewater: COD: 26 go 2 /L NH 4 +1 ~ 0, PO 4-3 ~ 0

31 Length of feast phase [h] Maximum PHA content [%VSS] Enrichment and accumulation Results: Length of the feast phase decreases in time PHA production capacity increases in time qpcr: P. acidivorans is 57-63% of total biomass Syn. Bu +Ac Real WW Cycle numbers

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34 34 De pilot gaat verhuizen (mei 2014)

35 Products / Intermediates VFA or carboxylate Platform V F A Biopolymers Alcohols Paper WW Volatile Fatty Acids (C 2 /C 3 /C 4 ) P L A T F O R M Biogas Electrons Biomethane MCFA (C 6 /C 8 ) e-products Etc. 35

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