TDA RESEARCH, INC. — Department of Energy SBIR Phase I: 13b

Description

Fast pyrolysis is a thermal processes used to convert lignocellulosic biomass into a liquid product that can easily be stored, transported, or utilized as fuel or source of chemicals. As of today, the economics of the fast pyrolysis process to make just bio-fuels is marginal. The U.S. Department of Energy is interested in improving the profitability of fast pyrolysis by developing processes that convert its waste aqueous stream into value-added products. General statement of how this problem is being addressed. Since the polymer sector has a 7- fold greater value per unit mass than the transportation/fuel sector, integrating the production of biofuels with that of bioplastics is one of the most effective way to improve the economics of bio-fuel production from biomass. This project proposes the catalytic conversion of a major component of the aqueous waste of fast pyrolysis into a bio-plastic that could be used as a renewable and biodegradable replacement for polyethylene. Polyethylene is the largest volume plastics and its market is large enough to accept the outputs of many fats pyrolysis plants. A preliminary technoeconomic analysis indicated that the raw material used for the manufacture of the proposed bio-plastic could be separated and purified from the fast pyrolysis waste stream at an estimated cost of $0.3- 0.4/lb, which makes this monomer competitive with commodity monomers. For example, bio-ethylene costs $0.90-1.20/lb and petrochemical ethylene costs $0.30-0.60/lb. What is to be done in Phase I? The objective of this DOE SBIR Phase I project is to develop an improved catalytic process that will enable the production of high molecular weight bio-plastic from the aqueous waste stream of fast pyrolysis. We will characterize the performance, processing parameters of this new bio-plastic to identify optimal target applications. We will demonstrate this bio-plastic has the properties needed to compete against traditional petrochemical and renewable polymers on the basis of both cost and performance. Commercial Applications and Other Benefits. Applications for this technology include anything that today is made with polyethylene. The most promising market applications are those where the incentive to use renewable materials is high, e.g. higher volume applications, but limitations of existing renewable technologies have not allowed the switch from petroleum-based polymers to occur. Singleuse bags and food packaging are our early target applications. This technology offers disruptive advantages over competitive bio-plastics because the production of the monomer does not compete with the food supply chain (as with corn or sugar cane derived monomers), the polymer is biodegradable, and the monomer and degradation products are natural metabolites and nonpersistent chemicals. Furthermore, this technology promises a sustainable economic advantage due to its synergy with bio-fuel production, which reduces capital investment. Key Words. Fast Pyrolysis Improved Economics, Catalytic Conversion of Bio-Fuel Waste Stream, Bio-based Materials, Bio-plastic, Renewable Polymer, Cellulosic Feedstock. Summary for Members of Congress. Bio-fuels can be produced by thermal processing of agricultural feedstocks, however the economics of this process today is marginal. Profitability could be improved if bio-fuel production is integrated with that of higher-margin products such as bio-plastics. This project will develop a catalytic process to convert a waste stream from bio-fuel production into a renewable and biodegradable bio-plastic that could be used to replace polyethylene in many applications, including plastic bags, food packaging and disposable tableware.