Periodic Reporting for period 1 - BIOCTANE (Synergetic integration of BIOteChnology and thermochemical CaTalysis for the cAscade coNvErsion of organic waste to jet-fuel)
Reporting period: 2022-11-01 to 2024-02-29
BIOCTANE project aims to develop a process for the conversion of organic waste materials naturally characterized by a high-water content (e.g. food-waste, organic material from the food processing industry) into sustainable aviation fuels. With the goal to maximize the transfer efficiency of the organic carbon into the respective fuel products, biochemical and thermocatalytic processes will be combined in a robust and efficient cascade process where the complex organic waste streams will be converted to platform chemicals (acetoin and 2,3-Butanediol) that will be later downstream catalytically processed to hydrocarbons compatible with jet-fuel formulations. The wet organic matter inaccessible by the biotechnological conversion steps will be gasified under hydrothermal catalytic conditions to hydrogen (H2) and intermediate products, such as carboxylates, useable as an additional feedstock in the biotechnological conversion steps.
There is a growing demand for alternative sustainable feedstock-based ways to produce jet-fuel. This implies the development of new production chains consisting of the integration of catalytic conversion processes not been connected before and not been analyzed for efficiency improvement and scalability within this specific context. The BIOCTANE project aims to contribute to the development of these demanded new routes, reaching a TRL level of 4. To succeed in the concept proposed in BIOCTANE project, the following aspects need to be developed:
- New strategies for eco-engineering the biological mixed cultures processes towards stabilized and optimized conversion of complex organic waste streams.
- An improved mixotrophic strain for the continuous production of platform chemicals that can be used for further processing into fuel components.
- New robust catalysts producing selectively H2 from wet biomass under hydrothermal conditions.
- New or improved catalysts to address the integration of typically independent reactions into a one-step process for the conversion of platform chemicals into jet-fuel range hydrocarbons.
- A full process that allows elucidating the techno-economic requirements for full market integration.
There is a growing demand for alternative sustainable feedstock-based ways to produce jet-fuel. This implies the development of new production chains consisting of the integration of catalytic conversion processes not been connected before and not been analyzed for efficiency improvement and scalability within this specific context. The BIOCTANE project aims to contribute to the development of these demanded new routes, reaching a TRL level of 4. To succeed in the concept proposed in BIOCTANE project, the following aspects need to be developed:
- New strategies for eco-engineering the biological mixed cultures processes towards stabilized and optimized conversion of complex organic waste streams.
- An improved mixotrophic strain for the continuous production of platform chemicals that can be used for further processing into fuel components.
- New robust catalysts producing selectively H2 from wet biomass under hydrothermal conditions.
- New or improved catalysts to address the integration of typically independent reactions into a one-step process for the conversion of platform chemicals into jet-fuel range hydrocarbons.
- A full process that allows elucidating the techno-economic requirements for full market integration.
During this first reporting period, the most suitable substrate (food waste) has been experimentally identified, together with the operating conditions and biotic parameters in dark fermentation to convert efficiently food waste to organic acids. First attempts have been made to couple dark fermentation and microbial electrolysis cells as strategy to maximize the conversion of organic waste into carboxylic acids, with very promising results.
Genetic engineering on the bacterium Cupriavidus necator has been successfully applied to convert the organic acids to acetoin and 2,3-butanediol (2,3-BDO). A membrane biofilm reactor has been designed and built and initial test runs has shown biofilm formation of the organism on the membrane.
The synthesis and characterization of new catalytic formulations for the chemical conversion of 2,3-BDO and acetoin to jet fuels has progressed satisfactorily. The C-C coupling of pure acetoin and biomass-derived platform molecules has been successfully carried out and research on the subsequent catalytic hydrodeoxygenation treatment has been started. Pure 2,3-BDO has been fully dehydrated to C4 olefins that will be converted into oligomers with a tandem catalytic system in the same reactor.
Regarding the hydrothermal gasification of the organic matter not converted in the biotechnological steps, two supports have been identified for the catalyst manufacture with suitable stability.
Finally, the system boundaries and the most important assumptions for the simulation and assessment of the overall BIOCTANE process have been defined. Process modelling of the first process steps have also been started.
Genetic engineering on the bacterium Cupriavidus necator has been successfully applied to convert the organic acids to acetoin and 2,3-butanediol (2,3-BDO). A membrane biofilm reactor has been designed and built and initial test runs has shown biofilm formation of the organism on the membrane.
The synthesis and characterization of new catalytic formulations for the chemical conversion of 2,3-BDO and acetoin to jet fuels has progressed satisfactorily. The C-C coupling of pure acetoin and biomass-derived platform molecules has been successfully carried out and research on the subsequent catalytic hydrodeoxygenation treatment has been started. Pure 2,3-BDO has been fully dehydrated to C4 olefins that will be converted into oligomers with a tandem catalytic system in the same reactor.
Regarding the hydrothermal gasification of the organic matter not converted in the biotechnological steps, two supports have been identified for the catalyst manufacture with suitable stability.
Finally, the system boundaries and the most important assumptions for the simulation and assessment of the overall BIOCTANE process have been defined. Process modelling of the first process steps have also been started.
The synergetic coupling of biotechnological, thermochemical and catalytic routes proposed in BIOCTANE is a disruptive strategy that may result in an efficient valorization of biogenic wastes, maximizing the recovery of mass and energy. During this reporting period, new developments in the field of the biotechnological conversion of organic waste into platform molecules (acetoin and 2,3-Butanediol) have been achieved, such as the optimization of operating conditions and biotic parameters in dark fermentation or the genetic modification of the bacterium Cupriavidus necator to selectively produce the platform molecules. Likewise, catalysts and operating conditions have been identified for the direct conversion of the platform molecules into jet-fuels. However, more research is still needed as the project is on the earlier stages of research. Moreover, estimated TRL to be achieved is 4, so upscaling actions will be needed once the project is finished in order to reach a market impact.