WP1 – User Requirements and Digital Tools
Requirements and validation methods were established for both target applications: automotive polyamides and membrane-grade PBIs. Performance criteria covering thermal, mechanical, dielectric, electrochemical and durability properties were defined together with testing protocols and benchmark materials. Digital tools for fermentation control, metabolic modelling and machine-learning-based polymer design were also developed. Key deliverables and the first project milestone were successfully completed.
WP2 – From Biomass to Monomers
Second-generation woody biomass was successfully converted into amino acid precursors and monomers. Biomass processing was optimized, improving sugar quality and fermentability. Engineered microbial strains achieved amino acid 1 concentrations above 90 g/L, significantly exceeding the project target of 50 g/L. Initial proof-of-concept production of amino acid 2 was demonstrated, and utilization of lignin-derived aromatic compounds was validated.
Monomer synthesis was optimized through the development of a safer, more sustainable and resource-efficient process requiring fewer reaction steps, less energy and reduced reagent consumption. These results provide a strong basis for future pilot-scale production.
WP3 – Development of Novel Biobased Polymers
New families of polyamides and polybenzimidazoles were synthesized from the BIOPYRANIA monomers. A broad library of polyamides with diverse thermal properties was prepared. Challenges related to molecular weight development and undesired crosslinking during processing were identified and mitigation strategies were developed.
For PBIs, the initially planned hydrothermal polymerization route was not successful. However, an alternative synthesis route enabled the preparation of high-molecular-weight PBIs that were subsequently functionalized for membrane applications. Despite some delays, milestone materials were delivered to project partners and valuable structure–property relationships were established.
WP4 – Validation and Recycling
Validation activities started for both application areas. Commercial benchmark materials were characterized to establish reference datasets. BIOPYRANIA PBIs were successfully processed into membranes using DMSO, overcoming earlier solubility limitations. Recycling activities focused on literature review and process preparation, while experimental recycling will continue once sufficient quantities of optimized polymers become available.
WP5 – Safety, Sustainability and Techno-Economic Assessment
Safe-and-Sustainable-by-Design (SSbD) principles were implemented throughout the value chain. Occupational risk assessments were completed for biomass processing, amino acid production, monomer synthesis and polymer manufacturing. Most activities were classified as low- to medium-risk, and appropriate safety measures were confirmed. Risk assessment methodologies and exposure evaluation tools were established to support future scale-up activities.
WP6 – Dissemination and Exploitation
A project website, stakeholder database and communication plan were established. Ninety-three stakeholders were identified and categorized. BIOPYRANIA joined forces with related Horizon Europe projects through the BIOPOLY cluster. Key Exploitable Results (KERs) were identified and exploitation, intellectual property and business-planning activities were initiated, laying the foundation for future commercialization.
WP7 – Project Management
Project governance, communication procedures, risk management and decision-making structures were successfully implemented. Four consortium meetings were organized during the reporting period, and supporting tools such as a SharePoint platform, innovation management framework and advisory board were established. All management-related deliverables were submitted on schedule.
