Periodic Reporting for period 1 - GAFT (Production of High-quality Fatty Acids Feedstock for use in SAF Production)
Reporting period: 2023-07-03 to 2024-07-02
The GAFT project presents two innovations in biofuel production processes, for formic acid and for lipids, both essential for future sustainable aviation fuel. Our patented process to produce potassium formate (PF) from CO2, water, and renewable electricity enables a higher concentration to be produced using conventional equipment. We then convert PF to formic acid (FA).
We have also selected and adapted non-GMO microorganisms using FA and glycerol as substrates to produce lipids to be used as feedstock for HEFA to produce Sustainable Aviation Fuel (SAF). The remaining biomass by-product is crude microbiological protein that can be used as feed.
GAFT dramatically improves the production of SAF by being more energy efficient, using just enough energy to produce a C1 hydrocarbon from CO2 and subsequently, via fermentation, to produce fatty acid feedstock for the only currently available commercial technology to produce SAF, the HEFA process.
We have also selected and adapted non-GMO microorganisms using FA and glycerol as substrates to produce lipids to be used as feedstock for HEFA to produce Sustainable Aviation Fuel (SAF). The remaining biomass by-product is crude microbiological protein that can be used as feed.
GAFT dramatically improves the production of SAF by being more energy efficient, using just enough energy to produce a C1 hydrocarbon from CO2 and subsequently, via fermentation, to produce fatty acid feedstock for the only currently available commercial technology to produce SAF, the HEFA process.
We have successfully developed a new electrolyzer generation in GAFT based on a new cell design. Compared to previous designs, the new “finite zero-gap” cell design improve current density and Faradaic efficiency by two-fold, resulting in a production rate up by a factor 4. Optimization work is ongoing to improve the finite zero-gap design further. Ongoing optimization efforts focus on material and structural enhancements to further improve performance. Additionally, pre-engineering work has begun to prepare for future upscaling and technical validation.
Furthermore, we have successfully demonstrated that a pH-stat bioreactor approach is suitable for the conversion of formic acid as sole carbon source into microbial biomass.
We have optimized and refined our lipid extraction method by testing various biobased organic solvents and extraction conditions, showing that the optimal solvent can be recycled while maintaining extraction efficiency. In addition, we have developed a novel method for transesterification, resulting in the production of fatty acid methyl esters (FAME).
Furthermore, we have successfully demonstrated that a pH-stat bioreactor approach is suitable for the conversion of formic acid as sole carbon source into microbial biomass.
We have optimized and refined our lipid extraction method by testing various biobased organic solvents and extraction conditions, showing that the optimal solvent can be recycled while maintaining extraction efficiency. In addition, we have developed a novel method for transesterification, resulting in the production of fatty acid methyl esters (FAME).
A new CO2 electrolyzer generation is developed by optimizing cell design to improve performance. After testing three different cell designs, we found that a finite zero-gap design is the best alternative. In brief, the finite zero-gap design both increase by two-fold the Faradaic efficiency and the current density compared to our previous design, resulting in higher production rate per surface area.
The conversion of formic acid in a minimal salt medium was successfully demonstrated in a bioreactor. First fed-batch fermentation showed an optical density of above 60 for the oleaginous micro-organisms. Further improvements towards productivity and yield are feasible, however further development is required.
Furthermore, we have developed a complete novel method by which we were able to produce fatty acid methyl esters (FAME). In addition, we screened and selected biobased organic solvents and developed efficient and scalable extraction and distillation methods in order to ensure a sustainable downstream process.
The conversion of formic acid in a minimal salt medium was successfully demonstrated in a bioreactor. First fed-batch fermentation showed an optical density of above 60 for the oleaginous micro-organisms. Further improvements towards productivity and yield are feasible, however further development is required.
Furthermore, we have developed a complete novel method by which we were able to produce fatty acid methyl esters (FAME). In addition, we screened and selected biobased organic solvents and developed efficient and scalable extraction and distillation methods in order to ensure a sustainable downstream process.