Periodic Reporting for period 2 - CO2TEXTILE (Novel business model enabled by a patented fermentation technology to produce 100% biodegradable textile fibres from CO2-emissions)
Periodo di rendicontazione: 2023-09-01 al 2025-08-31
CO2BioClean tackles plastic pollution and industrial CO2 by converting captured emissions into fully biodegradable PHA biopolymers for textile fibres. With global plastics at 360 Mt in 2018 (40 Mt in textiles) and ~80 Mt discarded annually—around 8 Mt entering oceans already burdened with 150 Mt (projected 250 Mt by 2030)—a scalable alternative is urgent. In Europe, industry emitted 3.5 Gt CO2 in 2017, paying €87.5B in allowances at €55/t. Converting just 10% of these emissions via CO2BioClean could meet ~90% of Europe’s annual plastic demand and avoid ~200 Mt CO2 from conventional plastic production, advancing the EU’s 2050 climate‑neutrality goals while easing EUA cost pressures and strengthening competitiveness in energy‑intensive sectors like steel and chemicals.
The core innovation links CO2‑emitting industries with the textile value chain using a patented, chemolithoautotrophic fermentation that converts industrial CO2 into 100% biodegradable PHA. The process is up to 5× more cost‑efficient than existing routes, converting ~1.5 t CO2 into 1 t PHA that can be spun into fibres and sold at ~€3/kg. Materials are compostable within <1 year under composting conditions (ASTM D6400/D6868) and marine biodegradable, mitigating plastic pollution and microplastics. A non‑toxic solvent extraction enables direct fibre‑ready output, lowering processing costs. Altogether, CO2BioClean establishes a circular, EU‑anchored pathway from captured CO2 to market‑ready sustainable textiles.
The main impacts of the project are:
• Validated compostability (ASTM D6400/D6868), marine biodegradability, performance parity (<10% thermal deviation), and textile durability (50 washes); pilot delivers customer‑grade fibres.
• Market creation since tuneable PHA and fibre diameters (~1–100 µm) plus direct fibre‑readiness support price parity and broad applications (products from T‑shirts to raincoats).
• System change: on‑site CO2 valorisation offsets EUA costs and builds EU‑anchored circular textiles, reducing imports and microplastics.
• Climate/environment impact since each tonne of PHA replaces fossil fibres; 1.5–2.5 t CO2 converted at source per tonne of PHA.
• Cost advantage by efficient fermentation and non‑toxic extraction producing direct, distributable fibres, cutting processing costs and matching petrochemical price points.
• Circularity by converting CO2 emissions into 100% biodegradable products with <1‑year composting time, closing the loop.
The core innovation links CO2‑emitting industries with the textile value chain using a patented, chemolithoautotrophic fermentation that converts industrial CO2 into 100% biodegradable PHA. The process is up to 5× more cost‑efficient than existing routes, converting ~1.5 t CO2 into 1 t PHA that can be spun into fibres and sold at ~€3/kg. Materials are compostable within <1 year under composting conditions (ASTM D6400/D6868) and marine biodegradable, mitigating plastic pollution and microplastics. A non‑toxic solvent extraction enables direct fibre‑ready output, lowering processing costs. Altogether, CO2BioClean establishes a circular, EU‑anchored pathway from captured CO2 to market‑ready sustainable textiles.
The main impacts of the project are:
• Validated compostability (ASTM D6400/D6868), marine biodegradability, performance parity (<10% thermal deviation), and textile durability (50 washes); pilot delivers customer‑grade fibres.
• Market creation since tuneable PHA and fibre diameters (~1–100 µm) plus direct fibre‑readiness support price parity and broad applications (products from T‑shirts to raincoats).
• System change: on‑site CO2 valorisation offsets EUA costs and builds EU‑anchored circular textiles, reducing imports and microplastics.
• Climate/environment impact since each tonne of PHA replaces fossil fibres; 1.5–2.5 t CO2 converted at source per tonne of PHA.
• Cost advantage by efficient fermentation and non‑toxic extraction producing direct, distributable fibres, cutting processing costs and matching petrochemical price points.
• Circularity by converting CO2 emissions into 100% biodegradable products with <1‑year composting time, closing the loop.
During the project, we have performed the following activities related to the product development:
• Designed and validated a high‑yield, chemolithoautotrophic fermentation using non‑pathogenic gram‑negative strains to convert captured industrial CO2 (with H2) directly into PHA; established process parameters and redox pathway activation for autotrophic metabolism.
• Built and operated 10 L bioreactor prototypes producing PHA from industrial‑grade CO2; optimized yields and downstream extraction; verified compostability (ASTM D6400/D6868) and marine biodegradability.
• Conducted material characterization and performance testing; demonstrated <10% deviation in key thermal transitions and textile stability through laundering and ironing.
• Developed a non‑toxic solvent extraction route that outputs filament‑ready PHA fibres, reducing processing costs; integrated fibre‑spinning concepts for pilot in‑line production.
• Collected parameters scale‑up engineering for a 10,000 L pilot (~3 t/year) and prepared field testing at Infraserv Industriepark Höchst, including fibre‑spinning integration.
• Completed feasibility and demonstrations with SABIOMATERIALS, producing first consumer articles (socks, baskets) from CO2‑PHA to validate end‑to‑end continuity.
• Advanced IP and freedom to operate filed European patent, conducted FTO assessment, secured trademark, and progressed business/risk plans for industrial deployment.
Our main achievements reached during the project include:
• Proven prototype conversion efficiency: up to ~1 kg PHA from ~2.5 kg CO2, validating bioprocess scalability, strain selection, and process control for consistent quality.
• Validated material performance and end-user viability: CO2‑PHA matches reference thermal/mechanical properties (DSC/TGA/ISO 527; <10% deviation), is compostable per ASTM D6400/D6868, marine biodegradable, and maintains textile durability after 50 wash cycles at 40°C and ironing, supporting substitution in fibre applications.
• Established tuneable PHA composition and fibre diameters (~1–100 µm) enabling different applications and reducing the downstream costs. Ou top applications include biodegradable textiles (monofilaments and multifilaments), films for packaging, tree shelters and ingredients for cosmetics.
• Achieved integrated industrial design: on‑site CO2 capture and immediate bioconversion create a circular route, avoid atmospheric release, and enable EUA cost offsets while producing saleable feedstock.
• Secured pilot implementation pathway with partners to finalize parameters for first commercial‑scale site, including fibre‑spinning for direct distribution.
• Our pilot plan started operations in summer 2024. The cumulated produced PHA (including third party PHA) reached the 2 Kg (~2,21 tons).
• Designed and validated a high‑yield, chemolithoautotrophic fermentation using non‑pathogenic gram‑negative strains to convert captured industrial CO2 (with H2) directly into PHA; established process parameters and redox pathway activation for autotrophic metabolism.
• Built and operated 10 L bioreactor prototypes producing PHA from industrial‑grade CO2; optimized yields and downstream extraction; verified compostability (ASTM D6400/D6868) and marine biodegradability.
• Conducted material characterization and performance testing; demonstrated <10% deviation in key thermal transitions and textile stability through laundering and ironing.
• Developed a non‑toxic solvent extraction route that outputs filament‑ready PHA fibres, reducing processing costs; integrated fibre‑spinning concepts for pilot in‑line production.
• Collected parameters scale‑up engineering for a 10,000 L pilot (~3 t/year) and prepared field testing at Infraserv Industriepark Höchst, including fibre‑spinning integration.
• Completed feasibility and demonstrations with SABIOMATERIALS, producing first consumer articles (socks, baskets) from CO2‑PHA to validate end‑to‑end continuity.
• Advanced IP and freedom to operate filed European patent, conducted FTO assessment, secured trademark, and progressed business/risk plans for industrial deployment.
Our main achievements reached during the project include:
• Proven prototype conversion efficiency: up to ~1 kg PHA from ~2.5 kg CO2, validating bioprocess scalability, strain selection, and process control for consistent quality.
• Validated material performance and end-user viability: CO2‑PHA matches reference thermal/mechanical properties (DSC/TGA/ISO 527; <10% deviation), is compostable per ASTM D6400/D6868, marine biodegradable, and maintains textile durability after 50 wash cycles at 40°C and ironing, supporting substitution in fibre applications.
• Established tuneable PHA composition and fibre diameters (~1–100 µm) enabling different applications and reducing the downstream costs. Ou top applications include biodegradable textiles (monofilaments and multifilaments), films for packaging, tree shelters and ingredients for cosmetics.
• Achieved integrated industrial design: on‑site CO2 capture and immediate bioconversion create a circular route, avoid atmospheric release, and enable EUA cost offsets while producing saleable feedstock.
• Secured pilot implementation pathway with partners to finalize parameters for first commercial‑scale site, including fibre‑spinning for direct distribution.
• Our pilot plan started operations in summer 2024. The cumulated produced PHA (including third party PHA) reached the 2 Kg (~2,21 tons).
Beyond the technical results described above, the project has important environmental and economic impacts. It contributes to the EU priorities regarding the Green Deal and the ETS objectives by valorising industrial CO2 into biodegradable products and enabling circular carbon pathways in hard‑to‑abate sectors.
By achieving the on‑site conversion of industrial CO2 into biodegradable PHA, it prevents CO2 emissions and mitigates microplastic pollution from synthetic fibres, directly supporting the EU 2050 climate neutrality objective. Furthermore, it transforms a liability into an asset, by valorising CO2 into saleable polymer feedstock, enabling EUA cost avoidance and strengthening EU energy‑intensive sectors versus non‑EU producers.
The project transforms the market because the direct extraction/fibre‑readiness and tuneable PHA enable price‑competitive sustainable fibres at parity with petrochemical peers, unlocking mass‑market eco‑fibres and supporting EU nearshoring of sustainable textile production at price parity, strengthening the EU industrial competitiveness.
Additionally, it promotes a circular economy, creating a scalable cross‑sector value chain linking CO2 emitters with textile producers. This establishes a circular pathway from captured CO2 to biodegradable end products that mitigate microplastics.
By achieving the on‑site conversion of industrial CO2 into biodegradable PHA, it prevents CO2 emissions and mitigates microplastic pollution from synthetic fibres, directly supporting the EU 2050 climate neutrality objective. Furthermore, it transforms a liability into an asset, by valorising CO2 into saleable polymer feedstock, enabling EUA cost avoidance and strengthening EU energy‑intensive sectors versus non‑EU producers.
The project transforms the market because the direct extraction/fibre‑readiness and tuneable PHA enable price‑competitive sustainable fibres at parity with petrochemical peers, unlocking mass‑market eco‑fibres and supporting EU nearshoring of sustainable textile production at price parity, strengthening the EU industrial competitiveness.
Additionally, it promotes a circular economy, creating a scalable cross‑sector value chain linking CO2 emitters with textile producers. This establishes a circular pathway from captured CO2 to biodegradable end products that mitigate microplastics.