Since the beginning of the AgriChemWhey project numerous milestones have been achieved, especially in relation to process integration, optimisation and scale-up. The highlights and achievements include all aspects of the project and are presented below:
• Successful installation and commissioning of the pilot plant using whey permeate and delactosed permeate waste streams as the carbon feedstocks of interest.
• Construction, installation and setup of an analytical laboratory with complex instrumentation suitable for detailed physicochemical analysis of various sample types.
• A fermentation specific laboratory was installed to allow for sterile and non-sterile fermentation experimentation to be carried out.
• Construction, installation and setup of a microbiology laboratory lab suitable for intricate practical work tasks such as bacterial propagation, chemically defined media preparation and bacterial enumeration.
• Validation of the upstream demineralisation process using multiple whey permeate streams.
• Cutting-edge optimisation of the upstream demineralisation process was completed to achieve the highest demineralisation rates for various feedstock types. This included assessment of a new technology for the upstream treatment of whey permeate by ultrasonification followed by a cleanup by microfiltration and concentration by nanofiltration.
• Comprehensive datasets generated for the fermentative performance of several production strains on dairy whey waste material.
• Cost-benefit analysis completed to determine the most cost-effective and efficient fermentation process design suitable for industrial scale operations.
• Pilot scale validation of the fermentation process using both WP and DLP as a substrate successfully completed with multiple replicates.
• Setup and integration of the downstream purification process to purify the lactic acid fermentation broth to generate a high quality demineralised dilute lactic acid product.
• Laboratory and pilot-scale production of high quality L-lactic acid.
• Pilot-scale production of high quality polymer grade LA and the subsequent production of 4kg of polylactide derived from our dairy waste stream valorisation platform.
• Detailed technical simulations and modelling of the chemical process to upscale this novel 2nd generation dairy waste stream valorisation platform to commercial scale operations.
• Research carried out on the lacto-gypsum side stream to validate its use as a slurry additive to reduce both ammonia and methane emissions from stored slurry and its potential as an amendment for organic manure for gaseous emissions abatement. The results also showed that its use has the potential to increase Hydrogen-Sulphide (H2S) gas production from cattle slurry. Lastly, an experimental design was developed for field experiments to evaluate lacto-gypsum as an amendment to
restore soil health.
• The properties of PLA and composites produced from ACW lactic acid were evaluated. The results show that the addition of Calcium Phosphate (ACW side-stream) to PLA resulted in an increased water contact angle, indicating that the surfaces became more hydrophobic. Additionally, ACW-PLA composites formulated with various concentrations of CaP demonstrated improved mechanical properties; however, further optimisation is needed.
• Detailed engineering works have been completed on the 20,000mt LA production capacity industrial scale plant.
• Integrated life cycle assessment modelling for both pilot-scale and industrial scale ongoing to calculate the potential environmental impact of this valorisation platform in terms of emissions, resource consumption and industrial symbiosis.
• Active collaboration of AgriChemWhey with the Bioeconomy sector to represent and promote the project at different conferences, events and workshops.
• Significant technical progress on the development of an alternative bio-based food preservative.
