Periodic Reporting for period 2 - ABACUS (Algae for a biomass applied to the production of added value compounds)
Período documentado: 2018-11-01 hasta 2020-07-31
Algae production in Europe is currently limited to a few small industries, serving mainly niche applications. This sector is ripe for further expansion. However, creating viable schemes for growing algae and converting them into successful commercial products remains a challenge. The commercialisation of high value compounds from microalgae could grow the existing industry considerably, while product innovation based on new targets could open new markets. This rationale underpinned the work achieved during the ABACUS project. Two market surveys were performed to identify the major trends and specifications for terpenes and carotenoids in the field of cosmetics, food, nutraceuticals and fragrances. From this, a roadmap was drawn considering algae strains, products of interest and target markets. >150 microalgae/cyanobacteria were screened based on biomass productivity, biochemical proximate analyses and genotyping criteria. Moreover, 17 genetically-engineered cyanobacteria were constructed, and 4 of them were proven to have long-term stability for production of terpenes. Pilot-scale cultivation of 7 algae species was improved, allowing reduction in maintenance and operational costs. 4 scenarii out of the 5 ultimately selected were tested up to real industrial scale, delivering altogether more than 200kgs of tailored microalgae biomasses enriched in carotenoids with a very high productivity (exceeding 1g/L/day) and at high concentrations (approaching 10g/L). Green extraction and fractionation/purification procedures employing compressed fluids were developed to increase yields (>20%) and purities (10 to 15% total carotenoid content). In addition, an integrated green biorefinery process yielding multiple active fractions from one single biomass was developed. The physico-chemical characters of the purified algae extracts and their technical acceptability were assessed for the targeted markets. Formulation and preservation strategies for active extracts to be used in cosmetics were elaborated and tested. 3 scenarii with different technological and geographical options were evaluated through LCA and LCCA. In addition, innovative probes and sensors were developed for process monitoring and automation. An optomicrofluidic system and a non-invasive turbidity probe were designed and implemented to monitor biomass growth, whereas a non-invasive RGB probe and an online microGC system were used to monitor the yield in compounds of interest without need for sampling, fractionation and off-line analysis. Some of these new devices were integrated in a commercial, industry-compliant, automated demonstrator. A continuous gas-stripping process for simultaneous production and purification of light terpenes was also demonstrated at lab scale. Several of the ABACUS actions will be pursued beyond the lifespan of the project through the unwinding of a business-oriented technology implementation plan.
Two market studies and a field market survey were performed to identify relevant market trends. This led to the identification of the major product specifications in the field of cosmetics, food, nutraceuticals and fragrances. With all this information, the initial roadmap of the project was drawn, with main strains, products of interest and target markets defined.
>150 candidate micro-algae/cyanobacteria species were included into the screening process at lab scale. A suite of standard methods, for algal cultivation, biochemical analysis and genetical engineering was developed and applied. The main technical outputs are the completion of the screening of strains and the construction and validation of GM-cyanobacteria with induced capacity to produce light terpenes with long-term phylogenetic stability.
Pilot-scale cultivation of 7 algae strains was performed, focussing on scale-up of cultures, light & media optimization, water treatment and recycling, and PBR improvements in order to reduce maintenance and operational costs. +50% productivities in both biomass and target coumpounds were obtained for several of the studied production scenarios. New tools (probes and sensors) for process monitoring and automation were developed, and some of them were included in a commercial demonstrator consisting of 16x28L FPA PBRs.
The 5 most promising scenarii for large-scale cultivation were defined between the several partners operating industrial PBRs, and industrial scale trials were performed. Altogether, the large scale cultures delivered more than 200kgs of tailored biomass for downstream processing activities.
Green extraction and fractionation/purification procedures employing innovative compressed fluids were developed. Fractionation of wet biomass (no drying) was applied to increase yields and purities. An integrated processes with multiple product outputs was considered and the fractions/extracts produced characterized. Moreover, a one-step one-pot extraction-purification procedure with PLE was developed to produce directly pure carotenoid extract from a given algal biomass.
Applicability activities defined the main compounds to quantify in algae main extracts and physico-chemical features to analyze in the by-products. Formulation and preservation strategies for active extracts to be used in cosmetic were elaborated and tested experimentally.
An LCA model including all process steps and based on secondary data extracted from literature was implemented as well as the collection of real lab- & industrial-scale data related to the extraction processes.
Proactive involvement of all project partners in 51 conferences & workshops, 3 business fairs and 5 BBI brokerage events increased the outreach of the project. An international workshop with >100 participants was organized, and 2 promotional videos were achieved and disseminated on public social media. So far, results of the project delivered 13 peer-reviewed scientific articles, 2 book chapters and 13 publications in conference proceedings.
>150 candidate micro-algae/cyanobacteria species were included into the screening process at lab scale. A suite of standard methods, for algal cultivation, biochemical analysis and genetical engineering was developed and applied. The main technical outputs are the completion of the screening of strains and the construction and validation of GM-cyanobacteria with induced capacity to produce light terpenes with long-term phylogenetic stability.
Pilot-scale cultivation of 7 algae strains was performed, focussing on scale-up of cultures, light & media optimization, water treatment and recycling, and PBR improvements in order to reduce maintenance and operational costs. +50% productivities in both biomass and target coumpounds were obtained for several of the studied production scenarios. New tools (probes and sensors) for process monitoring and automation were developed, and some of them were included in a commercial demonstrator consisting of 16x28L FPA PBRs.
The 5 most promising scenarii for large-scale cultivation were defined between the several partners operating industrial PBRs, and industrial scale trials were performed. Altogether, the large scale cultures delivered more than 200kgs of tailored biomass for downstream processing activities.
Green extraction and fractionation/purification procedures employing innovative compressed fluids were developed. Fractionation of wet biomass (no drying) was applied to increase yields and purities. An integrated processes with multiple product outputs was considered and the fractions/extracts produced characterized. Moreover, a one-step one-pot extraction-purification procedure with PLE was developed to produce directly pure carotenoid extract from a given algal biomass.
Applicability activities defined the main compounds to quantify in algae main extracts and physico-chemical features to analyze in the by-products. Formulation and preservation strategies for active extracts to be used in cosmetic were elaborated and tested experimentally.
An LCA model including all process steps and based on secondary data extracted from literature was implemented as well as the collection of real lab- & industrial-scale data related to the extraction processes.
Proactive involvement of all project partners in 51 conferences & workshops, 3 business fairs and 5 BBI brokerage events increased the outreach of the project. An international workshop with >100 participants was organized, and 2 promotional videos were achieved and disseminated on public social media. So far, results of the project delivered 13 peer-reviewed scientific articles, 2 book chapters and 13 publications in conference proceedings.
>150 candidate strains were accurately screened at lab scale with assessment of criteria such as biomass productivity, comprehensive biochemical proximate analyses and genotyping. This will lead to at least one additional peer-reviewed publication.
17 cyanobacteria were genetically engineered for the production of light terpenes. Their genetic stability was verified during more than a year. A continuous gas-stripping process for simultaneous production and purification of light terpenes was demonstrated at lab scale.
Several of the ABACUS proprietary strains exhibited +80% productivities compared to state of the art. This ensures freedom to operate in value chains for future industrial developments.
Several carotenoid producing strains were grown at pilot scale and/or industrial scale at very high productivity (exceeding 1g/L/day) and at high concentrations (approaching 10 g/L). Algal biomass with target terpenoid contents exceeding 5% was obtained. Supply of light was optimized allowing productivity increases of +62% to +110%. Optimization of culture media (less ingredients) resulted in elevated growth at reduced costs. All these achievements will significatively improve profitability of targeted algae-based ingredients.
Several new probes and sensors were designed to facilitate monitoring and automation of industrial PBRs, corresponding to a crucial need of the industry. Some of these new sensors and probes were integrated in a commercial, industry-compliant, demonstrator.
17 cyanobacteria were genetically engineered for the production of light terpenes. Their genetic stability was verified during more than a year. A continuous gas-stripping process for simultaneous production and purification of light terpenes was demonstrated at lab scale.
Several of the ABACUS proprietary strains exhibited +80% productivities compared to state of the art. This ensures freedom to operate in value chains for future industrial developments.
Several carotenoid producing strains were grown at pilot scale and/or industrial scale at very high productivity (exceeding 1g/L/day) and at high concentrations (approaching 10 g/L). Algal biomass with target terpenoid contents exceeding 5% was obtained. Supply of light was optimized allowing productivity increases of +62% to +110%. Optimization of culture media (less ingredients) resulted in elevated growth at reduced costs. All these achievements will significatively improve profitability of targeted algae-based ingredients.
Several new probes and sensors were designed to facilitate monitoring and automation of industrial PBRs, corresponding to a crucial need of the industry. Some of these new sensors and probes were integrated in a commercial, industry-compliant, demonstrator.