Periodic Reporting for period 4 - SWEETWOODS (Production and deploying of high purity lignin and affordable platform chemicals through wood-based sugars)
Okres sprawozdawczy: 2022-12-01 do 2024-05-31
In SWEETWOODS project, the first-of-a-kind wood fractionation flagship plant was built in Estonia that uses sustainable hardwood biomass. The developed process combines innovative pre-treatment technology which allows over 90% efficiency and exceptionally high-quality hydrolysis lignin and sugars production. Sugars and lignin have been further processed and converted into high-value biomaterials replacing fossil-based chemicals in a wide range of products from construction materials to cosmetics.
The SWEETWOODS project had six core objectives targeted to: 1) Show the successful and profitable production - on an industrial scale - of high-purity lignin along with penta- and hexa-carbon carbohydrates from hardwood; 2) Use all main components of the biomass feedstock while minimising any diversion of carbon content streams to low-value uses; 3) Produce high-purity lignin for drop-in applications and validate depolymerised lignin fractions for a range of novel applications, namely rigid polyurethane foam boards for building insulation and polymer compounds intended for injection moulding; 4) Produce high-purity sugars - glucose, xylose and demonstrate production of derivates of those (fructose, glucosone) - for novel end-use cases, namely producing bio-IBN; 5) Establish markets for lignin and novel sugar-based platform chemicals; 6) Evaluate the environmental and socio-economic performance of the SWEETWOODS plant process and of the developed products through a Life Cycle Sustainability Assessment, as well as a viability analysis.
The project has addressed the environmental issues related to the reliance on fossil-based value chains and high CO2 emissions. The project has been an important corner stone at EU level to support the shift to renewable materials derived biomaterials production at scale to replace fossil-based chemicals, to support meeting net zero targets of the industries and the transition to the circular economy and more environmentally friendly and healthy society.
The SWEETWOODS project had six core objectives targeted to: 1) Show the successful and profitable production - on an industrial scale - of high-purity lignin along with penta- and hexa-carbon carbohydrates from hardwood; 2) Use all main components of the biomass feedstock while minimising any diversion of carbon content streams to low-value uses; 3) Produce high-purity lignin for drop-in applications and validate depolymerised lignin fractions for a range of novel applications, namely rigid polyurethane foam boards for building insulation and polymer compounds intended for injection moulding; 4) Produce high-purity sugars - glucose, xylose and demonstrate production of derivates of those (fructose, glucosone) - for novel end-use cases, namely producing bio-IBN; 5) Establish markets for lignin and novel sugar-based platform chemicals; 6) Evaluate the environmental and socio-economic performance of the SWEETWOODS plant process and of the developed products through a Life Cycle Sustainability Assessment, as well as a viability analysis.
The project has addressed the environmental issues related to the reliance on fossil-based value chains and high CO2 emissions. The project has been an important corner stone at EU level to support the shift to renewable materials derived biomaterials production at scale to replace fossil-based chemicals, to support meeting net zero targets of the industries and the transition to the circular economy and more environmentally friendly and healthy society.
During the final Reporting Period, significant progress was made in the SWEETWOODS project, culminating in the successful commissioning and continuous production at Fibenol Imavere biorefinery to produce low-carbon high-value cellulosic sugars (20 000 tons/year) and Lignova lignin (6500 tons/year) to replace fossil components in various applications. The commissioning process was completed in two phases: at first the core functionalities, including the Sunburst™ pretreatment were established, followed by the commissioning and ramp-up phase of the plant in production capacity.
MetGen concentrated on the On-Site Manufacturing (OSM) concept and tested raw ferment hydrolysis on Fibenol’s biomass. This approach achieved an 85-96% hydrolysis yield in 68 hours. MetGen also conducted techno-economic evaluations and successfully scaled up key enzyme technologies, including cellulase for hydrolysis, pyranose oxidase for sugar conversion, xylanase for hydrolysis, and laccase for lignin depolymerization, with industrial-scale campaigns in Bulgaria.
TECNARO showcased two demonstrators using SWEETWOODS high-purity lignin: a novel tree shelter and music instruments made from ARBOFORM®, a lignin-based thermoplastic compound.
Recticel screened lignopolyol grades and produced small hand-mix samples, which replaced up to 40 parts polyol with NANOPolyol.
GBE optimized and demonstrated the production of bio-IBN from Fibenol sugars and validated an alternative production protocol that achieved stable productivity. A new 5 m3 bioconversion unit for the production of cosmetic-grade IBN was commissioned, which successfully demonstrated the valorization of wood-based sugars into high-value IBN-derived products.
The environmental, economic, and social impacts of the SWEETWOODS technology have been comprehensively assessed through the Life Cycle Sustainability Assessment (LCSA), which integrated LCA, LCC, and S-LCA results. The LCA results indicated that the SWEETWOODS technology significantly reduces environmental impacts compared to traditional fossil-based processes. The sustainability impact score was defined to relate these impacts, with higher scores indicating greater overall sustainability. This assessment confirmed the SWEETWOODS technology is a sustainable alternative, meeting stringent environmental and social standards while maintaining economic viability.
The project achieved significant outreach through participation in numerous conferences, events, and workshops, both online and on-site. Social media updates, scientific publications, and promotional materials played crucial roles in disseminating information and experiences. Fibenol has ensured comprehensive IP portfolio, securing a competitive advantage. SWEETWOODS project demonstrated the feasibility and scalability of Fibenol's biomass processing technology, achieving significant milestones in exploitation and production capacity, technological advancements and sustainability assessments.
MetGen concentrated on the On-Site Manufacturing (OSM) concept and tested raw ferment hydrolysis on Fibenol’s biomass. This approach achieved an 85-96% hydrolysis yield in 68 hours. MetGen also conducted techno-economic evaluations and successfully scaled up key enzyme technologies, including cellulase for hydrolysis, pyranose oxidase for sugar conversion, xylanase for hydrolysis, and laccase for lignin depolymerization, with industrial-scale campaigns in Bulgaria.
TECNARO showcased two demonstrators using SWEETWOODS high-purity lignin: a novel tree shelter and music instruments made from ARBOFORM®, a lignin-based thermoplastic compound.
Recticel screened lignopolyol grades and produced small hand-mix samples, which replaced up to 40 parts polyol with NANOPolyol.
GBE optimized and demonstrated the production of bio-IBN from Fibenol sugars and validated an alternative production protocol that achieved stable productivity. A new 5 m3 bioconversion unit for the production of cosmetic-grade IBN was commissioned, which successfully demonstrated the valorization of wood-based sugars into high-value IBN-derived products.
The environmental, economic, and social impacts of the SWEETWOODS technology have been comprehensively assessed through the Life Cycle Sustainability Assessment (LCSA), which integrated LCA, LCC, and S-LCA results. The LCA results indicated that the SWEETWOODS technology significantly reduces environmental impacts compared to traditional fossil-based processes. The sustainability impact score was defined to relate these impacts, with higher scores indicating greater overall sustainability. This assessment confirmed the SWEETWOODS technology is a sustainable alternative, meeting stringent environmental and social standards while maintaining economic viability.
The project achieved significant outreach through participation in numerous conferences, events, and workshops, both online and on-site. Social media updates, scientific publications, and promotional materials played crucial roles in disseminating information and experiences. Fibenol has ensured comprehensive IP portfolio, securing a competitive advantage. SWEETWOODS project demonstrated the feasibility and scalability of Fibenol's biomass processing technology, achieving significant milestones in exploitation and production capacity, technological advancements and sustainability assessments.
The SWEETWOODS project has enabled Fibenol to scale up a unique wood fractionation platform, to convert wood residues into high-quality biobased raw materials, using 100% renewable energy and high recycling of process water. The modular Sunburst pre-treatment process build up has allowed decentralized primary processing and the conversion of the biomass into transportable sugar-derived intermediates and LIGNOVA lignin. Further plans include the extension at the Imavere demonstration plant and the development of the first industrial plant in the Baltics by 2030.
MetGen advanced its METNIN technology, improved the process parameters and developed key products like METNIN SHIELD and METNIN Resins. An LCA study showed a >85% reduction in GHG emissions. MetGen reached to the MoU with a global engineering company and has explored building its own METNIN demo facility.
Recticel introduced depolymerized lignin into rigid foam formulations and has aligned with its sustainability strategy to achieve 40% recycled or bio-based content of its products by 2030.
TECNARO developed new materials for extrusion processes and has opened new markets for lignin-based materials in packaging, agriculture, and automotive interiors.
Global Bioenergies converted hardwood-based hydrolysate into bio-IBN and has enabled the production of IBN molecules from bio-based sources. Global Bioenergies developed 2-step "high purity" production strategy and processes to produce cosmetic and biofuel ingredients.
The SWEETWOODS development plant has been assessed by using LCA methodology, the Environmental Product Declaration (EPD) on Lignova™ lignin and wood sugars has been published.
In conclusion of the action, the first-of-a-kind hardwood biorefining technology and plant has been built up, high-purity Lignova lignin and wood sugars products have been developed, the sustainability assessments and the feasibility of the conversion of the wood residues into low carbon innovative biobased materials have been demonstrated at scale. The socio-economic impacts have included the creation of broad new market opportunities and partnerships, new jobs. The SWEETWOODS has shown the way towards greener future, enabling the reduction of the reliance from fossil-based chemicals, and strongly contributing to the defossilization and environmental sustainability.
MetGen advanced its METNIN technology, improved the process parameters and developed key products like METNIN SHIELD and METNIN Resins. An LCA study showed a >85% reduction in GHG emissions. MetGen reached to the MoU with a global engineering company and has explored building its own METNIN demo facility.
Recticel introduced depolymerized lignin into rigid foam formulations and has aligned with its sustainability strategy to achieve 40% recycled or bio-based content of its products by 2030.
TECNARO developed new materials for extrusion processes and has opened new markets for lignin-based materials in packaging, agriculture, and automotive interiors.
Global Bioenergies converted hardwood-based hydrolysate into bio-IBN and has enabled the production of IBN molecules from bio-based sources. Global Bioenergies developed 2-step "high purity" production strategy and processes to produce cosmetic and biofuel ingredients.
The SWEETWOODS development plant has been assessed by using LCA methodology, the Environmental Product Declaration (EPD) on Lignova™ lignin and wood sugars has been published.
In conclusion of the action, the first-of-a-kind hardwood biorefining technology and plant has been built up, high-purity Lignova lignin and wood sugars products have been developed, the sustainability assessments and the feasibility of the conversion of the wood residues into low carbon innovative biobased materials have been demonstrated at scale. The socio-economic impacts have included the creation of broad new market opportunities and partnerships, new jobs. The SWEETWOODS has shown the way towards greener future, enabling the reduction of the reliance from fossil-based chemicals, and strongly contributing to the defossilization and environmental sustainability.