Periodic Reporting for period 2 - INCITE (Innovative Chemoenzymatic Integrated Processes)
Período documentado: 2021-03-01 hasta 2022-08-31
According to the European Environmental Agency (EEA), the EU chemical industry, including pharmaceuticals, emitted a total of 128.2 million tons of CO2 equivalent in 2015, thus having a considerable impact on the environment. Due to the increasing concern on climate change and environmental issues, the focus of manufacturing industries has been gradually shifting towards the development of alternative greener, safer and sustainable processes. Chemo-enzymatic conversion therefore presents immense opportunities for developing sustainable processes. Enzymatic processes are particularly interesting to produce chiral molecules because of their high regio- and enantio-selectivity, which greatly simplifies
downstream processing compared to traditional chemical synthesis. Additionally, their compatibility with ambient pressures and temperatures conditions is on the plus side for reducing the environmental footprint of the produced molecules.
In that context, the INCITE project aims to demonstrate novel integrated upstream and downstream processing paths involving flow chemistry and membrane technology in chemo-enzymatic processes. The modularity and flexibility of the developed processes will be showcased through two demonstration cases in real industrial settings and will be using hydrolases for the sustainable, safe and energy-efficient production of commodity and fine chiral chemicals. The first demonstration case involves esterase-catalyzed production of a chiral molecule used as starting material for applications in crop protection and public health, whereas the second demonstration case relates to solvent-free synthesis of oleochemical esters using lipase enzymes. Compared to traditional chemical synthesis processes, these chemo-enzymatic processes have clear advantages of greater efficiency, higher product quality and smaller environmental footprint. Their development to TRL7 will open up the way to their industrialization and thus lead to major positive economic and environmental impacts.
downstream processing compared to traditional chemical synthesis. Additionally, their compatibility with ambient pressures and temperatures conditions is on the plus side for reducing the environmental footprint of the produced molecules.
In that context, the INCITE project aims to demonstrate novel integrated upstream and downstream processing paths involving flow chemistry and membrane technology in chemo-enzymatic processes. The modularity and flexibility of the developed processes will be showcased through two demonstration cases in real industrial settings and will be using hydrolases for the sustainable, safe and energy-efficient production of commodity and fine chiral chemicals. The first demonstration case involves esterase-catalyzed production of a chiral molecule used as starting material for applications in crop protection and public health, whereas the second demonstration case relates to solvent-free synthesis of oleochemical esters using lipase enzymes. Compared to traditional chemical synthesis processes, these chemo-enzymatic processes have clear advantages of greater efficiency, higher product quality and smaller environmental footprint. Their development to TRL7 will open up the way to their industrialization and thus lead to major positive economic and environmental impacts.
Over the course of the second period, process innovation activities in the oleochemical track have led to the successful demonstration at laboratory scale of a solvent free enzymatic synthesis of a broad range of esters (Isoamyl laurate, methyl oleate, 2-ethyl hexyl palmitate, -oleate and -laurate, polyol and MCT esters) showcasing the extension and replication of the INCITE technology. A selection of 5 esters have undergone thorough evaluation in cosmetics throughout the second reporting period.
Pilot scale efforts have then led to the optimized production of 3 targeted esters: the lead compound IPP (to be later transferred to the demo plant) and two additional esters (Isoamyl laurate and medium chain triglycerides). This also allowed the production of samples that have then been made freely available to prospective customers via the INCITE project website (Isopropyl palmitate and isoamyl laurate).
Design and engineering studies have led to the construction of the flow chemistry reactors and corresponding subunits of the agrochemical track. A modular skid type design for the Flow Chemistry subunits has been elaborated.
Overall, detailed engineering of the oleochemical plant and of the first part of the agrochemical process are also essentially complete and have been reported on; orders of main demo equipments have been placed and are on the respective sites of OLEON and ENDURA.
The construction of the demo plants is now well under way. Overall, civil works started for the agrochemical demo plant, the structure being in place. In the oleochemical demo plant, civil works, structure, reactor vessels, main supporting equipment have been installed.
In parallel, transversal activities have taken place to support the INCITE project development and maximise impact. The goal and scope of the Life Cycle sustainability assessment have been defined and reported on. System boundaries, scenarios to be considered, benchmark processes and functional unit of the study have been defined for both tracks and initial flowsheets, mass and energy balances have been developed for respective processes to pave the way for the full LCA.
Activities towards the identification of horizontal knowledge have started and resulted in a first set of solutions and lessons learned from both tracks. This material has also been the focus of vertical training activities that have been deployed thanks to the creation and opening to the public of 10 training modules, bearing on technologies developed in INCITE. The opening of these training modules has been accompanied by the broadcast of a first series of 5 webinars. Overall, almost 600 students were trained between December 2021 and September 2022.
These activities have also been supported by the deployment of the Dissemination and Communication Strategy of INCITE with project information sharing on a regular basis via INCITE’s website and accounts on social networks (LinkedIn (https://www.linkedin.com/company/incite-project) Twitter (https://twitter.com/INCITE_EU)) with quantified and good uptake by the project communities. Elaboration of a series of success stories focusing on INCITE partners also took place with the aim to put a spotlight on partners and their innovation activities.
Pilot scale efforts have then led to the optimized production of 3 targeted esters: the lead compound IPP (to be later transferred to the demo plant) and two additional esters (Isoamyl laurate and medium chain triglycerides). This also allowed the production of samples that have then been made freely available to prospective customers via the INCITE project website (Isopropyl palmitate and isoamyl laurate).
Design and engineering studies have led to the construction of the flow chemistry reactors and corresponding subunits of the agrochemical track. A modular skid type design for the Flow Chemistry subunits has been elaborated.
Overall, detailed engineering of the oleochemical plant and of the first part of the agrochemical process are also essentially complete and have been reported on; orders of main demo equipments have been placed and are on the respective sites of OLEON and ENDURA.
The construction of the demo plants is now well under way. Overall, civil works started for the agrochemical demo plant, the structure being in place. In the oleochemical demo plant, civil works, structure, reactor vessels, main supporting equipment have been installed.
In parallel, transversal activities have taken place to support the INCITE project development and maximise impact. The goal and scope of the Life Cycle sustainability assessment have been defined and reported on. System boundaries, scenarios to be considered, benchmark processes and functional unit of the study have been defined for both tracks and initial flowsheets, mass and energy balances have been developed for respective processes to pave the way for the full LCA.
Activities towards the identification of horizontal knowledge have started and resulted in a first set of solutions and lessons learned from both tracks. This material has also been the focus of vertical training activities that have been deployed thanks to the creation and opening to the public of 10 training modules, bearing on technologies developed in INCITE. The opening of these training modules has been accompanied by the broadcast of a first series of 5 webinars. Overall, almost 600 students were trained between December 2021 and September 2022.
These activities have also been supported by the deployment of the Dissemination and Communication Strategy of INCITE with project information sharing on a regular basis via INCITE’s website and accounts on social networks (LinkedIn (https://www.linkedin.com/company/incite-project) Twitter (https://twitter.com/INCITE_EU)) with quantified and good uptake by the project communities. Elaboration of a series of success stories focusing on INCITE partners also took place with the aim to put a spotlight on partners and their innovation activities.
The INCITE project is on course to address the following key impacts which will be formally assessed over the third period of the project:
- It is expected that at least a 20 to 75% decrease in greenhouse gas emissions compared to conventional processes will be observed
- The process demonstrations of INCITE are expected to provide significant resource and energy efficiency gains by 40-60%
- For the agrochemical route, the modularity of the total process formed by several subunits will allow to implement the total loop process with reasonable investments. In sum a reduction of >10% in CAPEX is reached. This coupled with the enzymatic nature of the process are expected to reduce the OPEX by 15%.
- For the oleochemical route, the modular nature of reactor and post-treatment units allow a 50% CAPEX decrease. This coupled with the enzymatic nature of the process and associated operating conditions (low temperature, low pressure, recyclability of the enzyme) are expected to lead to a 50% reduction in OPEX.
- Knowledge gained by the consortium partners have started to be disseminated among the academic and non-academic target groups: topics and content have been defined for 10 learning modules, now open to the public and built up around the overarching theme of green chemistry and encompassing training on enzymatic production ranging from general knowledge to more advanced in-depth training for professionals and operators.
- It is expected that at least a 20 to 75% decrease in greenhouse gas emissions compared to conventional processes will be observed
- The process demonstrations of INCITE are expected to provide significant resource and energy efficiency gains by 40-60%
- For the agrochemical route, the modularity of the total process formed by several subunits will allow to implement the total loop process with reasonable investments. In sum a reduction of >10% in CAPEX is reached. This coupled with the enzymatic nature of the process are expected to reduce the OPEX by 15%.
- For the oleochemical route, the modular nature of reactor and post-treatment units allow a 50% CAPEX decrease. This coupled with the enzymatic nature of the process and associated operating conditions (low temperature, low pressure, recyclability of the enzyme) are expected to lead to a 50% reduction in OPEX.
- Knowledge gained by the consortium partners have started to be disseminated among the academic and non-academic target groups: topics and content have been defined for 10 learning modules, now open to the public and built up around the overarching theme of green chemistry and encompassing training on enzymatic production ranging from general knowledge to more advanced in-depth training for professionals and operators.