Periodic Reporting for period 2 - BIOCOMEM (Bio-based copolymers for membrane end products for gas separations)
Reporting period: 2021-12-01 to 2023-11-30
Membrane-based separation techniques offer an alternative with the potential for far lower energy consumption. Wider adoption of these techniques would reduce GHG as a result. In addition, by using membranes manufactured from bio-based materials, it would increase overall sustainability and further reduce the environmental impact. However, such products need to be able to withstand long-term operation at temperature and pressure variations and prolonged contact with degradative substances. Such membranes require a complex structure that rely on highly specific methods of production.
The BIOCOMEM project developed and validated gas separation membranes at TRL 5 using bio-based polymers with improved gas separation performance that the fossil fuel based polymers.
More in detail, the BIOCOMEM project achieved.
• Produced two new bio-based PEBA co-polymers at pilot scale.
• These polymers have good properties for CO2 capture from residual flue gases.
• Two polymers were processed into thin film composite membrane at pilot scale
• Another polymer was processed into asymmetric hollow fiber membrane at pilot scale. Hollow fiber membranes have the advantage, respect to thin film composite membranes, that these use about 80 % of biobased polymer and have potential to be recyclable.
• Two demonstrator modules were tested at TRL5
BIOCOMEM project demonstrated that membrane-based separation techniques using PEBA-type (Polyether block amide) copolymers are more efficient than their heat-based equivalent methods with consequences in the reduction of the overall environmental impact of separation processes. Nevertheless, life cycle assessment revealed that because of a high estimated lifetime of the membrane, most of (99%) carbon footprint of a membrane separation system is given by the energy requirement of the compression stage and not of the membrane production step. This makes the use of bio based polymers instead of fossil fuel polymers less important.
The BIOCOMEM project developed and validated gas separation membranes at TRL 5 using bio-based polymers with improved gas separation performance that the fossil fuel based polymers.
More in detail, the BIOCOMEM project achieved.
• Produced two new bio-based PEBA co-polymers at pilot scale.
• These polymers have good properties for CO2 capture from residual flue gases.
• Two polymers were processed into thin film composite membrane at pilot scale
• Another polymer was processed into asymmetric hollow fiber membrane at pilot scale. Hollow fiber membranes have the advantage, respect to thin film composite membranes, that these use about 80 % of biobased polymer and have potential to be recyclable.
• Two demonstrator modules were tested at TRL5
BIOCOMEM project demonstrated that membrane-based separation techniques using PEBA-type (Polyether block amide) copolymers are more efficient than their heat-based equivalent methods with consequences in the reduction of the overall environmental impact of separation processes. Nevertheless, life cycle assessment revealed that because of a high estimated lifetime of the membrane, most of (99%) carbon footprint of a membrane separation system is given by the energy requirement of the compression stage and not of the membrane production step. This makes the use of bio based polymers instead of fossil fuel polymers less important.
Maastricht University (UM) developed two new classes of poly(ether-b-amide) (PEBA) polymers for gas separation membranes. The monomers used for the polyamide block are biobased and their introduction offers the potential to improve the PEBA solubility and membrane processability. In prototype B, the polyamide is based on biobased dimer fatty acid and in prototype C the polyamide is based on a sugar derivative. The prototype B and prototype C polymers could be processed into membranes by Tecnalia and Hereon.
The best PEBA polymer compositions from prototype B were upscaled by Arkema and further used by Tecnalia and Helmholtz-Zentrum Hereon for making membrane modules. Prototype C was limited to lab scale synthesis, but the amount of polymer was enough for extensive membrane evaluation at Hereon.
These membranes have good properties for CO2 capture from residual flue gases.
The upscaled multilayer thin-film composite membranes by Hereon were integrated into membrane modules at two different scales:
1. A demonstrator module “K100 PN40” (prototype A1) containing 0.45 m² of membrane area, which will be tested at the DMT facilities in Netherlands for natural and biogas upgrading.
2. Two lab-scale modules “K100” (prototypes A1 and C) with 0.06 m² of total membrane area each, which will be further tested at TUE for diverse CO2 separations.
Tecnalia developed with prototype B co-polymer hollow fiber membranes.
Eindhoven University of Technology has finalized the design of a superstructure-based mathematical model for the optimization of CO2 removal in three applications including post-combustion CO2 capture, natural gas sweetening and biogas upgrading. The multi-stage membrane process was investigated in terms of energy consumption, membrane area and gas processing cost. Additional sensitivity analyses were undertaken to characterize the influence of membrane properties and separation targets on the process layout, power consumption and membrane area. The results revealed that high purity and recovery at a minimum cost could be achieved by the three-stage process in post-combustion CO2 capture and natural gas while in biogas upgrading the two-stage configuration exhibited the best performance.
In addition Eindhoven University of Technology has launched the TRL5 demonstration campaign at its own laboratories. Data will be shared in future open access scientific publications.
The first experimental campaign in relevant environment has been successfully completed at DMT Environmental Technology facilities. CO2 separation from biogas has been demonstrated at TRL5 during 240h of operation using the up-scaled thin-film composite membrane (TFCM) prepared by Helmholtz-Zentrum Hereon.
At B4Plastics, we have gained valuable insights in the process of upscaling the foundational components necessary for the development of gas separation membranes.
This progress has paved the way for a subsequent project named Cumeri, where B4Plastics, Tecnalia and Uinversity of Maastricht aim to elevate the knowledge acquired from Biocomem to a higher Technology Readiness Level 7 (TRL7).
For B4Plastics, as a company participating in BioCoMem, it has been a very positive experience as they have adopted a broader perspective, recognizing the interplay between chemistry, scale-up processes, and the crucial properties required to meet specific criteria for successful gas separation.
Two patent applications and 2 scientific publications have been achieved within the time frame of the project. Other four scientific publications are being written after the end of the project.
The best PEBA polymer compositions from prototype B were upscaled by Arkema and further used by Tecnalia and Helmholtz-Zentrum Hereon for making membrane modules. Prototype C was limited to lab scale synthesis, but the amount of polymer was enough for extensive membrane evaluation at Hereon.
These membranes have good properties for CO2 capture from residual flue gases.
The upscaled multilayer thin-film composite membranes by Hereon were integrated into membrane modules at two different scales:
1. A demonstrator module “K100 PN40” (prototype A1) containing 0.45 m² of membrane area, which will be tested at the DMT facilities in Netherlands for natural and biogas upgrading.
2. Two lab-scale modules “K100” (prototypes A1 and C) with 0.06 m² of total membrane area each, which will be further tested at TUE for diverse CO2 separations.
Tecnalia developed with prototype B co-polymer hollow fiber membranes.
Eindhoven University of Technology has finalized the design of a superstructure-based mathematical model for the optimization of CO2 removal in three applications including post-combustion CO2 capture, natural gas sweetening and biogas upgrading. The multi-stage membrane process was investigated in terms of energy consumption, membrane area and gas processing cost. Additional sensitivity analyses were undertaken to characterize the influence of membrane properties and separation targets on the process layout, power consumption and membrane area. The results revealed that high purity and recovery at a minimum cost could be achieved by the three-stage process in post-combustion CO2 capture and natural gas while in biogas upgrading the two-stage configuration exhibited the best performance.
In addition Eindhoven University of Technology has launched the TRL5 demonstration campaign at its own laboratories. Data will be shared in future open access scientific publications.
The first experimental campaign in relevant environment has been successfully completed at DMT Environmental Technology facilities. CO2 separation from biogas has been demonstrated at TRL5 during 240h of operation using the up-scaled thin-film composite membrane (TFCM) prepared by Helmholtz-Zentrum Hereon.
At B4Plastics, we have gained valuable insights in the process of upscaling the foundational components necessary for the development of gas separation membranes.
This progress has paved the way for a subsequent project named Cumeri, where B4Plastics, Tecnalia and Uinversity of Maastricht aim to elevate the knowledge acquired from Biocomem to a higher Technology Readiness Level 7 (TRL7).
For B4Plastics, as a company participating in BioCoMem, it has been a very positive experience as they have adopted a broader perspective, recognizing the interplay between chemistry, scale-up processes, and the crucial properties required to meet specific criteria for successful gas separation.
Two patent applications and 2 scientific publications have been achieved within the time frame of the project. Other four scientific publications are being written after the end of the project.
BIOCOMEM results go beyond the state of the art also because:
• Membranes are based on a half bio base polymer (there are no bio-based membranes in the state of the art).
• Polymer is much cheaper than the state of the art (Polyactive).
• The developed polymers have excellent CO2 permeability exceeding the benchmark fossil fuel-based polymers (CO2 permeability = 120 Barrer for PEO-bPA6 or 150 Barrer for PEO-b-PBT, see D2.2 Industrial membrane requirements) at a comparable selectivity.
Therefore, these polymers outperform state of the art membranes for post combustion gas treatment. Target membrane performance for biogas and natural gas upgrading have not been achieved. Nevertheless, using the experimental data, system modelling (WP2) and techno-economic analysis (WP6) show that three-stage separation would give competitive separation systems and that developed membranes can be implemented in these applications.
In addition, BIOCOMEM project also contributed to specific BBI JU KPIs and had socio-economic impact and wider societal implications because:
• It has established a framework for new cross-sectoral interconnections and cooperation between actors from different sectors. Follow up project, CUMERI is a consequence.
• It has created new bio-based value chains.
• It has developed new methods for product fabrication using bio based polymers
• It has improved the EU’s innovation capacity and knowledge integration.
• It will brings a positive environmental impact: by using biomass as a feedstock (rather than fossil fuels) it will use renewable rather than finite resources. In addition, its CO2 filtering technology will prevent atmospheric release of this GHG.
• Membranes are based on a half bio base polymer (there are no bio-based membranes in the state of the art).
• Polymer is much cheaper than the state of the art (Polyactive).
• The developed polymers have excellent CO2 permeability exceeding the benchmark fossil fuel-based polymers (CO2 permeability = 120 Barrer for PEO-bPA6 or 150 Barrer for PEO-b-PBT, see D2.2 Industrial membrane requirements) at a comparable selectivity.
Therefore, these polymers outperform state of the art membranes for post combustion gas treatment. Target membrane performance for biogas and natural gas upgrading have not been achieved. Nevertheless, using the experimental data, system modelling (WP2) and techno-economic analysis (WP6) show that three-stage separation would give competitive separation systems and that developed membranes can be implemented in these applications.
In addition, BIOCOMEM project also contributed to specific BBI JU KPIs and had socio-economic impact and wider societal implications because:
• It has established a framework for new cross-sectoral interconnections and cooperation between actors from different sectors. Follow up project, CUMERI is a consequence.
• It has created new bio-based value chains.
• It has developed new methods for product fabrication using bio based polymers
• It has improved the EU’s innovation capacity and knowledge integration.
• It will brings a positive environmental impact: by using biomass as a feedstock (rather than fossil fuels) it will use renewable rather than finite resources. In addition, its CO2 filtering technology will prevent atmospheric release of this GHG.