bioplastic-2014
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Bioplastics Production
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What are bioplastics?
Compostable plastics
-or-
Any plastics-made from
organisms (or organism by-
products)
Mixture of Acids that
could be made into
bioplastics
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Why Bioplastic?
Plastics are predominantly made from crude oil
Renewable resourcesare becoming a more viable andpromising alternative for the plastics industry
When plastics made from petroleum are burned, theyrelease the carbon dioxide contained in the petroleum intothe atmosphere, leading to global warming.
The use ofbioplasticsoffers significant advantages not onlyin an ecological sensebut alsoin aneconomical sense.
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Polystyrene: Coffee cups, Fast-food
Polyethylene:
HDPE: Milk containers
LDPE: Plastic bags, Packaging
Polyvinyl chloride: Piping, Meat wrap
Polyethylene terephthalate: Soda bottles
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Oil use: 100 billionpounds of plastics areproduced in NorthAmerica annually
Only 3% of these plasticsare recycled
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Importance
2003- North America
107 billion pounds of
synthetic plastics
produced from petroleum
Take >50 years to degrade
Improper disposal and
failure to recycleoverflowing landfills
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Making Bioplastics
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Enzymes are used to break starch in the plants down intoglucose, which is fermented and made into lactic acid.
This lactic acid is polymerized and converted into a plasticcalled polylactic acid, which can be used in themanufacture of products after being heated and shaped.
If something made of bioplastic is buried in the ground,microorganisms will break it down into carbon dioxide andwater.
StarchGlucoseLactic acidPoly lactic acid (PLA)
Bioplastics Production
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Goal of Bioplastic Production
1. To save resourcesby
either reducing the
production of standard
Polypropylene plastics
2. To save the
environmentby
making plasticsbiodegradable
Bioplastic
degradation speed
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Bioplastic production:
1. Using Soy-based bioplastics
2. Using Starch-based Bioplastics
3. Using Bacteria to make bioplastics
4. Poly-3-Hydroxyalkanoate
(PHA)/Hydroxybutyrate (PHB)
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Soy-based Bioplastics
One of the hottest sectionsin bioplastics researchtoday.
Pure Soy Bioplastic hasmany undesirable traits.
Mixtures of Soy with othersubstances are currently
being attempted.
Soy Protein
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Bacteria-based Bioplastics
Mixture of bacteria can create acids whenfermented.
The ratio of different acids is based on pH.The bacteria are fed glucose solution and
fermented.
The acids can be used to make bioplastics
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PHA/PHB
Easily biodegradable Easily processed
Very Expensive
Methylobacterium sp V49 is PHB producer
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Starch-based bioplastics
Make up about 50% of the current
bioplastic market
This is called thermo-plastical starch
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Use of Bioplastic
Bioplastics are already being used in
automobile interiorsand in cases for
consumer electronics.
Toyota Motor Corp. became the first
automaker in the world to use bioplastics inthe manufacture of auto parts.
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Toyota Motor is building a plant to undertake test
production of bioplastic at a factory in Japan, withproduction due to begin in August 2004.
The company plans to produce 1,000 tons of
bioplastic annually, which will be used not just in carparts but in many other plastic products as well.
Toyota also plans to use bioplastics in the
construction of the exhibitionpavilionsat the 2005World Exposition, Aichi, Japan, so that noconstruction waste is generated when the pavilionsare dismantled at the end of the event.
Used in Automobile
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Used in Electronic Devices
Mitsubishi Plastics has already succeeded in raisingthe heat-resistance and strength of polylactic acid by
combining it with other biodegradable plastics and
filler, and the result was used to make the plastic
casing of a new version of Sony Corp.'s Walkman
Mitsubishi Plastics had previously looked at
bioplastic as something that would mainly be used inthe manufacture of casings and wrappings.
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NEC Corp., is turning its attention to kenaf, a type of
fibrous plant native to tropical areas of Africa andAsia that is known to grow more than five meters in
just half a year.
A mixture ofpolylactic acid andkenaf fiberthat is20% fiber by weight allows for a plastic that is strongenough and heat resistant enough to be used inelectronic goods.
The goal is to begin using this new plastic in realproducts, such as computer cases.
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The use of bioplastics for shopping bagsis already
very common. After their initial use they can be reused as bagsfor organic waste and then be composted.
Trays and containersfor fruit, vegetables, eggs
and meat,bottles for soft drinks and dairyproducts are also already widely manufacturedfrom bioplastics.
Used in packaging
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Due to their specific characteristics, bioplastics areused as a basis for the production of sanitary
products.
These materials are breathable and allow water vaporto permeate, but at the same time they are waterproof.
Foils made of soft bioplastic are already used asdiaper foil, bed underlay, ladies sanitary products andas disposable gloves.
Used in Sanitary Products
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Your foodcomes from
nature..Now so
does yourcontainer
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Applications
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Energy storage for bacteria
Physical properties of
polyethylene, polystyrene,
and synthetic polyesters
Polyhydroxyalkanoates
H
C CH2O C
CH3 O
Polyhydroxybutyrate
(PHB)
Polyhydroxyvalerate
(PHV)
H
C CH2O C
CH2 O
CH3
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Anaerobic
Environment
Abundant carbon
source
3-hydroxyacyl-CoA
polymerization
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Polyhydroxyalkanoates (PHAs)
Produced under conditions of:
Low limiting nutrients (P, S, N, O)
Excess carbon
2 different types:
Short-chain-length 3-5 Carbons
Medium-chain-length 6-14 Carbons
~250 different bacteria have been foundto produce some form of PHAs
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Polyhydroxybutyrate (PHB)
Example of short-chain-length PHA
Produced in activatedsludge
Found inAlcaligeneseutrophus
Accumulatedintracellularly asgranules (>80% cell dry
weight) Lee et al., 1996
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PHA Biosynthesis
Ojumu et al., 2004
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A carbon source (corn) is ground into a mash
and fed to PHA-forming bacteria
Glucose is extracted as the microbes fermentthe mash and store the energy as PHAs
The cells are washed and lysed
The PHAs are separated by centrifuge and
washed again
30% PHA by dry weight
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Recovery of PHAs from Cells
PHA producing microorganisms stainedwith Sudan black or Nile blue
Cells separated out by centrifugation orfiltration
PHA is recovered using solvents
(chloroform) to break cell wall & extractpolymer
Purification of polymer
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Organisms
Nostoc muscorum Synechocystis sp. PCC 6803 Synechococcus sp. MA1
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Plastics are resistant to biodegradation accumulating at the
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The Korean research center KAIST has announced thatthey have found a way to produce PLA using bio-engineered
Escherichia coli.
As of Jun 2010, NatureWorks was the primary producerof PLA (bioplastic) in the United States.
Plastics are resistant to biodegradation accumulating at therate of 25 million tonnes per year. Much disposed in landfillsites. Possibility of recycling plastics is limited andincineration yields toxic compounds
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Organisms
Ralstonia eutropha
Alcaligenes latus
Azotobacter vinelandii Paracoccus denitrificans
Recombinant E.coli
Bacillus subtilis
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The biosynthesis of PHA is usually caused
by certain deficiency conditions (e.g. lack
of macro elements such as phosphorus,
nitrogen, trace elements, or lack ofoxygen) and the excess supply of carbon
sources.
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Simplify Extraction
Secretion Mechanisms
1. Exploit natural secretion
mechanisms
2. Transform cell with plasmidcontaining lysis gene
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High start-up costs (3-5 x
higher than petroleum-basedplastics)
Labor intensive processing
High energy demands
Challenges Facing Bioplastics
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