Development of an innovative algae-based approach for producing CO2 derived biopolymers

The Department of Energy is seeking to invest in research and development of technologies that can economically convert CO2 into plastic in the form of pellets, foams, or fibers. The lack of new CO2 to plastic technologies and the higher cost of current CO2 conversion approaches significantly restrains their applications in many segments. Therefore, novel technologies need to transform carbon emissions into plastics with less complex industrial processes. In response to topic 23b, we proposed an innovative technology that converts industrial waste CO2 stream and algal biomass into high value biopolyols targeting polyurethane (PU) foam application via sustainable thermochemical pathways. The waste CO2 stream is from the anaerobic digestion process, while the digester effluent can be used for on-site algae cultivation. Biodegradable polycarbonate polymers will be synthesis from CO2 and crude glycerol ( byproducts of the algae oil to biodiesel process) derived bioepoxide. In addition, the developed technologies will significantly advance CO2 utilization technologies and unlock many industrial opportunities, particularly for biopolymer manufacturers. The overall goal of this Phase II project is to develop and scale up a novel, cost-effective approach to successfully convert waste CO2 into high-value versatile biopolymers. Five specific objectives and relevant activities will be carried out in this project. 1) Pilot scale liquefaction of algal biomass for biopolyols production. 2) Synthesis of bio-epoxy monomers from algae oil and crude glycerol 3) Pilot scale bio-based polycarbonate polyols production via the polymerization of CO2 and epoxy monomers in the presence of a proprietary catalyst system. 4) Applications of the CO2-derived biopolymers in consumer packaging products 5) Conducting TEA and LCA of the proposed system. 6) Module design of the system for scale-up CO2 capture and conversion technologies are crucial for achieving net-zero carbon emissions by 2050, but it is challenging to convert CO2 into valuable green products under cost-effective solutions. Therefore, we will advance CO2-to-plastic technologies to effectively incorporate CO2 into high-value biopolymers with multiple applications, thereby providing a new economical avenue for bioplastics manufacturers. The proposed technology has a positive impact on society by reducing dependence on non-renewable resources and promoting sustainable products. Our technology has the potential to create new jobs in the agricultural and bio-based manufacturing sectors.