Flow Chemistry for Pre-pilot Scale Production of Algae-Based Diisocyanates

Algenesis Materials is developing sustainable, biodegradable, high quality polyurethanes derived from algae biomass. To increase the biocontent and sustainability of our products, we must tackle the challenge of developing biobased replacements for one of the key petroleum-derived monomers for polyurethanes – diisocyanates. Nearly 5 billion kilograms of diisocyanates are produced annually using a highly dangerous reaction involving the toxic chemical phosgene, which was used as a chemical weapon in World War I. To eliminate the use of phosgene and derive diisocyanates from sustainable sources, including algae, we previously successfully developed in our Phase I project a flow chemistry methodology and system – that does not require phosgene – for producing the aliphatic azelaic dihydrazide (ADH) from biologicallyderived azelaic acid (AA) at a production rate of 1 kg/week. Dihydrazides are a key intermediate in the conversion of diacids to diisocyanates, heptamethylene diisocyanate (7HDI) in this case. Flow chemistry is inherently scalable to industrial production levels and a flow chemistry system to convert ADH to 7HDI has already been developed at the lab scale. Thus, in this Phase II proposal, we will expand upon our Phase I work by first scaling the flow chemistry system for conversion of ADH to 7HDI at a rate of 1 kg/week. We will then demonstrate the entire scaled system for converting AA ? HpMDI to produce =1 kg/week of 7HDI. Finally, we will increase the flow rates of both systems to achieve =5 kg/week 7HDI production. The resulting 7HDI (=50 kg) derived from algae biomass will be sufficient to produce enough 100% biobased and biodegradable TPUs (=200 kg) to coat =2,000 yards of fabric for incorporation into prototype commercial products, such as travel bags or rain coats, through our commercial research and development partners. These products will be analyzed for their performance properties and ability to biodegrade. The success of this project will be a first of its kind production of 100% biobased diisocyanate and TPUs without the use of phosgene, with the potential to rapidly scale and commercialize drop-in replacements for petroleum-derived diisocyanates. Further, these biobased diisocyanates will enable our PU products to be 100% bio- or algae-content and 100% biodegradable at the end of their product lifetime – a truly sustainable, high performance product. Such materials will have additional environmental benefits through their reduction in reliance on petroleum, by not generating persistent microplastics, and by enabling a pathway to valorize large scale algae biomass and biofuel production, a key goal of the US Department of Energy for developing sustainable and economically viable biofuels.