Microbial community-based polyhydroxyalkanoates (PHAs) production from wastewater: Techno-economic analysis and ex-ante environmental assessment

Innovations in poly(3-hydroxybutyrate-co-3-hydroxyvalerate) and nanocomposites for sustainable food packaging via biochemical biorefinery platforms: A comprehensive review

The substantial build-up of non-biodegradable plastic waste from packaging sector not only poses severe environmental threats but also hastens the depletion of natural petroleum-based resources. Presently, poly (3-hydroxybutyrate-co-3-hydroxy valerate) (PHBV), received enormous attention as ideal alternatives for such traditional petroleum-derived plastics based on their biocompatibility and superior mechanical properties. However, high cost of such copolymer, due to expensive nature of feedstock, inefficient microbial processes and unfavorable downstream processing strategies restricts its large-scale commercial feasibility in the packaging sector. This review explores merits and challenges associated with using potent agricultural and industrial waste biomasses as sustainable feedstocks alongside improved fermentation and downstream processing strategies for the biopolymer in terms of biorefinery concept. Despite PHBV's attractive properties, its inherent shortcomings like weak thermal stability, poor mechanical properties, processability difficulty, substantial hydrophobicity and comparatively higher water vapor permeability (WVP) demand the development of its composites based on the application. Based on this fact, the review assessed properties and potential applications of PHBV-based composite materials having natural raw materials, nanomaterials and synthetic biodegradable polymers. Besides, the review also enlightens sustainability, future prospects, and challenges associated with PHBV-based composites in the field of food packaging while considering insights about economic evaluation and life cycle assessment.

A Review of Polyhydroxyalkanoates: Characterization, Production, and Application from Waste

The search for alternatives to petrochemical plastics has intensified, with increasing attention being directed toward bio-based polymers (bioplastics), which are considered healthier and more environmentally friendly options. In this review, a comprehensive overview of polyhydroxyalkanoates (PHAs) is provided, including their characterization, applications, and the mechanisms underlying their biosynthesis. PHAs are natural polyesters produced by a wide range of prokaryotic and some eukaryotic organisms, positioning them as a significant and widely studied type of bioplastic. Various strategies for the production of PHAs from agroindustrial waste, such as cacao shells, cheese whey, wine, wood, and beet molasses, are reviewed, emphasizing their potential as sustainable feedstocks. Industrial production processes for PHAs, including the complexities associated with extraction and purification, are also examined. Although the use of waste materials offers promise in reducing costs and environmental impact, challenges remain in optimizing these processes to enhance efficiency and cost-effectiveness. The need for continued research and development to improve the sustainability and economic viability of PHA production is emphasized, positioning PHAs as a viable and eco-friendly alternative to conventional petroleum-based plastics.

Innovative biomaterials for food packaging: Unlocking the potential of polyhydroxyalkanoate (PHA) biopolymers

Polyhydroxyalkanoate (PHA) biopolyesters show a good balance between sustainability and performance, making them a competitive alternative to conventional plastics for ecofriendly food packaging. With an emphasis on developments over the last decade (2014-2024), this review examines the revolutionary potential of PHAs as a sustainable food packaging material option. It also delves into the current state of commercial development, competitiveness, and the carbon footprint associated with PHA-based products. First, a critical examination of the challenges experienced by PHAs in terms of food packaging requirements is undertaken, followed by an assessment of contemporary strategies addressing permeability, mechanical properties, and processing considerations. The various PHA packaging end-of-life options, including a comprehensive overview of the environmental impact and potential solutions will also be discussed. Finally, conclusions and future perspectives are elucidated with a view of prospecting PHAs as future green materials, with a blend of performance and sustainability of food packaging solutions.

Compiling life cycle inventories for wastewater-derived products

With the paradigm shift in wastewater management from pollutant removal to resource recovery, more wastewater-derived products are emerging from different recovery pathways. It is becoming increasingly important to understand the potential environmental impacts of these products through life cycle assessment (LCA). This study aims to compile life cycle inventories of wastewater-derived products from the perspective of the product end users (e.g., agricultural sector, packaging industry), and to explore the challenges of their compilation. Using inventories from wastewater resource recovery LCA literature, we compiled an attributional inventory (88 sets) and a consequential inventory (33 sets) of three categories of wastewater-derived products - phosphorus compounds, nitrogen compounds, and biopolymers. The two inventories differ by the choices of system boundary, how foreground systems are being modelled, and how co-products are being handled. We found that while there is a large body of literature related to wastewater resource recovery LCA, very few studies (29 out of 174 for the three categories of products) are suitable for end users to successfully compile inventories of derived products. The inventories were assessed by the technology readiness level assessment, the data quality assessment, and the cumulative energy demand indicator. The inventories can be used directly by end users or served as "screening" inventories for end users to prioritize data collection effort. The identified challenges of inventory compilation include diverse recovery settings, the absence of baseline scenarios, the multifunctional nature of wastewater treatment plants, the lack of inventory transparency and completeness, and low technology readiness level for some recovery pathways. While established or emerging approaches exist to address most of these challenges for end users, wastewater resource recovery LCA practitioners can enhance their assessments to be more end-user-oriented. This can be achieved by including baseline non-recovery scenarios, disclosing detailed life cycle inventory by system components, and assessing a wide variety of operating scenarios. Addressing some of these compilation challenges would enhance the comprehensiveness and quality of wastewater-derived product inventories.

Polyhydroxyalkanoate recovery overview: properties, characterizations, and extraction strategies

Due to their excellent properties, polyhydroxyalkanoates are gaining increasing recognition in the biodegradable polymer market. These biogenic polyesters are characterized by high biodegradability in multiple environments, overcoming the limitation of composting plants only and their versatility in production. The most consolidated techniques in the literature or the reference legislation for the physical, chemical and mechanical characterisation of the final product are reported since its usability on the market is still linked to its quality, including the biodegradability certificate. This versatility makes polyhydroxyalkanoates a promising prospect with the potential to replace fossil-based thermoplastics sustainably. This review analyses and compares the physical, chemical and mechanical properties of poly-β-hydroxybutyrate and poly-β-hydroxybutyrate-co-β-hydroxyvalerate, indicating their current limitations and strengths. In particular, the copolymer is characterised by better performance in terms of crystallinity, hardness and workability. However, the knowledge in this area is still in its infancy, and the selling prices are too high (9-18 $ kg-1). An analysis of the main extraction techniques, established and in development, is also included. Solvent extraction is currently the most widely used method due to its efficiency and final product quality. In this context, the extraction phase of the biopolymer production process remains a major challenge due to its high costs and the need to use non-halogenated toxic solvents to improve the production of good-quality bioplastics. The review also discusses all fundamental parameters for optimising the process, such as solubility and temperature.

Embracing Sustainability: The World of Bio-Based Polymers in a Mini Review

The proliferation of polymer science and technology in recent decades has been remarkable, with synthetic polymers derived predominantly from petroleum-based sources dominating the market. However, concerns about their environmental impacts and the finite nature of fossil resources have sparked interest in sustainable alternatives. Bio-based polymers, derived from renewable sources such as plants and microbes, offer promise in addressing these challenges. This review provides an overview of bio-based polymers, discussing their production methods, properties, and potential applications. Specifically, it explores prominent examples including polylactic acid (PLA), polyhydroxyalkanoates (PHAs), and polyhydroxy polyamides (PHPAs). Despite their current limited market share, the growing awareness of environmental issues and advancements in technology are driving increased demand for bio-based polymers, positioning them as essential components in the transition towards a more sustainable future.

Production of polyhydroxyalkanoates using sewage and cheese whey

Recently, polyhydroxyalkanoates (PHAs) have been produced using raw sewage in our laboratory; however, the production concentrations are low. Therefore, this study aimed to enhance PHA production by applying different strategies. PHA production was higher in sewage-containing medium than in mineral salt medium and was enhanced 22-fold after glucose supplementation. A relatively high degree of glucose consumption (83.6 ± 1.59 %) was also achieved. Bacteria incubated with cheese whey diluted with sewage showed higher PHA production than bacteria incubated with cheese whey diluted with distilled water did. The expression of the PHA synthase gene (phaC) was evaluated via real-time polymerase chain reaction using low- and high-carbon-containing sewage. Relatively higher phaC expression levels were observed in high-carbon-containing sewage but at lower nitrogen concentrations. The characteristics of the produced PHA were comparable to those of standard PHA. Therefore, this study revealed that the bacterium Bacillus sp. CYR1 can produce PHA from low- or high-carbon-containing wastewater.

Exploring the Feasibility of Cell-Free Synthesis as a Platform for Polyhydroxyalkanoate (PHA) Production: Opportunities and Challenges

The extensive utilization of traditional petroleum-based plastics has resulted in significant damage to the natural environment and ecological systems, highlighting the urgent need for sustainable alternatives. Polyhydroxyalkanoates (PHAs) have emerged as promising bioplastics that can compete with petroleum-based plastics. However, their production technology currently faces several challenges, primarily focused on high costs. Cell-free biotechnologies have shown significant potential for PHA production; however, despite recent progress, several challenges still need to be overcome. In this review, we focus on the status of cell-free PHA synthesis and compare it with microbial cell-based PHA synthesis in terms of advantages and drawbacks. Finally, we present prospects for the development of cell-free PHA synthesis.

Production of medium-chain-length PHA in octanoate-fed enrichments dominated by Sphaerotilus sp

Medium-chain-length polyhydroxyalkanoate (mcl-PHA) production by using microbial enrichments is a promising but largely unexplored approach to obtain elastomeric biomaterials from secondary resources. In this study, several enrichment strategies were tested to select a community with a high mcl-PHA storage capacity when feeding octanoate. On the basis of analysis of the metabolic pathways, the hypothesis was formulated that mcl-PHA production is more favorable under oxygen-limited conditions than short-chain-length PHA (scl-PHA). This hypothesis was confirmed by bioreactor experiments showing that oxygen limitation during the PHA accumulation experiments resulted in a higher fraction of mcl-PHA over scl-PHA (i.e., a PHA content of 76 wt% with an mcl fraction of 0.79 with oxygen limitation, compared to a PHA content of 72 wt% with an mcl-fraction of 0.62 without oxygen limitation). Physicochemical analysis revealed that the extracted PHA could be separated efficiently into a hydroxybutyrate-rich fraction with a higher M_w and a hydroxyhexanoate/hydroxyoctanoate-rich fraction with a lower M_w . The ratio between the two fractions could be adjusted by changing the environmental conditions, such as oxygen availability and pH. Almost all enrichments were dominated by Sphaerotilus sp. This is the first scientific report that links this genus to mcl-PHA production, demonstrating that microbial enrichments can be a powerful tool to explore mcl-PHA biodiversity and to discover novel industrially relevant strains.

Systematizing Microbial Bioplastic Production for Developing Sustainable Bioeconomy: Metabolic Nexus Modeling, Economic and Environmental Technologies Assessment

The excessive usage of non-renewable resources to produce plastic commodities has incongruously influenced the environment's health. Especially in the times of COVID-19, the need for plastic-based health products has increased predominantly. Given the rise in global warming and greenhouse gas emissions, the lifecycle of plastic has been established to contribute to it significantly. Bioplastics such as polyhydroxy alkanoates, polylactic acid, etc. derived from renewable energy origin have been a magnificent alternative to conventional plastics and reconnoitered exclusively for combating the environmental footprint of petrochemical plastic. However, the economically reasonable and environmentally friendly procedure of microbial bioplastic production has been a hard nut to crack due to less scouted and inefficient process optimization and downstream processing methodologies. Thereby, meticulous employment of computational tools such as genome-scale metabolic modeling and flux balance analysis has been practiced in recent times to understand the effect of genomic and environmental perturbations on the phenotype of the microorganism. In-silico results not only aid us in determining the biorefinery abilities of the model microorganism but also curb our reliance on equipment, raw materials, and capital investment for optimizing the best conditions. Additionally, to accomplish sustainable large-scale production of microbial bioplastic in a circular bioeconomy, extraction, and refinement of bioplastic needs to be investigated extensively by practicing techno-economic analysis and life cycle assessment. This review put forth state-of-the-art know-how on the proficiency of these computational techniques in laying the foundation of an efficient bioplastic manufacturing blueprint, chiefly focusing on microbial polyhydroxy alkanoates (PHA) production and its efficacy in outplacing fossil based plastic products.

Formation of polyhydroxyalkanoates using agro and industrial waste as a substrate - a review

In the present scenario, rising environmental concerns of non-biodegradable plastic pollution and depletion of petroleum based raw materials lead to the development of biopolymers. The biodegradability of biopolymers gives them a specific advantage for the environmental concerns. Polyhydroxyalkanoates (PHAs) are a type of biopolymers which are synthesized by microorganisms. Although there are different substrates available in pure forms which are currently used in the production of PHA, 40% of production cost depends on the expensive substrate which is a major disadvantage and make it far from many applications. The use of an inexpensive carbon source which is high in organic matter content such as waste streams of process industries can make this process viable and diminish PHA production cost. This study explores the current research initiatives on various agricultural and industrial waste feedstocks, formulations and processing conditions for producing PHA in a way that is both inexpensive and beneficial to the environment. The creation of fermentation conditions and metabolic engineering techniques for promoting microbial growth and PHA synthesis were also discussed in the review.

Can Biomass Mastication Assist the Downstreaming of Polyhydroxyalkanoates Produced from Mixed Microbial Cultures?

Polyhydroxyalkanoates (PHAs) are natural polyesters which biodegrade in soils and oceans but have more than double the cost of comparable oil-based polymers. PHA downstreaming from its biomass represents 50% of its overall cost. Here, in an attempt to assist downstreaming, mastication of wet biomasses is tested as a new mechanical continuous biomass pretreatment with potential for industrial upscaling. Downstreaming conditions where both product recovery and purity are low due to the large amount of treated wet biomass (50% water) were targeted with the following process: extraction of 20 g in 100 mL solvent at 30 °C for 2 h, followed by 4.8 h digestion of 20 g in 0.3 M NaOH. Under the studied conditions, NaOH digestion was more effective than solvent extraction in recovering larger PHA amounts, but with less purity. A nearly 50% loss of PHA was seen during digestion after mastication. PHAs downstreamed by digestion with large amounts of impurities started to degrade at lower temperatures, but their melt elasticity was thermally stable at 170 °C. As such, these materials are attractive as fully PHA-compatible processing aids, reinforcing fillers or viscosity modifiers. On the other hand, wet biomass mastication before solvent extraction improves PHA purity and thermal stability as well as the melt rheology, which recovers the viscoelasticity measured with a PHA extracted from a dried biomass.

Process Design for Value-Added Products in a Biorefinery Platform from Agro and Forest Industrial Byproducts

Agroforestry wastes are industrial byproducts available locally such as eucalyptus sawdust (EUC) and sugarcane bagasse (SCB). These byproducts can be used as lignocellulosic raw materials to produce high-value products. This study is a techno-economic analysis of four potential scenarios to produce polyhydroxybutyrate (PHB) and levulinic acid (LA) from hemicellulosic sugars by a fermentative pathway in a biomass waste biorefinery. Mass and energy balances were developed, and technical and economic assessments were carried out to obtain gas, char, and tar from residual solids from autohydrolysis treatment. It was determined that microbial culture could be an attractive option for added-value product production. More than 1500 t/year of PHB and 2600 t/year of LA could be obtained by the proposed pathways. Microbial and enzymatic conversion of LA from sugars could significantly improve energy consumption on the conversion strategy. The products from solid residual valorization (char and tar) are the most important for economic performance. Finally, a variation in specific variables could mean substantial improvements in the final indicators of the processes, reaching a higher NPV than USD 17 million.

Enhanced production of biobased, biodegradable, Poly(3-hydroxybutyrate) using an unexplored marine bacterium Pseudohalocynthiibacter aestuariivivens, isolated from highly polluted coastal environment

The production and disposal of plastics from limited fossil reserves, has prompted research for greener and sustainable alternatives. Polyhydroxyalkanoates (PHAs) are biocompatible, biodegradable, and thermoprocessable polyester produced by microbes. PHAs found several applications but their use is limited due to high production cost and low yields. Herein, for the first time, the isolation and characterization of Pseudohalocynthiibacter aestuariivivens P96, a marine bacterium able to produce surprising amount of PHAs is reported. In the best growth condition P96 was able to reach a maximum production of 4.73 g/L, corresponding to the 87 % of total cell dry-weight. Using scanning and transmission microscopy, lab-scale fermentation, spectroscopic techniques, and genome analysis, the production of thermoprocessable polymer Polyhydroxybutyrate P(3HB), a PHAs class, endowed with mechanical and thermal properties comparable to that of petroleum-based plastics was confirmed. This study represents a milestone toward the use of this unexplored marine bacterium for P(3HB) production.

Comprehensive Techno-environmental Evaluation of a Pilot-Scale PHA Production from Food Waste in China

Polyhydroxyalkanoates (PHAs), a biodegradable plastic that might replace petroleum-based plastics, can be recovered from organic waste using mixed microbial cultures (MMCs). Research in this field has been ongoing for about 25 years and is now in a critical commercialization period. However, few pilot-scale studies are available to analyze its technical feasibility and environmental impact. We ran an MMC PHA production pilot plant for 6 months using local food waste as the feedstock. The traditional three-stage process achieved PHA content of 47.91 ± 1.91% dry cell weight and volumetric productivity of 9.94 ± 0.01 g/L·d, while a novel rapid proliferation stage was built in, the PHA content and productivity could reach 41.39 ± 2.39% cell dry weight and 20.02 ± 0.01 g/L·d, respectively. Life cycle assessment using field data showed that greenhouse warming potential was much more than five times that of the known literature, and the fossil depletion potential was 10.30 (scenario #1)/7.59 (scenario #2) times higher than petroleum-based polyethylene (PE) plastic. However, establishing a resource-energy-water union instead of an isolated plant could achieve environmental benefits compared to PE plastic. This techno-environmental analysis provides emerging MMC PHA producers worldwide with a valuable reference for further development opportunities and market planning.

Production and recovery of polyhydroxyalkanoates (PHA) from waste streams - A review

Polyhydroxyalkanoates (PHA) are the more attractive sustainable green plastic, and it has the potential to replace petroleum-based plastics (PBP) in the global market. Recently, most of the developed and developing countries have banned the use of traditional PBP. This increases the demand for green plastic production and positively impacts the global market. Producing green plastic from various waste streams such as whey, animal, and crude glycerol will be eco-friendly and cost-effective. However, the factors influencing the environmental sustainability of PHA production from different waste streams are still unclear. This review could be reinforced concrete to researchers to gather deep knowledge on techno-economic analysis, life-cycle assessment, environmental and ecological risks caused during PHA production from different waste streams.

Simultaneous Production of Biohydrogen (bioH2) and Poly-Hydroxy-Alkanoates (PHAs) by a Photoheterotrophic Consortium Bioaugmented with Syntrophomonas wolfei

Mixed cultures represent better alternatives to ferment organic waste and dark fermentation products in anerobic conditions because the microbial associations contribute to electron transfer mechanisms and combine metabolic possibilities. The understanding of the microbial interactions in natural and synthetic consortia and the strategies to improve the performance of the processes by bioaugmentation provide insight into the physiology and ecology of the mixed cultures used for biotechnological purposes. Here, synthetic microbial communities were built from three hydrogen (bioH2) and poly-hydroxy-alkanoates (PHA) producers, Clostridium pasteurianum, Rhodopseudomonas palustris and Syntrophomonas wolfei, and a photoheterotrophic mixed consortium C4, and their performance was evaluated during photofermentation. Higher hydrogen volumetric production rates (H2VPR) were determined with the consortia (28–40 mL/Lh) as compared with individual strains (20–27 mL/Lh). The designed consortia reached the highest bioH2 and PHA productions of 44.3 mmol and 50.46% and produced both metabolites simultaneously using dark fermentation effluents composed of a mixture of lactic, butyric, acetic, and propionic acids. When the mixed culture C4 was bioaugmented with S. wolfei, the bioH2 and PHA production reached 32 mmol and 50%, respectively. Overall, the consumption of organic acids was above 50%, which accounted up to 55% of total chemical oxygen demand (COD) removed. Increased bioH2 was observed in the condition when S. wolfei was added as the bioaugmentation agent, reaching up to 562 mL of H2 produced per gram of COD. The enhanced production of bioH2 and PHA can be explained by the metabolic interaction between the three selected strains, which likely include thermodynamic equilibrium, the assimilation of organic acids via beta-oxidation, and the production of bioH2 using a proton driving force derived from reduced menaquinone or via electron bifurcation.

Valorization of wastewater to recover value-added products: A comprehensive insight and perspective on different technologies

In recent years, due to rapid globalization and urbanization, the demand for fuels, energy, water and nutrients has been continuously increasing. To meet the future need of the society, wastewater is a prominent and emerging source for resource recovery. It provides an opportunity to recover valuable resources in the form of energy, fertilizers, electricity, nutrients and other products. The aim of this review is to elaborate the scientific literature on the valorization of wastewater using wide range of treatment technologies and reduce the existing knowledge gap in the field of resource recovery and water reuse. Several versatile, resilient environmental techniques/technologies such as ion exchange, bioelectrochemical, adsorption, electrodialysis, solvent extraction, etc. are employed for the extraction of value-added products from waste matrices. Since the last two decades, valuable resources such as polyhydroxyalkanoate (PHA), matrix or polymers, cellulosic fibers, syngas, biodiesel, electricity, nitrogen, phosphorus, sulfur, enzymes and a wide range of platform chemicals have been recovered from wastewater. In this review, the aspects related to the persisting global water issues, the technologies used for the recovery of different products and/or by-products, economic sustainability of the technologies and the challenges encountered during the valorization of wastewater are discussed comprehensively.

A plant wide simulation of polyhydroxyalkanoate production from wastewater and its conversion to methyl crotonate

This work simulates the production of methyl crotonate from various industrial wastewaters. In the upstream process, wastewater is fermented into volatile fatty acids which are then converted into polyhydroxyalkanoates (PHA) by means of mixed microbial cultures. In the downstream, PHA undergoes a series of thermolysis and esterification reactions to produce methyl crotonate. The origin of the wastewater was found to have a great influence on the composition of the PHA with the effluent of a candy bar factory producing a high polyhydroxybutyrate/polyhydroxyvalerate ratio of 86/14 in favour of methyl crotonate production. It was observed that the use of intracellular polyhydroxybutyrate, instead of purified, significantly lowers the number of separation steps and yet reduces the methyl crotonate recovery by only 20 %. An operating pressure higher than 18 bar led to more transesterification of polyhydroxybutyrate, producing byproducts instead of methyl crotonate. Finally, a 3 h reaction was found sufficient for completion of polyhydroxybutyrate conversion.

Production of a newly discovered PHA family member with an isobutyrate-fed enrichment culture

Abstract

Using microbial enrichment cultures for the production of waste-derived polyhydroxyalkanoates (PHAs) is a promising technology to recover secondary resources. Volatile fatty acids (VFAs) form the preferred substrate for PHA production. Isobutyrate is a VFA appearing in multiple waste valorization routes, such as anaerobic fermentation, chain elongation, and microbial electrosynthesis, but has never been assessed individually on its PHA production potential. This research investigates isobutyrate as sole carbon source for a microbial enrichment culture in comparison to its structural isomer butyrate. The results reveal that the enrichment of isobutyrate has a very distinct character regarding microbial community development, PHA productivity, and even PHA composition. Although butyrate is a superior substrate in almost every aspect, this research shows that isobutyrate-rich waste streams have a noteworthy PHA-producing potential. The main finding is that the dominant microorganism, a Comamonas sp., is linked to the production of a unique PHA family member, poly(3-hydroxyisobutyrate) (PHiB), up to 37% of the cell dry weight. This is the first scientific report identifying microbial PHiB production, demonstrating that mixed microbial communities can be a powerful tool for discovery of new metabolic pathways and new types of polymers.

Key points

• PHiB production is a successful storage strategy in an isobutyrate-fed SBR

• Isomers isobutyrate and butyrate reveal a very distinct PHA production behavior

• Enrichments can be a tool for discovery of new metabolic pathways and polymers

Graphical abstract

Supplementary Information

The online version contains supplementary material available at 10.1007/s00253-021-11742-9.

A comparative analysis of biopolymer production by microbial and bioelectrochemical technologies

Production of biopolymers from renewable carbon sources provides a path towards a circular economy. This review compares several existing and emerging approaches for polyhydroxyalkanoate (PHA) production from soluble organic and gaseous carbon sources and considers technologies based on pure and mixed microbial cultures. While bioplastics are most often produced from soluble sources of organic carbon, the use of carbon dioxide (CO₂) as the carbon source for PHA production is emerging as a sustainable approach that combines CO₂ sequestration with the production of a value-added product. Techno-economic analysis suggests that the emerging approach of CO₂ conversion to carboxylic acids by microbial electrosynthesis followed by microbial PHA production could lead to a novel cost-efficient technology for production of green biopolymers.

Biopolymers production from renewable carbon sources.

Polyhydroxyalkanoates synthesis using acidogenic fermentative effluents

Polyhydroxyalkanoates (PHA) are natural polyesters synthesized by microbes which consume excess amount of carbon and less amount of nutrients. It is biodegradable in nature, and it synthesized from renewable resources. It is considered as a future polymer, which act as an attractive replacement to petrochemical based polymers. The main hindrance to the commercial application of PHA is the high manufacturing cost. This article provides an overview of different cost-effective substrates, their characteristics and composition, major strains involved in economical production of PHA and biosynthetic pathways leading to accumulation of PHA. This review also covers the operational parameters, various fermentative modes including batch, fed-batch, repeated fed-batch and continuous fed-batch systems, along with advanced feeding strategies such as single pulse carbon feeding, feed forward control, intermittent carbon feeding, feast famine conditions to observe their effects for improving PHA synthesis and associated challenges. In addition, it also presents the economic analysis and future perspectives for the commercialization of PHA production process thereby making the process sustainable and lucrative with the possibility of commercial biomanufacturing.

A shortcut to carbon-neutral bioplastic production: Recent advances in microbial production of polyhydroxyalkanoates from C1 resources

Since the 20th century, plastics that are widely being used in general life and industries are causing enormous plastic waste problems since improperly discarded plastics barely degrade and decompose. Thus, the demand for polyhydroxyalkanoates (PHAs), biodegradable polymers with material properties similar to conventional petroleum-based plastics, has been increased so far. The microbial production of PHAs is an environment-friendly solution for the current plastic crisis, however, the carbon sources for the microbial PHA production is a crucial factor to be considered in terms of carbon-neutrality. One‑carbon (C1) resources, such as methane, carbon monoxide, and carbon dioxide, are greenhouse gases and are abundantly found in nature and industry. C1 resources as the carbon sources for PHA production have a completely closed carbon loop with much advances; i) fast carbon circulation with direct bioconversion process and ii) simple fermentation procedure without sterilization as non-preferable nutrients. This review discusses the biosynthesis of PHAs based on C1 resource utilization by wild-type and metabolically engineered microbial host strains via biorefinery processes.

Techno-economic assessment of a sustainable and cost-effective bioprocess for large scale production of polyhydroxybutyrate

The rapid depletion of crude-oil resource which sustains a conventional petroleum refinery together with its environmental impact has led to the search for more sustainable alternatives. In this context, biorefinery serves to fulfil the aim by utilizing waste resources. Hence, this study focused on techno-economic assessment of PHB production at large scale from waste carob pods in a closed-loop biorefinery setup. Firstly, the use of pure sugars in SC1 was shifted to use of carob pods as feedstock in SC2, upgradation of stirred tank bioreactor with novel annular gap bioreactor in SC3 and replacing the conventional centrifugation process with the upcoming ceramic membrane separation process in SC4. An Aspen plus™ flowsheet was developed by including the aforementioned novel strategies for PHB production. The effectiveness of PHB production under various scenarios was evaluated based on its pay-out period and turnover accumulated at the end of 7th year of a PHB plant operation. Instead of pure sugars as the feedstock (SC1), carob pod extract (SC2) reduced the pay-out period from 12.6 to 6.8 years. Likewise, switching onto ABR from the conventional STBR further decreased the pay-out period to 4.8 years. Finally, the use of ceramic membranes (SC4) instead of centrifugation resulted in a similar pay-out period of 4.8 years with increased turnover of about 1.4 billion USD. Thus, the use of carob pods along with an improved PHB titre in ABR and incorporation of affordable ceramic membrane technology for PHB rich biomass separation resulted in a highly cost-effective PHB production strategy.

Technical, economic and environmental feasibility of resource recovery technologies from wastewater

An enormous amount of wastewater is generated across the world from different industrial or municipal sectors. Traditional wastewater treatment plants (WWTP) have primarily focused on the treatment of wastewater rather than the recovery of valuable resources. A shift from a linear to a circular economy may offer a unique platform for recovering valuable resources including energy, nutrients, and high-value goods from wastewater. However, transitioning from conventional frameworks to sustainable WWT systems remains a significant challenge. Thus, this review paper focuses on the avenues of resource recovery from WWTPs, by evaluating the potential for nutrients, water, and energy recovery from different types of wastewaters and sewage sludge. It discusses in detail a variety of available and advanced technologies for resource recovery. Further, the feasibility of these technologies from a sustainable standpoint is discussed, covering the technical, economic, and environmental facets.

Properties of Degradable Polyhydroxyalkanoates (PHAs) Synthesized by a New Strain, Cupriavidus necator IBP/SFU-1, from Various Carbon Sources

The bacterial strain isolated from soil was identified as Cupriavidus necator IBP/SFU-1 and investigated as a PHA producer. The strain was found to be able to grow and synthesize PHAs under autotrophic conditions and showed a broad organotrophic potential towards different carbon sources: sugars, glycerol, fatty acids, and plant oils. The highest cell concentrations (7–8 g/L) and PHA contents were produced from oleic acid (78%), fructose, glucose, and palm oil (over 80%). The type of the carbon source influenced the PHA chemical composition and properties: when grown on oleic acid, the strain synthesized the P(3HB-co-3HV) copolymer; on plant oils, the P(3HB-co-3HV-co-3HHx) terpolymer, and on the other substrates, the P(3HB) homopolymer. The type of the carbon source influenced molecular-weight properties of PHAs: P(3HB) synthesized under autotrophic growth conditions, from CO₂, had the highest number-average (290 ± 15 kDa) and weight-average (850 ± 25 kDa) molecular weights and the lowest polydispersity (2.9 ± 0.2); polymers synthesized from organic carbon sources showed increased polydispersity and reduced molecular weight. The carbon source was not found to affect the degree of crystallinity and thermal properties of the PHAs. The type of the carbon source determined not only PHA composition and molecular weight but also surface microstructure and porosity of the polymer films. The new strain can be recommended as a promising P(3HB) producer from palm oil, oleic acid, and sugars (fructose and glucose) and as a producer of P(3HB-co-3HV) from oleic acid and P(3HB-co-3HV-co-3HHx) from palm oil.

Poly-β-Hydroxybutyrate Production by Rhodopseudomonas sp. Grown in Semi-Continuous Mode in a 4 L Photobioreactor

The synthesis of polyhydroxybutyrate (PHB) by photosynthetic non-sulfur bacteria is a potential approach for producing biodegradable plastics. In this work, acetate was used as a single carbon source to study the effect on PHB formation in Rhodopseudomonas sp. cultured in a cylindrical four-liter photobioreactor under semi-continuous mode. The cultivation process is divided into a symmetrical growth phase and a PHB accumulation phase separated temporally. The symmetrical growth phase (nutrient sufficient conditions) was followed by a sulfur-limited phase to promote PHB accumulation. The main novelty is the progressive lowering of the sulfur concentration into Rhodopseudomonas culture, which was obtained by two concomitant conditions: (1) sulfur consumption during the bacterial growth and (2) semi-continuous growth strategy. This caused a progressive lowering of the sulfur concentration into Rhodopseudomonas culturedue to the sulfur-free medium used to replace 2 L of culture (50% of the total) that was withdrawn from the photobioreactor at each dilution. The PHB content ranged from 9.26% to 15.24% of cell dry weight. At the steady state phase, the average cumulative PHB was >210 mg/L. Sulfur deficiency proved to be one of the most suitable conditions to obtain high cumulative PHB in Rhodopseudomonas culture.

Established and Emerging Producers of PHA: Redefining the Possibility

The polyhydroxyalkanoate was discovered almost around a century ago. Still, all the efforts to replace the traditional non-biodegradable plastic with much more environmentally friendly alternative are not enough. While the petroleum-based plastic is like a parasite, taking over the planet rapidly and without any feasible cure, its perennial presence has made the ocean a floating island of life-threatening debris and has flooded the landfills with toxic towering mountains. It demands for an immediate solution; most resembling answer would be the polyhydroxyalkanoates. The production cost is yet one of the significant challenges that various corporate is facing to replace the petroleum-based plastic. To deal with the economic constrain better strain, better practices, and a better market can be adopted for superior results. It demands for systems for polyhydroxyalkanoate production namely bacteria, yeast, microalgae, and transgenic plants. Solely strains affect more than 40% of overall production cost, playing a significant role in both upstream and downstream processes. The highly modifiable nature of the biopolymer provides the opportunity to replace the petroleum plastic in almost all sectors from food packaging to medical industry. The review will highlight the recent advancements and techno-economic analysis of current commercial models of polyhydroxyalkanoate production. Bio-compatibility and the biodegradability perks to be utilized highly efficient in the medical applications gives ample reason to tilt the scale in the favor of the polyhydroxyalkanoate as the new conventional and sustainable plastic.

Review and perspectives of enhanced volatile fatty acids production from acidogenic fermentation of lignocellulosic biomass wastes

Lignocellulosic biomass wastes are abundant resources that are usually valorized for methane-rich biogas via anaerobic digestion. Conversion of lignocellulose into volatile fatty acids (VFA) rather than biogas is attracting attention due to the higher value-added products that come with VFA utilization. This review consolidated the latest studies associated with characteristics of lignocellulosic biomass, the effects of process parameters during acidogenic fermentation, and the intensification strategies to accumulate more VFA. The differences between anaerobic digestion technology and acidogenic fermentation technology were discussed. Performance-enhancing strategies surveyed included (1) alkaline fermentation; (2) co-digestion and high solid-state fermentation; (3) pretreatments; (4) use of high loading rate and short retention time; (5) integration with electrochemical technology, and (6) adoption of membrane bioreactors. The recommended operations include: mesophilic temperature (thermophilic for high loading rate fermentation), C/N ratio (20-40), OLR (< 12 g volatile solids (VS)/(L·d)), and the maximum HRT (8-12 days), alkaline fermentation, membrane technology or electrodialysis recovery. Lastly, perspectives were put into place based on critical analysis on status of acidogenic fermentation of lignocellulosic biomass wastes for VFA production.

Integrated review of resource recovery on aerobic granular sludge systems: Possibilities and challenges for the application of the biorefinery concept

Aerobic Granular Sludge (AGS) is a biological treatment technology that has been extensively studied in the last decade. The possibility of resource recovery has always been highlighted in these systems, but real-scale applications are still scarce. Therefore, this paper aimed to present a systematic review of resources recovery such as water, energy, chemicals, raw materials, and nutrients from AGS systems, also analyzing aspects of engineering and economic viability. In the solid phase, sludge application in agriculture is an interesting possibility. However, the biosolids' metal concentration (the granules have high adsorption capacity due to the high concentration of extracellular polymeric substances, EPS) may be an issue. Another possibility is the recovery of Polyhydroxyalkanoates (PHAs) and Alginate-like exopolymers (bio-ALE) in the solid phase, emphasizing the last one, which has already been made in some Wastewater Treatment Plants (WWTPs), named and patented as Kaumera® process. The Operational Expenditure (OPEX) can be reduced by 50% in the WWTP when recovery of ALE is made. The ALE recovery reduced sludge yield by up to 35%, less CO₂ emissions, and energy saving. Finally, the discharged sludge can also be evaluated to be used for energetic purposes via anaerobic digestion (AD) or combustion. However, the AD route has faced difficulties due to the low biodegradability of aerobic granules.

Environmental life cycle assessment of polyhydroxyalkanoates production from cheese whey

Cheese whey (CW) is the main by-product of the dairy industry and is often considered one of the main agro-industrial biowaste streams to handle, especially within the European Union, where the diary activities play an essential role in the agrarian economy. In the paper, Life Cycle Assessment (LCA) is used to analyse the feasibility of producing polyhydroxyalkanoates (PHA) as the main output of an innovative CW valorisation route which is benchmarked against a conventional anaerobic digestion (AD) process. To this aim, the LCA inventory data are derived from lab-scale PHA accumulation tests performed on real CW, while data from the literature of concern are used for modelling both the PHA extraction from the accumulating biomass and for the alternative CW valorisation through AD. The comparison shows that AD would have better environmental performances than the baseline PHA production scenario. For example, the climate change indicator values result 44.8 and -35.7 kg CO₂ eq./t CW for the baseline PHA recovery and AD, respectively. LCA proved to be a useful tool to highlight the weak points of innovative processes and suggest proper improvements. Once improved and again analysed through the LCA, the PHA production process from CW shows that environmental performance comparable to AD may be achieved. With reference, again, to the climate change indicator the value can be reduced to -50.3 kg CO₂ eq./t CW for the improved PHA production process.

Polyhydroxyalkanoate (PHA) production via resource recovery from industrial waste streams: A review of techniques and perspectives

The problem of waste generation in the form of wastewater and solid wastes has caused an urgent, yet persisting, global issue that calls for the development of sustainable treatment and resource recovery technologies. The production of value-added polyhydroxyalkanoates (PHAs) from industrial waste streams has attracted the attention of researchers and process industries because they could replace traditional plastics. PHAs are biopolymers with high degradability, with a variety of applications in the manufacturing sector (e.g. medical equipment, packaging). The aim of this review is to describe the techniques and industrial waste streams that are applied for PHA production. The different enrichment and accumulation techniques that employ mixed microbial communities and carbon recovery from industrial waste streams and various downstream processes were reviewed. PHA yields between 7.6 and 76 wt% were reported for pilot-scale PHA production; while, at the laboratory-scale, yields from PHA accumulation range between 8.6 and 56 wt%. The recent advances in the application of waste streams for PHA production could result in more widely spread PHA production at the industrial scale via its integration into biorefineries for co-generation of PHAs with other added-value products like biohydrogen and biogas.

Emergent Approaches to Efficient and Sustainable Polyhydroxyalkanoate Production

Petroleum-derived plastics dominate currently used plastic materials. These plastics are derived from finite fossil carbon sources and were not designed for recycling or biodegradation. With the ever-increasing quantities of plastic wastes entering landfills and polluting our environment, there is an urgent need for fundamental change. One component to that change is developing cost-effective plastics derived from readily renewable resources that offer chemical or biological recycling and can be designed to have properties that not only allow the replacement of current plastics but also offer new application opportunities. Polyhydroxyalkanoates (PHAs) remain a promising candidate for commodity bioplastic production, despite the many decades of efforts by academicians and industrial scientists that have not yet achieved that goal. This article focuses on defining obstacles and solutions to overcome cost-performance metrics that are not sufficiently competitive with current commodity thermoplastics. To that end, this review describes various process innovations that build on fed-batch and semi-continuous modes of operation as well as methods that lead to high cell density cultivations. Also, we discuss work to move from costly to lower cost substrates such as lignocellulose-derived hydrolysates, metabolic engineering of organisms that provide higher substrate conversion rates, the potential of halophiles to provide low-cost platforms in non-sterile environments for PHA formation, and work that uses mixed culture strategies to overcome obstacles of using waste substrates. We also describe historical problems and potential solutions to downstream processing for PHA isolation that, along with feedstock costs, have been an Achilles heel towards the realization of cost-efficient processes. Finally, future directions for efficient PHA production and relevant structural variations are discussed.

Bio-based polyhydroxyalkanoates blends and composites

Polyhydroxyalkanoates (PHAs) are linear semicrystalline polyesters produced naturally by a wide range of microorganisms for carbon and energy storage. PHAs can be used as replacements for petroleum-based polyethylene (PE) and polypropylene (PP) in many industrial applications due to their biodegradability, excellent barrier, mechanical, and thermal properties. The overall industrial applications of PHAs are still very limited due to the high production cost and high stiffness and brittleness. Therefore, new novel cost-effective production method must be considered for the new generation of PHAs. One approach is based on using different type feedstocks and biowastes including food byproducts and industrial and manufacturing wastes, can lead to more competitive and cost-effective PHAs products. Modification of PHAs with different function groups such as carboxylic, hydroxyl, amine, epoxy, etc. is also a relatively new approach to create new functional materials with different industrial applications. In addition, blending PHA with biodegradable materials such as polylactide (PLA), poly(ε-caprolactone) (PCL), starch, and distiller’s dried grains with solubles (DDGS) is another approach to address the drawbacks of PHAs and will be summarized in this chapter. A series of compatibilizers with different architectures were successfully synthesized and used to improve the compatibility and interfacial adhesion between PHAs and PCL. Finer morphology and significantly improvement in the mechanical properties of PHA/PCL blends were observed with a certain type of block compatibilizer. In addition, the improvement in the blend morphology and mechanical properties were found to be strongly influenced by the compatibilizer architecture.

Scaling-up microbial community-based polyhydroxyalkanoate production: status and challenges

Conversion of organic waste and wastewater to polyhydroxyalkanoates (PHAs) offers a potential to recover valuable resources from organic waste. Microbial community-based PHA production systems have been successfully applied in the last decade at lab- and pilot-scales, with a total of 19 pilot installations reported in the scientific literature. In this review, research at pilot-scale on microbial community-based PHA production is categorized and subsequently analyzed with focus on feedstocks, enrichment strategies, yields of PHA on substrate, biomass PHA content and polymer characterization. From this assessment, the challenges for further scaling-up of microbial community-based PHA production are identified.

An environmental and economic assessment of bioplastic from urban biowaste. The example of polyhydroxyalkanoate

Bio-based and biodegradable plastics promise considerable reductions in our dependency on fossil fuels and in the environmental impacts of plastic waste. This study quantifies the environmental and economic consequences of diverting municipal food waste and wastewater sewage sludge from traditional management to the biorefinery-based production of polyhydroxyalkanoates (PHA) in five geographical regions. The results show that PHA can outperform fossil polyurethane and PHA from first-generation biomass (sugarcane and maize) with respect to both environmental impacts and societal costs (four times lower impacts and eight times lower costs than polyurethane). To outperform other fossil polymers like low-density polyethylene (LDPE), biorefinery performance should be improved further by more efficient utilization of sodium hypochlorite during PHA extraction, minimization of methane leakage in biogas facilities, upgrading of biogas to biomethane, and more effective handling of the liquid fraction from digestate dewatering.

Techno-economic evaluation and life-cycle assessment of poly(3-hydroxybutyrate) production within a biorefinery concept using sunflower-based biodiesel industry by-products

This study presents techno-economic evaluation of a biorefinery concept using biodiesel industry by-products (sunflower meal and crude glycerol) to produce poly(3-hydroxybutyrate) (PHB), crude phenolic extracts (CPE) and protein isolate (PI). The PHB production cost at two annual production capacities ($12.5/kg for 2,500 t PHB/year and $7.8/kg for 25,000 t PHB/year) was not cost-competitive to current PHB production processes when the revenues derived from co-products were not considered. Sensitivity analysis projected the economic viability of a biorefinery concept that could achieve a minimum selling price of $1.1/kg PHB similar to polypropylene. The annual PHB production capacity and the identification of marketable end-uses with respective market prices for the co-products CPE and PI were crucial in attaining process profitability. Greenhouse gas emissions (ca. 0.64 kg CO_2-eq/kg PHB) and abiotic depletion potential (61.7 MJ/kg PHB) were lower than polypropylene. Biorefining of sunflower meal and crude glycerol could lead to sustainable PHB production.

Identifying economical route for crude glycerol valorization: Biodiesel versus polyhydroxy-butyrate (PHB)

Crude glycerol, a by-product of biodiesel industry, has been used for production of biodiesel and polyhydroxy-alkanoates. But question is: which product is economically favorable using crude glycerol as substrate? In this study, energy balance and economic assessment has been carried out for crude glycerol valorization for B10 biodiesel and polyhydroxy-butyrate (PHB) production. For same quantity of crude glycerol utilized, energy ratio for B10 production was higher than PHB production while unit production cost for B10 was lower than that of PHB. For 50 million L plant capacity of biodiesel, unit production cost was 0.77 $/L B10 while for 2 million kg plant capacity of PHB, unit production cost was 4.88 $/kg PHB. Thus, in present scenario production of biodiesel seems economically better than production of PHA with crude glycerol as raw material. This study is useful for researchers, environmental scientists and industries in identifying effective route for crude glycerol valorization.

Recovery of Polyhydroxyalkanoates From Single and Mixed Microbial Cultures: A Review

An overview of the main polyhydroxyalkanoates (PHA) recovery methods is here reported, by considering the kind of PHA-producing bacteria (single bacterial strains or mixed microbial cultures) and the chemico-physical characteristics of the extracted polymer (molecular weight and polydispersity index). Several recovery approaches are presented and categorized in two main strategies: PHA recovery with solvents (halogenated solvents, alkanes, alcohols, esters, carbonates and ketones) and PHA recovery by cellular lysis (with oxidants, acid and alkaline compounds, surfactants and enzymes). Comparative evaluations based on the recovery, purity and molecular weight of the recovered polymers as well as on the potential sustainability of the different approaches are here presented.

Vapor-phase conversion of aqueous 3-hydroxybutyric acid and crotonic acid to propylene over solid acid catalysts

Vapor phase conversion of 3-hydroxybutyric and crotonic acid to propylene in a continuous-flow reactor over silica–alumina and niobium catalysts demonstrates a new strategy for producing renewable fuels and chemicals from wastewater carbon.

Environmental assessment of complex wastewater valorisation by polyhydroxyalkanoates production

Polyhydroxyalkanoates (PHA) are biodegradable polymers with renewable origin that are expected to substitute conventional petrochemical plastics. However, before they are commercialized, life-cycle environmental validation is needed, to prove that there is an actual benefit with the replacement of non-renewable plastics with PHA. Nowadays, environmental evaluations assessing bioplastics production at full-scale are scarce due to the lack of data, so experimental results were used to evaluate the feasibility of PHA production employing high load wastewater. A three-stage PHA production system utilising a mixed microbial culture (MMC) was successfully operated for two years employing complex wastewater from a fish-canning industry. The results obtained were scaled-up to define and compare a circular economy scenario performance, with PHA production, with the current linear approach (i.e. effluent generation, treatment and discharge). To the best of our knowledge, this is the first time that the environmental performance of a MMC-based full-scale PHA production system using saline wastewater is evaluated. Results show an average improvement of ca. 25% for nine out of ten studied categories if the circular economy approach is implemented. The sludge management strategy was a key factor for the environmental validation of the process, and if composting is applied instead of anaerobic digestion, the improvement is reported in eight categories. When a more conservative replacement yield of fossil-based plastic was tested, the circular economy approach was the preferable option in 8 out of 10 categories. The significance of the downstream process was also confirmed by this study, although it was not a barrier to show the feasibility of producing added-value bioproducts under a circular economy approach. Finally, this work proposes new process integration strategies to reduce the environmental burdens of PHA production and increase the body of knowledge on MMC-based processes, an area where LCA case studies are still scarce.

Established and advanced approaches for recovery of microbial polyhydroxyalkanoate (PHA) biopolyesters from surrounding microbial biomass

Downstream processing for recovery of microbial polyhydroxyalkanoate (PHA) biopolyesters from biomass constitutes an integral part of the entire PHA production chain; beside the feedstocks used for cultivation of PHA-production strains, this process is currently considered the major cost factor for PHA production.

Besides economic aspects, PHA recovery techniques need to be sustainable by avoiding excessive use of (often precarious!) solvents, other hazardous chemicals, non-recyclable compounds, and energy. Moreover, the applied PHA recovery method is decisive for the molecular mass and purity of the obtained product, and the achievable recovery yield. In addition to the applied method, also the PHA content in biomass is decisive for the feasibility of a selected technique. Further, not all investigated recovery techniques are applicable for all types of PHA (crystalline versus amorphous PHA) and all PHA-producing microorganisms (robust versus fragile cell structures).

The present review shines a light on benefits and shortcomings of established solvent-based, chemical, enzymatic, and mechanical methods for PHA recovery. Focus is dedicated on innovative, novel recovery strategies, encompassing the use of “green” solvents, application of classical “PHA anti-solvents” under pressurized conditions, ionic liquids, supercritical solvents, hypotonic cell disintegration for release of PHA granules, switchable anionic surfactants, and even digestion of non-PHA biomass by animals.

The different established and novel techniques are compared in terms of PHA recovery yield, product purity, impact on PHA molar mass, scalability to industrial plants, and demand for chemicals, energy, and time.

Life Cycle Assessment and Energy Balance of a Novel Polyhydroxyalkanoates Production Process with Mixed Microbial Cultures Fed on Pyrolytic Products of Wastewater Treatment Sludge

A “cradle-to-grave” life cycle assessment is performed to identify the environmental issues of polyhydroxyalkanoates (PHAs) produced through a hybrid thermochemical-biological process using anaerobically digested sewage sludge (ADSS) as feedstock. The assessment includes a measure of the energy performance of the process. The system boundary includes: (i) Sludge pyrolysis followed by volatile fatty acids (VFAs) production; (ii) PHAs-enriched biomass production using a mixed microbial culture (MMC); (iii) PHAs extraction with dimethyl carbonate; and iv) PHAs end-of-life. Three scenarios differing in the use of the syngas produced by both pyrolysis and biochar gasification, and two more scenarios differing only in the external energy sources were evaluated. Results show a trade-off between environmental impacts at global scale, such as climate change and resources depletion, and those having an effect at the local/regional scale, such as acidification, eutrophication, and toxicity. Process configurations based only on the sludge-to-PHAs route require an external energy supply, which determines the highest impacts with respect to climate change, resources depletion, and water depletion. On the contrary, process configurations also integrating the sludge-to-energy route for self-sustainment imply more onsite sludge processing and combustion; this results in the highest values of eutrophication, ecotoxicity, and human toxicity. There is not a categorical winner among the investigated configurations; however, the use of a selected mix of external renewable sources while using sludge to produce PHAs only seems the best compromise. The results are comparable to those of both other PHAs production processes found in the literature and various fossil-based and bio-based polymers, in terms of both non-biogenic GHG emissions and energy demand. Further process advancements and technology improvement in high impact stages are required to make this PHAs production process a competitive candidate for the production of biopolymers on a wide scale.

The SPPD-WRF Framework: A Novel and Holistic Methodology for Strategical Planning and Process Design of Water Resource Factories

This paper guides decision making in more sustainable urban water management practices that feed into a circular economy by presenting a novel framework for conceptually designing and strategically planning wastewater treatment processes from a resource recovery perspective. Municipal wastewater cannot any longer be perceived as waste stream because a great variety of technologies are available to recover water, energy, fertilizer, and other valuable products from it. Despite the vast technological recovery possibilities, only a few processes have yet been implemented that deserve the name water resource factory instead of wastewater treatment plant. This transition relies on process designs that are not only technically feasible but also overcome various non-technical bottlenecks. A multidimensional and multidisciplinary approach is needed to design water resource factories (WRFs) in the future that are technically feasible, cost effective, show low environmental impacts, and successfully market recovered resources. To achieve that, the wastewater treatment plant (WWTP) design space needs to be opened up for a variety of expertise that complements the traditional wastewater engineering domain. Implementable WRF processes can only be designed if the current design perspective, which is dominated by the fulfilment of legal effluent qualities and process costs, is extended to include resource recovery as an assessable design objective from an early stage on. Therefore, the framework combines insights and methodologies from different fields and disciplines beyond WWTP design like, e.g., circular economy, industrial process engineering, project management, value chain development, and environmental impact assessment. It supports the transfer of the end-of-waste concept into the wastewater sector as it structures possible resource recovery activities according to clear criteria. This makes recovered resources more likely to fulfil the conditions of the end-of-waste concept and allows the change in their definition from wastes to full-fledged products.

Optimization of Green Extraction and Purification of PHA Produced by Mixed Microbial Cultures from Sludge

Sludge from municipal wastewater treatment systems can be used as a source of mixed microbial cultures for the production of polyhydroxyalkanoates (PHA). Stored intracellularly, the PHA is accumulated by some species of bacteria as energy stockpile and can be extracted from the cells by reflux extraction. Dimethyl carbonate was tested as a solvent for the PHA extraction at different extraction times and biomass to solvent ratios, and 1-butanol was tested for purifying the obtained PHA at different purification times and PHA to solvent ratios. Overall, only a very small difference was observed in the different extraction scenarios. An average extraction amount of 30.7 ± 1.6 g of PHA per 100 g of biomass was achieved. After purification with 1-butanol, a visual difference was observed in the PHA between the tested scenarios, although the actual purity of the resulting samples did not present a significant difference. The overall purity increased from 91.2 ± 0.1% to 98.0 ± 0.1%.