NSF convergence accelerator track m: nature inspired BIO-manufactured terminal hydroxylated fatty acid copolyesters

This National Science Foundation (NSF) Convergence Accelerator Track M award of $649,990 to Rensselaer Polytechnic Institute (RPI) supports the development and commercialization of a family of sustainable bio-based plastics derived from hydroxy fatty acids. Key activities include scaling up monomer synthesis, conducting polymer characterization and recycling assessments, and performing techno-economic and life cycle analyses. RPI is collaborating with Danimer Scientific, a bioplastics manufacturer, to scale up fermentation and polymerization processes. The Ohio State University is contributing techno-economic and life cycle assessments. This project is funded under the NSF Technology, Innovation, and Partnerships program (CFDA 47.084), which supports translational research to address national and societal challenges. The intended outcome is the creation of a versatile, recyclable bioplastic material inspired by natural cutin polymer networks.

Abstract

This project brings together a diverse, intellectually and technically driven group of scientists, engineers, staff from a biobased plastic manufacturer unified by the common goal of further developing and commercializing a versatile family of sustainable plastics based on poly(?-hydroxyfatty acids), p(?-hofas). These polymers were inspired by cutin polymer networks that function to waterproof and protect leaves and fruits and consist of ?-hofa building blocks. Insights from cutin structure, that evolved over millions of years, provide an approach to RE-design polyethylene (PE) to expand its properties that have proved highly valuable in many applications. Cutin has long methylene spacers, a characteristic of PE, while incorporating groups along polymer chains that can be cleaved by chemical or biochemical processes. Combining methylene spacers with readily cleavable groups results in plastics that provide desirable characteristics of both PE and cutin. The intended result is p(?-hofas) and copolymers that are designed for reprocessing for the next life cycle. Efforts will focus on research plan development, team formation leading to a proof-of-concept and meetings for training and cross-cohort collaboration. The research program will provide proof of concept through a convergent research approach. The activities during phase 1 will also identify gaps in skills/capabilities that guide the selection of additional team members. The following describes tasks that will be completed during the phase 1 program. Using methyl-tetradecanoic acid as the feedstock, the project team will upscale monomer synthesis from 1 l to 100 l. This work will provide insights into scale-up activities to be performed in phase 2. Downstream processing (DSP) and monomer purification will be performed at multiple scales. Polymerizations will be performed to provide prototype materials. These materials will be used to benchmark the physico-mechanical properties of prototype materials to those of current biodegradable bioplastics. Investigations will assess the chemical and biological recycling of p(?-HOC14:0). System-level techno-economic analyses (tea) and life cycle assessment (LCA) will be performed. Also, phase 1 participants in the workforce development program will initiate activities and develop detailed plans for implementation. An overall review by the PI, in consultation with the full program team, will determine required team expansions. This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the foundation's intellectual merit and broader impacts review criteria.- subawards are planned for this award.