PHA is not just a bioplastic!

Polyhydroxyalkanoates (PHA) have evolved into versatile biopolymers, transcending their origins as mere bioplastics. This extensive review delves into the multifaceted landscape of PHA applications, shedding light on the diverse industries that have harnessed their potential. PHA has proven to be an invaluable eco-conscious option for packaging materials, finding use in films foams, paper coatings and even straws. In the textile industry, PHA offers a sustainable alternative, while its application as a carbon source for denitrification in wastewater treatment showcases its versatility in environmental remediation. In addition, PHA has made notable contributions to the medical and consumer sectors, with various roles ranging from 3D printing, tissue engineering implants, and cell growth matrices to drug delivery carriers, and cosmetic products. Through metabolic engineering efforts, PHA can be fine-tuned to align with the specific requirements of each industry, enabling the customization of material properties such as ductility, elasticity, thermal conductivity, and transparency. To unleash PHA's full potential, bridging the gap between research and commercial viability is paramount. Successful PHA production scale-up hinges on establishing direct supply chains to specific application domains, including packaging, food and beverage materials, medical devices, and agriculture. This review underscores that PHA's future rests on ongoing exploration across these industries and more, paving the way for PHA to supplant conventional plastics and foster a circular economy.

Production of polyhydroxybutyrate by coupled saccharification-fermentation of inulin

Inulin is a fructose-based polysaccharide that can be found in several plant species, from grass and onions to chicory roots; thus, it has the potential to be an excellent renewable source of fructose for several industrial applications. Among them, inulin hydrolysis can be coupled to a fermentation operation to produce polyhydroxybutyrate (PHB) using Cupriavidus necator H16. This work reports the PHB production process involving chicory root inulin hydrolysis using inulinase Novozym 960 followed by a C. necator fermentation. It was found that the maximum saccharification (95% wt.) was reached at 269 U/ginulin after 90 min. The hydrolysates obtained were then inoculated with C. necator, leading to a biomass concentration of 4 g/L with 30% (w/w) polymer accumulation. Although PHB production was low, during the first hours, the cell growth and polymer accumulation detected did not coincide with a fructose concentration decrease, suggesting a simultaneous saccharification and fermentation process, potentially alleviating the product inhibition inherent to the inulinase-fructose system. The characterization of the obtained PHB showed a polymer with more homogeneous values of Mw, and better thermal stability than PHB produced using pure fructose as a fermentation substrate. The results obtained demonstrate a viable alternative carbon substrate for PHB production, opening the possibility for inulin-rich renewable feedstock valorization.

Influence of Rheological and Morphological Characteristics of Polyhydroxybutyrate on Its Meltblown Process Behavior

Polyhydroxybutyrate (PHB) is a promising biopolymer. However, processing PHB in pure form in thermoplastic processes is limited due to its rapid degradation, very low initial crystallization rate, strong post-crystallization, and its low final stretchability. In this article, we screened commercial PHBs for morphological characteristics, rheological properties, and "performance" in the meltblown process in order to reveal process-relevant properties and overcome the shortcoming of PHB in thermoplastic processes for fiber formation. An evaluation of degradation (extruded (meltblown) material vs. granules) was performed via rheological and SEC analysis. The study revealed large differences in the minimum melt temperature (175 up to 200 °C) and the grade-dependent limitation of accessible throughput on a 500 mm plant. The average fiber diameter could be lowered from around 10 μm to 2.4 μm in median, which are the finest reported values in the literature so far. It was found that the determination of the necessary process temperature can be predicted well from the complex shear viscosity. Different to expectations, it became apparent that a broader initial molar mass distribution (>8) is suitable to overcome the state-of-the art limitations of PHAs in order to stabilize fiber formation, increase the productivity, and obtain better resistance towards thermal degradation in process. Accordingly, longer polymer chain fractions could be more affected by degradation than medium and short polymer chains in the distribution. Further, a low initial narrow distributed molar mass resulted in too brittle fabrics.

Enhancing Production of Medium-Chain-Length Polyhydroxyalkanoates from Pseudomonas sp. SG4502 by tac Enhancer Insertion

Pseudomonas sp. SG4502 screened from biodiesel fuel by-products can synthesize medium-chain-length polyhydroxyalkanoates (mcl-PHAs) using glycerol as a substrate. It contains a typical PHA class II synthase gene cluster. This study revealed two genetic engineering methods for improving the mcl-PHA accumulation capacity of Pseudomonas sp. SG4502. One way was to knock out the PHA-depolymerase phaZ gene, the other way was to insert a tac enhancer into the upstream of the phaC1/phaC2 genes. Yields of mcl-PHAs produced from 1% sodium octanoate by +(tac-phaC2) and ∆phaZ strains were enhanced by 53.8% and 23.1%, respectively, compared with those produced by the wild-type strain. The increase in mcl-PHA yield from +(tac-phaC2) and ∆phaZ was due to the transcriptional level of the phaC2 and phaZ genes, as determined by RT-qPCR (the carbon source was sodium octanoate). ¹H-NMR results showed that the synthesized products contained 3-hydroxyoctanoic acid (3HO), 3-hydroxydecanoic acid (3HD) and 3-hydroxydodecanoic acid (3HDD) units, which is consistent with those synthesized by the wild-type strain. The size-exclusion chromatography by GPC of mcl-PHAs from the (∆phaZ), +(tac-phaC1) and +(tac-phaC2) strains were 2.67, 2.52 and 2.60, respectively, all of which were lower than that of the wild-type strain (4.56). DSC analysis showed that the melting temperature of mcl-PHAs produced by recombinant strains ranged from 60 °C to 65 °C, which was lower than that of the wild-type strain. Finally, TG analysis showed that the decomposition temperature of mcl-PHAs synthesized by the (∆phaZ), +(tac-phaC1) and +(tac-phaC2) strains was 8.4 °C, 14.7 °C and 10.1 °C higher than that of the wild-type strain, respectively.

A Polyhydroxybutyrate (PHB)-Biochar Reactor for the Adsorption and Biodegradation of Trichloroethylene: Design and Startup Phase

In this work, polyhydroxy butyrate (PHB) and biochar from pine wood (PWB) are used in a mini-pilot scale biological reactor (11.3 L of geometric volume) for trichloroethylene (TCE) removal (80 mgTCE/day and 6 L/day of flow rate). The PHB-biochar reactor was realized with two sequential reactive areas to simulate a multi-reactive permeable barrier. The PHB acts as an electron donor source in the first “fermentative” area. First, the thermogravimetric (TGA) and differential scanning calorimetry (DSC) analyses were performed. The PHB-powder and pellets have different purity (96% and 93% w/w) and thermal properties. These characteristics may affect the biodegradability of the biopolymer. In the second reactive zone, the PWB works as a Dehalococcoides support and adsorption material since its affinity for chlorinated compounds and the positive effect of the “coupled adsorption and biodegradation” process has been already verified. A specific dechlorinating enriched culture has been inoculated in the PWB zone to realize a coupled adsorption and biodegradation process. Organic acids were revealed since the beginning of the test, and during the monitoring period the reductive dichlorination anaerobic pathway was observed in the first zone; no chlorinated compounds were detected in the effluent thanks to the PWB adsorption capacity.

Poly(lactic acid) (PLA) and polyhydroxyalkanoates (PHAs), green alternatives to petroleum-based plastics: a review

In spite of the fact that petroleum-based plastics are convenient in terms of fulfilling the performance requirements of many applications, they contribute significantly to a number of ecological and environmental problems. Recently, the public awareness of the negative effects of petroleum-based plastics on the environment has increased. The present utilization of natural resources cannot be sustained forever. Furthermore, oil is often subjected to price fluctuations and will eventually be depleted. The increase in the level of carbon dioxide due to the combustion of fossil fuel is causing global warming. Concerns about preservation of natural resources and climate change are considered worldwide motivations for academic and industrial researchers to reduce the consumption and dependence on fossil fuel. Therefore, bio-based polymers are moving towards becoming the favorable option to be utilized in polymer manufacturing, food packaging, and medical applications. This paper represents an overview of the feasibility of both Poly Lactic Acid (PLA) and polyhydroxyalkanoates (PHAs) as alternative materials that can replace petroleum-based polymers in a wide range of industrial applications. Physical, thermal, rheological, and mechanical properties of both polymers as well as their permeability and migration properties have been reviewed. Moreover, PLA's recyclability, sustainability, and environmental assessment have been also discussed. Finally, applications in which both polymers can replace petroleum-based plastics have been explored and provided.

Characterization of Polyhydroxyalkanoates Produced at Pilot Scale From Different Organic Wastes

Polyhydroxyalkanoates (PHAs) production at pilot scale has been recently investigated and carried out exploiting different process configurations and organic wastes. More in detail, three pilot platforms, in Treviso (North-East of Italy), Carbonera (North-East of Italy) and Lisbon, produced PHAs by open mixed microbial cultures (MMCs) and different organic waste streams: organic fraction of municipal solid waste and sewage sludge (OFMSW-WAS), cellulosic primary sludge (CPS), and fruit waste (FW), respectively. In this context, two stabilization methods have been applied, and compared, for preserving the amount of PHA inside the cells: thermal drying and wet acidification of the biomass at the end of PHA accumulation process. Afterward, polymer has been extracted following an optimized method based on aqueous-phase inorganic reagents. Several PHA samples were then characterized to determine PHA purity, chemical composition, molecular weight, and thermal properties. The polymer contained two types of monomers, namely 3-hydroxybutyrate (3HB) and 3-hydroxyvalerate (3HV) at a relative percentage of 92.6-79.8 and 7.4-20.2 w/w, respectively, for Treviso and Lisbon plants. On the other hand, an opposite range was found for 3HB and 3HV monomers of PHA from Carbonera, which is 44.0-13.0 and 56.0-87.0 w/w, respectively. PHA extracted from wet-acidified biomass had generally higher viscosity average molecular weights (M v ) (on average 424.8 ± 20.6 and 224.9 ± 21.9 KDa, respectively, for Treviso and Lisbon) while PHA recovered from thermally stabilized dried biomass had a three-fold lower M v .

Recent Advances in 3D Printing of Polyhydroxyalkanoates: A Review

In the 21st century, additive manufacturing technologies have gained in popularity mainly due to benefits such as rapid prototyping, faster small production runs, flexibility and space for innovations, non-complexity of the process and broad affordability. In order to meet diverse requirements that 3D models have to meet, it is necessary to develop new 3D printing technologies as well as processed materials. This review is focused on 3D printing technologies applicable for polyhydroxyalkanoates (PHAs). PHAs are thermoplastics regarded as a green alternative to petrochemical polymers. The 3D printing technologies presented as available for PHAs are selective laser sintering and fused deposition modeling. Stereolithography can also be applied provided that the molecular weight and functional end groups of the PHA are adjusted for photopolymerization. The chemical and physical properties primarily influence the processing of PHAs by 3D printing technologies. The intensive research for the fabrication of 3D objects based on PHA has been applied to fulfil criteria of rapid and customized prototyping mainly in the medical area.

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%.

Biosynthesis of poly-3-hydroxybutyrate from grass silage by a two-stage fermentation process based on an integrated biorefinery concept

Grass silage as a renewable feedstock for an integrated biorefinery includes nutrients and carbon sources directly available in the press juice (PJ) and in lignocellulosic saccharides from the plant framework. Here, a novel two-stage fed-batch fermentation process for biosynthesis of poly-3-hydroxybutyrate (PHB) by Cupriavidus necator DSM 531 is presented. For bacterial growth, nutrient-rich PJ was employed as a fermentation medium, without any supplements. Saccharides derived from the mechano-enzymatic hydrolysis of the press cake (PC) were subjected to a lactic acid fermentation process, before the fermentation products were fed into the polymer accumulation phase. By combination of pH-stat feeding and cell recycling, the PHB content in 22 g L^-1 total-dry cells reached 39% after 32 h of cultivation. Using mimicked hydrolyzate of diluted PJ artificially supplemented with glucose and xylose, the resulting cell dry weight of 21 g L^-1 contained 42% PHB.

Conversion of polyhydroxyalkanoates to methyl crotonate using whole cells

Isolated polyhydroxyalkanoates (PHA) can be used to produce biobased bulk chemicals. However, isolation is complex and costly. To circumvent this, whole cells containing PHA may be used. Here, PHA containing 3-hydroxybutyrate and small amounts of 3-hydroxyvalerate was produced from wastewater and used in the conversion of the 3-hydroxybutyrate monomer to methyl crotonate. Due to the increased complexity of whole cell reaction mixtures compared to pure PHA, the effect of 3-hydroxyvalerate content, magnesium salts and water content was studied in order to evaluate the need for downstream processing. A water content up to 20% and the presence of 3-hydroxyvalerate have no influence on the conversion of the 3-hydroxybutyrate to methyl crotonate. The presence of Mg(2+)-ions resulted either in an increased yield or in byproduct formation depending on the counter ion. Overall, it is possible to bypass a major part of the downstream processing of PHA for the production of biobased chemicals.

Preparation and characterization of biodegradable blends of poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) and poly(butylene adipate-co-terephthalate)

Poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) (PHBH) was blended with poly(butylene adipate-co-terephthalate) (PBAT) by extrusion at different weight ratios (PHBH/PBAT: 100:0, 80:20, 60:40, 50:50, 40:60, 20:80 and 0:100). Films were then prepared from the blends and characterized in terms of their morphological, rheological, mechanical and thermal properties. The morphological and rheological results indicated that PHBH/PBAT blends are immiscible but exhibit possible molecular interaction. The crystallization temperature of PHBH in the blends decreased, indicating that the addition of PBAT inhibited the crystallization of PHBH. Blending PBAT with PHBH improved the processability compared with that of pure polymers. The mechanical properties, including tensile strength, elongation at break and tear strength, increased with increasing PBAT content. The PHBH/PBAT 20:80 blend exhibited significantly improved mechanical properties, which was due to the reinforcing and toughening effect of the finely dispersed PHBH phase.

Direct Production of Propene from the Thermolysis of Poly(β-hydroxybutyrate) (PHB). An Experimental and DFT Investigation

We demonstrate a synthetic route toward the production of propene directly from poly(β-hydroxybutyrate) (PHB), the most common of a wide range of high-molecular-mass microbial polyhydroxyalkanoates. Propene, a major commercial hydrocarbon, was obtained from the depolymerization of PHB and subsequent decarboxylation of the crotonic acid monomer in good yields (up to 75 mol %). The energetics of PHB depolymerization and the gas-phase decarboxylation of crotonic acid were also studied using density functional theory (DFT). The average activation energy for the cleavage of the R'C(O)O-R linkage is calculated to be 163.9 ± 7.0 kJ mol(-1). Intramolecular, autoacceleration effects regarding the depolymerization of PHB, as suggested in some literature accounts, arising from the formation of crotonyl and carboxyl functional groups in the products could not be confirmed by the results of DFT and microkinetic modeling. DFT results, however, suggest that intermolecular catalysis involving terminal carboxyl groups may accelerate PHB depolymerization. Activation energies for this process were estimated to be about 20 kJ mol(-1) lower than that for the noncatalyzed ester cleavage, 144.3 ± 6.4 kJ mol(-1). DFT calculations predict the decarboxylation of crotonic acid to follow second-order kinetics with an activation energy of 147.5 ± 6.3 kJ mol(-1), consistent with that measured experimentally, 146.9 kJ mol(-1). Microkinetic modeling of the PHB to propene overall reaction predicts decarboxylation of crotonic acid to be the rate-limiting step, consistent with experimental observations. The results also indicate that improvements made to enhance the isomerization of crotonic acid to vinylacetic acid will improve the direct conversion of PHB to propene.

Kinetics of Nonisothermal Degradation of Some Polymer Composites: Change of Entropy at the Formation of the Activated Complex from the Reagents

Studying the nonisothermal kinetics of degradation of rice husks in air or nitrogen atmosphere, polypropylene and tetrafluoroethylene-ethylene copolymer filled with different quantities of rice husks flour or the products of its thermal degradation, namely “white” or “black” rice husks ash, a linear dependence was observed between the and , known as the kinetic compensation effect or theta rule. A linear relationship was also established between and the change of the entropy for the formation of the activated complex from the reagents. These dependences are related to the assumption of identical kinetic mechanisms of thermal degradation of the composites studied. The negative values of obtained show that the activated complex is a “more organized” structure than the initial reactants and that these reactions may be classified as “slow” ones. It may be concluded that the products of the thermal degradation of rice husks in a fluidized bed reactor can successfully replace the more expensive synthetic fillers to obtain different polymer composites. These polymer composites can lead to the futuristic “organic-inorganic hybrid materials” with specific properties.

Bacterial synthesis of biodegradable polyhydroxyalkanoates

Various bacterial species accumulate intracellular polyhydroxyalkanoates (PHAs) granules as energy and carbon reserves inside their cells. PHAs are biodegradable, environmentally friendly and biocompatible thermoplastics. Varying in toughness and flexibility, depending on their formulation, they can be used in various ways similar to many nonbiodegradable petrochemical plastics currently in use. They can be used either in pure form or as additives to oil-derived plastics such as polyethylene. However, these bioplastics are currently far more expensive than petrochemically based plastics and are therefore used mostly in applications that conventional plastics cannot perform, such as medical applications. PHAs are immunologically inert and are only slowly degraded in human tissue, which means they can be used as devices inside the body. Recent research has focused on the use of alternative substrates, novel extraction methods, genetically enhanced species and mixed cultures with a view to make PHAs more commercially attractive.

Recent Advances in Polyhydroxyalkanoate Production by Mixed Aerobic Cultures: From the Substrate to the Final Product

Numerous bacteria have been found to exhibit the capacity for intracellular polyhydroxyalkanoates (PHA) accumulation. Current methods for PHA production at the industrial scale are based on their synthesis from microbial isolates in either their wild form or by recombinant strains. High production costs are associated with these methods; thus, attempts have been made to develop more cost-effective processes. Reducing the cost of the carbon substrates (e.g., through feeding renewable wastes) and increasing the efficiency of production technologies (including both fermentation and downstream extraction and recovery) are two such examples of these attempts. PHA production processes based on mixed microbial cultures are being investigated as a possible technology to decrease production costs, since no sterilization is required and bacteria can adapt quite well to the complex substrates that may be present in waste material. PHA accumulation by mixed cultures has been found under various operational conditions and configurations at both bench-scale and full-scale production. The process known as "feast and famine" or as "aerobic dynamic feeding" seems to have a high potential for PHA production by mixed cultures. Enriched cultures submitted to a transient carbon supply can synthesize PHA at levels comparable to those of pure cultures. Indeed, the intracellular PHA content can reach around 70% of the cell dry weight, suggesting that this process could be competitive with pure culture PHA production when fully developed. Basic and applied research of the PHA production process by mixed cultures has been carried out in the past decade, focusing on areas such as microbial characterization, process configuration, reactor operational strategies, process modeling and control, and polymer characterization. This paper presents a review of the PHA production process with mixed cultures, encompassing the findings reported in the literature as well as our own experimental results in relation to each of these areas.