Periodic Reporting for period 3 - VIVALDI (innoVative bIo-based chains for CO2 VALorisation as aDded-value organIc acids)
Periodo di rendicontazione: 2024-06-01 al 2025-05-31
VIVALDI proposes an innovative integrated biotechnological solution for the conversion of off-gas emissions into CO2-based chemicals. A multidisciplinary consortium of 16 partners from 9 EU countries representing technology developers, bio-based industries (BIs), end-users and knowledge hubs is working together to present BIs with an opportunity to shift towards circular economy by turning their CO2 emissions into added-value products, which can be again utilised e.g. as raw materials in the production of biomaterials. VIVALDI uses real off-gas emissions from four key BI sectors (Pulp & Paper, Food & Drinks, Bioethanol and Biochemicals) to produce 4 industrially relevant organic acids with different applications and market penetration: lactic acid (LA), succinic acid (SA), itaconic acid (IA) and 3-hydroxypropionic acid (3-HP). After capturing the CO2 from industrial off-gas streams, it will be electrochemically converted to methanol (MeOH) and formic acid (FA), which can serve as feedstocks for the bioproduction of the targeted acids. The acid production is carried out by a microbial fermentation process with specific engineered yeast strains of Pichia pastoris. Nutrients required for the bioproduction are recovered from the wastewaters using microbial electrochemical technologies, in which microorganisms are catalyzing electrochemical reactions . The individual technologies will be first optimized and the electrochemical reduction of CO2 to methanol and formic acid will then be integrated to the bioproduction step making it possible to produce added-value compounds from CO2 in the same environment. Finally, after custom-made downstream processing, the organic acids will be industrially benchmarked to ensure that they comply with current industrial standards. The benefits of VIVALDI’s implementation will be quantified with a comprehensive sustainability and circularity assessment (technical, environmental and socio-economic). To alleviate the adoption of VIVALDI’s solutions, market opportunities and regulation bottlenecks for the early adoption will be identified. A short animation presenting the VIVALDI project has also been launched and is available here (https://www.youtube.com/watch?v=u658_V1vasg(si apre in una nuova finestra)).
The project consistently surpassed the current state of the art (SOTA) across its individual technological steps. The first major outcome was in CO2 conversion to C1-Building Blocks, primarily formic acid (FA). A chemo-enzymatic CO2 purification process achieved over 95% CO2 purity from real industrial off-gases, with a 25% energy cost reduction for solvent regeneration. The electrochemical CO2 reduction for FA production demonstrated robust lab-scale performance, reaching 0.77 g/(L·h) with high efficiencies (85% coulombic, 41% carbon conversion). Crucially, the FA production process showed scalability (up to 400 cm2 electrodes) and exceptional long-term stability, operating for over 4000 hours with high Faradaic efficiency, advancing this technology to TRL 5.
The second key outcome focused on bioelectrochemical nutrient recovery from industrial wastewater. Ammonia recovery rates significantly exceeded targets, reaching up to 175 g N/m2/d. The energy demand was remarkably low at 1.5 kWh/kg N, alongside efficient hydrogen (H2) production. Recovered nutrients were successfully validated as microbial feedstock for fermentation processes, moving this component to TRL 5.
Thirdly, in yeast-based fermentation for organic acids, engineered P. pastoris strains achieved impressive titers, with SA and IA surpassing 100 g/L, and high theoretical yields (97% for SA, 77% for IA). A significant breakthrough was the successful single-reactor integration of CO2 reduction, fermentation, and IA production, simplifying the process and advancing it to TRL 5.
Fourth, novel downstream processing validated high purities for all four organic acids (LA >90%, SA >96%, IA >97%, 3-HP >96%). Bio-succinic acid was successfully used for biodegradable bioplastics, and bio-lactic acid for livestock growth, demonstrating real-world applicability and reaching TRL 5.
A comprehensive sustainability assessment provided robust data confirming the positive environmental, economic, and social balance of VIVALDI solutions, identifying exploitable products and technologies. This multi-faceted assessment identified two out of five organic acids and bioelectrochemical system technologies as economically exploitable with payback periods under 20 years, with FA profitability sensitive to electricity prices. The project also assessed socio-economic impacts across five case study locations.
Proactive engagement with stakeholders, including two innovation workshops and bilateral meetings with innovation/investment companies, fostered market feedback and collaboration. The project also identified regulatory barriers and contributed to shaping supportive policy frameworks for carbon capture and utilization technologies. Synergies were created with six other Horizon 2020 projects on decarbonization.
Finally, VIVALDI partners made extensive communication and dissemination efforts, completing all planned activities by M48. This included collaborations with other Horizon 2020 projects, 3 thematic workshops, 4 training sessions/webinars, 71 participations in scientific conferences/workshops, 26 publications in peer-reviewed scientific journals, 10 news releases, and 8 bilateral meetings with stakeholders.
The second key outcome focused on bioelectrochemical nutrient recovery from industrial wastewater. Ammonia recovery rates significantly exceeded targets, reaching up to 175 g N/m2/d. The energy demand was remarkably low at 1.5 kWh/kg N, alongside efficient hydrogen (H2) production. Recovered nutrients were successfully validated as microbial feedstock for fermentation processes, moving this component to TRL 5.
Thirdly, in yeast-based fermentation for organic acids, engineered P. pastoris strains achieved impressive titers, with SA and IA surpassing 100 g/L, and high theoretical yields (97% for SA, 77% for IA). A significant breakthrough was the successful single-reactor integration of CO2 reduction, fermentation, and IA production, simplifying the process and advancing it to TRL 5.
Fourth, novel downstream processing validated high purities for all four organic acids (LA >90%, SA >96%, IA >97%, 3-HP >96%). Bio-succinic acid was successfully used for biodegradable bioplastics, and bio-lactic acid for livestock growth, demonstrating real-world applicability and reaching TRL 5.
A comprehensive sustainability assessment provided robust data confirming the positive environmental, economic, and social balance of VIVALDI solutions, identifying exploitable products and technologies. This multi-faceted assessment identified two out of five organic acids and bioelectrochemical system technologies as economically exploitable with payback periods under 20 years, with FA profitability sensitive to electricity prices. The project also assessed socio-economic impacts across five case study locations.
Proactive engagement with stakeholders, including two innovation workshops and bilateral meetings with innovation/investment companies, fostered market feedback and collaboration. The project also identified regulatory barriers and contributed to shaping supportive policy frameworks for carbon capture and utilization technologies. Synergies were created with six other Horizon 2020 projects on decarbonization.
Finally, VIVALDI partners made extensive communication and dissemination efforts, completing all planned activities by M48. This included collaborations with other Horizon 2020 projects, 3 thematic workshops, 4 training sessions/webinars, 71 participations in scientific conferences/workshops, 26 publications in peer-reviewed scientific journals, 10 news releases, and 8 bilateral meetings with stakeholders.
VIVALDI is developing breakthrough technologies for the conversion of CO2 into added-value chemicals and it is aiming to be a pioneer in triggering off the transformation of current biorefineries into plants with negative GHG emissions. The advances made will drive the increase of the technology readiness level (TRL) of the technologies from 3 up to 5. The VIVALDI concept is expected to set the path towards the implementation of a new CO2-based industrial sector that is environmentally and economically competitive with the current fossil-based alternatives, fostering the transition into carbon negative economy. We envisage that the VIVALDI approach can be extended also either to other bioproducts or to other industry sectors, creating new value chains for the CO2 utilisation sector. VIVALDI will also boost cooperation within strategic partners —major emitters, technology adopters and end-users of bio-based products—with tailor-made communication activities. Nutrients required for the fermentation will be recovered from industrial wastewaters using novel microbial electrochemical technologies for ammonia recovery and cation recovery. Methodologies developed for the downstream processing of the organic acids are focusing on minimizing the addition of chemicals and waste generation. Besides the expected impacts related to the mitigation of GHG emissions and the decrease of the energy demand, VIVALDI will promote industrial symbiosis, fostering efficient and sustainable energy and material reuse and the reduction of environmental footprint of the industries. To ensure that the process is comprehensively evaluated, VIVALDI is tackling the social, economic and institutional/regulatory dimensions of CO2 valorisation and the consortium is actively engaging with multiple societal actors (researchers, industry, policymakers and civil society) and other relevant stakeholders.