Clara Bilbao

CO2 emissions and biomass to produce new biodegradable and renewable polymers.

Plastic plays an essential role in modern society, but it also has a significant impact on the environment and climate. The EU's transition towards a circular, resource-efficient and climate-neutral economy, together with the ambition to achieve zero pollution, has triggered a general rethink of how plastic is produced, used and managed at the end of its useful life. In this context, bio-based, biodegradable and compostable plastic is appearing in our daily lives as an alternative. Although this plastic currently accounts for only 0.5% (2.3 MT) of more than 400 million tonnes of plastic produced annually, Plastics Europe predicts that the replacement of fossil-based plastics with circular plastics from recycled and renewable raw materials will be gradual and could reach 25% by 2030 and 65% by 2050 with the right policies and support for the development of innovation projects in the plastics sector.

On the other hand, in order to achieve Europe's ambitious climate targets, CO2 emissions have to be reduced significantly in the coming years. While much of this can be achieved by investing in energy efficiency and renewable energy, the need for technologies to capture, store and use CO2 as a raw material is becoming increasingly important. This will be particularly important in sectors where it is more difficult to reduce emissions, such as cement and energy recovery from waste. In order to meet climate neutrality targets, the EU will have to be prepared to capture at least 50 million tonnes of CO2 per year by 2030, 80 million tonnes by 2040 and around 450 million tonnes by 2050. Based on these two challenges, the PREBIO2 "Renewable, BIOdegradable and BIOcompatible polycarbonates from CO2 for strategic sectors in the Basque Country" project, in which the GAIKER technology centre, member of the Basque Research & Technology Alliance (BRTA), TECNALIA (leader), the UPV/EHU, BCMaterials, NEIKER and ACLIMA are participating, aims to help develop new biodegradable and renewable polymers using CO2 emissions and biomass as raw materials.

PREBIO2, has focused on generating knowledge of the synthesis of polycarbonates, a specific type of plastic, from CO2, as well as their processing and use in different applications for agriculture, health and printed electronics. Most polycarbonates are non-renewable, non-biodegradable and are derived from bisphenol A (BPA), a substance of concern because of its potential risk to human health, according to recent reviews by the EFSA European Food Safety Agency.

This project has developed:
● Artificial Intelligence models to predict macroscopic characteristics of materials (polymers) based on their molecular design (monomer structure). The most important contribution of AI in this case is that it can significantly reduce experiment times, which will bring about a real revolution in the design of new materials.
● Processes for the synthesis of different types of polycarbonates from CO2.
● Plastic transformation processes by extrusion and 3D printing for the manufacture of biodegradable films and parts for agriculture.
 ● Composites based on CO2-derived polycarbonates and carbonaceous fillers to manufacture sensors
● Validation of the absence of cytotoxicity of the materials developed, opening the door to their use in the field of healthcare.

The continuation of the research lines started in the project and the transfer of PREBIO2 results are an opportunity to increase business competitiveness in different aspects: eco-design of products, development of more sustainable production processes, reduction in the consumption of fossil raw materials and direct reduction of CO2 emissions, in line with the European ecological transition objectives, which will bring about a profound change in current production models.

With a budget of more than €600,000 and a duration of 2 years, PREBIO2 has received funding from the Elkartek Collaborative Research grant programme of the Basque Government's Department of Economic Development, Sustainability and Environment.

GAIKER's work
The GAIKER Technology Centre, an expert in the development of materials and applications based on functional, sustainable and bio-based polymers, is working on the research of formulation activities using compounding technologies for the new 100% renewable polycarbonates to adapt them to the different transformation and functionality processes required in the target applications. It also deals with 3D printing and extrusion techniques for obtaining biodegradable sheets and films for agricultural applications or in sensors with conductive and piezo-resistive characteristics based on the new polycarbonates.

The European FENICE project aims to develop battery boxes that are recyclable, lightweight and fire resistant.

The GAIKER Technology Centre, member of the Basque Research & Technology Alliance, BRTA, is participating in the European Fire Resistant Environmental Friendly Composites (FENICE) project, the aim of which is to develop lighter and safer battery boxes for the automotive sector, which are recyclable thanks to the use of sustainable and innovative materials.

This research stems from the need to find efficient and affordable solutions to build lighter and fire resistant battery boxes for the electrification of vehicles. It involves 10 international partners who will be responsible for developing and designing their own process know-how to a TRL8 technology maturity level (complete and certified system through testing and demonstration in a real environment).

In the course of the project, different materials based on fibre-metal laminates (FML) and innovative composites with advantages in terms of sustainability and safety will be developed. For the production of these materials, pre-impregnated glass fibres and basalt will be used to ensure a competitive cost of the final material and a reduction in environmental impact.

The main reason for the choice of FML materials is that they have good fire performance properties. In addition to FML, this research also proposes the use of reinforced geopolymers as another solution for the manufacture of battery boxes, which also have excellent thermal properties and reaction to fire.

GAIKER, expert in laboratory tests for the characterisation of materials, has a reaction to fire laboratory that is accredited by ENAC and by the European entity ILAC-MRA. Its task in this project will be to carry out fire tests on the materials developed, as well as mechanical tests on the specimens, before and after their exposure to fire, to observe their residual resistance.

The FENICE project, which started in 2022 and will end in 2025, has been funded by the European Institute of Innovation and Technology (EIT) under Horizon 2020, the EU's Framework Programme for Research and Innovation.

More information on the project at:https://www.fenice-composites.eu/

The NEOPLAST2 project is researching the basis to provide the Basque industrial sector with ways of closing the cycles of plastic materials by applying chemical recycling technologies, treating their waste and generating valuable products.

The GAIKER Technology Centre, a member of the Basque Research & Technology Alliance, BRTA, is the coordinator of the NEOPLAST 2 project whose objective is to carry out research to develop, improve and adapt chemical recycling processes that facilitate the conversion of different plastic waste into high quality resources, capable of meeting the specifications demanded by the most demanding secondary raw material markets. The aim is to generate knowledge so that the industrial secor can make a better, more sustainable and circular use of plastic materials.

Improving the management of plastic waste has become a global requirement because of its impact on people, ecosystems and the natural environment. Chemical recycling has been confirmed as part of the solution, both to make use of plastic waste that is difficult or unfeasible to recycle by conventional mechanical means, and to obtain chemically recycled products that are virtually indistinguishable from the initial raw materials.

The NEOPLAST 2 project, which is currently addressing the product generation and quality improvement phases, was set up to research and develop different chemical recycling processes to their full extent. In particular, work is being carried out to increase the selectivity of solvolysis reactions of plastic consisting of condensation polymers or of pyrolysis and gasification processes of plastic mixtures, and also to define adsorption or extraction operations that succeed in purifying substances and fractions, such as monomers or oils, to demonstrate that it is possible, feasible and environmentally beneficial to produce new chemically recycled plastics.

Funded by the Basque Government, through its ELKARTEK collaborative research grant programme in 2023-2024, the NEOPLAST 2 project (Ref. KK-2020/00107), in addition to the GAIKER technology centre leading it, includes the participation of four other Basque technological agents, the Chemical Engineering Department and the Chemical Engineering and Environment Department of the UPV/EHU, TECNALIA and POLYMAT, which put forward their knowledge to convert plastic waste into products by thermochemical and solvolytic means combined with catalysis, process control, product purification or chemical synthesis.

Thanks to this research GAIKER, a reference in mechanical and chemical recycling, with extensive experience in waste characterisation and treatment, obtaining products, designing recycling schemes and scaling operations and processes, will have the full knowledge to understand and effectively apply chemical recycling by catalytic solvolysis. Specifically, by converting polyester (PET) and polyurethane (PU) waste, controlling reaction parameters and conditions and improving the grade of the resulting products, it will generate monomers and chemical products with high added value by achieving grades for the most demanding applications, such as the synthesis of new resins.

The SMYRNA project seeks to unite technological synergies and capabilities to keep Basque industry competitive in the field of water treatment.

The GAIKER Technology Centre, member of the Basque Research & Technology Alliance, BRTA, is participating in the "New materials and processes in physicochemical water treatment, SMYRNA” project.

The aim of this project is to bring together technological synergies and complementary capabilities among the six entities participating in the proposal for the development of new advanced materials and processes in the field of water treatment. The aim is to relaunch Basque industry through the development of new materials and processes in physicochemical treatment technologies.

The new regulations on water treatment foster the re-use and efficiency in the use of water in industrial processes. In the coming years, this will require the adaptation of these processes in terms of water saving through re-use and resource recovery of critical materials, biomaterials derived from sewage sludge and energy generated from biogas. There is a need to move from a concept of treatment for landfill to a concept of treatment for re-use, which leads to the need to address the following challenges:
•    Develop new materials to increase the efficiency of existing water treatment processes.
•    Eliminate emerging compounds present in the water and which may pose risks to the environment or to health.
•    Guarantee the sanitary quality of treated water
•    Increase the energy efficiency of the processes while facilitating the recovery of value-added compounds in liquid streams.

Facing these challenges means addressing them with a vision of sustainability, adopting technologies that reduce the use of chemical compounds and energy.

The SMYRNA project seeks to address these challenges and to do so, it proposes different strategic lines, such as the development of materials for their incorporation in water treatment systems and the development of new water treatment schemes for the elimination of compounds of emerging concern (CEC), pathogens and for the recovery of materials.

Funded by the Basque Government as part of the Elkartek collaborative research grant programme, the SMYRNA project will conclude at the end of this year. GAIKER, as an expert in advanced physicochemical treatment systems and water re-use technologies, will be responsible for developing new materials for the filtration and treatment of water by means of additive manufacturing and membrane modification and for testing and validating the materials developed. On the other hand, it will evaluate different treatments of emerging pollutants by means of advanced oxidation, adsorption and membrane separation processes. It will also carry out different water disinfection systems and assess their toxicity. Finally, it will collaborate in the simulation and modelling of the different innovative water treatment processes evaluated.

A new edition of in-cosmetics Global will be held in Paris from 16th to 18th April

 GAIKER, member of the Basque Research & Technology Alliance (BRTA), will be present at the latest edition of in-cosmetics Global to be held in Paris from 16th to 18th April. 

The Centre will present its range of R&D&I services in the field of dermo-cosmetics at a stand shared with Dr. Goya Análisis and Anmar Clinical Services. in-cosmetics Global is the world's leading event for personal care ingredients. This event brings together leading ingredient suppliers with finished product manufacturers to inspire tomorrow's cutting-edge cosmetics.
Visit us at Stand 1U85!

>> Further information

With the Plastic2Plastic project, pyrolysis oils have been obtained from plastic waste for use as feedstock in the refinery sector and petrochemical industry.

The Plastic2Plastic project in which the GAIKER Technology Centre, member of the Basque Research & Technology Alliance, BRTA, has participated along with Zorroza Gestión S.L., the project leader, and Petronor, has come to an end with satisfactory results.

Plastic2Plastic started in 2021 with the aim of obtaining pyrolysis oils of sufficient quality for the manufacture of new products from plastic waste destined for landfill. This would give a second life to such waste and provide savings on raw materials and energy.

This was a continuity project, as GAIKER and PETRONOR had also been working on the REQUIPLAST project, which had studied the use of reject flows, with a high plastic content, to obtain oils with a homogeneous and controlled composition by means of the pyrolysis process.

This new research, financed by the Basque Government's Public Company for Environmental Management, Ihobe, as part of its circular eco-innovation aid programme, has addressed some of the key aspects previously identified in REQUIPLAST, such as:
The preparation and conditioning of waste for the subsequent pyrolysis process based on composition and morphology criteria.
The development of a robust and simple process that operates at moderate temperature and pressure conditions and which allows high yields of pyrolysis oils of a quality accepted by industrial pyrolysis oil conditioning facilities, for use as subsequent material.
The verification and control of the quality of the oils produced.
The evaluation of the options for material recovery of the by-products, such as the carbonaceous solid.

GAIKER has extensive experience in the development of processes for the chemical recycling of plastic, and also has a wide variety of sorting and conditioning equipment and pilot plants for scaling up thermochemical pyrolysis processes. For this reason, it has been responsible for both the definition of the waste sorting and conditioning processes and the optimisation of the selective pyrolysis process in this project. It has also analysed the pyrolysis oils and the carbonaceous product obtained in order to evaluate options for material recovery.