BIO-SURFEST

Development of novel environmentally added-value surfactants and esters by biotechnological processes from fats and oils waste streams

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 Obiettivo del progetto (Objective)

'Currently, different origin waste oils have been used mostly as animal feed, raw material for soap makers, and feed stock for fatty acid production. The existent patents and commercial processes to make fatty acids from waste oils always refers to hydrolysis and acidification steps using strong acids such as sulphuric or hydrochloridic acids, producing a mixture of fatty acids, inorganic salts, water, and other small components such as glycerine or phospholipids. Waste technical fats can provide a raw material basis for the production of surfactants. This amount of waste oil will serve as raw material for obtaining bio-surfactant and ester oils by biotechnological processes. This project Bio-SURFEST will develop two biotechnological processes at semi-industrial scale in order to produce two different classes of bio-products, bio-surfactants and ester oils (non useful for biodiesel production). Bio-surfactants will be produced by fermentative process and ester oils will be produced by enzymatic catalysis. Both biotechnological methods will use as raw materials or feedstock fry waste oil or technical fats. The main goal of the project Bio-SURFEST is to obtain high-value compounds such as bio-surfactants and ester oils from waste oils or technical fats, which represent a low value residue from a great variety of industries like hotels, restaurants, vegetable oil industry, biodiesel producers, etc. The aim of the present project is to determine suitable technical and economical production methods in order to obtain biosurfactants and other bio-products of high added value. Bio-SURFEST is focusing on the biotechnological optimisation of bio-products synthesis, using techniques such as fermentation and enzymatic catalysis. Using this approach, tailor-made bio-products will be obtained, purified and finally tested for their use in different applications.'

Introduzione (Teaser)

Hotels, restaurants, vegetable oil industries and biodiesel producers are sources of cheaper oils and oil wastes. Use of such waste streams to produce bioproducts' such as biosurfactants and ester oils could sustainably reduce production costs.

Descrizione progetto (Article)

The EU-funded http://www.biosurfest.com (BIO-SURFEST) project worked on the semi-industrial scale production of biosurfactants and ester oils using such waste streams. The fermentation process wwas developed to produce biosurfactants and enzymatic catalysis was used to manufacture esters oils.

Comprehensive characterisation of waste streams revealed that oil wastes such as waste cooking oil and restaurant grease are the most suitable substrates for producing biosurfactants and ester oils. Other waste streams including olive oil mill wastewater and cheese whey were also investigated for use as raw material.

Requirements and specifications for the two biotechnological processes were determined for lab scale production. The biosurfactants should be non-toxic, ethylene oxide-free, sulphate-free, biodegradable, and capable of withstanding extreme conditions of temperature, pH and salinity. Ester oils need to be biodegradable, non-toxic, and compatible with materials like plastics, resins, rubbers and elastomers. Based on market needs, researchers focused on producing biosurfactants such as rhamnolipid and sophorolipid and ester oils such as ethyl esters and monoacylglycerides.

After successful validation of fermentative and enzymatic catalysis at lab scale, pilot plants were designed to up-scale production. Process ptimisation and validation followed and bioproducts were produced with good yield and consistent quality.

In parallel, the team carried out environmental impact assessment, techno-economic analysis and a life cycle assessment to ensure optimal exploitation of these bioprocesses and bioproducts. Bio-based products were found to be more expensive to produce than their non-bio-based counterparts due to issues with economy of scale and technology maturity.

Two main business models were proposed by project partners involving the commercial development of such plants and production of bioproducts'. Safety, non-toxicity and eco-friendliness of these methods and products feature highly in the exploitation strategy.

The EU bio-based market is estimated to be worth billions of EUROs and this market is expected to grow. Besides increasing employment opportunities, product and process commercialisation will enhance EU competitiveness in several industrial sectors.