Toray Industries, Inc. and PTT Global Chemical Public Company Limited (Headquarters: Bangkok, Thailand, CEO: Mr. Narongsak Jivakanun hereinafter referred to as “GC”) have established a first-of-a-kind series of manufacturing technologies for bio-based adipic acid (see note 1) through the fermentation of bio-muconic acid (note 2) using starch residues (note 3) and 100% bio-based nylon 66 using it.
As there is a global demand to reduce greenhouse gas emissions and reduce dependence on fossil resources, the chemical industry is attracting attention to the effective use of renewable resources such as biomass raw materials that do not compete with food. Cassava pulp (note 4) is a residue discharged in the process of producing starch from cassava, which is grown in large quantities for food applications, and is a raw material that can be expected to be stably supplied. By utilizing such unused resources, it is less likely to lead to new farmland expansion, which will lead to a reduction in the risk of indirect land use change (ILUC). To this end, the development of technology is also important to leverage unused resources converting to valued products.
The following is an overview of the demonstration tests conducted by the two companies along a series of manufacturing processes in establishing this technology.
| Engineering | Body | Implementation details and points |
|---|---|---|
| ① Saccharification | Toray | We have demonstrated the production of 5 dry-tons of glucose sugar per day using 66 tons of starch residue (cassava pulp) with approximately 85% moisture as raw materials. Energy-saving and high-quality saccharification technology using separation membranes. |
| ② Fermentation | GC | We can stably produce a fermented broth of bio-muconic acid with high efficiency from sugars made from GC’s proprietary strain. This showed the successful validation of technology from lab through to pilot scale fermenter (approx. 50 m³). |
| ③ Refinement | Collaboration between the two companies | High-purity bio-muconic acid is refined from the fermentation broth using the unique technology developed by both companies. The high quality of refined bio-muconic acid can be converted to bio-based adipic acid. |
| ④ Chemical Conversion | Toray | Bio-based adipic acid is produced from bio-muconic acid. Ensuring the high purity quality required for nylon 66 polymerization. |
| ⑤ Polymerization and fibrosis | Toray | Successful polymerization and fiber processing of nylon 66 on a lab scale using bio-based adipic acid and bio-based hexamethylenediamine (HMDA). |
In the future, we will work to scale up and reduce costs in the production of bio-muconic acid and bio-based adipic acid, and Toray will continue to build a supply chain with the goal of starting sales of textile products using 100% bio-based nylon 66 by FY2028.
Toray and GC will continue to work closely together to actively work towards the realization of a recycling-oriented society through the development and dissemination of materials derived from biomass resources.
This content is the result obtained by the Ministry of Economy, Trade and Industry (METI) “FY2023 Supplementary Budget Project for Future-Oriented Co-Creation in the Global South”.
Figure: Flow from cassava pulp (starch residue) to nylon 66 product
Reference
November 11, 2024
Toray and PTT Global Chemical Agree to Explore Mass Production Technology to Build Supply Structure for Non-Edible Biomass-Derived Nylon
https://www.toray.com/news/article.html?contentId=x1tdy8vx
Notes
- Adipic acid
The main raw material of nylon 66 (polyamide 66). - Muconic acid
It is a type of C6 compound derived from biomass resources and is used as a raw material for adipic acid and other materials. - Starch residue
It refers to “residue” such as fiber that is discharged in the process of extracting and producing starch from potatoes and grains. - Cassava pulp
Substances that are not originally intended to be produced directly in the process of producing starch from Cassava. Cassava pulp contains polysaccharides such as starch, cellulose, and pectin, and can be hydrolyzed by enzymes to produce sugars that are raw materials for fermentation.
