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The present invention is in the field of recycling plastics.
The following references are cited throughout this disclosure using numbers inside brackets (e.g., [1]).
Polyester, containing the ester functional group in every repeating unit, is a major industrial polymer with an annual global production of approximately 57 million metric tons. Polyethylene terephthalate (PET) is the most prevalent polyester, claiming about 50% of total polyester production [3,4]. Despite being ranked as the most recycled plastic in the US, the recycling rate of PET is less than 20% [5]. On the other hand, polylactic acid (PLA, a polyester from renewable sources) represents one of the largest sectors in the emerging bioplastic business. In 2021, the PLA market reached 0.46 million metric tons and is speculated to expand [6]. PLA is a desirable plastic to consumers as it is bio-based and degradable. In reality, degradation of PLA was found to be very slow in landfills and soil, and mostly negligible in seawater [7-10]. PLA is considered biodegradable only under high temperature and moisture conditions—accessible in industrial composting facilities [11]. Paradoxically, because PLA is considered as a (bio)degradable polymer and has a relatively lower volume than other conventional plastics, there is a lack of motivation to recycle PLA. As the market share for PLA rises, we foresee an increasing amount of PLA waste ending up in landfills or natural environments should no PLA-specific recycling action take place. This will create new plastic wastes and is against the main motivation to use PLA.
A key challenge in plastic recycling is the mixing of very different types of plastics in the recycling stream. With the growth of the PLA market, there has been an increasing concern that more PLA will be present as contaminants that disrupt existing PET recycling processes [12]. In particular, similar appearances, chemical functional groups, and applications of PET and PLA lead to significant waste stream separation challenges in plastic recycling facilities including mechanical recycling of PET [12, 13]. The ramification of this contamination is devaluing of recycled feedstock, and compromised properties of recycled polymers.
Chemical recycling has been highlighted as an alternative route in dealing with cross-contaminated plastics. The depolymerized products, usually monomeric precursors of PET and PLA, can be separated and resynthesized into new polymers that maintain properties comparable to virgin plastics. In doing so, this process creates a venue to close the recycling loop of cross-contaminated PET and PLA.
The majority of chemical recycling of polyesters involves catalysts such as metallic and organocatalysts, with the latter being promising “green” substitutes for traditional metallic catalysts [14]. Among the organocatalysts, ionic liquids (ILs, organic salts of loosely coordinated ions with melting point below 100° C.) have proven to be catalytically efficient and are able to achieve high depolymerization and product yield [15]. One of the most important characteristics of ILs is tunable properties, a function of the specific combinations of cations and anions, making them task-specific.
While many studies have utilized ILs to depolymerize PET and PLA, the focus was restricted to individual polymers. Moreover, a majority of these depolymerization efforts employed either pure ILs or ILs in organic solvents, such as ethylene glycol and alcohols [16-18]. Surprisingly, there has been relatively little emphasis on hydrolytic depolymerization of polyesters using ILs. Water is a good solvent for chemical reactions in terms of cost, process safety, and environmental impact. Specific imidazolium-based ILs were found to improve the solubility of PET and PLA in water and subsequently facilitate the depolymerization [19, 20].
Applying water as the solvent also allows the potential biological use of depolymerized PET/PLA via microorganisms. Some previous studies disclosed the use of terephthalate as the carbon source with the terephthalate degradation pathway in microbes [21-24]. For example, up-cycling of PET to the biodegradable plastic PHA was achieved with Pseudomonas umsongensis sp. GO16 with a maximal PHA accumulation rate at 8.4 mg PHA/I/h for 12 h [25]. Lactic acid was also used as the carbon source for Pseudomonas putida KT2440 at high concentration, >10 g/L, and can be converted to PLA homopolymer [26].
The present invention provides for a method for depolymerizing a mixture of plastics, said method comprising: (a) providing a composition comprising two of more plastics, (b) introducing a solvent comprising an ionic liquid (IL) or deep eutectic solvents (DES) and optionally water to the composition to form a solvent-plastic composition, such as an aqueous solvent-plastic composition, and (c) incubating the solvent-plastic composition for a period of time to produce a depolymerized composition such that at least portions of the two of more plastics are depolymerized into monomers.
In some embodiments, the method further comprises: (d) introducing a microbe to the depolymerized composition such that the microbe utilizes the monomer(s) as a carbon source to produce a biofuel or bioproduct.
In some embodiments, the method further comprises: (e) separating the monomer, biofuel, or bioproduct from the depolymerized composition. In some embodiments, the method further comprises separating the monomers produced from a first plastic from the monomers produced from a second plastic. In some embodiments, the bioproduct is a terephthalic acid. In some embodiments, the method comprises biopolymerizing the separated monomers to form a polymer, such as a biopolymer or synthetic polymer.
In some embodiments, the plastic is a polyalkylene, polystyrene, a polyester, or a halogen substituted derivative thereof. In some embodiments, the polyalkylene is polyethylene, polypropylene, polybutylene, or the like. In some embodiments, the halogen substituted polyalkylene is polyhaloethylene (such as polyvinyl chloride), polyhalopropylene, polyhalobutylene, or the like. In some embodiments, the polyester is polyalkylene terephthalate (such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT), or poly(cyclohexylenedimethylene terephthalate) (PCT),) or polylactic acid (PLA). In some embodiments, the composition comprises a mixture of two, three, four, five, six, seven, eight, nine, ten, or more plastics.
In some embodiments, the polyester has the following chemical structure:
In some embodiments, R and R′ are each independently H, alkyl, aryl, alkene, alkyne, or substituted thereof. In some embodiments, n is at least 100, 500, 1000, 5,000, 10,000, or 50,000.
In some embodiments, the (b) introducing a solvent to the composition to form a solvent-plastic composition step comprises forming a solvent-plastic composition comprising equal to or more than about 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% IL or DES loading (wt %). In some embodiments, the (b) introducing an ionic liquid (IL) to the composition to form a solvent-plastic composition step comprises introducing a solvent to the composition to form a solvent-plastic composition comprising equal to or more than about 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, or 100% solvent loading (wt %). In some embodiments, the solvent comprises equal to or more than about 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, or 100% IL or DES (wt %), and optionally water, wherein optionally the balance of the solvent is water. In some embodiments, the (b) introducing an ionic liquid (IL) or DES to the composition to form a solvent-plastic composition step comprises introducing water to the composition, or the IL or DES itself is in an aqueous solution.
In some embodiments, the period of time is equal to or more than about 1 minute, 5 minutes, 10 minutes, 20 minutes, 30 minutes, 40 minutes, 50 minutes, 1 hour, 2 hours, 3, hours, 4 hours, 5 hours, or 6 hours.
In some embodiments, the (c) incubating the solvent-plastic composition for a period of time to produce a depolymerized composition step comprises heating the depolymerized composition to a temperature of about 30° C., 40° C., 50° C., 60° C., 70° C., 80° C., 90° C., 100° C., 110° C., 120° C., 130° C., 140° C., 150° C., 160° C., 170° C., 180° C., 190° C., or 200° C. In some embodiments, the (c) incubating the solvent-plastic composition for a period of time to produce a depolymerized composition step is performed at about room temperature, or about 25° C.
In some embodiments, the (c) incubating the solvent-plastic composition for a period of time to produce a depolymerized composition step produces a yield of equal to or more than about 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95%, 98%, 99%, or 100% of a plastic, or each of the two, three, four, five, six, seven, eight, nine, ten, or more plastics, depolymerized.
In some embodiments, the method results in a yield of equal to or more than about 80%, 85%, 90%, or 95% of monomeric products from the plastics.
In some embodiments, step (a) does not comprise, or lacks, introducing or adding any water to the plastic or a mixture of plastics. In some embodiments, the amount of water in the mixture, excluding or including water or moisture naturally found in the plastic or mixture of plastics is no more than about 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, or 0.1% by weight or volume of the mixture.
In some embodiments, the composition or solvent, or any other composition, has a water content of about 0.1%, 0.5%, 1%, 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90%, or any range from any two preceding values, by weight or volume. In some embodiments, the composition or solvent, or any other composition, has an IL or DES content of about 0.1%, 0.5%, 1%, 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90%, or any range from any two preceding values, by weight or volume. In some embodiments, the composition or solvent, or any other composition, or any of the steps, has a temperature of 100° C., 110° C., 120° C., 130° C., 140° C., 150° C., 160° C., 170° C., 180° C., 190° C., 200° C., 210° C., or 220° C., or any range from any two preceding values, such as about 160° C. to 200° C.
In some embodiments, the introducing step comprises a solid loading of the plastic, or mixture thereof, of about 1%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, or 60%, or any range from any two preceding values.
The present invention provides for compositions and methods described herein. In some embodiments, the compositions and methods further comprise steps, features, and/or elements described in U.S. Patent Application Publication No. 2020/0216863, hereby incorporated by reference in its entirety.
In some embodiments, the method is a one-pot method, which does not require any solid-liquid separation step. In some embodiments, the one-pot method does not require adjustment of the pH level in the one-pot composition. In some embodiments, the one-pot method does not require any dilution, or addition of water or medium. In some embodiments, the growth of the microbe occurs in the same one-pot composition. In some embodiments, the IL, or mixture thereof, is renewable as it can be continuous in use.
The invention uses ionic liquids to depolymerize plastics into monomers in aqueous solutions. The method allows the chemical recycling of plastics and mixtures of plastics.
Ionic liquids are found to depolymerize plastics, in particular polyesters, such as polyethylene terephthalate (PET) and polylactic acid (PLA). Most previous studies have reported the depolymerization of individual plastics using ionic liquids in the presence of organic solvents. Without using organic solvents, the process depolymerizes PET and PLA using ionic liquids and water as the aqueous solvent system. Among all the ionic liquids studied, cholinium lysinate [Ch][Lys] shows the most promising depolymerization efficiency and product yield. Up to 100% depolymerization was achieved for both PET and PLA at 160° C. with 20% [Ch][Lys] loading for 6 hours. The same process has shown high efficiency for the plastic mixture, resulting in over 95% depolymerization of a plastic mixture made of equal amount of PET and PLA. The yield of lactic acid (from PLA) and terephthalic acid (from PET) are 98% and 99%, respectively, from the PET/PLA mixture.
The present invention may be useful in the petrochemical industry. As the producer of plastics, petrochemical companies have been looking for sustainable solutions for plastics recycling. The products of plastic recycling, especially chemical recycled products, can be used as starting substrate for making virgin plastics or other chemicals. Given the vast presence of plastic wastes, they could potentially displace a significant amount of the fossil fuels used in the petrochemical industry.
The present invention may be useful in waste management industries. The waste management sector is trying to reduce the amount of waste that ends up in landfills, given the limit of available land and cost of landfilling. Recycling of the plastic wastes could potentially bring profits to the industry through selling the recycled products and reduce the quantity of landfilling wastes.
The present invention may be useful in cleaning the environment. Companies are looking to remove plastics from the environment and reduce the pollution. Instead of simply collecting plastic waste, they would like to make use of the plastic waste and turn the waste into valuable products.
The present invention described herein has the one or more of the following key points of differentiation when compared to other methods: (1) Using water as solvent instead of organic solvents (such as alcohol or ethylene glycol, or the like). The present invention is safer and greener and is a process that is of lower cost and higher reliability. (2) Processing a plastic mixture instead of a single stream of a single type of plastics. Currently, most plastic wastes contain a mixture of different plastics. Conventional recycling method relies on a wholly mechanical means of separation of the individual plastics. This present invention overcomes the major challenge in plastic recycling (both technically and financially) of separating the plastics. This present invention depolymerizes a plastic mixture and thus significantly lowers the process cost.
The foregoing aspects and others will be readily appreciated by the skilled artisan from the following description of illustrative embodiments when read in conjunction with the accompanying drawings.
Before the invention is described in detail, it is to be understood that, unless otherwise indicated, this invention is not limited to particular ILs, or processes, as such may vary. It is also to be understood that the terminology used herein is for purposes of describing particular embodiments only and is not intended to be limiting.
In this specification and in the claims that follow, reference will be made to a number of terms that shall be defined to have the following meanings:
The terms “optional” or “optionally” as used herein mean that the subsequently described feature or structure may or may not be present, or that the subsequently described event or circumstance may or may not occur, and that the description includes instances where a particular feature or structure is present and instances where the feature or structure is absent, or instances where the event or circumstance occurs and instances where it does not.
The term “about” when applied to a value, describes a value that includes up to 10% more than the value described, and up to 10% less than the value described.
Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limits of that range is also specifically disclosed. Each smaller range between any stated value or intervening value in a stated range and any other stated or intervening value in that stated range is encompassed within the invention. The upper and lower limits of these smaller ranges may independently be included or excluded in the range, and each range where either, neither or both limits are included in the smaller ranges is also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the invention.
In some embodiments, the method uses a one-pot methodology, for example, using method steps and compositions as taught in U.S. Patent Application Publication No. 2020/0216863 (which is incorporated by reference). In some embodiments, the method further comprises heating the one-pot composition, optionally also comprising the microbe, to a temperature that is equal to, about, or near the optimum temperature for the growth of the microbe. In some embodiments, the microbe is a genetically modified host cell capable of utilizing the monomer produced as a carbon source, and produces a biofuel or bioproduct, and/or chemical compound. In some embodiments, there is a plurality of microbes.
Ionic Liquid
Ionic liquids (ILs) are salts that are liquids rather than crystals at room temperatures. It will be readily apparent to those of skill that numerous ILs can be used in the present invention. In some embodiments, the IL is suitable for pretreatment of biomass and for the hydrolysis of cellulose by thermostable cellulase. Suitable ILs are taught in ChemFiles (2006) 6(9) (which are commercially available from Sigma-Aldrich, Milwaukee, Wis.). Such suitable ILs include, but are not limited to, 1-alkyl-3-alkylimidazolium alkanate, 1-alkyl-3-alkylimidazolium alkylsulfate, 1-alkyl-3-alkylimidazolium methylsulfonate, 1-alkyl-3-alkylimidazolium hydrogensulfate, 1-alkyl-3-alkylimidazolium thiocyanate, and 1-alkyl-3-alkylimidazolium halide, wherein an “alkyl” is an alkyl group comprising from 1 to 10 carbon atoms, and an “alkanate” is an alkanate comprising from 1 to 10 carbon atoms. In some embodiments, the “alkyl” is an alkyl group comprising from 1 to 4 carbon atoms. In some embodiments, the “alkyl” is a methyl group, ethyl group or butyl group. In some embodiments, the “alkanate” is an alkanate comprising from 1 to 4 carbon atoms. In some embodiments, the “alkanate” is an acetate. In some embodiments, the halide is chloride.
In some embodiments, the IL includes, but is not limited to, 1-ethyl-3-methylimidazolium acetate (EMIN Acetate), I-ethyl-3-methylimidazolium chloride (EMIN Cl), 1-ethyl-3-methylimidazolium hydrogensulfate (EMIM HOSO3), 1-ethyl-3-methylimidazolium methylsulfate (EMIM MeOSO3), 1-ethyl-3-methylimidazolium ethylsulfate (EMIM EtOSO3), 1-ethyl-3-methylimidazolium methanesulfonate (EMIM MeSO3), 1-ethyl-3-methylimidazolium tetrachloroaluminate (EMIM AICl4), 1-ethyl-3-methylimidazolium thiocyanate (EMIM SCN), 1-butyl-3-methylimidazolium acetate (BMIM Acetate), 1-butyl-3-methylimidazolium chloride (BMIM Cl), 1-butyl-3-methylimidazolium hydrogensulfate (BMIM HOSO3), 1-butyl-3-methylimidazolium methanesulfonate (BMIM MeSO3), 1-butyl-3-methylimidazolium methylsulfate (BMIM MeOSO3), 1-butyl-3-methylimidazolium tetrachloroaluminate (BMIM AICl4), 1-butyl-3-methylimidazolium thiocyanate (BMIM SCN), 1-ethyl-2,3-dimethylimidazolium ethylsulfate (EDIM EtOSO3), Tris(2-hydroxyethyl)methylammonium methylsulfate (MTEOA MeOSO3), 1-methylimidazolium chloride (MIM Cl), 1-methylimidazolium hydrogensulfate (MIM HOSO3), 1,2,4-trimethylpyrazolium methylsulfate, tributylmethylammonium methylsulfate, choline acetate, choline salicylate, cholinium lysinate, and the like.
In some embodiments, the ionic liquid is a chloride ionic liquid. In other embodiments, the ionic liquid is an imidazolium salt. In still other embodiments, the ionic liquid is a 1-alkyl-3-imidazolium chloride, such as 1-ethyl-3-methylimidazolium chloride or 1-butyl-3-methylimidazolium chloride.
In some embodiments, the ionic liquids used in the invention are pyridinium salts, pyridazinium salts, pyrimidium salts, pyrazinium salts, imidazolium salts, pyrazolium salts, oxazolium salts, 1,2,3-triazolium salts, 1,2,4-triazolium salts, thiazolium salts, isoquinolium salts, quinolinium salts isoquinolinium salts, piperidinium salts and pyrrolidinium salts. Exemplary anions of the ionic liquid include, but are not limited to halogens (e.g., chloride, fluoride, bromide and iodide), pseudohalogens (e.g., azide and isocyanate), alkyl carboxylate, sulfonate, acetate and alkyl phosphate.
Additional ILs suitable for use in the present invention are described in U.S. Pat. Nos. 6,177,575; 9,765,044; and 10,155,735; U.S. Patent Application Publication Nos. 2004/0097755 and 2010/0196967; and PCT International Patent Application Nos. PCT/US2015/058472, PCT/US2016/063694, PCT/US2017/067737, and PCT/US2017/036438 (all of which are incorporated in their entireties by reference). It will be appreciated by those of skill in the art that others ILs that will be useful in the process of the present invention are currently being developed or will be developed in the future, and the present invention contemplates their future use. The ionic liquid can comprise one or a mixture of the compounds.
In some embodiments, the IL is a protic ionic liquid (PIL). Suitable protic ionic liquids (PILs) include fused salts with a melting point less than 100° C. with salts that have higher melting points referred to as molten salts. Suitable PILs are disclosed in Greaves et al. “Protic Ionic Liquids: Properties and Applications” Chem. Rev. 108(1):206-237 (2008). PILs can be prepared by the neutralization reaction of certain Brønsted acids and Brønsted bases (generally from primary, secondary or tertiary amines, which are alkaline) and the fundamental feature of these kinds of ILs is that their cations have at least one available proton to form hydrogen bond with anions. In some embodiments, the protic ionic liquids (PILs) are formed from the combination of organic ammonium-based cations and organic carboxylic acid-based anions. PILs are acid-base conjugate ILs that can be synthesized via the direct addition of their acid and base precursors. In some embodiments, the PIL is a hydroxyalkylammonium carboxylate. In some embodiments, the hydroxyalkylammonium comprises a straight or branched C1, C2, C3, C4, C5, C6, C7, C8, C9, or C10 chain. In some embodiments, the carboxylate comprises a straight or branched C1, C2, C3, C4, C5, C6, C7, C8, C9, or C10 chain. In some embodiments, the carboxylate is substituted with one or more hydroxyl groups. In some embodiments, the PIL is a hydroxyethylammonium acetate.
In some embodiments, the protic ionic liquid (PIL) is disclosed by U.S. Patent Application Publication No. 2004/0097755, hereby incorporated by reference.
Suitable salts for the method include combinations of organic ammonium-based cations (such as ammonium, hydroxyalkylammonium, or dimethylalkylammonium) with organic carboxylic acid-based anions (such as acetic acid derivatives (C1-C8), lactic acid, glycolic acid, and DESs such as ammonium acetate/lactic acid) or amino acid-base anions (such as lysine, alanine, and glycine).
In some embodiments, the IL comprises (a) a phosphonium-based cation (such as tetraoctylphosphonium, tetrabutylphosphonium, tetraethylphosphonium, trioctylmethylphosphonium, trihexylmethylphosphonium, tributylmethylphosphonium, or triethylmethylphosphonium), or a mixture thereof, and (b) (i) an organic carboxylic acid-based anion (such as acetic acid derivatives (C1-C8), lactic acid, or glycolic acid), or a mixture thereof, (ii) a sugar acid (such as gluconic acid, aldonic acid, aldaric acid, or uronic acid), or a mixture thereof, or (iii) an amino acid-base anion (such as lysine, alanine, or glycine), or a mixture thereof, or (iv) a mixture thereof.
In some embodiments, the IL comprises (a) a cholinium (choline)-based cation, or a mixture thereof, and (b) (i) an organic carboxylic acid-based anion (such as acetic acid derivatives (C1-C8), lactic acid, glycolic acid, or gluconic acid), (ii) an amino acid-base anion (such as lysine, alanine, or glycine), or a mixture thereof, or (iii) other anion (such as hydroxide, sulfate, chloride, phosphate, or acetate), or a mixture thereof, or (iv) a mixture thereof. In some embodiments, the IL is cholinium gluconate.
Suitable IL also includes a distillable IL (such as ethanolamine or diethanolamine. Suitable IL are disclosed in Chen et al. “Distillable Ionic Liquids: reversible Amide O Alkylation”, Angewandte Comm. 52:13392-13396 (2013), King et al. “Distillable Acid-Base Conjugate Ionic Liquids for Cellulose Dissolution and Processing”, Angewandte Comm. 50:6301-6305 (2011), and Vijayaraghavan et al. “CO2-based Alkyl Carbamate Ionic Liquids as Distillable Extraction Solvents”, ACS Sustainable Chem. Engin. 2:31724-1728 (2014), all of which are hereby incorporated by reference.
Suitable PIL, such as distillable PIL, are disclosed in Idris et al. “Distillable Protic Ionic Liquids for Keratin Dissolution and Recovery,” ACS Sustainable Chem. Engin. 2:1888-1894 (2014) and Sun et al. “One-pot integrated biofuel production using low-cost biocompatible protic ionic liquids,” Green Chem. 19(13):3152-3163 (2017), all of which are hereby incorporated by reference.
In some embodiments, the PILs are formed with the combination of organic ammonium-based cations and organic carboxylic acid-based anions. PILs are acid-base conjugate ILs that can be synthesized via the direct addition of their acid and base precursors. Additionally, when sufficient energy is employed, they can dissociate back into their neutral acid and base precursors, while the PILs are re-formed upon cooling. This presents a suitable way to recover and recycle the ILs after their application. In some embodiments, the PIL (such as hydroxyethylammonium acetate—[Eth][OAc]) is an effective solvent for biomass pretreatment and is also relatively cheap due to its ease of synthesis (Sun et al., Green Chem. 19(13):3152-3163 (2017)).
Deep Eutectic Solvent (Des)
DESs are systems formed from a eutectic mixture of Lewis or Brønsted acids and bases which can contain a variety of anionic and/or cationic species. DESs can form a eutectic point in a two-component phase system. DESs are formed by complexation of quaternary ammonium salts (such as choline chloride) with hydrogen bond donors (HBD) such as amines, amides, alcohols, or carboxylic acids. The interaction of the HBD with the quaternary salt reduces the anion-cation electrostatic force, thus decreasing the melting point of the mixture. DESs share many features of conventional ionic liquid (IL), and promising applications would be in biomass processing, electrochemistry, and the like. In some embodiments, the DES is any combination of Lewis or Brønsted acid and base. In some embodiments, the Lewis or Brønsted acid and base combination used is distillable. In some embodiments, the DES is betainium gluconate.
In some embodiments, DES is prepared using an alcohol (such as glycerol or ethylene glycol), amines (such as urea), and an acid (such as oxalic acid or lactic acid). The present invention can use renewable DESs with lignin-derived phenols as HBDs. Both phenolic monomers and phenol mixture readily form DES upon heating at 100° C. with specific molar ratio with choline chloride. This class of DES does not require a multistep synthesis. In some embodiments, the DES is synthesized from lignin which is a renewable source. Both monomeric phenols and phenol mixture can be used to prepare DES.
The DES, or mixture thereof, is bio-compatible: meaning the DES, or mixture thereof, does not reduce or does not significantly reduce the enzymatic activity of the enzyme, and/or is not toxic, and/or does not reduce or significantly reduce, the growth of the microbe. A “significant” reduction is a reduction to 70, 80, 90, or 95% or less of the enzyme's enzymatic activity and/or the microbe's growth (or doubling time), if the DES, or mixture thereof, was not present.
In some embodiments, the DES, or mixture thereof, comprises a quaternary ammonium salt and/or glycerol. In some embodiments, the DES, or mixture thereof, comprises a quaternary ammonium salt and/or glycerol. In some embodiments, the quaternary ammonium salt and/or glycerol have a molar ratio of about 1:1 to about 1:3. In some embodiments, the quaternary ammonium salt and/or glycerol have a molar ratio of about 1:1.5 to about 1:2.5. In some embodiments, the quaternary ammonium salt and/or glycerol have a molar ratio of about 1:1.8 or 1:1.9 to about 1:2.1 or 1:2.2. In some embodiments, the quaternary ammonium salt and/or glycerol have a molar ratio of about 1:2. In some embodiments, the quaternary ammonium salt is a choline halide, such choline chloride.
In some embodiments, the DES is distillable if the DES can be recovered at least equal to or more than about 50%, 55%, 60%, 65%, 70%, 75%, 80%, or 85% yield by distilling over vacuum at a temperature at about 100° C., 110° C., 120° C., 130° C., 140° C., 150° C., or 160° C., or any temperature between any two of the preceding temperatures.
In some embodiments, the DES can be one taught in WO 2018/204424 (Seema Singh et al.), which is hereby incorporated in its entirety by reference.
Microbe
In some embodiments, the microbe is any prokaryotic or eukaryotic cell, with any genetic modifications, taught in U.S. Pat. Nos. 7,985,567; 8,420,833; 8,852,902; 9,109,175; 9,200,298; 9,334,514; 9,376,691; 9,382,553; 9,631,210; 9,951,345; and 10,167,488; and PCT International Patent Application Nos. PCT/US14/48293, PCT/US2018/049609, PCT/US2017/036168, PCT/US2018/029668, PCT/US2008/068833, PCT/US2008/068756, PCT/US2008/068831, PCT/US2009/042132, PCT/US2010/033299, PCT/US2011/053787, PCT/US2011/058660, PCT/US2011/059784, PCT/US2011/061900, PCT/US2012/031025, and PCT/US2013/074214 (all of which are incorporated in their entireties by reference).
Generally, although not necessarily, the microbe is a yeast or a bacterium. In some embodiments, the microbe is Rhodosporidium toruloides or Pseudomonas putida. In some embodiments, the microbe is a Gram-negative bacterium. In some embodiments, the microbe is of the phylum Proteobactera. In some embodiments, the microbe is of the class Gammaproteobacteria. In some embodiments, the microbe is of the order Enterobacteriales. In some embodiments, the microbe is of the family Enterobacteriaceae. Examples of suitable bacteria include, without limitation, those species assigned to the Escherichia, Enterobacter, Azotobacter, Erwinia, Bacillus, Pseudomonas, Klebsielia, Proteus, Salmonella, Serratia, Shigella, Rhizobia, Vitreoscilla, and Paracoccus taxonomical classes. Suitable eukaryotic microbes include, but are not limited to, fungal cells. Suitable fungal cells are yeast cells, such as yeast cells of the Saccharomyces genus.
Yeasts suitable for the invention include, but are not limited to, Yarrowia, Candida, Bebaromyces, Saccharomyces, Schizosaccharomyces and Pichia cells. In some embodiments, the yeast is Saccharomyces cerevisae. In some embodiments, the yeast is a species of Candida, including but not limited to C. tropicalis, C. maltosa, C. apicola, C. paratropicalis, C. albicans, C. cloacae, C. guillermondii, C. intermedia, C. lipolytica, C. panapsilosis and C. zeylenoides. In some embodiments, the yeast is Candida tropicalis. In some embodiments, the yeast is a non-oleaginous yeast. In some embodiments, the non-oleaginous yeast is a Saccharomyces species. In some embodiments, the Saccharomyces species is Saccharomyces cerevisiae. In some embodiments, the yeast is an oleaginous yeast. In some embodiments, the oleaginous yeast is a Rhodosporidium species. In some embodiments, the Rhodosporidium species is Rhodosporidium toruloides.
In some embodiments the microbe is a bacterium. Bacterial host cells suitable for the invention include, but are not limited to, Escherichia, Corynebacterium, Pseudomonas, Streptomyces, and Bacillus. In some embodiments, the Escherichia cell is an E. coli, E. albertii, E. fergusonii, E. hermanii, E. marmotae, or E. vulneris. In some embodiments, the Corynebacterium cell is Corynebacterium glutamicum, Corynebacterium kroppenstedtii, Corynebacterium alimapuense, Corynebacterium amycolatum, Corynebacterium diphtheriae, Corynebacterium efficiens, Corynebacterium jeikeium, Corynebacterium macginleyi, Corynebacterium matruchotii, Corynebacterium minutissimum, Corynebacterium renale, Corynebacterium striatum, Corynebacterium ulcerans, Corynebacterium urealyticum, or Corynebacterium uropygiale. In some embodiments, the Pseudomonas cell is P. putida, P. aeruginosa, P. chlororaphis, P. fluorescens, P. pertucinogena, P. stutzeri, P. syringae, P. cremoricolorata, P. entomophila, P. fulva, P. monteilii, P. mosselii, P. oryzihabitans, P. parafluva, or P. plecoglossicida. In some embodiments, the Streptomyces cell is a S. coelicolor, S. lividans, S. venezuelae, S. ambofaciens, S. avermitilis, S. albus, or S. scabies. In some embodiments, the Bacillus cell is a B. subtilis, B. megaterium, B. licheniformis, B. anthracis, B. amyloliquefaciens, or B. pumilus.
Towards One-Pot Conversion of Synthetic Polyester Mixtures Using Biocompatible Aqueous Ionic Liquid
Plastic wastes pose a significant long-term threat to both the environment and public health. Different types of plastics are often mixed together at waste collection and processing facilities, which makes efficient recycling very challenging. The increasing popularity of polylactic acid (PLA) produces more cross-contamination in the recycling of polyethylene terephthalate (PET)—one of the most used and recycled plastics. This study demonstrates the feasibility of applying ionic liquids (ILs) in the chemical recycling of PET and PLA mixtures using water as the bulk solvent. Four ILs, including two cholinium-based ILs and two imidazolium-based ILs, were investigated in terms of their ability to depolymerize PET and PLA. Cholinium-based ILs showed higher depolymerization efficiency over imidazolium-based ILs with cholinium lysinate [Ch][Lys] performing the best; the yields of products, terephthalic acid (TPA) and lactic acid (LA) followed the same trend. This observation agreed with the results of molecular dynamic simulation, where [Ch][Lys] was found to have better polymer dissolution compared to the other ILs. In addition to IL type, temperature and time effectively influenced the reaction and were further studied to depolymerize PET/PLA mixture. Over 95% of theoretical monomer yields were achieved using 20 wt % [Ch][Lys] loading at reaction temperature of 160° C. for 6 h. The depolymerized plastics were directly subjected to the biological conversion using Pseudomonas putida. Depolymerized PLA resulted in a much higher cell growth than the depolymerized PET. This is due to the lack of a catabolic pathway for TPA in Pseudomonas putida and can be resolved by adding the pathway via strain engineering. The integration of polymer hydrolysis and biological valorization in this work underscores the potential of an IL-based one-pot upcycling technology for plastic mixture.
In this example, we investigated the hydrolysis of PET and PLA using different ILs in water. In particular, the work focused on the hydrolytic depolymerization of the mixture of PET and PLA using a biocompatible cholinium-based IL. After obtaining the highest depolymerization efficiency and product yields, microbial cell growth test was carried out using Pseudomonas putida KT2440 in order to understand the potential of biological valorization of the depolymerized polyester mixture.
Results and Discussion
Screening of Ionic Liquids in Depolymerization of PET and PLA
ILs have been employed to depolymerize individual polyesters such as PET and PLA [14, 17]. Most of them are conventional imidazolium-based, including the ones that contain halometallates. With the progress in the IL research, economic and biocompatible cholinium-based ILs have attracted high interest [27, 28]. Building upon this, the current study explored two cholinium-based ILs, cholinium lysinate ([Ch][Lys]) and cholinium phosphate ([Ch]3[Phos]), along with two imidazolium-based ILs, 1-ethyl-3-methylimidazolium acetate ([C2C1im][Ac]) and 1-ethyl-3-methylimidazolium chloride ([C2C1im]Cl). The reaction temperatures (180° C. for PET and 130° C. for PLA) were set below the melting point of the employed PET (235° C.) and PLA (153° C.), as the main purpose is to compare the catalytic efficiency of different ILs in polyester depolymerization.
Hydrolytic depolymerization of PET and PLA involves chain scission of ester linkages, where a carboxyl end group is released. It was reported that PET and PLA depolymerization can occur under base catalysis, as the hydroxide ion deprotonates the oxygen atom of water and increases its nucleophilicity in attacking the ester groups. As illustrated in Table 1, the pH of the reaction solution before and after depolymerization reaction aligns with the depolymerization efficiency across ILs, where cholinium-based ILs demonstrated higher pH over imidazolium-based ILs. We hypothesized that the pH influenced by IL was the major driving force of PET and PLA depolymerization. To test the hypothesis, a set of control experiments were conducted using only water and alkaline water as the solvent. For the alkaline water, NaOH was added to adjust the pH to mimic that of employed 10 wt % aqueous [Ch][Lys] (with pH 11.8). Surprisingly, the pH adjusted reaction system showed no difference versus the water control; both PET and PLA were barely depolymerized with negligible product yields. The findings were different from some previous studies where alkaline conditions formed by 0.6 M NaOH (pH˜13) were found to facilitate the depolymerization of PET and PLA [29, 30]. This is likely due to the relatively lower NaOH molarity (and lower pH) in the control, as PET hydrolysis is proved to be positively related to NaOH concentration [31].
Molecular weight distribution profiles of the depolymerized stream from each polymer corroborate the observed product yield as seen in
Understanding the Effect of Ionic Liquids on the Depolymerization of Polyester by Molecular Dynamics Simulations
To understand the effect of IL/water mixtures and water on the depolymerization of polyesters, molecular dynamics (MD) simulations were performed using PLA as a model substrate (
To obtain the structural arrangements and microscopic interactions, radial distribution functions (g(r) or RDFs) between PLA and the investigated solvent systems were calculated. The RDF (g(r)) is defined as the probability of identifying a molecule at a distance of ‘r’ from the reference molecule [32]. The RDF plots are a powerful tool for analyzing the structural and explicit interactions between solute and solvent(s). In general, g(r) intensity is related to the strength of contact probability between the solute and solvent. In this study, the RDF was plotted between the oxygen (O) atom of the PLA molecule and the anion/cation of IL and water, and the results are depicted in
Furthermore, the RDF and number of hydrogen bonds (HBs) between water and anion of ILs have been calculated and the results are shown in
In addition to MD simulations, Hansen solubility parameter (HSP) was also taken into consideration to understand why [Ch][Lys] was better than other ILs studied here. HSP is a critical property of a molecular species that analyzes polarity and quantifies the “like seeks like” principle. For instance, a given solute (e.g., PLA/PET) is considered to be highly miscible/soluble in a given solvent (ILs in the present case), if the HSP values of the solute and the solvent are similar. The HSP values of PET, PLA, ILs, and water are presented in Table 2. The total solubility parameters of PLA and PET are 20.87 MPa1/2 and 21.66 MPa1/2, respectively. On the other hand, the solubility parameter of [Ch][Lys] and [Ch]3[Phos] are 26.30 MPa1/2, and 28.25 MPa1/2 which are close to the PLA and PET's HSP values, advocating higher miscibility of these polyesters in [Ch][Lys] and [Ch]3[Phos]. In contrast, the solubility parameters of [Emim][Ac], [Emim]Cl, and water are much higher than PLA and PET, implying that [Emim][Ac], [Emim]Cl, and water have weaker affinity with plastic that leads to a lower depolymerization and conversion rates. As a result of these observations, it can be established that polyester depolymerization is largely influenced and governed by the choice of ion combination in any given IL. The order of solvent HSP values that is close to polyesters is as follows: [Ch][Lys]>[Ch]3[Phos]>[Emim]Cl>[Emim][Ac]>water, which is in line with the experimental observations.
Depolymerization of PET/PLA Mixtures Using [Ch][Lys]
As discussed previously, the current waste management facilities will not completely eliminate the PLA contamination when sorting PET for recycling. With the increasing prevalence of PLA, it is likely that more PLA will end up in the PET recycling stream. Chemical recycling is an alternative to mechanical recycling in regard to dealing with PLA contaminants. Herein, we prepared a PLA/PET mixture by combining PLA and PET at 1:1 mass ratio and investigated the IL-catalyzed hydrolysis of these polyester mixtures. Given its high catalytic activity, [Ch][Lys] was selected as the IL in the reaction. It should be emphasized that [Ch][Lys] is a favorable choice not only because of its high depolymerization efficiency but also because it is economic, biocompatible, less toxic, and environmentally friendly [27].
A range of IL loading (10-90 wt % [Ch][Lys]) was applied to maximize depolymerization efficiency and product yields of PET/PLA mixture. The initial set of experiments was carried out at 160° C. for two hours. As shown in
On one hand, the major hydrolytic reaction was found to occur on the external surface of PET where the solubility is the reaction rate determining step [19, 31]. ILs could dissolve polymers like PET and PLA to facilitate higher depolymerization at higher IL loading [28, 36, 37]. On the other hand, the lack of water likely impeded hydrolytic reaction and limited the polymers from complete depolymerization. Both the product yields and the gel permeation chromatography (GPC) results provide clues to this explanation. At higher IL loadings of 60 and 90 wt %, GPC revealed partial depolymerization into monomers and oligomers along with partial (low molecular weight) polymer dissolution (see
Although [Ch][Lys] is considered as cost-competitive compared to other conventional ILs, IL usage is often the major cost contributor in the process economics [38, 39]. In order to explore the way to reduce IL loading, a set of experiments was conducted by increasing the reaction time from 2 h to 6 h. Overall, reaction time extension improved both depolymerization and product yields at low IL loadings (
Overall, the yield of LA was higher than that of TPA. It is apparent that PLA is the major contributor to the depolymerization of PET/PLA mixture at 10 wt % and 20 wt % IL loadings. This is likely due to the fact that the PLA under investigation has lower glass transition (˜62° C.) and melting point (153° C.) compared to PET (onset from 235° C.) (
Though not implemented in the current study, we anticipate the process of product recovery to be relatively simple. Because of the presence of [Ch][Lys], the pH of the reaction system is high (Table 1). TPA is water soluble under alkaline conditions but is insoluble in acidic pH [40]. One can take advantage of this property and recover TPA by adjusting the pH to acidic followed by filtration. LA can be recovered as suggested in a previous study through the precipitation of lactate in the form of calcium lactate by adding calcium carbonate [20]. After filtration, the calcium lactate can then be converted back to water soluble lactic acid by adding a stronger acid. The IL remains in the solution and can be recycled and reused after necessary conditioning such as pH adjustment, salt removal, etc.
Bioconversion of Depolymerize PET/PLA and Conceptualization of One-Pot Process
In addition to separating and purifying the products for chemical applications, hydrolysis of PET and PLA provides a large amount of organic acids that can potentially serve as the carbon source pool for microbes. Herein, Pseudomonas putida KT2440 was selected as the microbe to investigate the cell growth using the depolymerized PET/PLA mixture [41-43]. Previous studies have demonstrated successful fermentation processes using pretreated lignocellulosic biomass in the presence of [Ch][Lys] [38, 39, 44, 45]. In the current work, the supernatant of most efficiently depolymerized PET/PLA (20 wt % [Ch][Lys] at 160° C. for 6 h) was subjected to different dilutions before feeding to Pseudomonas putida KT2440 (
Due to the fact that the depolymerized PET/PLA comprises multiple carbon sources (e.g., TPA, LA, and [Ch][Lys]), it is essential to identify the major contributors for the cell growth. Two additional tests were performed. For the first test, PET and PLA were depolymerized separately under 20 wt % [Ch][Lys] at 160° C. for 6 hours. The depolymerized products were then diluted 20-fold to prepare the media for cell growth test. A media prepared with only [Ch][Lys] was used as the IL control.
To validate this hypothesis, a second cell growth test was conducted using synthetic TPA and LA as the media. TPA, LA, and TPA/LA mixture were prepared to match the concentrations in the depolymerized polymers. As
As mentioned earlier, the cell growth in depolymerized PLA and depolymerized mixture was either similar to or higher than the cell growth in 10 mM glucose media. In addition to the higher cell density, cell growth in depolymerized PLA and depolymerized mixture were found to have 4-5 h shorter lag phase than the 10 mM glucose control. The mechanism of such phenomena remains to be explained, but it indicates the potential to use depolymerized mixture as carbon sources for microbial fermentation, especially when the strain is to be engineered to catabolize TPA.
Experimental Section
Materials
Both polyethylene terephthalate (PET) and polylactic acid (PLA) were obtained from Goodfellow. PET (Cat. ES306030) was received as powder with particle size of 300 micron. PLA (Cat. ME346310) was received as nominal granule (3-5 mm) and further comminuted using a Wiley Mill (Thomas Scientific, Swedesboro, NJ) with a 2 mm sieve. Differential scanning calorimetry (DSC, Mettler Toledo, Columbus, OH) analysis was performed to determine the glass transition time of the polymers. As
Depolymerization Reaction, Mass Balance, and Yield Calculations
The depolymerization reaction of polyesters were conducted in a 15 mL pressure tube (Ace Glass Inc., Vineland, NJ) at ° C. temperature for one hour. For reactions with individual plastic, 0.5 g of PET (or PLA) was mixed thoroughly with 4.5 g of solvent (90% of water+10% of different amounts of ILs). For reactions with plastic mixture, 0.25 g of PET and 0.25 g of PLA were used instead. The tube was immersed in a preheated oil bath at a desired temperature. Upon completion of the reaction, the tube was taken out from the oil bath and cooled to room temperature.
The reaction residue was transferred to a 50 mL falcon tube, where solid residue was recovered through centrifugation. The solid fraction was washed with 5 mL deionized water three times before being dried in a lyophilizer (Labconco, Kansas City, MO). The liquid fraction was sampled for product analysis. The depolymerization and product yield are defined as follows:
Depolymerization=Wsubstrate−W1Wsubstrate100%
Yield=Wproduct/MproductWsubstrate/Msubstrate×100%
where Wsubstrate, W1, and Wproduct correspond to the weight of starting polymer substrate, the weight of residual polymer, and the weight of monomeric products after depolymerization (TPA from PET and LA from PLA measured by HPLC), respectively. Mproduct represents the molecular weight of TPA or LA (TPA: 166.13 g/mol, LA: 90.08 g/mol); and Msubstrate represents the molecular weight of repeating unit in each polyester (PET: 210.18 g/mol; PLA: 72.06 g/mol).
Product Analysis
Terephthalic acid (TPA) and lactic acid (LA) were measured on a Thermo Scientific Ultimate 3000 HPLC (Waltham, MA, USA) equipped with a Bio-Rad Aminex HPX-87H column (300×7.8 mm, Hercules, CA, USA) and a Refractive Index (RI) detector. Then 4 mM sulfuric acid was used as the mobile phase at a flow rate of 1.0 mL/min. The column oven temperature was maintained at 65° C.
Molecular Weight Distribution Analysis
Molecular weight distribution of the reaction mixtures was measured through gel permeation chromatography (GPC). The analysis was performed on an Agilent 1260 infinity LC instrument equipped with a refractive index detector and a PL aquagel-OH column. Water was used as the mobile phase (1 mL/min-1, column temperature 35° C.) for the separation of products. Agilent's pre-weighed calibration kit of Polyethylene Glycol (PEG)/Polyethylene Oxide (PEO) (part no. PL2070-020) was used to calibrate the molecular weight distribution.
Molecular Dynamics Simulations
The polymeric structure of PLA was composed of 20 monomeric units (
The initial configuration for all the investigated systems was prepared according to the percentage of IL to water using PACKMOL [55]. The plastic (PLA) molecule was solvated in five different solvent systems: [Ch][Lys]+water, [Ch]3[Phos]+water, [C2C1im][Ac]+water, [C2C1im]Cl+water, and water. The simulation details such as the number of solvent molecules, polyester molecules, and final box size are summarized in Table 3. The potential energy of the system was first minimized for 3 00 000 steps using a steepest-descent algorithm. The system was then heated and equilibrated for 16 ns under the NPT ensemble using the Langevin thermostat and Nose-Hoover Langevin barostat [56, 57]. SHAKE algorithm was implemented to constrain all the hydrogen involved bonds [58]. The Particle Mesh Ewald (PME) method was implemented to treat long-range electrostatic interactions at a cut-off distance of 12 Å with an accuracy of 10-6 [59]. Three separate production runs with a time length of 300 ns were performed on each simulated system, starting with a different initial velocity distribution. At every 10 ps, the production coordinates were saved for structural and dynamics analysis. A 2 femtoseconds (fs) time step was used to integrate the equations of motion. All MD simulation trajectories were visualized and analyzed using TCL scripts and Visual Molecular Dynamics (VMD) tool [60]. The non-bonded interaction energies and the number of hydrogen bonds between PLA and IL/water were calculated per mole of PLA molecule.
Biological Conversion
Pseudomonas putida KT2440 was inoculated as the seed culture at 30° C. overnight. The cell culture was spun down and washed with 3-(N-morpholino)propane sulfonic acid (MOPS) buffer for 5 times to remove the carbon sources. 1% cell resuspension was inoculated into 500 μL growth media in 48 well plates. The growth media included MOPS rich buffer (Teknova, #M2105) and 25 μg/mL Chloramphenicol, added with different carbon sources to support the cell growth (Table 4). Cell growths were monitored continuously at OD600 nm for 72-120 h in the plate reader (Biotek-Synergy, Y-H1) at 30° C., 570 rpm.
Two cholinium-based and two imidazolium-based ILs were investigated to depolymerize PET and PLA in water. Terephthalic acid (TPA) and lactic acid (LA) were quantified to evaluate the catalytic performance of the ILs. Among the investigated ILs, [Ch][Lys] showed the better performance and was further studied in the depolymerization of PET/PLA mixture. The reaction achieved over 95% theoretical yields of both TPA and LA with 20 wt % [Ch][Lys] loading at a reaction temperature of 160° C. for 6 h. Given the biocompatibility of the IL and solvent system, the depolymerized plastics were directly subjected to the biological conversion using Pseudomonas putida.
The cell growth was much higher for depolymerized PLA than the depolymerized PET. This is in line with the report of a lacking metabolic pathway of TPA in Pseudomonas putida, which can be solved by engineering the strain to catabolize TPA. The findings reveal the potential of an IL-based one-pot conversion technology which integrates polymer hydrolysis and biological valorization of the plastics and plastic mixture in the IL-aqueous system. Waste plastics could serve as low or negative cost feedstock to provide a rich carbon source for microbial fermentation to produce advanced fuels and chemical products.
It is to be understood that, while the invention has been described in conjunction with the preferred specific embodiments thereof, the foregoing description is intended to illustrate and not limit the scope of the invention. Other aspects, advantages, and modifications within the scope of the invention will be apparent to those skilled in the art to which the invention pertains.
While the present invention has been described with reference to the specific embodiments thereof, it should be understood by those skilled in the art that various changes may be made, and equivalents may be substituted without departing from the true spirit and scope of the invention. In addition, many modifications may be made to adapt a particular situation, material, composition of matter, process, process step or steps, to the objective, spirit and scope of the present invention. All such modifications are intended to be within the scope of the claims appended hereto.
aδd, δp, and δh are the dispersion, polar, and hydrogen bond contributors.
bthe COSMOquick [35] tool is used to predict HSPs of [Ch]3[Phos] and [Emim]Cl;
cHSP values are computed using the molecular dynamics simulations;
dδe = {square root over (δp2 + δh2)} δe is the SP contribution from electrostatic term, i.e., summation of polar and hydrogen bonded).
aall media were filtered through 0.2 μm filter before inoculation
This application claims priority to, and the benefit of, U.S. provisional patent application Ser. No. 63/370,587 filed on Aug. 5, 2022, incorporated herein by reference in its entirety.
The invention was made with government support under Contract No. DE-AC02-05CH11231 awarded by the U.S. Department of Energy. The government has certain rights in the invention.
Number | Date | Country | |
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63370587 | Aug 2022 | US |