Carbon Polymerizing System

What it does

Carbon polymerizing system is a carbon-negative innovation that autonomously captures carbon molecules using bacterial fermentation techniques to produce environmentally friendly biodegradable plastic called polyhydroxybutyrate (PHB).

Your inspiration

Our paramount goal is to create green technology that addresses climate change through low-carbon manufacturing and aims for net-zero emissions. We are passionate about developing a carbon capture system that removes more CO2 from the atmosphere than it emits. We are particularly interested in bacteria-derived polyhydroxybutyrate, which can be produced by absorbing multiple carbon sources to generate carbon chain polymers within bacterial cells. This idea has led us to design a specific culturing process integrated with an autonomous manufacturing system that promotes carbon negativity in the biodegradable plastic production process.

How it works

Our design implements industrial automation to develop carbon-negative bioproduction. The bioreactor utilizes bacterial fermentation techniques; any added carbon sources, including fruit juice wastewater, vegetable and fruit biomass, and greenhouse gases, can be consumed by the bacteria. Under our specific chemical conditions, the bacteria polymerize these carbon molecules into PHB. Consequently, we obtain PHB granules by extracting the plastic from the bacterial cells through our designed system, which results in carbon negativity. With the implementation of a machine-learning-based SCADA system, the overall process can be automatically managed and manually controlled via the working interface. It shows how the entire system functions and displays real-time data for monitoring convenience. As a result, we can carry out the production process with less contamination at a promising production rate.

Design process

Our design process began with understanding how bacterial cells produce polyhydroxybutyrate (PHB). We engaged in hands-on cell culturing in the laboratory to comprehend the protocols for bioplastic polymer production. Step-by-step procedures, from bacterial culture to PHB extraction, were performed to gather valuable information for system design. Consequently, we prototyped by reverse engineering the laboratory procedures for PHB production, aiming for a fully autonomous system to maintain yield consistency. The bacterial cultivation media and PHB extraction agents were modified to lower carbon emissions compared to conventional methods. Firstly, we implemented a bioreactor system for automated cell culture that creates optimal environments for bacteria to accumulate PHB. Next, we fabricated an extraction system that integrates an articulated robot, centrifuge, media feeder, and small tube rotator for efficient small-scale extraction. This technique increases PHB yield compared to larger volume methods, based on our laboratory experience. Finally, we developed software to autonomously control the entire system under a machine learning-based SCADA system, optimizing culturing conditions during fermentation using feedback from previous production yields.

How it is different

What distinguishes us from others is our system’s ability to achieve negative carbon emissions. With our intelligent software, the operation can be optimized at maximum efficiency, while utilizing minimum energy consumption. Normally, PHB production line emits the smallest amount of carbon among all plastics and with our PHB production system, we are able to provide high grade bioplastics while deplete up to 2 kg of carbon dioxide equivalent of greenhouse gasses per 1 kg of the PHB produced. PHB has also added a significant value to the system with its great properties. Compared to other biodegradable plastics such as PLA, PHB has much more superior properties. When it comes to strength and durability, PHB can withstand higher temperatures up to 130°C where PLA starts to deform at only 53°C. Because PHB is produced in bacteria cells, the properties of PHB can be modified to suit any application just by adjusting the fermentation condition.

Future plans

Our next plan is to develop a carbon emission monitoring system integrated into our PHB manufacturing process that can track carbon credit records. We also plan to acquire two additional patents that extend from our current patent, focusing on our isolated bacterial strains for PHB production and the modified culturing process suitable for autonomously fermenting our new bacterial strains, integrated with the carbon emission tracking system.

Awards

- Grand Prize Award of the 8th Delta International Smart & Green Manufacturing Contest among 328 universities around the world (Delta World Cup 2022) - 2nd Runner Up at DELTA x DIPROM Angel Fund 2023 - First-Prize Winner at Innovation for Campus Sustainability 2024 - First-Runner Up at 3rd PIM International Hackathon