Methane to Biopolymers Allison Pieja, CTO Allison@MangoMaterials.com January 18, 2018
OPPORTUNITY Current bioplastics are expensive $3 Price per pound ($) $2 $1 $$$ $0 Oil-based Bio-based
Methane gas emissions Waste facility Microbial process Biodegradable products PHA biopolymer
Turning waste gas streams into ecofriendly, biodegradable materials that are economically competitive
VISION We strive to be a global leader in the bioindustrial revolution by converting abundant methane gas into low cost, high-value, biodegradable materials
VERSATILE TECHNOLOGY Methane platform technology can produce a portfolio of valuable bioproducts Industrial Plants Chemicals Wastewater Treatment Plants Landfills Agricultural Facilities Mango Materials Methane Platform Technology Materials Nutrition
BIOPOLYMER Polyhydroxyalkanoate (PHA) R O CH 3 O C C C C O C O C H 2 n H 2 n Polyhydroxyalkanoate (PHA) Poly-3-hydroxybutyrate (PHB) PHB is one type of PHA
DISPOSAL ENVIRONMENTS
PHA PRODUCTION IN TYPE II METHANOTROPHS Carbon dioxide (or bicarbonate) Methane Methanol Formaldehyde Formate CH CH 4HCHO HCOO - 4 3 OH CO 2 SERINE CYCLE TCA CYCLE acetyl-coa cell material PHA CYCLE PHA
HIGH PERFORMANCE PHA meets wide range of desirable properties Reference: Ravenstijn 2014
APPLICATIONS
INITIAL MARKET ENTRY TEXTILE FIBERS PHA can be formed into biodegradable biopolyester fibers for the $2 trillion fashion industry.* A sustainable alternative to petroleum-based polyester, our naturally occurring biopolyester can be used with other natural textile materials to produce a truly sustainable product. CAPS & CLOSURES PHA can be used for high performance caps and closures. We have an environmentally friendly solution for small packaging items that often end up in the oceans. Caps are in high demand worldwide, with the global plastic caps and closures market estimated to reach $39 billion in 2021.** Fish icon made by Freepik @ www.flaticon.com is licensed by CC 3.0 *Cobbing. Timeout for Fast Fashion. ** Mordor Intelligence. Global Plastic Caps and Closures Market, 2017-2022.
FIBERS STORY
INDUSTRIAL PILOT RUN
Mango Materials incorporated 2012 Postcode Lottery Green Challenge grand prize winner ($650K) USDA ARS partnership is awarded to leverage $40M worth of equipment and lab space 2011 2013 $225K WERF grant awarded for integration with water resource recovery facilities 2015 Field Pilot Operation $750K NASA Phase II STTR grant awarded for membrane-based bioreactor 2017 2010 2012 2014 2016 Molly Morse (CEO) and Allison Pieja (CTO) study PHA production at Stanford University Master Service Agreement with SVCW facilitates use of raw biogas to produce PHA on site A Phase I NSF-SBIR grant determines waste methane can successfully be used to make PHA $500K Phase II NSF- SBIR grant increases yields and scale of Mango Materials biopolymer production Equity raise and grant matching funds used to build field pilot unit Biodegradable fiber for textile is $125K NASA developed Phase I STTR grant awarded for membrane-based bioreactor
MANGO MATERIALS TEAM
KEY PARTNERSHIPS - USDA We have world-class expertise in polymer characterization, processing, biodegradation, and analysis
KEY PARTNERSHIPS - SVCW Testing biogas in field environment Candle Flare Anaerobic Digester Mango Materials
PILOT PLANT Production team creates customer samples and prototypes Location Methane Partner Facility Type Initial Year of Operation PHA Production Capacity Number of Fermentation Runs Redwood City, CA Silicon Valley Clean Water Wastewater treatment plant 2015 500 lbs/year 50+
TECHNOECONOMIC & LIFE CYCLE ANALYSES
TEA: challenges Literature studies Refining inputs at early-stage Selecting platform for model Working with partners on models
TEA: our model Goal: show that we can be competitive with current polymers Uses Excel Easily modifiable Demonstrates that our cost can be <$1/lb Shows sensitivity to personnel, scale
LCA Why haven t we done one? We haven t needed to yet. When we do one, we want to do it well and that s hard.
LCA: we haven t needed one yet. Focus on critical path Investments to date haven t required full LCA Alternate environmental accounting Mixed responses to LCAs
LCA: when we do one, we want to do it well and that s hard. Expensive! Quality of output depends on inputs Difficult to fully define process at earlystage Hard to account for scale-up (change in efficiency & equipment) How to choose boundaries
What would help us complete these analyses? Funding earmarked for LCAs for earlystage companies Workshops/webinars geared towards startups Guidelines for preparation
WHAT DOES THE FUTURE HOLD?
BUSINESS MODEL Flexible business model to operate own plants or license technology $/MMBTU PHA Methane producers $/pound Plastics converters, formers, and distributors Methane Royalty License Dedicated large-scale facilities
SCALE-UP Mango Materials scales production from lab to commercial plant 20L fermenter 500L fermenter 70,000L fermenter 1,000,000L fermenter 300,000 lb capacity 10,000,000 lb capacity Research lab at USDA Pilot plant at Silicon Valley Clean Water Demonstration plant 2018 First-of-its-kind commercial plant 2020+
DECENTRALIZED PRODUCTION
10 A CLOSED LOOP BIOECONOMY IS NOW POSSIBLE LET S BUILD IT!
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