The $5 trillion world chemical compounds sector is a basis of our trendy financial system. It’s additionally the largest industrial client of oil and fuel and has the third-largest carbon footprint. Propped up by many years of inefficient, vitality intensive and soiled processes, the chemical compounds business is below intense stress to scrub up its act. 

Based seven years in the past, Houston-based Solugen has developed a course of that harnesses biology to provide a spread of merchandise, from plant vitamins to corrosion inhibitors, eliminating the carbon-intensive fossil gasoline feedstocks and dangerous chemical waste streams related to standard petrochemicals.

In late October, the corporate introduced that it’s constructing a brand new 500,000-square-foot biomanufacturing facility, referred to as Bioforge 2, in Marshall, Minnesota. Scheduled for phase-one launch within the first half of 2025, Solugen’s second business facility marks the start of a brand new period for the chemical compounds business, whereby a variety of the chemical compounds might be produced at scale at a single plant with no carbon emissions or waste.

“One of many largest challenges for the chemical business is dashing up the tempo of innovation to develop new catalysts for desired chemical transformations rapidly,” stated Karthish Manthiram, a professor of chemistry and chemical engineering on the California Institute of Know-how. “Solugen has confirmed that their platform results in quick outcomes, assuaging this bottleneck.”

Increasing the market

The worldwide inexperienced chemical compounds market was valued at $82.5 billion in 2022 and is predicted to have an annual progress price of 12.1 p.c between now and 2030. However it has struggled to give you options that may attain business scale rapidly.

A spread of firms are trying to alter that. Origin Supplies, which turns wooden chips into precursors of polyethylene terephthalate, or PET, generally utilized in plastic packaging, started working its first commercial-scale facility in June. In the meantime, Newlight Applied sciences has been harnessing the facility of microbes at its plant in Huntington Seashore, California, to seize greenhouse gases since 2020. The microbes produce a resin that can be utilized in foodware and textiles. Each startups have raised a whole lot of thousands and thousands of {dollars} in funding.

Solugen is distinguished by the flexibility of its course of and the velocity at which it scales. Whereas rivals produce a restricted vary of merchandise, Solugen claims that its genetically engineered enzymes — organic catalysts that may facilitate the chemical response of 1 molecule to a different whereas remaining unchanged themselves — might be designed to provide a number of molecules.

“The effectivity and scalability of our course of imply we will present our clients with the identical chemistries they know and belief at a decrease price, greater efficiency and rather more favorable environmental profile,” stated Tom Richardson, interim chief business officer at Solugen.

Chemical processes can take effectively over a decade to go from idea to manufacturing, however Solugen has taken its versatile platform from a napkin-scribbled concept to not one however two business scale amenities in seven years.

Accelerated by AI

The corporate had its genesis throughout an innovation growth within the subject of artificial biology — the science that redesigns organisms for helpful functions by engineering them to have new skills. At this time, utilizing synthetic intelligence, Solugen can design enzymes at a price unimaginable 10 years in the past.

The method of manufacturing chemical compounds is remarkably easy in comparison with conventional petrochemicals. Corn sugar is fed right into a reactor, the place it’s transformed by the enzymes into an energetically favorable intermediate. After that, extra conventional chemical reactions remodel the intermediate into the ultimate product.

The third step is purification, the place water and hint impurities are evaporated off to achieve the customer-specified focus.

Whereas a conventional petrochemical course of would possibly flip 50 p.c of its fossil gasoline feedstock into the specified product, the Bioforge converts about 96 p.c of its corn sugar feed. The workforce goals to push that as much as 100% inside just a few years, Richardson stated.

The entire course of is carbon-negative as a result of corn absorbs carbon from the ambiance to develop, and the plant itself runs totally on wind vitality.

With the arrival of Bioforge 2, the chemical compounds business lastly has a course of that produces zero carbon emissions and no waste and might make a versatile vary of merchandise. In the long run, Solugen hopes to construct a community of sustainable chemical vegetation that may function a lot nearer to shoppers than hazardous petrochemicals ever may. All of this, Richardson stated, will turn into a part of a “decentralized bioeconomy.”

“We envision a world the place you may have totally carbon-negative cities the place each single materials you could see, really feel and contact might be produced with Solugen’s chemistry that’s sequestering CO2 from the ambiance,” Richardson stated.

Different firms will begin following in Solugen’s footsteps, stated John Cumbers, founder and CEO of the artificial biology skilled community SynBioBeta: “Their success may function a beacon for different startups and innovators seeking to harness the facility of biology for industrial functions.”