Engineered microbes turn biodiesel waste into plastic ingredient at 300-liter scale - Engineering - Energy & Green Tech

Microbial-based process for 1,3-propanediol (1,3-PDO) production. Credit: Nature Chemical Engineering (2026). DOI: 10.1038/s44286-026-00389-w

Naphtha, an essential feedstock for the petrochemical industry, has faced sharp price increases and supply instability in recent years, driving demand for sustainable alternatives. The KAIST-Hanwha Solutions Future Technology Research Institute, has secured bio-technology capable of mass-producing eco-friendly raw materials for plastics and textiles using waste resources, offering an alternative to petroleum-derived naphtha.

The new technology addresses both resource supply stability and environmental concerns simultaneously.

The study, led by Distinguished Professor Sang-yup Lee of the Department of Chemical and Biomolecular Engineering, was published in the journal Nature Chemical Engineering.

This platform uses "glycerol," a byproduct discarded during the biodiesel production process, as a raw material. The team engineered high-efficiency microorganisms to convert this waste into 1,3-propanediol (1,3-PDO), a key material for plastics and cosmetics, and optimized the fermentation process for industrial application.

The research team succeeded in maintaining a high production level even in a 300L pilot process, which serves as a test production stage before application in large-scale plant facilities, moving beyond the laboratory scale.

This study also used computer simulations to predict which genes to engineer, which resulted in improved production levels. The team also developed the fermentation system without antibiotic supplementation—a significant advance, as antibiotic use in industrial fermentation raises concerns about antimicrobial resistance and regulatory hurdles for food, cosmetic, and pharmaceutical applications.

Schematic diagram of microbial-based metabolic engineering strategies for 1,3-PDO production. Credit: Nature Chemical Engineering (2026). DOI: 10.1038/s44286-026-00389-w

The achievement reflects a 10-year partnership between KAIST and Hanwha Solutions that began in November 2015, with researchers from both sides working together directly on the experiments.

Through the KAIST-Hanwha Solutions Future Technology Research Institute, the collaboration has produced six patent applications and 13 published papers, standing as a representative model of industry-academic cooperation in South Korea.

Jung-dae Kim, head of the Research Institute at Hanwha Solutions, said, "This research is highly significant in that it confirms the possibility of replacing existing petrochemical processes using bio-based raw materials. We expect it to be an important foundation for sustainable chemical material production and industrial application in the future."

KAIST Distinguished Professor Sang Yup Lee of the Department of Chemical and Biomolecular Engineering said, "This research is a case showing that microorganism-based chemical production can be sufficiently expanded to an actual industrial scale beyond the laboratory. It will contribute to producing various chemical materials in a more eco-friendly way in the future." 

Provided by The Korea Advanced Institute of Science and Technology (KAIST) 

by The Korea Advanced Institute of Science and Technology (KAIST)

edited by Sadie Harley, reviewed by Robert Egan 

Source: Engineered microbes turn biodiesel waste into plastic ingredient at 300-liter scale