20/05/2026 (Interesting Engineering) - The new process turns biodiesel byproduct glycerol into 1,3-propanediol, a key industrial material, and has already shown strong results in a 300-liter pilot run.

Researchers in South Korea have introduced a new biotechnology platform that may help the petrochemical industry rely less on petroleum-based naphtha. On May 19, the Korea Advanced Institute of Science and Technology and Hanwha Solutions announced they have developed a way to mass-produce eco-friendly raw materials for plastics and textiles from waste generated by biodiesel production.

The study, led by Sang-yup Lee, comes at a time when global naphtha prices are volatile due to supply constraints and higher demand from the petrochemical industry. Researchers say their new process could make industrial feedstocks more reliable and reduce environmental impact.

Waste glycerol turned into industrial material

The platform uses glycerol, a byproduct of biodiesel production. Instead of throwing it away, the team engineered microorganisms that turn it into 1,3-propanediol (1,3-PDO), a material used in plastics, cosmetics, and textiles. Researchers said they improved the fermentation process so it works for large-scale industrial production, not just small lab experiments.

The team demonstrated the technology in a 79-gallon (300-liter) pilot-scale process, an important step before using it in large factories. Maintaining high production at this scale was a major step toward commercial use.

According to the researchers, this system could serve as an alternative to petroleum-based naphtha, a key raw material in the petrochemical industry.

Computer simulations improved production

The scientists used computer simulations to determine which genes to modify in the microorganisms. This approach improved production efficiency and increased output during the process.

Another important step was removing the need for antibiotics during fermentation. Antibiotics are often used in industrial fermentation, but they can raise concerns about antimicrobial resistance and make regulatory approval more difficult in areas such as food, cosmetics, and pharmaceuticals.

By creating an antibiotic-free fermentation system, the researchers believe the platform could face fewer regulatory hurdles in future industrial applications.

Decade-long partnership produced patents and studies

This research is the result of almost 10 years of teamwork between KAIST and Hanwha Solutions, which started in November 2015. Scientists and engineers from both groups worked closely together during the experiments.

During the partnership, the institute filed six patent applications and published 13 research papers. This collaboration is seen as a leading example of industry-academic cooperation in advanced chemical and biotechnology research 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.”

Researchers see path toward greener manufacturing

The researchers believe the platform could help develop more environmentally friendly methods for producing chemicals and use industrial waste more effectively.

Lee said this achievement shows that using microorganisms to produce chemicals can go beyond the lab and into large-scale manufacturing. “It will contribute to producing various chemical materials in a more eco-friendly way in the future,” he added.

https://interestingengineering.com/energy/kaist-plastic-ingredient-biodiesel-waste