All-polyamide composite coated fabric (APCCF) materials were developed and used as the material of construction of textile bioreactors as a replacement of traditional costly steel-/concreate-based bioreactors. Then, APCCF-bioreactor was used to cultivate filamentous fungus Neurospora intermedia to produce ethanol and fungal biomass. The results showed similar performance of the fungus cultivated in stain-less steel bioreactors. Techno-economical analysis for a 5000-m³ APCCF bioreactor for fermentation facility would lead to a reduction of the annual production cost of the facility by $128,000,000 compared to similar stainless-steel processes. The comparative analyses (including mechanical and morphological analyses, density measurements and techno-economical analysis) revealed that the APCCF is a better candidate for material of construction of the textile bioreactor. The APCCF is a 100% recyclable single polymer composite which was prepared from textile production line waste.

Polyamides (PAs) are one of the most important engineering polymers; however, the difficulty in dissolving them hinders their applications. Formic acid (FA) is the most common solvent for PAs, but it has industrial limitations. In this contribution, we proposed a new solvent system for PAs by replacing a portion of the FA with urea and calcium chloride (FAUCa). Urea imparts the hydrogen bonding and calcium ion from the calcium chloride, as a Lewis acid was added to the system to compensate for the pH decrease due to the addition of urea. The results showed that the proposed solvent (FAUCa) could readily dissolve PAs, resulting in less decrease in the mechanical properties during the dissolution. The composite prepared using the FAUCa has almost the same properties like the one prepared using the FA solution. The solution was applied on a polyamide 66 fabric to make an all-polyamide composite coated-fabric, which then was characterized. The FAUCa solution had a higher viscosity than the one prepared using the neat FA solvent, which can be an advantage in the applications which needs higher viscosity like preparing the all-polyamide composite coated-fabric. A more viscouse solution makes a denser coating which will increase the water-/gas-tightness. In conclusion, using the FAUCa solvent has two merits: 1. replacement of 40 % of the FA with less harmful and environmentally-friendly chemicals and 2. enabling for the preparation of more viscouse solutions, which makes denser coating.