Process design and analysis for the production of sustainable bioplastic

다국어 초록 (Multilingual Abstract)

The use of plastic or synthetic polymer is getting accelerated as the global population grows. Most of the plastic has been produced from fossil fuel and it causes considerable concern about climate change and fossil depletion. Lignocellulosic biomass is a sustainable carbon source and can produce various fuels and chemicals by replacing conventional fossil fuel. Although many studies have been performed to produce bio-based plastic from lignocellulosic biomass, there is a limitation due to the fact that they mainly focused on the element technologies. However, for commercialization, the development of an integrated process is indispensable by designing a separation process. Therefore, in this Master’s study, we develop the integrated process producing bioplastic and biodegradable plastic monomers and analyze to estimate the feasibility and sustainability of the developed process.
In Application Ⅰ, we propose a process for synthesis of 2,5-furandicarboxylic acid (FDCA), which is a monomer of bioplastic, from biomass-derived cellulose through catalytic conversion. Cellulose is dehydrated to 5-hydroxymethylfurfural and subsequently oxidized to FDCA. To reduce utility consumption, we designed a heat exchanger network for heat integration. The minimum selling price (MSP) of FDCA is determined to be $1,532/ton, which is comparable to the market price of terephthalic acid (TPA). Through the LCA, we quantify the environmental impact and figure out how to enhance the developed process in terms of sustainability viewpoints.
In Application Ⅱ, we propose an integrated process for the production of lactic acid, which is a biodegradable plastic monomer, from lignocellulosic biomass through biochemical conversion. Biomass is produced to lactic acid via dry dilute acid pretreatment, biodetoxification, and simultaneous saccharification and fermentation. We conduct heat integration and reduce utility consumption mainly required in the separation subsystem. Our TEA reveals that the MSP of lactic acid is determined to be $1,498/ton, which is approximate to the market price of lactic acid ($1,526/ton). Further, we evaluate the proposed process via integrative analyses including pioneer plant, and uncertainty analyses to quantify the risk and uncertainty during the construction and fluctuation of market situation. Through the LCA, we found the major contributor to environment and suggest the method for improving the sustainability of the process.

목차 (Table of Contents)

• Contents Ⅰ
• Table Contents Ⅲ
• Figure Contents Ⅳ
• Abstract Ⅵ
• Chapter 1. Introduction 1
• 1. Research background and motivation 1
• 2. Technical challenges and literature survey 5
• 3. Application study 7
• 4. Objectives of the research 7
• Chapter 2. Methods 8
• 1. Simulation 8
• 2. Techno-economic analysis 8
• 3. Pioneer plant analysis 9
• 4. Uncertainty analysis 9
• 5. Life-cycle assessment 10
• Chapter 3. Application Ⅰ: biomass to 2,5-furandicarboxylic acid (bioplastic monomer) 17
• 1. Process development 17
• 1.1. Process description 17
• 1.2. Heat integration 22
• 2. Techno-economic analysis 22
• 2.1. Capital and operating costs 22
• 2.2. Minimum selling price 28
• 2.3. Pioneer plant analysis 28
• 2.4. Sensitivity analysis 37
• 3. Life-cycle assessment 41
• 3.1. Environmental impact assessment 41
• 4. Summary 46
• Chapter 4. Application Ⅱ: biomass to lactic acid (biodegradable plastic monomer) 47
• 1. Process development 47
• 1.1. Process description 47
• 1.2. Heat integration 52
• 2. Techno-economic analysis 52
• 2.1. Capital and operating costs 52
• 2.2. Minimum selling price 57
• 2.3. Pioneer plant analysis 64
• 2.4. Sensitivity analysis 64
• 2.5. Uncertainty analysis 67
• 3. Life-cycle assessment 67
• 3.1. Environmental impact assessment 68
• 4. Summary 72
• Chapter 5. Conclusions and future study 73
• References 74
• List of publications 79