Process Integration for the Production of Bioplastic Monomer: Techno-Economic Analysis and Life-Cycle Assessment

Abstract

The transition from fossil fuels to biomass as a source of polymeric materials is regarded as a sustainable approach. 2,5-Furandicarboxylic acid (FDCA) is an alternative to terephthalic acid (TPA), a petrochemical monomer used to produce polyethylene terephthalate (PET). Polycondensation of FDCA yields polyethylene furan-2,5-dicarboxylate (PEF), which exhibits superior properties to PET. In this study, an integrated process was developed for converting biomass-derived glucose into FDCA. Heat integration through pinch analysis was employed to minimize energy consumption. The minimum selling price (MSP) was calculated based on discounted cash flow analysis. The MSP of FDCA was estimated to be $1064/tonne, which is cost-competitive compared to the most recent (June 2023) production cost of TPA, with an MSP of $1110/tonne. Life-cycle assessment was used to estimate the environmental impacts associated with FDCA production. Finally, a sensitivity analysis was performed to identify the impact of the key process parameters on the economic and environmental performance. The results show that a variation of ±20% in the feedstock price can impact the MSP to vary ±7% and the global warming potential to vary ±12%.