Towards greener approach: Techno-economic insights into formaldehyde bio production from a hybrid pine and mustard biomass combination

Abstract

In an era marked by environmental crises and dwindling fossil resources, the need to revolutionize industrial processes for sustainability is paramount. Formaldehyde synthesis, a pivotal precursor in industries spanning polymers, resins, and textiles, stands at a critical juncture where innovation and necessity intersect. Conventional methods of formaldehyde production, despite their efficiency, remain tethered to non-renewable feedstocks and energy-intensive techniques, perpetuating ecological harm and resource constraints. This study explores eco-friendly pathways for formaldehyde production. Recent strides in bio-based chemistry enable the creation of formaldehyde from renewable biomass, reducing energy use and carbon emissions. Decentralized production with locally sourced biomass boosts supply chain resilience and community-centered sustainability. The research employs Aspen Plus® software to model a two-step process: gasification of a hybrid pine and mustard biomass blend to produce bio-methanol, followed by its oxidation into formaldehyde. Sensitivity analyses demonstrate temperature's impact on syngas composition, with higher temperatures favoring hydrogen production. The air-to-biomass ratio affects carbon dioxide content and energy content, crucial for efficient energy production. In formaldehyde synthesis, the air-to-methanol ratio significantly influences yield. Economically, formaldehyde bio- production shows promise, with an 8.50% return on investment and a 22.16-year payback period. An annual net profit of $2.41 million is projected, with a break-even point at $53.47 million in total sales revenue. This research underscores the convergence of sustainability, innovation, and economic viability in formaldehyde bio-production, offering valuable insights for environmentally friendly chemical manufacturing and the broader transition to ecological progress.