Minimum Selling Price Research Articles

Comparative techno-economic and carbon footprint analysis of 2,3-butanediol production through aerobic and anaerobic bioconversion of carbon dioxide with green hydrogen

Renewable CO2 and hydrogen have the potential to be the feedstocks of a decarbonized chemical industry, and biochemical conversions offer new alternatives for the industry. There are two options among chemolithotrophic bacteria capable of CO2 fixation: under aerobic conditions, through the use of the Calvin-Benson-Basham cycle, known to produce large-chain compounds, and under anaerobic conditions, through the Wood-Ljungdahl pathway, known to produce short-chain organic molecules. Here, we report a comparison of both bioconversions, made at a simulated industrial scale, considering techno-economic and environmental variables, and using renewable CO2 and H2 as feedstocks. 2,3-butanediol, a mid-range chain compound that can be produced via both routes, was selected for comparison. The comparison was set up in Chile due to expected low-cost renewable hydrogen and renewable CO2 availability. The assessment showed that the minimum selling price of 2,3-butanediol in the anaerobic case was higher (3.91 (USD kg−1)) than in the aerobic case (3.36 (USD kg−1)), with hydrogen being the largest expense in both processes (50 % and 70 % of total expenses respectively). Further, owing to metabolic restrictions, the anaerobic process required almost five times more CO2 than the aerobic process to produce the same amount of 2,3-butanediol. A Monte Carlo analysis showed that in most scenarios the aerobic process was more economically favorable. In environmental terms, the aerobic process had a smaller carbon footprint in all the evaluated scenarios. Therefore, the results suggest that the aerobic process is a more suitable alternative to anaerobic bacteria-based processes for producing 2,3-butanediol from renewable CO2 and hydrogen.

Techno-economic and sustainability assessment of the power to MeOH processes: The present and future perspective

This study presents a comprehensive analysis of a Power-to-Methanol (PtM) process, which converts CO2 and H2 derived from electrolysis of water into methanol (MeOH) using renewable energy sources. The process is analyzed for its technical, economic, and environmental aspects, focusing on production costs and the minimum selling price of MeOH. The simulation results show an energy efficiency of 56 % in the optimal state, with a CO2 consumption of 1.4 kg-CO2/kg-MeOH. Economic evaluations for 2023 indicate production costs of US$ 631 and 643 for PtM processes equipped with membrane and amine absorption technologies, respectively. The study also predicts the cost of production and minimum selling price of MeOH from 2023 to 2030 based on the trends of electrolyzer capital investment and renewable resource prices. The results provide valuable insights for the development and evaluation of sustainable MeOH production processes.

Integration of plant and microbial oil processing at oilcane biorefineries for more sustainable biofuel production

AbstractOilcane—an oil‐accumulating crop engineered from sugarcane—and microbial oil have the potential to improve renewable oil production and help meet the expected demand for bioderived oleochemicals and fuels. To assess the potential synergies of processing both plant and microbial oils, the economic and environmental implications of integrating microbial oil production at oilcane and sugarcane biorefineries were characterized. Due to decreased crop yields that lead to higher simulated feedstock prices and lower biorefinery capacities, current oilcane prototypes result in higher costs and carbon intensities than microbial oil from sugarcane. To inform oilcane feedstock development, we calculated the required biomass yields (as a function of oil content) for oilcane to achieve financial parity with sugarcane. At 10 dw% oil, oilcane can sustain up to 30% less yield than sugarcane and still be more profitable in all simulated scenarios. Assuming continued improvements in microbial oil production from cane juice, achieving this target results in a minimum biodiesel selling price of 1.34 [0.90, 1.85] USD∙L−1 (presented as median [5th, 95th] percentiles), a carbon intensity of 0.51 [0.47, 0.55] kg CO2e L−1, and a total biodiesel yield of 2140 [1870, 2410] L ha−1 year−1. Compared to biofuel production from soybean, this outcome is equivalent to 3.0–3.9 as much biofuel per hectare of land and a 57%–63% reduction in carbon intensity. While only 20% of simulated scenarios fell within the market price range of biodiesel (0.45–1.11 USD∙L−1), if the oilcane biomass yield would improve to 25.6 DMT∙ha−1∙y−1 (an equivalent yield to sugarcane) 87% of evaluated scenarios would have a minimum biodiesel selling price within or below the market price range.

Techno-economic assessment of modified Fischer-Tropsch synthesis process for direct CO2 conversion into jet fuel

Direct use of CO2 through modified Fischer-Tropsch synthesis (FTS) process presents a viable approach for the production of carbon–neutral jet fuel. However, achieving high performance for the CO2-FTS process remains a significant challenge. Current technology can only achieve low CO2 conversion and low jet fuel yield using tailored catalysts, which hinders the commercial deployment of direct CO2-FTS process. This paper presents a techno-economic assessment (TEA) of jet fuel production via CO2-FTS process at commercial-scale. Two ex-situ water removal configurations: (a) multi-stage CO2-FTS process and (b) CO2-FTS with tail gas recycle process were conducted to assess their potential for performance improvement. Process performance was evaluated using a model developed in Aspen Plus® linking with Aspen Custom Modeller® (ACM), while economic evaluation was carried out in Aspen Process Economic Analyzer®. The CO2-FTS model was based on first principles and modified Anderson-Schulz-Flory (ASF) distribution. Results indicated that both ex-situ water removal configurations can significantly improve the process performance. CO2-FTS process with 90% tail gas recycle has the best performance for both technical and economic analysis. The process achieved 85.8% CO2 conversion and 35.6% jet fuel yield with the lowest energy demand of 4.57 MWh per tonne of produced jet fuel. Moreover, it boasts the lowest minimum selling price (MSP) of jet fuel at US$2.6/kg despite incurring the second-highest capital expenditure cost of M$ 451.3. A comparison of the two ex-situ water removal configurations at 61.9% and 76.5% CO2 conversion, suggests that both processes exhibit comparable technical performances, yet the recycling of tail gas holds the potential to reduce economic costs. Consequently, this study will inspire researchers on process improvement and cost reduction of the commercial-scale CO2-FTS jet fuel production.

Scale sensitivity of ethanol production via consolidated bioprocessing with consideration of feedstock cost

AbstractWe examine feedstock cost and minimum selling price for ethanol production from corn stover as a function of scale, stover yield, participation rate, and price incentives for two conversion technologies: a conventional base case featuring thermochemical pretreatment with added cellulase, and an advanced case featuring consolidated bioprocessing with cotreatment (C‐CBP). Delivered feedstock cost ranged from $85 Mg−1 at small (10 million gallons year−1 or ~38 million L year−1) scale with high yield and participation rates to $124 Mg−1 at large scale (60 million gallons year−1 or 227 million L year−1) and low yield and participation rates. The minimum ethanol selling price (MESP) was approximately twofold lower for the advanced case compared with the base case. The payback period was several times lower for the advanced case compared with the base case, with increasing disparity at smaller scales, and was highly sensitive to ethanol price supports. For both C‐CBP and the conventional processing paradigm, MESP decreased with increasing scale, indicating that the cost penalty due to higher feedstock transport distances was more than outweighed by lower capital costs. However, the cost penalty for operation at small scale, expressed in $ gallon−1 ethanol, is lower for C‐CBP than for the conventional paradigm by roughly twofold. Particularly for initial applications of C‐CBP, we speculate that this cost penalty will likely be modest compared with the anticipated benefits of small‐scale operation such as increased opportunity to use existing infrastructure, easier plant siting and supply chain establishment, and lower total investment required.

Innovative recycling and conversion of aluminum waste to hydrogen and aluminum chloride: Enhancing economic feasibility and sustainability in Saudi Arabia

The rapid industrialization and urbanization in Saudi Arabia have led to significant challenges in waste management, particularly in recycling aluminum waste. This study explores an innovative approach for converting aluminum waste, specifically beverage cans, into valuable products such as aluminum chloride (AlCl3) and hydrogen (H2). The process involves the chemical reaction of aluminum with hydrochloric acid (HCl), producing AlCl3 and H2, and is modeled using Aspen Plus software. Two scenarios are evaluated: one without recycling and one incorporating recycling processes. In the first scenario, the direct conversion process yields 355 tons of AlCl3 and 9 tons of H2 per day from 100 metric tons of aluminum waste. The minimum selling price (MSP) of AlCl3 is calculated to be $764 per ton, with an annual profit of $25 million, assuming a market price of $1000 per ton. However, the economic viability of this scenario is highly sensitive to conversion efficiencies and market conditions. The second scenario integrates a recycling loop, processing 90 % of the aluminum waste back into aluminum, significantly enhancing economic stability. This scenario produces 35 tons of AlCl3 and 1 ton of H2 per day, with an MSP of $1068 per ton. Despite the higher MSP, the inclusion of recycled aluminum, sold at $2400 per ton, results in a higher annual profit of $38 million, demonstrating greater economic resilience and sustainability. This study provides a comprehensive techno-economic analysis, highlighting the dual benefits of waste reduction and resource recovery. By optimizing reaction conditions and incorporating recycling, the proposed process aligns with Saudi Arabia's Vision 2030 sustainability goals, offering a viable pathway for enhancing economic feasibility and environmental sustainability in aluminum waste management.

Techno-economic Analysis Conversion of Empty and Partially Filled Paddy Grain Waste into Glucose through Bioconversion Route

Waste generated from Malaysia’s paddy milling factories, known as empty and partially filled paddy grain (EPFG), has been improperly managed as it can be further utilized for sustainable resources such as feedstock via biorefinery. However, the critical driver for a biorefinery is whether the proposed design is profitable. In this study, the conversion of EPFG into glucose as an alternative to sustainable management was analysed in terms of their economic performance as feedstock. The process design involved the production of non-concentrated glucose from EPFG using hydrothermal pre-treatment and enzymatic process, which led to the 76% conversion yield. The economic performance for the plant is at 1.04 million USD, 46.9%, and 34.3% for net present value (NPV), return on investment (ROI), and internal rate return (IRR), respectively. The minimum sugar selling price (MSSP), when zero NPV, is at 0.42 $/kg when the co-product revenue is considered. Sensitivity analysis results indicate that the MSSP is highly sensitive to plant size. This economic evaluation serves as an introductory guide to assess the economic performance of paddy milling waste to glucose via enzymatic hydrolysis. The results of the present study could provide insight for the Malaysian paddy industry in managing the EPFG, hence increasing their market potential.

Economic feasibility of the biorefinery processing bamboo residues with biphasic phenoxyethanol-acid pretreatment technology: Techno-economic analysis

This study conducted a techno-economic analysis to assess the economic feasibility of a biorefinery converting bamboo residues to bioproducts via phenoxyethanol-acid pretreatment. The analysis is integrated with a rigorous process simulation model with the support of experiment data. The bioproducts include ethanol or polylactic acid (PLA), with lignin-based wood adhesive as the byproduct. The minimum selling price (MSP) is $515-$819 per t ethanol and $1,512-$1,842 per t PLA when biphasic treatment is deployed, compared to the MSP of $2,318-$2,721 per t ethanol and $2,859-$3,211 per t PLA for no biphasic pretreatment. Adopting a ratio of 1:1 phenoxyethanol: acid solution (1%) in pretreatment decreases the final product yield but leads to lower MSP than 4:1 phenoxyethanol: acid solution (1%) due to lower phenoxyethanol consumption. A sensitivity analysis identifies the key drivers of reducing MSP, including increasing economic gain from the lignin-based wood adhesive, lowering the phenoxyethanol cost, and expanding plant capacity.

Machine learning-enabled techno-economic uncertainty analysis of sustainable aviation fuel production pathways

Stochastic techno-economic analysis (TEA) is pivotal in assessing the financial viability and risks inherent in biofuel production processes. In this method, the Monte Carlo approach entails the random sampling of input variables and multiple runs of the TEA model to create probability distributions of economic metrics. However, traditional Monte Carlo TEA, reliant on iterative calls to process simulation, is resource-intensive and time-consuming, hindering widespread adoption. To address these challenges, we present an accessible framework that harnesses machine learning methods to estimate techno-economic uncertainty in biofuel production pathways. Our approach streamlines the conventional simulation process by automating dataset generation and machine learning model training. These trained models enable rapid predictions of minimum fuel selling prices at any scale, accommodating randomized input variables based on their defined distributions. We illustrate the efficacy of our framework through examples from sustainable aviation fuel production pathways. Our research entails identifying the primary factors influencing uncertainties in minimum selling prices, exploring the synergistic effects of pathway inputs, and assessing how price variability is impacted by financial, technical, and supply chain factors. These examples underscore the framework's effectiveness in addressing breakeven price uncertainties in biofuel production across diverse input scenarios.

Techno-economic analysis of bioplastic and biofuel production from a high-ash microalgae biofilm cultivated in effluent from a municipal anaerobic digester

Rotating Algae Biofilm Reactors (RABRs) are a promising technology for efficient treatment of wastewater and production of algae-based bioproducts. However, RABR-grown algae can contain a high content of ash (30–60 wt%, dry basis), which influences the technical and economic feasibility of bioproduct conversion processes. In this report, experimental studies and economic analysis were conducted to compare different processes for bioproduct conversion of a high-ash microalgae biofilm grown using a RABR treating 0.6 million gallons per day of anaerobic digestion centrate at the Central Valley Water Reclamation Facility in Salt Lake City, UT. Process and economic models were developed and compared for three conversion processes: 1) the production of bioplastics, 2) the production of bioplastics with a lipid-extraction pretreatment, and 3) the production of biocrude via hydrothermal liquefaction. Techno-economic analysis was performed for each conversion process, including three cases for algae productivity: 231, 391, and 577 metric tons per year (dry basis). The calculated value for the minimum plastic selling price (MPSP) of bioplastics produced from algae ranges from $4050 to $3520 per metric ton based on the baseline and final productivity cases of the RABR, respectively. The extraction of lipids in addition to bioplastic production results in an MPSP of $4570 to $4000 per metric ton for the same productivity cases. The relatively small production scale and complex processing for hydrothermal liquefaction results in a minimum fuel selling price of the biocrude of $5.32 per gallon of gasoline equivalent. The conversion process for bioplastic production from whole algae has the highest income:expense ratio and the most cost-competitive pricing of the three modeled processes.

From waste to advanced resource: Techno-economic and life cycle assessment behind the integration of polyester recycling and glucose production to valorize fast fashion garments

This work demonstrates the technical, economical, and environmental viability of integrating enzymatic hydrolysis, mechanical refining, and total chlorine-free (TCF) bleaching processes for industrial-scale production of glucose from textile waste. The process features an innovative mechanical refining pretreatment coupled with TCF oxidation of dyes to achieve over 90% improvement in enzymatic hydrolysis yields of cotton textile waste while also promoting the purification and recycling of synthetic fibers. A comprehensive techno-economic analysis was performed based on a 14,000 bone dry tons (BD tons) annual glucose production line, utilizing both 100% cotton and cotton/polyester blends, reveals capital investments ranging from USD 5.6 to 7.9 million, with manufacturing costs per ton of glucose varying between USD 215 and USD 475, depending on the textile blend used. The cotton/polyester 50/50 blend scenario had the lowest minimum selling price (USD 290 per ton of glucose) due to the revenue from the unhydrolyzed synthetic fibers, which are a valuable and key co-product. A sensitivity analysis highlights the significant influence of recycled polyester content and market prices on the economics. Additionally, a life cycle assessment was performed to compare the carbon footprint of the four scenarios. In contrast to other existing pretreatments that can contribute to up to 70% of the emissions in enzymatic hydrolysis of textiles, the mechanical refining pretreatment can contribute as low as 10% of the total emissions in the process proposed in this work. While certain challenges remain, such as the development of a robust supply chain model, the conversion pathway shown in this work for upcycling cotton textile waste into value-added chemicals represents a promising opportunity to combat textile landfilling and foster the circular economy within the industry.

Process scale-up simulation and techno-economic assessment of ethanol fermentation from cheese whey.

Production of cheese whey in the EU exceeded 55 million tons in 2022, resulting in lactose-rich effluents that pose significant environmental challenges. To address this issue, the present study investigated cheese-whey treatment via membrane filtration and the utilization of its components as fermentation feedstock. A simulation model was developed for an industrial-scale facility located in Italy's Apulia region, designed to process 539m3/day of untreated cheese-whey. The model integrated experimental data from ethanolic fermentation using a selected strain of Kluyveromyces marxianus in lactose-supplemented media, along with relevant published data. The simulation was divided into three different sections. The first section focused on cheese-whey pretreatment through membrane filtration, enabling the recovery of 56%w/w whey protein concentrate, process water recirculation, and lactose concentration. In the second section, the recovered lactose was directed towards fermentation and downstream anhydrous ethanol production. The third section encompassed anaerobic digestion of organic residue, sludge handling, and combined heat and power production. Moreover, three different scenarios were produced based on ethanol yield on lactose (YE/L), biomass yield on lactose, and final lactose concentration in the medium. A techno-economic assessment based on the collected data was performed as well as a sensitivity analysis focused on economic parameters, encompassing considerations on cheese-whey by assessing its economical impact as a credit for the simulated facility, dictated by a gate fee, or as a cost by considering it a raw material. The techno-economic analysis revealed different minimum ethanol selling prices across the three scenarios. The best performance was obtained in the scenario presenting a YE/L = 0.45g/g, with a minimum selling price of 1.43 €/kg. Finally, sensitivity analysis highlighted the model's dependence on the price or credit associated with cheese-whey handling. This work highlighted the importance of policy implementation in this kind of study, demonstrating how a gate fee approach applied to cheese-whey procurement positively impacted the final minimum selling price for ethanol across all scenarios. Additionally, considerations should be made about the implementation of the simulated process as a plug-in addition in to existing processes dealing with dairy products or handling multiple biomasses to produce ethanol.

Biobased propylene and acrylonitrile production in a sugarcane biorefinery: Identification of preferred production routes via techno-economic and environmental assessments

Four alternative, sugar-derived chemical intermediates were compared for the production of propylene and acrylonitrile in energy self-sufficient biorefineries, annexed to an existing sugarcane mill, to assess economic feasibility and environmental sustainability. Aspen Plus® process simulations considered ethanol and isopropanol produced from A-molasses as intermediates for propylene production, while propylene and 3-hydroxypropionic acid (3-HP) from A-molasses were compared for acrylonitrile production. The minimum selling prices (MSPs) for propylene-from-ethanol (3634 $/t), propylene-from-isopropanol (8151 $/t), acrylonitrile-from-propylene (4698 $/t), and acrylonitrile-from-3-HP (5957 $/t) were 280 %, 752 %, 302 % and 409 % above the market prices of fossil-based equivalents. Nonetheless, the propylene biorefineries achieved up to 97 % reduction in greenhouse gas (GHG) emissions, whilst acrylonitrile biorefineries had up to 43 % reduction compared to fossil-based production processes. Based on process yields, energy demand and GHG emissions, ethanol was identified as the preferred intermediate route for all four biorefinery scenarios, while substantial price-premiums will be required for industrial production.

Economic validation and comparison of microbial tryptophan, erythritol and collagen production in an integrated sugarcane biorefinery

Low sugar prices present a significant challenge to the global sugarcane industry, prompting the exploration of diversification strategies for expanding product portfolios. Techno-economic analyses and environmental sustainability assessments were carried out to evaluate the microbial production of tryptophan, erythritol, and collagen from A-molasses in a biorefinery annexed to an existing sugarcane mill. Tryptophan production exhibited the highest profitability, with a minimum selling price (MSP) at 59.7 % of its current market price, although the achievable production volumes of tryptophan from one sugar mill would oversupply the global market. Due to the larger market size of for collagen the achievable production capacity in the collagen scenario would avoid market saturation, reducing the risk of oversupply and rendering it more economically viable. In contrast, erythritol production was marginally not profitable, with an MSP exceeding the current market price by 1 %, primarily attributed to high operational costs. All scenarios demonstrated relatively low greenhouse gas (GHG) emissions (ranging from 9.1 to 16.5 kg CO2eq/kg product), with tryptophan production emerging as the most environmentally favourable option due to minimal chemical and freshwater usage. When compared with literature-reported data on ethanol and short-chain fructooligosaccharides (scFOS), only collagen and ethanol production were deemed viable, based on their favourable profitability and contribution to the market.

COMPARING vaccine manufacturing technologies recombinant DNA vs in vitro transcribed (IVT) mRNA

Vaccine manufacturing fosters the prevention, control, and eradication of infectious diseases. Recombinant DNA and in vitro (IVT) mRNA vaccine manufacturing technologies were enforced to combat the recent pandemic. Despite the impact of these technologies, there exists no scientific announcement that compares them. Digital Shadows are employed in this study to simulate each technology, investigating root cause deviations, technical merits, and liabilities, evaluating cost scenarios. Under this lens we provide an unbiased, advanced comparative technoeconomic study, one that determines which of these manufacturing platforms are suited for the two types of vaccines considered (monoclonal antibodies or antigens). We find recombinant DNA technology to exhibit higher Profitability Index due to lower capital and starting material requirements, pertaining to lower Minimum Selling Price per Dose values, delivering products of established quality. However, the potency of the mRNA, the streamlined and scalable synthetic processes involved and the raw material availability, facilitate faster market penetration and product flexibility, constituting these vaccines preferable whenever short product development cycles become a necessity.

Economic and environmental impact analysis of cellulose nanofiber-reinforced concrete mixture production

Incorporating cellulose nanofibers into concrete has a positive impact on its strength. This study evaluated how cellulose nanofiber-reinforced concrete affected the economic and environmental performance compared to conventional concrete. The estimated minimum selling price per unit mass (m3) per unit compressive strength (MPa) of cellulose nanofiber-reinforced concrete mixture is 12 % lower ($2.52/m3/MPa) compared to the minimum selling price of conventional concrete mixture ($2.87/m3/MPa). However, when comparing the minimum selling price on a mass basis, the cellulose nanofiber-reinforced concrete mixture showed a 3.33 % higher minimum selling price ($150/m3) than the conventional concrete mixture ($145/m3). Similarly, the estimated global warming impact of cellulose nanofiber-reinforced concrete mixture was higher by 0.59 % when evaluated on a mass basis (509.88 kg CO2 eq/m3) but 14.5 % lower when evaluated on per m3 per unit compressive strength basis (8.57 kg CO2 eq/m3/MPa), compared to conventional concrete mixture (506.88 kg CO2 eq/m3 or 10.02 kg CO2 eq/m3/MPa).

Maximizing biomass utilization: An integrated strategy for coproducing multiple chemicals

Lignocellulosic biomass is one of the viable solutions to alleviate the global warming. However, the limited utilization of biomass majorly focused on cellulose and hemicellulose restricts the economic and environmental feasibilities. To cope with this issue, we proposed an integrated process of co-producing 1,6-hexanediol (1,6-HDO) with tetrahydrofuran and adipic acid from biomass, referred to as Strategy A. To compare the impacts of lignin upgrading and feedstock, Strategy B, which co-produces tetrahydrofuran alone, and Strategy C, which is the traditional route to produce 1,6-HDO from fossil fuels, were used. Heat networks are also designed to reduce operating costs and indirect carbon emissions due to energy consumption, saving 87% and 83% of the heat and cooling requirements, respectively, in Strategy A. The market competitiveness of Strategy A was evaluated by determining the minimum selling price through techno-economic analysis, and sustainability was thoroughly investigated by quantifying the environmental impacts through both midpoint and endpoint life-cycle assessments (LCAs). Strategy A was found to be the most favorable both economically (US$3,402/ton) and environmentally (−26.9 kg CO2 eq.). This indicates that lignin valorization is not only economically but also environmentally preferred. Finally, changes in economic and environmental feasibilities depending on economic, process, and environmental parameters were investigated using sensitivity and uncertainty analyses. The results of these analyses provide valuable insight into bio-based chemical production.

Life cycle GHG emissions and economic viability of two levulinic acid production processes from biomass: A case study of Japan and Canada

We evaluated CO2 equivalent (CO2eq) greenhouse gas (GHG) emissions and minimum selling price of levulinic acid (LA) produced in two biomass-waste-based processes: the AlCl3/choline chloride (ChCl) process, and the formic acid (FA) process, with catalysts recycling. Six scenarios were synthesized to compare the performances of the two processes in Japan and Canada. In the AlCl3/ChCl process, the total GHG emission was 11.35–11.56 kg-CO2eq/kg-LA and those from the energy input to the pretreatment and ChCl production were 5.22 and 3.90 kg-CO2eq/kg-LA, respectively. In the FA process, the total GHG emission was 9.46–9.68 and 22.29–22.51 kg-CO2eq/kg-LA for 60 wt% and 80 wt% FA, respectively. The operational emissions for makeup FA input were 7.65 and 20.80 kg-CO2eq/kg-LA (60 wt% and 80 wt%, respectively), which accounted for more than 80% in all scenarios. The optimization of the product purge volume, FA concentration in the pretreatment, and FA production using biomass and/or renewable energy are critical parameters to reduce overall environmental impacts of the processes. The liquid content of the solid residue (moisture, water soluble organic matters, and catalyst) had insignificant influences on the GHG emission and minimum selling price. In the FA process, combustion of solid residue can compensate the GHG emissions from the reaction and separation units.

Resources, energy consumption and economic analysis for flame synthesis of ternary cathode materials

Cathode materials account for around one third of the manufacturing cost of lithium-ion battery, which are the major factor preventing the wider applications of power battery packs. Flame synthesis (FS) is a new manufacturing technology of nanostructured materials with few equipment and high efficiency, which potentially can substantially bring down the manufacturing cost of cathode materials. The primary objective of the present study was to quantitatively evaluate the resources, energy consumption and economic feasibility of large-scale production of cathode materials though FS. In the analysis process, the mass flow of reactants and resultants as well as the minimum cathode material selling price (MCSP) of ternary cathode material LiNixCoyMn(1-x-y)O2 (x + y + z = 1) produced by FS were calculated, and compared with that of the conventional hydroxide co-precipitation method. Results show that the production of ternary cathode material through FS can reduce CO2 emissions by ∼60% and water consumption by ∼30%. MCSP of LiNi0.5Co0.2Mn0.3O2 (NCM523), LiNi0.6Co0.2Mn0.2O2 (NCM622), and LiNi0.8Co0.1Mn0.1O2 (NCM811) produced by FS are 224.8 k¥/t, 235.1 k¥/t, 240.0 k¥/t, which respectively are about 2%, 10% and 14% lower than the average selling prices in Chinese market, indicating that FS is economically feasible for producing ternary cathode materials. Particularly, for the production of high-nickel cathode materials, FS has notable potential in simplifying the production process and manufacturing costs. Sensitivity analysis of NCM811 produced by FS shows that when raw material price, fuel and power costs are reduced by 25%, MCSP can be as low as 186.4 k¥/t. When the metal cation concentration of the solution increases to 3.2 mol/L, it enables FS to meet the most rigorous energy consumption limitation standards in China. When the lithium excess is reduced from 10% to 5%, MCSP of NCM811 can be further reduced by 5.6 k¥/t, indicating that lithium loss due to high temperatures in FS is a moderate factor for reducing the manufacturing cost. Finally, this work presents a life cycle assessment (LCA) of NCM materials produced by FS in China. Comparison to the global warming potential (GWP) of the co-precipitation method in the literature indicated that GWP of FS is lower.

Process Modelling of Integrated Bioethanol and Biogas Production from Organic Municipal Waste

One of the key guidelines in the European waste management policy is the diversion of waste from landfills, preventing harmful effects on human health and the environment and ensuring that economically valuable waste materials are efficiently recycled and reused through proper management. The organic fraction of municipal waste is abundant and contains biodegradable ingredients such lignocellulose, starch, lipids, pectin, and proteins, making it suitable for biotechnological production. Taking into account that a large amount of organic waste is disposed of in landfills, within this work, the amount of organic waste disposed of in the landfill in Banja Luka was considered. Four simulation model scenarios of the integrated production of bioethanol and biogas are generated, and their process and economic aspects are discussed. In the first two modelled scenarios, the pretreatment conditions (1% sulfuric acid and a different neutralization agent) were varied, while in the other two, the share of the amount of raw material used for the production of bioethanol, i.e., biogas, was varied (split factor: 10–90%). The modelled plant, with a designed capacity of 6 tons/h of organic waste, is a significant bioethanol producer, generating 5,000,000 L/year. The profitability indicators, when examined, revealed that dedicating a portion of the organic municipal waste input exclusively to biogas production leads to decreased process efficiency. Based on the modeled process parameters, ethanol’s minimum feasible selling price is $0.6616 per liter, while regarding the composition of organic municipal waste, carbohydrates have the most significant impact on the viability of the process. The developed model represents an excellent basis for further development of this integrated bioprocess in such a way that it can be modified with new process parameters or economic or ecological indicators and used at all levels of bioprocess design. Additionally, the obtained sustainable integrated bioethanol and biogas production plant models could support forthcoming steps in municipal waste management by providing reliable data on the conditions under which the integrated process of bioethanol and biogas production would take place, as well as the technical feasibility and economic profitability of such organic municipal waste utilization.