From laboratory to industrial scale scale-up calculations of - PowerPoint PPT Presentation

From laboratory to industrial scale scale-up calculations of chemical processes for LCA Fabiano Piccinno 1,2 Roland Hischier 1 , Stefan Seeger 2 , Claudia Som 1 1 Empa, Technology and Society Lab, St. Gallen, Switzerland 2 University of Zurich, Department of Chemistry, Zurich, Switzerland

Outline  Scale-up framework  Case study: NanoCelluComp

Scale-up of chemical processes fda.gov frings.com

Scale-up framework

Scale-up procedure Scale-up of Scale-up of Plant flow Plant flow Linkage of Linkage of Lab protocol Lab protocol each process each process Perform LCA Perform LCA chart chart process step process step step step

Material and energy in- and output of a reaction process  Focus on liquid phase batch reactor processes Heating Energy Heating Energy Heating Energy Heating Energy Stirring Energy Stirring Energy Stirring Energy Stirring Energy Heating Energy Heating Energy Heating Energy Other Energy Other Energy Other Energy Chemicals, Chemicals, Chemicals, Water Water Water Reaction Process Reaction Process Reactants Reactants Reactants Reactants Processing, Purification, Processing, Purification, Processing, Purification, Heated Liquid Phase Batch Heated Liquid Phase Batch Heated Liquid Phase Batch Heated Liquid Phase Batch Reaction Reaction Reaction Reaction Product Product Product Solvent Solvent Solvent Solvent Mixture Mixture Mixture Mixture Isolation Steps Isolation Steps Isolation Steps Reaction Step Reaction Step Reaction Step Reaction Step Heat Recovery (Co-/By-Product) (Co-/By-Product) (Co-/By-Product) (Catalyst) (Catalyst) (Catalyst) (Catalyst) Wastewater Wastewater Wastewater Waste Heat Waste Heat Waste Heat Emissions Emissions Emissions Waste Waste Waste Waste Heat Waste Heat Waste Heat Emissions Emissions Emissions Emissions Waste Heat Material Recovery Water Recovery

Production plant with multiple reaction processes Outputs Outputs Outputs Outputs Outputs Outputs Inputs Inputs Inputs Inputs Inputs Inputs Reaction Reaction Reaction Reaction Reaction Reaction Reaction Intermediate Intermediate Intermediate Intermediate Product Product Product Product Process Process 3 Process 3 Product Product Process 1a Process 1a Process 2 Process 2 Intermediate e t a Product t i c d u e Heat/Material Recovery Heat/Material Recovery Heat/Material Recovery Heat/Material Recovery d m o r r e P t n I Reaction Reaction Process 1b Process 1b Outputs Outputs Inputs Inputs Infrastructure Chemical Production Plant

Case study

Lab production and plant flow chart Waste- water Production of GripX Hazardous waste Boiling in Enzymatic Addition of Addition of Carrot Liberated Nanocellulose Homogen- Coated MFC Water and Depolymerizati Coating, Carrier Wet Spinning izing Yarn Waste MFC Aging Breakdown on Polymer Waste- Waste- Waste- water water water Byproducts (hemicellulose, pectins...) Production of 94 kg per batch  ~ 700 t/a

Scenario Analyses Stirred heated Enzyme Deactivation Solvent Recovery Starting material: reaction tank  Heat  Without  Whole Carrot  Bleach (ClO2)  With (95 %)  Carrot Pomace Heated pressure batch reactor with Reaction tank intank homogenizer Stirred heated with homogenizer reaction tank Heated drum rolls Yarn Collection Pump Coagulation bath Washing bath Filter tank with pump Degassing tank

Scenario Analyses Stirred heated Heat Recovery reaction tank Preheat inlet stream with waste heat Heated pressure batch reactor with Reaction tank intank homogenizer Stirred heated with homogenizer reaction tank Heated drum rolls Yarn Collection Pump Coagulation bath Washing bath Filter tank with pump Degassing tank

LCIA – production of 1 kg spun yarn 8 ReCiPe Endpoint - total 7 Whole Carrots Carrot Pomace 6 5 4 3 2 Heat Heat 1 0 1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 10 C -1 -2 -3 -4 MFC Liberation GripX -5 Spinning Acetone C Pumping C Infrastructure -6 electricity (solvent incineration) heat (solvent incineration)

LCIA – production of 1 kg spun yarn 8 ReCiPe Endpoint - total 7 Whole Carrots Carrot Pomace 6 5 4 3 2 Bleach Bleach Heat Heat 1 0 1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 10 C -1 -2 -3 -4 MFC Liberation GripX -5 Spinning Acetone C Pumping C Infrastructure -6 electricity (solvent incineration) heat (solvent incineration)

LCIA – production of 1 kg spun yarn 8 ReCiPe Endpoint - total 7 Whole Carrots Carrot Pomace 6 5 4 3 2 Bleach Bleach Heat Heat 1 Heat Heat 0 1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 10 C -1 -2 -3 -4 MFC Liberation GripX -5 Spinning Acetone C Pumping C Infrastructure -6 electricity (solvent incineration) heat (solvent incineration)

LCIA – production of 1 kg spun yarn 8 ReCiPe Endpoint - total 7 Whole Carrots Carrot Pomace 6 5 4 3 2 Bleach Bleach Heat Heat 1 Heat Heat Heat Heat 0 1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 10 C -1 -2 -3 -4 MFC Liberation GripX -5 Spinning Acetone C Pumping C Infrastructure -6 electricity (solvent incineration) heat (solvent incineration)

LCIA – production of 1 kg spun yarn 8 ReCiPe Endpoint - total 7 Whole Carrots Carrot Pomace 6 5 4 3 2 Bleach Bleach Bleach Bleach Heat Heat 1 Heat Heat Heat Heat 0 1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 10 C -1 -2 -3 -4 MFC Liberation GripX -5 Spinning Acetone C Pumping C Infrastructure -6 electricity (solvent incineration) heat (solvent incineration)

LCIA – production of 1 kg spun yarn 8 8 ReCiPe Endpoint - total ReCiPe Endpoint - total 7 7 Whole Carrots Carrot Pomace 6 6 5 5 4 4 3 3 2 2 Bleach Bleach Bleach Bleach Heat Heat 1 1 Heat Heat Heat Heat Heat Heat Heat Heat 0 0 1 C 1 C 2 C 2 C 3 C 3 C 4 C 4 C 5 C 5 C 6 C 6 C 7 C 7 C 8 C 8 C 9 C 9 C 10 C 10 C -1 -2 -3 -4 MFC Liberation GripX -5 Spinning Acetone C Pumping C Infrastructure -6 electricity (solvent incineration) heat (solvent incineration)

LCIA – Comparison with Lab Scale and Competing Fibres ReCiPe Endpoint Indicators Carbon Fibre Glass Fibre Bleach 10 C, no Acetone Bleach 10 C Heat 1 C Lab Scale 0 1 2 3 4 5 6 7 8 ecosystem quality - total human health - total resources - total

Conclusions  Framework helpful in predicting LCA  Scenario analyses for understanding  Treat results with caution  LCA results help to focus on key contributors and optimize process

Acknowledgement: Contact: Fabiano Piccinno fabiano.piccinno@uzh.ch

LCIA – production of 1 kg spun yarn 0,3 Photochemical Oxidant Formation Potential 0,25 0,2 0,15 NMVOC Eq [kg] 0,1 0,05 0 1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 10 C -0,05 MFC Liberation GripX -0,1 Spinning Acetone C Pumping C Infrastructure electricity (solvent incineration) heat (solvent incineration)

Application – Motorhome Example Production of bioresin or conventional resin Hand lay-up Composite to Nanocellulose Composite Production of Use of Municipal Waste Production for Yarn Motorhome Motorhome Incineration Motorhome • System 10 C (lowest impact) used for Cellulose • Functional Unit: 1 Motohome • Transports not included

Global Warming Potential GF 300 GF 80 NFC/Bio- Epoxy 300 NFC/Bio- Epoxy 80 0 20 40 60 80 100 120 CO2 Eq [t]