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

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

Jul 19, 2023 127 likes •370 views

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,

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SLIDE 1

From laboratory to industrial scale

scale-up calculations of chemical processes for LCA

Fabiano Piccinno1,2 Roland Hischier1, Stefan Seeger2, Claudia Som1

1Empa, Technology and Society Lab, St. Gallen, Switzerland 2University of Zurich, Department of Chemistry, Zurich, Switzerland

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SLIDE 2

Outline

 Scale-up framework  Case study: NanoCelluComp

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SLIDE 3

fda.gov frings.com

Scale-up of chemical processes

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SLIDE 4

Scale-up framework

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SLIDE 5

Scale-up procedure

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

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SLIDE 6

Material and energy in- and output of a reaction process

 Focus on liquid phase batch reactor processes

Heated Liquid Phase Batch Reaction Step

Processing, Purification, Isolation Steps

Product

(Co-/By-Product)

Heating Energy Stirring Energy

Solvent Reactants

(Catalyst)

Waste Heat Waste Heat Waste Wastewater Heating Energy Chemicals, Water

Reaction Mixture

Heat Recovery Material Recovery Water Recovery Emissions Emissions Other Energy

Reaction Process

Heated Liquid Phase Batch Reaction Step

Processing, Purification, Isolation Steps

Product

(Co-/By-Product)

Heating Energy Stirring Energy

Solvent Reactants

(Catalyst)

Waste Heat Waste Heat Waste Wastewater Heating Energy Chemicals, Water

Reaction Mixture

Emissions Emissions Other Energy

Reaction Process

Heated Liquid Phase Batch Reaction Step

Processing, Purification, Isolation Steps

Product

(Co-/By-Product)

Heating Energy Stirring Energy

Solvent Reactants

(Catalyst)

Waste Heat Waste Heat Waste Wastewater Heating Energy Chemicals, Water

Reaction Mixture

Emissions Emissions Other Energy

Heated Liquid Phase Batch Reaction Step

Heating Energy Stirring Energy

Solvent Reactants

(Catalyst)

Waste Heat

Reaction Mixture

Emissions

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SLIDE 7

Production plant with multiple reaction processes

Reaction Process 1a

Intermediate Product Intermediate Product

Product

Reaction Process 2

Intermediate Product

Reaction Process 3 Reaction Process 1b

Inputs Outputs Inputs Outputs Inputs Outputs Inputs Outputs

Infrastructure Chemical Production Plant

Heat/Material Recovery Heat/Material Recovery

Reaction Process 1a

Intermediate Product I n t e r m e d i a t e P r

  • d

u c t

Product

Reaction Process 2

Intermediate Product

Reaction Process 3 Reaction Process 1b

Inputs Outputs Inputs Outputs Inputs Outputs Inputs Outputs Heat/Material Recovery Heat/Material Recovery

Reaction Process

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SLIDE 8

Case study

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SLIDE 9

Carrot Waste

Boiling in Water and Breakdown

Liberated MFC Coated MFC

Addition of Carrier Polymer

Addition of Coating, Aging Production

  • f GripX

Enzymatic Depolymerizati

  • n

Homogen- izing Wet Spinning

Byproducts (hemicellulose, pectins...)

Waste- water Waste- water Waste- water

Nanocellulose Yarn

Hazardous waste Waste- water

Lab production and plant flow chart

Production of 94 kg per batch  ~ 700 t/a

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SLIDE 10

Filter tank with pump Coagulation bath Reaction tank with homogenizer Stirred heated reaction tank Heated pressure batch reactor with intank homogenizer Degassing tank Washing bath Heated drum rolls Pump Yarn Collection Stirred heated reaction tank

Scenario Analyses Starting material:

 Whole Carrot  Carrot Pomace

Enzyme Deactivation

 Heat  Bleach (ClO2)

Solvent Recovery

 Without  With (95 %)

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SLIDE 11

Filter tank with pump Coagulation bath Reaction tank with homogenizer Stirred heated reaction tank Heated pressure batch reactor with intank homogenizer Degassing tank Washing bath Heated drum rolls Pump Yarn Collection Stirred heated reaction tank

Scenario Analyses

Preheat inlet stream with waste heat

Heat Recovery

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SLIDE 12

LCIA – production of 1 kg spun yarn

  • 6
  • 5
  • 4
  • 3
  • 2
  • 1

1 2 3 4 5 6 7 8 1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 10 C

ReCiPe Endpoint - total

MFC Liberation GripX Spinning Acetone C Pumping C Infrastructure electricity (solvent incineration) heat (solvent incineration)

Whole Carrots Carrot Pomace

Heat Heat

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SLIDE 13
  • 6
  • 5
  • 4
  • 3
  • 2
  • 1

1 2 3 4 5 6 7 8 1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 10 C

ReCiPe Endpoint - total

MFC Liberation GripX Spinning Acetone C Pumping C Infrastructure electricity (solvent incineration) heat (solvent incineration)

Whole Carrots Carrot Pomace

Heat Heat Bleach Bleach

LCIA – production of 1 kg spun yarn

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SLIDE 14
  • 6
  • 5
  • 4
  • 3
  • 2
  • 1

1 2 3 4 5 6 7 8 1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 10 C

ReCiPe Endpoint - total

MFC Liberation GripX Spinning Acetone C Pumping C Infrastructure electricity (solvent incineration) heat (solvent incineration)

Heat Heat

Whole Carrots Carrot Pomace

Heat Heat Bleach Bleach

LCIA – production of 1 kg spun yarn

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SLIDE 15
  • 6
  • 5
  • 4
  • 3
  • 2
  • 1

1 2 3 4 5 6 7 8 1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 10 C

ReCiPe Endpoint - total

MFC Liberation GripX Spinning Acetone C Pumping C Infrastructure electricity (solvent incineration) heat (solvent incineration)

Heat Heat Heat Heat

Whole Carrots Carrot Pomace

Heat Heat Bleach Bleach

LCIA – production of 1 kg spun yarn

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SLIDE 16
  • 6
  • 5
  • 4
  • 3
  • 2
  • 1

1 2 3 4 5 6 7 8 1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 10 C

ReCiPe Endpoint - total

MFC Liberation GripX Spinning Acetone C Pumping C Infrastructure electricity (solvent incineration) heat (solvent incineration)

Heat Heat Heat Heat

Whole Carrots Carrot Pomace

Heat Heat Bleach Bleach Bleach Bleach

LCIA – production of 1 kg spun yarn

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SLIDE 17
  • 6
  • 5
  • 4
  • 3
  • 2
  • 1

1 2 3 4 5 6 7 8 1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 10 C

ReCiPe Endpoint - total

MFC Liberation GripX Spinning Acetone C Pumping C Infrastructure electricity (solvent incineration) heat (solvent incineration)

Heat Heat Heat Heat

1 2 3 4 5 6 7 8 1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 10 C

ReCiPe Endpoint - total

Heat Heat Heat Heat

Whole Carrots Carrot Pomace

Heat Heat Bleach Bleach Bleach Bleach

LCIA – production of 1 kg spun yarn

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SLIDE 18

1 2 3 4 5 6 7 8

Lab Scale 1 C 10 C 10 C, no Acetone Glass Fibre Carbon Fibre

ReCiPe Endpoint Indicators

ecosystem quality - total human health - total resources - total Heat Bleach

LCIA – Comparison with Lab Scale and Competing Fibres

Bleach

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SLIDE 19

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

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SLIDE 20

Fabiano Piccinno fabiano.piccinno@uzh.ch

Acknowledgement: Contact:

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SLIDE 21
  • 0,1
  • 0,05

0,05 0,1 0,15 0,2 0,25 0,3 1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 10 C

NMVOC Eq [kg]

Photochemical Oxidant Formation Potential

MFC Liberation GripX Spinning Acetone C Pumping C Infrastructure electricity (solvent incineration) heat (solvent incineration)

LCIA – production of 1 kg spun yarn

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SLIDE 22

Application – Motorhome Example

  • System 10 C (lowest impact) used for Cellulose
  • Functional Unit: 1 Motohome
  • Transports not included

Nanocellulose Yarn

Hand lay-up Composite Production for Motorhome Production of bioresin

  • r conventional resin

Production of Motorhome Use of Motorhome

Composite to Municipal Waste Incineration

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SLIDE 23

Global Warming Potential

20 40 60 80 100 120

NFC/Bio- Epoxy 80 NFC/Bio- Epoxy 300 GF 80 GF 300 CO2 Eq [t]