Polyhydroxybutyrate Production from Switchgrass
Polyhydroxybutyrate Production Costs Report | Issue A | Q3 2024
| Report Details |
| 10 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 10 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This report presents the Economic analysis of Polyhydroxybutyrate (PHB) production from switchgrass. In this process, switchgrass is gasified to synthesis gas (syngas), which is fermented to PHB. The economic analysis presented is based on a plant constructed in the United States.
The report provides a comprehensive study of Polyhydroxybutyrate production and related Polyhydroxybutyrate production cost, covering three key aspects: a complete description of the Polyhydroxybutyrate production process examined; an in-depth analysis of the related Polyhydroxybutyrate plant capital cost (Capex); and an evaluation of the respective Polyhydroxybutyrate plant operating costs (Opex).
The Polyhydroxybutyrate production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Polyhydroxybutyrate plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Polyhydroxybutyrate plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises three major sections: (1) Syngas Formation; (2) Fermentation; and (3) Products Treatment.
Syngas Formation. Switchgrass is fed to a mill grinder and sent to a fluidized bed reactor along with preheated air from the Syngas Conditioning downstream. The biomass is oxidized into a mixture of carbon compounds and hydrogen. The outlet gas stream from the reactor is fed to a set of cyclones to remove solids, that are disposed as waste, while the gas is routed to a Syngas Reformer, which converts hydrocarbons to hydrogen and carbon monoxide. The reformer outlet stream is thermally treated to 30 °C in the Syngas Conditioning area, which is also fed with process water make-up.
Fermentation. The fermentation is carried out under anaerobic conditions in agitated jacketed fermenters. Fresh Syngas is mixed with recycled gas from the Hydrogen Purification and fed to the fermenters. The bacteria “Rhodospirillum rubrum” uses carbon monoxide to produce polyhydroxybutyrate (PHB). Fermentation broth is sent to the PHB Recovery area, while a hydrogen gas stream is sent to Hydrogen Purification.
Products Treatment. The hydrogen-rich stream from the fermenters is to a hybrid membrane/pressure swing adsorption system. The exhaust gas from the membrane is recycled to the fermenters, and a 99.9% purity hydrogen stream is obtained from the PSA. The fermentation broth is fed to centrifuges to separate fermentation media from cells, which are sent to a stirred tank. Surfactant is also fed, breaking cell walls and liberating the PHB granules in the liquid medium, which is mixed with sodium hypochlorite solution and sent to centrifuges. The concentrated PHB is routed to a spray dryer, then to an extruder, and finally is packed in bags and stored.
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Polyhydroxybutyrate production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Polyhydroxybutyrate process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Polyhydroxybutyrate production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Polyhydroxybutyrate plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
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Polyhydroxybutyrate Production from Natural Gas
This study approaches the economics of Polyhydroxybutyrate (PHB) from natural gas in the United States. In the process examined, methane contained in the natural gas feedstock is fermented to Poly-3-hydroxybutyrate by a mixed methanotrophic culture of bacteria.
Details: 100 kta United States-based plant | Q3 2024 | 107 pages | Issue C From $799 USD
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