Bio-Butadiene Production from Glucose (Aerobic Fermentation)
Butadiene Production Costs Report | Issue D | Q2 2024
| Report Details |
| 165 kta United States-based plant | Q2 2024 | 107 pages |
This report presents a cost analysis of a 165 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
It presents the economics of bio-based 1,3-Butadiene (BD) production from glucose syrup in the United States using a direct aerobic fermentation process similar to the one proposed by Global Bioenergies.
The report provides a comprehensive study of Butadiene production and related Butadiene production cost, covering three key aspects: a complete description of the Butadiene production process examined; an in-depth analysis of the related Butadiene plant capital cost (Capex); and an evaluation of the respective Butadiene plant operating costs (Opex).
The Butadiene 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 Butadiene 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 Butadiene 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) Fermentation; (2) Fermentation broth treatment; and (3) Butadiene purification.
Fermentation. The culture media is prepared by diluting the glucose syrup and nutrients in water. A genetically re-engineered yeast is propagated in an aerobic pre-fermentation step to obtain the proper inoculum concentration. The fermentation is carried out in fed-batch mode and under aerobic process conditions, in agitated fermenters equipped with internal coil. The fermentation step generates fermenter off-gas, which comprises the crude Butadiene product, and fermentation broth.
Fermentation broth treatment. After fermentation, cell biomass is separated from the fermentation broth. The clarified broth then is submitted to an ultrafiltration step, used to remove the remaining contaminants. The resulting aqueous stream may be discarded as waste water.
Butadiene purification. Initially, off-gas is compressed and cooled. The compressed gas is fed in a absorber column, where N-dodecane solvent absorbs the Butadiene. In the next column, In the Stripper Column, Butadiene is separated from the solvent. The recovered solvent is fed into a decanter for water removal before being recycled to first column. The Butadiene-containing stream is transferred into the Adsorption System. There, The oxygenates are removed by adsorption in adequate media. The oxygenate-free crude Butadiene is further purified in a last distillation column for heavy ends impurities separation. Butadiene with purity >99.7 wt% is recovered.
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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 Butadiene 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 Butadiene 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 Butadiene 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 Butadiene 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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