Polylactic Acid Production from Raw Sugar
Polylactic Acid Production Costs Report | Issue B | Q4 2024
| Report Details |
| 140 kta Germany-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 140 kta (kilo metric ton per annum) Germany-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This study approaches the economics of Polylactic Acid production from raw sugar in Germany. Initially, raw sugar is hydrolyzed into invert sugars. The invert sugars are then fermented to produce lactic acid, in a process similar to Cargill process. The lactic acid is oligomerized and then depolymerized into lactide, which is finally polymerized to yield PLA by ring opening polymerization, similar to the one proposed by NatureWorks.
The report provides a comprehensive study of Polylactic Acid production and related Polylactic Acid production cost, covering three key aspects: a complete description of the Polylactic Acid production process examined; an in-depth analysis of the related Polylactic Acid plant capital cost (Capex); and an evaluation of the respective Polylactic Acid plant operating costs (Opex).
The Polylactic Acid 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 Polylactic Acid 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 Polylactic Acid 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) Oligomerization & Lactide Formation; (3) Lactide Polymerization.
Fermentation. The culture media used in fermentation is prepared by mixing process water, invert sugar and corn steep liquor. The fermentation is carried out in continuous mode and under anaerobic process conditions in an agitated, jacketed fermentor. The pH control of the fermentation is made by addition of recycled sodium carbonate. The fermentation mass yield of lactate on glucose ranges from 85 to 95 wt%. The lactate concentration obtained in the fermentation broth is about 10 wt%. After fermentation is complete, the fermentation liquor passes through filtration, evaporation and extraction steps, after which an 88 wt% Lactic Acid is obtained.
Oligomerization & Lactide Formation. Lactic acid is fed to the oligomerization reactor from which water vapor is removed, condensed, and sent to waste treatment. The resultant oligomer stream is mixed with catalyst and fed to the depolymerization reactor, essentially an evaporator operating under vacuum to break down the oligomers into lactide. Water, lactic acid and lactide are removed in the gaseous overhead stream. Most lactide and some impurities are condensed and sent to the drying column, where water is removed from the crude lactide. The remaining contaminants are removed in the lactide purification, leading to a 99.9% pure lactide.
Lactide Polymerization. The polymer grade lactide undergoes a melt-phase polymerization. Molten lactide, a stabilizer and catalyst are fed to the reactor. The polymer melt is then pumped to a devolatizer operating under vacuum to remove unreacted lactide in the gaseous stream, which is condensed and recycled to the purification unit. The devolatilized melt polymer is extruded, pelletized, and dried, resulting in the polylactic acid product.
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Production Process Information
Process Consumptions
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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 Polylactic Acid 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 Polylactic Acid 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 Polylactic Acid 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 Polylactic Acid 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
Other Polylactic Acid Production Cost Reports
Polylactic Acid Production from Lactic Acid
This report presents the economics of Polylactic Acid (PLA) production from lactic acid using a melt process similar to the one proposed by NatureWorks. In this process, lactic acid is first oligomerized and then depolymerized into lactide, a cyclic dimer of lactic acid, which is then polymerized to yield PLA by ring opening polymerization. The economic analysis presented is based on a plant constructed in the USA.
Details: 140 kta United States-based plant | Q4 2024 | 107 pages | Issue A From $1,199 USD
The cost analyses presented in this report target a 140 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
Polylactic Acid Production from Glucose
This study approaches the economics of Polylactic Acid production from glucose syrup in the United States. First, lactic acid is produced from glucose syrup using a fermentation process similar to Cargill process. Then, lactic acid is polymerized into poly(lactic acid) using a melt-phase polymerization process similar to the one proposed by NatureWorks.
Details: 50 kta United States-based plant | Q4 2024 | 107 pages | Issue C From $1,199 USD
The cost analyses presented in this report target a 50 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
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