Commodity Production Costs Report

Bio-Butanediol Production from Glucose (Direct Fermentation)

Butanediol Operating Costs & Plant Construction Costs

75 kta United States-based plant | 107 Pages | Issue A | Q3 2024
Starting at $799 USD | See Report Editions Prices

This report presents the economics of bio-based 1,4-Butanediol (BDO) production from glucose syrup in a plant located in the United States. This process, similar to the one proposed by Genomatica, consists in a direct fermentation of glucose syrup, producing BDO, which is then submitted to purifying steps.

The report provides a comprehensive study of Butanediol production and related Butanediol production cost, covering three key aspects: a complete description of the Butanediol production process examined; an in-depth analysis of the related Butanediol plant capital cost (Capex); and an evaluation of the respective Butanediol plant operating costs (Opex).

The Butanediol 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 Butanediol 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 Butanediol plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.

Key reference(s): ?

Butanediol Production Cost Report Process Schematic

The process under analysis comprises three major sections: (1) fermentation; (2) separation; and (3) purification.

* Fermentation. In the fermentation area, 1,4-Butanediol is produced by fermentation of glucose using a recombinant microorganism. The main fermentation is performed in fed-batch mode under aerobic process conditions in agitated, jacketed fermenters. The fermentation temperature is controlled by circulating cooling water through the fermenter jackets. The pH is controlled by ammonia injection.

* Separation. The resulting fermentation broth is a complex mixture of water, Butanediol, byproducts, cell bodies, residual media, residual substrate, and feedstock/media impurities, which needs to pass through a series of separation steps. Those steps include centrifugation, ultrafiltration, nanofiltration and ion exchange (targeting to remove cell debris, sugars and salts), as well as evaporation for removing water.

* Purification. The concentrated solution is fed to a distillation column for light end impurities separation and subsequently to another column, for heavy ends separation. The final product, obtained from the second column is high-purity 99.5 wt.% BDO.

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  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
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 80 Pages | 22 Tables | 9 Images

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Table of Contents


Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
  • Plant Capital Cost Details
  • Operating Cost Details
  • See All Features

 90 Pages | 28 Tables | 13 Images

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Updated with Q3 2024 Data

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Table of Contents


Features
  • 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
  • Costs in Different Countries Add-on
  • See All Features

  • 107 Pages | 34 Tables | 22 Images
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  • Updated with Q3 2024 Data
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Content Highlights

Plant Capital Cost Summary

Summary outlining the capital cost required for building the Butanediol 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 Butanediol 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 Butanediol 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 Butanediol 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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