Commodity Production Costs Report

Polylactic Acid Production from Glucose

Polylactic Acid Operating Costs & Plant Construction Costs

50 kta United States-based plant | 107 Pages | Issue C | Q3 2024
Starting at $1,199 USD | See Report Editions Prices

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.

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.

Key reference(s): ?

Polylactic Acid Production Cost Report 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, glucose and corn steep liquor. The fermentation is carried out in continuous mode and under anaerobic process conditions in an agitated, jacketed fermenter. 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%. Fermentation broth is continuously drawn out of the fermenter and passed 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. The resultant oligomer stream is mixed with catalyst and fed to the depolymerization reactor, which consists in a packed column operating under vacuum. 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 purification column, 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 column. The devolatilized melt polymer is extruded, pelletized, and dried, resulting in the polylactic acid product.

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

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Table of Contents


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  • Production Process Information
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  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
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  • Plant Capital Cost Details
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 90 Pages | 28 Tables | 13 Images

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Table of Contents


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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
  • Costs in Different Countries Add-on
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  • 107 Pages | 34 Tables | 22 Images
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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

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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.

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This study approaches the economics of Polylactic Acid production from corn in the United States. Initially, shelled corn is passed through a wet milling process to form corn starch, which is hydrolyzed to dextrose. Then, dextrose is fermented into lactic acid in a process similar to Cargill process. Finally, lactic acid is polymerized using a melt-phase polymerization process similar to the one proposed by NatureWorks.

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Polylactic Acid Production from Lactide

This report approaches the economics of producing Polylactic Acid (PLA) from lactide in a plant located in the United States. In the process examined, lactide, a cyclic dimer of lactic acid, undergoes a ring opening polymerization in the presence of a stannous octoate catalyst to be converted into Polylactic Acid.

Details: 80 kta United States-based plant | Q3 2024 | 107 pages | Issue E | From $799 USD

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Glucose Syrup Production

This report presents the economics of Glucose Syrup production from shelled corn. In this process, shelled corn is passed through a wet milling process to recover the corn starch, which, in turn, passes through two subsequent hydrolysis steps for the generation of glucose. The economic analysis performed assumes a plant located in the United States.

Details: 40 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD

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