Optimal Integrated Plant for Biodegradable Polymer Production

An integrated facility for the production of biodegradable polymers from biomass residues has been developed. Lignocellulosic residues (sawdust), CO2, and organic waste such as manure or sludge are the raw materials. Manure and sludge are digested to provide the nutrients needed to grow algae. Algae are used in full to oil and starch production. The oil is transesterified with methanol generated via biogas dry reforming to obtain biodiesel and glycerol. The starch is used together with glycerol and the pretreated sawdust for the production of the biodegradable polymer. A mathematical optimization approach is used to identify the best use of each resource and the optimal operation of the integrated facility for each case. 4732 kt/yr of manure or 4653 kt/yr of sludge was processed to produce 354 kt/yr of biopolymer and 84 Mgal/yr of fatty acid methyl ester, capturing 2.47 kg of CO2 per kg of biopolymer with production costs of 0.89 and 0.95 $/kg, respectively, and an investment capital of 717 and 712 M$, respectively.

Automated summary

An integrated facility has been developed to produce biodegradable polymers from biomass residues, such as sawdust, CO2, manure, and sludge. This facility utilizes digested manure and sludge to grow algae, which are then used for oil and starch production. The oil is processed to obtain biodiesel and glycerol, while the starch is combined with glycerol and pretreated sawdust to produce the biodegradable polymer. Mathematical optimization is used to determine the best utilization of resources and optimal operation of the facility. This process captures 2.47 kg of CO2 per kg of biopolymer, with production costs of 0.89 and 0.95 $/kg and an investment capital of 717 and 712 M$, respectively.