From laboratory to industrial scale FabianoPicci… · From laboratory to industrial scale scale-up...

From laboratory to industrial scalescale-up calculations of chemical processes for LCA

Fabiano Piccinno1,2

Roland Hischier1, Stefan Seeger2, Claudia Som1

1Empa, Technology and Society Lab, St. Gallen, Switzerland2University of Zurich, Department of Chemistry, Zurich, Switzerland

Outline

Scale-up framework

Case study: NanoCelluComp

fda.gov

frings.com

Scale-up of chemical processes

Scale-up framework

Scale-up procedure

Lab protocolLab protocolPlant flow

chart

Plant flow

chart

Scale-up of

each process

step

Scale-up of

each process

step

Linkage of

process step

Linkage of

process stepPerform LCAPerform LCA

Material and energy in- and output of a reaction process

Focus on liquid phase batch reactor processes

Heated Liquid Phase Batch Reaction Step

Processing, Purification, Isolation Steps Product

(Co-/By-Product)

Heatin

g Energy

Stirring En

ergy

Solvent

Reactants

(Catalyst)

Waste H

eat

Waste H

eat

Waste

Wastew

ater

Heatin

g Energy

Ch

emicals,

Water

Reaction Mixture

Hea

t R

eco

very

Material Recovery

Water Recovery

Emissio

ns

Emissio

ns

Oth

er Energy

Reaction Process



(Co-/By-Product)

Heatin

g Energy

Stirring En

ergy

Solvent

Reactants

(Catalyst)

Waste H

eat

Waste H

eat

Waste

Wastew

ater

Heatin

g Energy

Ch

emicals,

Water

Reaction Mixture

Emissio

ns

Emissio

ns

Oth

er Energy

Reaction Process



(Co-/By-Product)

Heatin

g Energy

Stirring En

ergy

Solvent

Reactants

(Catalyst)

Waste H

eat

Waste H

eat

Waste

Wastew

ater

Heatin

g Energy

Ch

emicals,

Water

Reaction Mixture

Emissio

ns

Emissio

ns

Oth

er Energy


Heatin

g Energy

Stirring En

ergy

Solvent

Reactants

(Catalyst)

Waste H

eat

Reaction Mixture

Emissio

ns

Production plant with multiple reaction processes

Reaction Process 1a

Intermediate Product

Inte

rmed

iate

Pro

du

ct

ProductReaction Process 2


Reaction Process 3

Reaction Process 1b

Inp

uts

Ou

tpu

ts Inp

uts

Ou

tpu

ts Inp

uts

Ou

tpu

ts

Inp

uts

Ou

tpu

ts

Infrastructure Chemical Production Plant

Hea

t/M

ater

ial R

eco

very

Hea

t/M

ater

ial R

eco

very

Reaction Process 1a


Inte

rmed

iate

Pro

du

ct

ProductReaction Process 2


Reaction Process 3

Reaction Process 1b

Inp

uts

Ou

tpu

ts Inp

uts

Ou

tpu

ts Inp

uts

Ou

tpu

ts

Inp

uts

Ou

tpu

ts

Hea

t/M

ater

ial R

eco

very

Hea

t/M

ater

ial R

eco

very

Reaction Process

Case study

Carrot Waste

Boiling in Water and

Breakdown

Liberated MFC

Coated MFCAddition of

Carrier Polymer

Addition of Coating,

Aging

Production of GripX

Enzymatic Depolymerizati

on

Homogen-izing

Wet Spinning

Byproducts (hemicellulose,

pectins...)

Waste-water

Waste-water

Waste-water

Nanocellulose Yarn

Hazardous waste

Waste-water

Lab production and plant flow chart

Production of 94 kg per batch ~ 700 t/a

Filter tank with pump

Coagulation bath

Reaction tank

with homogenizerStirred heated

reaction tank

Heated pressure

batch reactor with

intank homogenizer

Degassing tank

Washing bath

Heated

drum rolls

Pump

Yarn

Collection

Stirred heated

reaction tank

Scenario Analyses

Starting material:

Whole Carrot

Carrot Pomace

Enzyme Deactivation

Heat

Bleach (ClO2)

Solvent Recovery

Without

With (95 %)

Filter tank with pump

Coagulation bath

Reaction tank

with homogenizerStirred heated

reaction tank

Heated pressure

batch reactor with

intank homogenizer

Degassing tank

Washing bath

Heated

drum rolls

Pump

Yarn

Collection

Stirred heated

reaction tank

Scenario Analyses

Preheat inlet

stream with

waste heat

Heat Recovery

LCIA – production of 1 kg spun yarn

-6

-5

-4

-3

-2

-1

0

1

2

3

4

5

6

7

8

1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 10 C

ReCiPe Endpoint - total

MFC Liberation GripXSpinning AcetoneC Pumping C Infrastructureelectricity (solvent incineration) heat (solvent incineration)

Whole Carrots Carrot Pomace

He

at

He

at

-6

-5

-4

-3

-2

-1

0

1

2

3

4

5

6

7

8

1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 10 C




He

at

He

at

Ble

ach

Ble

ach


-6

-5

-4

-3

-2

-1

0

1

2

3

4

5

6

7

8

1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 10 C



He

at

Heat


He

at

He

at

Ble

ach

Ble

ach


-6

-5

-4

-3

-2

-1

0

1

2

3

4

5

6

7

8

1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 10 C



He

at

He

at

He

at

He

at


He

at

He

at

Ble

ach

Ble

ach


-6

-5

-4

-3

-2

-1

0

1

2

3

4

5

6

7

8

1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 10 C



He

at

He

at

He

at

He

at


He

at

He

at

Ble

ach

Ble

ach

Ble

ach

Ble

ach


-6

-5

-4

-3

-2

-1

0

1

2

3

4

5

6

7

8

1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 10 C



He

at

He

at

He

at

He

at

0

1

2

3

4

5

6

7

8

1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 10 C


He

at

He

at

He

at

He

at


He

at

He

at

Ble

ach

Ble

ach

Ble

ach

Ble

ach


0 1 2 3 4 5 6 7 8

Lab Scale

1 C

10 C

10 C, no Acetone

Glass Fibre

Carbon Fibre

ReCiPe Endpoint Indicators

ecosystem quality - total human health - total resources - total

Heat

Bleach

LCIA – Comparison with Lab Scale and Competing Fibres

Bleach

Conclusions

Framework helpful in predicting LCA

Scenario analyses for understanding

Treat results with caution

LCA results help to focus on key contributors

and optimize process

Fabiano Piccinno

[email protected]

Acknowledgement:

Contact:

mailto:[email protected]

-0,1

-0,05

0

0,05

0,1

0,15

0,2

0,25

0,3

1 C 2 C 3 C 4 C 5 C 6 C 7 C 8 C 9 C 10 C

NM

VO

C E

q[k

g]

Photochemical Oxidant Formation Potential



Application – Motorhome Example

• System 10 C (lowest impact) used for Cellulose

• Functional Unit: 1 Motohome

• Transports not included

Nanocellulose Yarn

Hand lay-up Composite

Production for Motorhome

Production of bioresin or conventional resin

Production of Motorhome

Use of Motorhome

Composite to Municipal Waste

Incineration

Global Warming Potential

0 20 40 60 80 100 120

NFC/Bio-Epoxy 80

NFC/Bio-Epoxy 300

GF 80

GF 300

CO2 Eq [t]

From laboratory to industrial scale FabianoPicci… · From laboratory to industrial scale scale-up...

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