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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
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
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
Emissio
ns
Emissio
ns
Oth
er Energy
Reaction Process
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
Emissio
ns
Emissio
ns
Oth
er Energy
Heated Liquid Phase Batch Reaction Step
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
Intermediate Product
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
Intermediate Product
Inte
rmed
iate
Pro
du
ct
ProductReaction Process 2
Intermediate Product
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
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
ReCiPe Endpoint - total
MFC Liberation GripXSpinning AcetoneC Pumping C Infrastructureelectricity (solvent incineration) heat (solvent incineration)
Whole Carrots Carrot Pomace
He
at
He
at
Ble
ach
Ble
ach
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)
He
at
Heat
Whole Carrots Carrot Pomace
He
at
He
at
Ble
ach
Ble
ach
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)
He
at
He
at
He
at
He
at
Whole Carrots Carrot Pomace
He
at
He
at
Ble
ach
Ble
ach
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)
He
at
He
at
He
at
He
at
Whole Carrots Carrot Pomace
He
at
He
at
Ble
ach
Ble
ach
Ble
ach
Ble
ach
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)
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
ReCiPe Endpoint - total
He
at
He
at
He
at
He
at
Whole Carrots Carrot Pomace
He
at
He
at
Ble
ach
Ble
ach
Ble
ach
Ble
ach
LCIA – production of 1 kg spun yarn
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
-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
MFC Liberation GripXSpinning AcetoneC Pumping C Infrastructureelectricity (solvent incineration) heat (solvent incineration)
LCIA – production of 1 kg spun yarn
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