Replacing fossil based PET with biobased PEF; process analysis, energy and GHG balance

Abstract

An energy and greenhouse gas (GHG) balance study was performed on the production of the bioplastic polyethylene furandicarboxylate (PEF) starting from corn based fructose. The goal of the study was to analyze and to translate experimental data on the catalytic dehydration of fructose to a simulation model, using the ASPEN Plus modeling software. The mass and energy balances of the simulation model results were then used as inputs for a process chain analysis (by application of the life cycle assessment methodology, LCA) and compared to its petrochemical counterpart polyethylene terephthalate (PET). The production of PEF can be divided into three main units: the production of fructose from corn starch; the conversion of fructose into Furanics and subsequent recovery and upgrading; and the oxidation to the monomer 2,5-furandicarboxylic acid (FDCA) and polymerization with ethylene glycol (EG) into PEF. The ASPEN Plus simulation model describes the conversion of fructose into Furanics, subsequent recovery and upgrading and a CHP unit. The production of fructose from corn starch and the oxidation and polymerization into PEF were based on the literature. In total, six model cases were analyzed, using different sets of underlying experimental data; four cases based on crystalline fructose and two cases on high fructose corn syrup (HFCS). Fructose can be converted into Furanics at efficiencies between 38% and 47%. The production of PEF can reduce the NREU approximately 40% to 50% while GHG emissions can be reduced approximately 45% to 55%, compared to PET for the system cradle to grave. These reductions are higher than for other biobased plastics, such as polylactic acid (PLA) or polyethylene (PE). With an annual market size of approximately 15 million metric tonnes (Mt) of PET bottles produced worldwide, the complete bottle substitution of PEF for PET would allow us to save between 440 and 520 PJ of non-renewable energy use (NREU) and to reduce GHG emissions by 20 to 35 Mt of CO2 equivalents. If also substantial substitution takes place in the PET fibres and film industry, the savings increase accordingly. The GHG emissions could be further reduced by a switch to lignocellulosic feedstocks, such as straw, but this requires additional research

Whole-Cell Biocatalytic Production of 2,5-Furandicarboxylic Acid

“…Some of these catalytic conversions show good promise, and the company Avantium has announced the start of a pilot plant for the production of FDCA and its methyl esters from fructose, via ethers of HMF, using a Co/Mn/Br catalyst (Munoz de Diego et al 2011;van Putten et al 2013). An energy and greenhouse gas balance study based on this chemical process, assuming a conversion efficiency from fructose to FDCA of 38-47 %, concluded that PEF production has the potential to reduce the nonrenewable energy use by approximately 40-50 %, while greenhouse gas emissions can be reduced by 45-55 % compared to the established PET process (Eerhart et al 2012).…”

“…Given the large market volume of these currently oil-based plastics [approximately 50 million tonnes per year for PET alone (de Jong et al 2012)], the possible impact of FDCA can be very high. Especially for PET-based bottles and packaging materials [approximately 15 million tonnes per year (Eerhart et al 2012)], there is a strong "green" customer demand, as illustrated by press releases by the Coca-Cola company and Danone. These companies have publicly stated the intent to develop and use FDCA-based PEF bottles, e.g., in collaboration with the company Avantium, which is developing a chemical FDCA production and polymerization process (Coca-Cola 2011;Avantium 2012).…”

Selective Aerobic Oxidation of 5‐HMF into 2,5‐Furandicarboxylic Acid with Pt Catalysts Supported on TiO2‐ and ZrO2‐Based Supports

“…Soluble metal bromide catalysts (Co/Mn/ Br) in acetic acid, normally employed for the conventional oxidation of para-xylene to terephthalic acid, have been tailored for the HMF oxidation. [12,13] Also, recoverable supported metallic nanoparticles, mainly Pt-, [14][15][16][17] Ru-, [18,19] and Au-based, [20][21][22][23][24] and bimetallic catalysts [25][26][27] that permit the reaction in an aqueous medium by using molecular oxygen or air have been investigated.…”

On choosing the most appropriate catalysts for the conversion of carbon dioxide to fuels and other commodities, and on the environmentally benign processing of renewable and nonrenewable feedstocks

“…Their work leads to the ready synthesis of polyethylene furandicarboxylate-also designated polyethylene furanoate, PEF-which is a viable substitute for polyethylene terephthalate (PET) [17], and is used extensively as a container material for portable water and mineral drinks.…”