by Dr Kapil S Lokare and Dr Kartina Cornish
Despite the common myth – Biomass Upgrading is a challenging science. Not only do the practitioners have to break down the complex biomass mixtures efficiently, but they must also contend with numerous other equally (and often times more) important considerations such as low oil prices (per barrel), process safety, waste streams, and chemical toxicity, recycling of solvents/catalysts, process economics, and a multitude of engineering/ technology considerations. Nevertheless, despite the challenges, the ideal outcome of these efforts when accomplished is quite satisfying: a simple, efficient, green, robust, and safe manufacturing process. A showcase of green chemistry, process intensification, and catalysis along with industrial fermentation – Butanol production (with a global market of about 350 million gallons per year) has garnered wide acclaim.
Butanol is an important industrial chemical, which is currently produced either by the Oxo-process starting from propylene with hydrogen and carbon monoxide (usually in the form of synthesis gas) over an expensive rhodium catalyst, or the Aldol-process starting from acetaldehyde, this is usually referred to as the – petroleum-derived approach as the components i.e., propylene and synthesis gas are derived from petroleum/fossil sources. Both these processes are inherently “not green”. The Oxo Process was developed and licensed to the industry through a tripartite collaboration beginning in 1971. The principals were Johnson Matthey & Co. Ltd. (now Johnson Matthey PLC), The Power-Gas Corporation Ltd. (a former name of Davy Process Technology Ltd., now a subsidiary of Johnson Matthey PLC) and Union Carbide Corporation (now a subsidiary of The Dow Chemical Company).
The second, “green” pathway is the ABE-fermentation process (Acetone, Butanol, Ethanol) that was pioneered by Chaim Weizmann during World War I. At the time, the petroleum-derived approach proved to be economically advantageous in comparison to the ABE-fermentation based processes. For this reason, most of the facilities using butanol / acetone fermentation process ceased to operate with a few exceptions in Mainland China. This happened after World War II when rapid development of the petrochemical industry took place.
However, crude oil price fluctuations, coupled with other geopolitical considerations across the globe have sparked an urgent interest in achieving a transition from non-renewable carbon resources to renewable bio-resources. In addition, researchers and start-ups from across the globe have reported on their staggering progress in research and development efforts towards the production of butanol from renewable resources. The ABE-process has since received wide acceptance for a second come back to match mandates around the world to meet the standard blends with the petroleum counterparts. Some start-ups have also claimed their niche in developing butanol from the ubiquitous carbon dioxide, or from Scotch whisky by-products!
A plethora of start-ups and joint ventures flourished since early 2000 and the numbers are growing steadily. For a global overview of start-ups or established organizations based on the biosynthetic approach alongside with the traditional petroleum based approach for comparison see Exhibit 1. The number of start-ups pursuing various aspects of butanol is flourishing more than ever – from carbon dioxide capture, to developing alcohol-to-jet (AtJ) fuel with the potential to deliver aviation biofuels, developing new microbial strains for efficient conversions to butanol, feedstock analysis, to downstream processing. With this astounding pace one would not be surprised to find a start-up next door aiming to be the next analogue of the Oxo-process to synthesize 100% of global butanol production using renewable resources!
Exhibit 1. Birds-Eye-View of Global Leaders in Butanol Production. Profiles assigned to the country in which the company or holding is headquartered. Color – Black (Petroleum Derived), Green (Bio-derived)
Butanol has since successfully made the transition from a commodity chemical to a fuel additive specially when it is compared to a much hygroscopic and less energy dense – ethanol. Butanol is versatile for many reasons – one could use it as a fuel additive or chemically transform it to high value high volume precursors such as butanal (global production around 6.6 x 106 tons/year), glycol ethers, butyl acrylates, solvents – butanol by itself can be used as a solvent or converted to the more widely used (“workhorse”) plasticizer such as 2-ethyl hexanol (global production around 2.5 x 106 tons/year) etc. So, if you are contemplating your niche in downstream processing to focus on renewable chemicals or plastics, you may consider butanol conversion to lucrative chemicals markets.
You may choose to go to the other end of the spectrum and consider making alcohol-to-jet (AtJ) fuels with the butanol platform. For example, a plane like a Boeing 747 consumes approximately 1 gallon of fuel (about 3.78 liters) per second. Over the course of a 10-hour flight, (say from Berlin, Germany to New York, United States) it burns about 36,000 gallons (150,000 liters). The Boeing 747 consumes approximately 5 gallons of fuel per mile (12 liters per kilometer). So you would make multitude volumes of the fuel to meet the blending requirements in the aviation department. With the right tools in your belt this is certainly achievable.
If you are a smaller/medium sized start-up with a novel idea working on designing a proof-of-concept pilot before venturing into a full scale demo or commercial plant or just planning to expand your patent portfolio or a big conglomerate planning to be brand ambassadors for developing sustainable solutions for tomorrow based on the butanol platform we would love to hear from you.
At Lee Enterprises Consulting Inc., our team of experts has over 1000 years of experience! In fact, our Emerging Technologies Team also has over 500 years of experience, with an average of 20 years’ experience per consultant. The Emerging Technologies Team at Lee Enterprises Consulting offers a range of access to butanol technologies, including market studies, and important considerations such as value/volume chain analysis, technology know how, process economics including economies of scale, lab-scale and industrial fermentation, separation technologies, green chemistry, engineering/technology, or arranging off-take agreements with customers, local and offshore. We also have full teams devoted to the design and fabrication of pilot plants; region specific legislations associated with the blending protocols, related documentation with RINs credits with our strategic partners.
Our management team and professionals with a background in butanol and associated technologies are ready to transform your idea into success.