Process design, simulation, and techno-economic analysis of integrated production of furfural and glucose derived from palm oil empty fruit bunches

Abstract

This study aims to propose a new process design, simulation, and techno-economic analysis of an integrated process plant that produces glucose and furfural from palm oil empty fruit bunches (EFB). In this work, an Aspen Plus-based simulation has been established to develop a process flow diagram of co-production of glucose and furfural along with the mass and energy balances. The plant’s economics are analyzed by calculating the fixed capital income (FCI), operating costs, and working capital. In contrast, profitability is determined using cumulative cash flow (CCF), net present value (NPV), and internal rate of return (IRR). The findings show that the production capacity of 10 kilotons per year (ktpy) of glucose and 4.96 ktpy of furfural with a purity of 98.21 and 99.54%—weight, respectively, was achieved in this study. The FCI is calculated as United States Dollar (USD) 20.80 million, while the working and operating expenses are calculated as USD 3.74 million and USD 16.93 million, respectively. This project achieves USD 7.65 million NPV with a positive IRR of 14.25% and a return on investment (ROI) of 22.06%. The present work successfully develops a profitable integrated process plant that is established with future upscaling parameters and key cost drivers. The findings provided in this work offer a platform and motivation for future research on integrated plants in the food, environment, and energy nexus with the co-location principle. Graphical Abstract

The application of process simulations in lignocellulosic biorefinery: a review

“…Mohammed et al 113 developed a process to produce furfural and glucose from empty fruit bundles of palm oil. The work established an Aspen plus-based simulation to develop a process for the co-production of furfural and glucose as well as to calculate the mass and energy balance.…”

“…Mohammed et al 113 . developed a process to produce furfural and glucose from empty fruit bundles of palm oil.…”

Furfural production from lignocellulosic biomass: one-step and two-step strategies and techno-economic evaluation

“…The total costs consist of a fixed capital investment (cost of new-plant construction), direct costs (external battery and the total costs of purchasing and installing all process equipment), indirect costs (legal expenses, construction costs, and contractor fees), operating costs (variable and fixed costs, raw materials, and utility costs), and working capital (cost needed to start and run a plant until it generates sufficient revenue to pay off debt and purchase inventory). 134 The variable operating costs (feedstocks, raw materials, waste handling, and byproduct credits) were determined based on the Aspen Plus process modeling results, and prices were obtained from prior studies. 135 The fixed operating capital (employee salaries, labor burden, maintenance, and property insurance) was estimated following the assumptions of the NREL TEA report.…”

“…Techno-economy assessment for furfural and co-product production Integrated production of furfural and glucose. Mohammed et al 134 developed a profitable integrated process plant that produced glucose and furfural from empty palm oil fruit bunches. The number of stages in the distillation column, reflux ratio, solvent type (butyl chloride or toluene), and recycling flow rate were evaluated to maximize the yield and purity of the products.…”

Simulation of Furfural and Levulinic Acid Production from Lignocellulosic Biomass

“…Rahman, et al examined the technoeconomics of levulinic acid, formic acid and furfural production from empty oil palm fruit bunches [24]. Mohammed, et al examined techno-economics of furfural and glucose production from empty oil palm fruit bunches [25]. Sato, et al examined the technoeconomics of levulinic acid production using formic acid co-product as catalyst [26].…”