Techno-Economic Assessment, Scalability, and Applications of Aerosol Lignin Micro- and Nanoparticles

Abstract

Lignin micro- and nanoparticles (LMNPs) synthesized from side-streams of pulp and paper and biorefinery operations have been proposed for the generation of new, high-value materials. As sustainable alternatives to particles of synthetic or mineral origins, LMNPs viability depends on scale-up, manufacturing cost, and applications. By using experimental data as primary source of information, along with industrial know-how, we analyze dry and spherical LMNPs obtained by our recently reported aerosol/atomization method. First, a preliminary evaluation toward the commercial production of LMNPs from industrial lignin precursors is presented. Following, we introduce potential LMNPs applications from a financial perspective. Mass and energy balances, operating costs, and capital investment are estimated and discussed in view of LMNPs scalability prospects. The main potential market segments identified (from a financial perspective) include composite nanofillers, solid foams, emulsion stabilizers, chelating agents, and UV protection. Our technical, financial, and market assessment represent the basis for R&D planning and efforts to lower the risk related to expected industrialization efforts. Manufacturing costs were estimated between 870 and 1170 USD/t; also, minimum selling prices varied from 1240 and 1560 USD/t, depending on raw materials used. Sensitivity analysis indicated that manufacturing cost can be as low as 600 USD/t, depending on the process conditions considered. Finally, based on the financial assessment, potential applications were identified.

Techno-economic assessment for the large-scale production of colloidal lignin particles

“…Assis et al used the aerosol method to produce lignin macro-and nanoparticles and have reported the manufacturing costs to be in the range of 800 to 1000 €/ton based on the type of raw material used. 42 This price is quite close to the cost of producing CLPs reported in this paper at 990€/ton. A preliminary assessment for the economic potential of colloidal lignin nanoparticles is carried out by identifying the most attractive applications of CLPs from economic perspective and global market size as summarized in the Table 3.…”

Spherical lignin particles: a review on their sustainability and applications

“…This would make such process scalable and cost-effective, with an estimated selling price of 1015 US$ per metric ton. 41 Recently, acetone-extracted lignin from hydrothermally treated wood was converted into lignin nanoparticles via the aerosol flow reactor. The authors experimentally demonstrated the possibility of achieving lower time and temperature for particle formation.…”

“…One reason for this may be their relatively higher production cost when compared to the direct utilization of lignosulfonates, or the fact that lignin particles have not yet been available in large quantities. However, recently, there has been significant advances in process engineering that is leading to large scale production of lignin particles at lower cost, 41,71 which will open opportunities for the utilization of technical lignin-based particles in large scale applications. A great advantage of lignin particles over their macromolecular counterpart is that they are readily dispersible in water, thus not being limited by solubility.…”

“…However, lignin particles possess even further advantages, and it is possible to achieve even better environmental metrics and sustainability scores, for example, in such applications as emulsion stabilizers, UV protection products, chelating agents, carbon nanofillers (other than carbon black), and for composite reinforcement, all of which are economically attractive. 41 Finally, these possibilities for substitution are of relatively limited market size but, as introduced in this review, other potential applications of larger scales can be considered for lignin particles, such as in thermoplastics, advanced resin composites, foams, bactericides, and others. It is apparent that, while LCA studies are available to assess the environmental impacts of lignocellulosic biorefineries, around the cellulosic and hemicellulose fractions, LCA studies on lignin, and especially lignin nanoparticles, are far less common.…”

“…In applications that require large volumes of particles the production process needs to be scalable. The techno-economical feasibility of production processes has been evaluated for both dry 41 and wet approaches 183 and both are scalable. For the wet approach, the most energy consuming steps are the drying of particles and recycling of the solvents.…”