Towards greener approach: Techno-economic insights into formaldehyde bio production from a hybrid pine and mustard biomass combination

Abstract

In an era marked by environmental crises and dwindling fossil resources, the need to revolutionize industrial processes for sustainability is paramount. Formaldehyde synthesis, a pivotal precursor in industries spanning polymers, resins, and textiles, stands at a critical juncture where innovation and necessity intersect. Conventional methods of formaldehyde production, despite their efficiency, remain tethered to non-renewable feedstocks and energy-intensive techniques, perpetuating ecological harm and resource constraints. This study explores ecofriendly pathways for formaldehyde production. Recent strides in bio-based chemistry enable the creation of formaldehyde from renewable biomass, reducing energy use and carbon emissions. Decentralized production with locally sourced biomass boosts supply chain resilience and community-centered sustainability. The research employs Aspen Plus (R) software to model a two-step process: gasification of a hybrid pine and mustard biomass blend to produce bio-methanol, followed by its oxidation into formaldehyde. Sensitivity analyses demonstrate temperature's impact on syngas composition, with higher temperatures favoring hydrogen production. The airto-biomass ratio affects carbon dioxide content and energy content, crucial for efficient energy production. In formaldehyde synthesis, the air-to-methanol ratio significantly influences yield. Economically, formaldehyde bio- production shows promise, with an 8.50% return on investment and a 22.16-year payback period. An annual net profit of $2.41 million is projected, with a break-even point at $53.47 million in total sales revenue. This research underscores the convergence of sustainability, innovation, and economic viability in formaldehyde bioproduction, offering valuable insights for environmentally friendly chemical manufacturing and the broader transition to ecological progress.