Published December 2022
To transition to more sustainable lifestyles, the society is utilizing various approaches, for example to generate chemicals sustainably, such that it can support the living standards of the modern society. Most of the chemicals are currently produced from non-renewable petroleum feedstocks. Renewable biomass resources are an alternative option for the production of the chemicals.
Ethanol is a versatile and valuable chemical that can be used as both, a fuel and a chemical intermediate. The global availability of renewable feedstocks, ethanol from non-food biomass, and the regional prices of ethanol versus ethylene impact the production of other chemicals from ethanol. Currently, 1,3-butadiene and n-butanol are two chemicals of interest in the industry. The primary driver of interest, in these chemicals derived from ethanol, is the need for renewable resources.
A major portion of 1,3-butadiene produced currently is a by-product of ethylene steam cracking of naphtha or gas oil feedstocks. A switch to lighter feedstocks has decreased the amount of 1,3-butadiene produced from ethylene cracking. However, the demand for 1,3-butadiene continues to increase, primarily due to the expansion of demand in the emerging markets, particularly for automobile tires. As a result of the decreasing trend in supply and the rising trend in demand, the price of 1,3-butadiene has drastically increased. This has led to an increased interest in the production of 1,3-butadiene from renewable sources.
n-Butanol derived from ethanol is currently of particular interest as a fuel. n-Butanol can easily replace gasoline in internal combustion engines without modification. Additionally, the transportability of n-butanol via pipeline is significantly superior to that of ethanol. Currently, ethanol as fuel accounts for more than 86% of the global consumption. However, the superior properties of n-butanol and cost-effective technology for its production from ethanol will encourage increased blending and utilization of renewable resources in motor fuel.
This report describes the process design and economics for the conversion of ethanol to 1,3-butadiene and to n-butanol. Recent advancements in catalysts, performance, and separations are reviewed, emphasizing technology-ready processes. Since the economics are highly dependent on location, an iPEP module with a user interface covering multiple geographical regions is also provided.