Techno-economic analysis of 1,4-butanediol production by a single-step bioconversion process

1,4-Butanediol (1,4-BDO) is one of the most important intermediate chemicals that is mainly produced using petrochemical routes. Recently, the route to 1,4-BDO from corn-based dextrose by single-step bioconversion has been commercialized. This paper analyzes the bio-based production route to 1,4-BDO and establishes the major capital and operating costs associated with production. Bioconversion was found to be the major capital cost component while the hydraulic load from bioconversion and other systems like membrane filtration was found to be the major operating cost component. The process was found to be economically feasible with a minimum sales price (MSP) of 1,4-BDO of $1.82/kg as compared to a market price of $2.5/kg. In addition, a mechanical vapor recompression scheme for the evaporator benefitted the process, increasing energy efficiency and therefore cost effectiveness. In general, improvements that enable the reduction of hydraulic loads lower the MSP of 1,4-BDO. The most dramatic cost savings are seen when bioconversion titers are increased. When the bioconversion titers are doubled to 280 g L-1, a 45% reduction in MSP is seen with respect to the baseline process. A sensitivity analysis shows that process is sensitive to feedstock prices but not sensitive to energy prices. (c) 2019 Society of Chemical Industry and John Wiley & Sons, Ltd.