Browsing by Author "Ierapetritou, Marianthi"
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Item Accelerating manufacturing for biomass conversion via integrated process and bench digitalization: a perspective(Reaction Chemistry and Engineering, 2022-01-25) Batchu, Sai Praneet; Hernandez, Borja; Malhotra, Abhinav; Fang, Hui; Ierapetritou, Marianthi; Vlachos, Dionisios G.We present a perspective for accelerating biomass manufacturing via digitalization. We summarize the challenges for manufacturing and identify areas where digitalization can help. A profound potential in using lignocellulosic biomass and renewable feedstocks, in general, is to produce new molecules and products with unmatched properties that have no analog in traditional refineries. Discovering such performance-advantaged molecules and the paths and processes to make them rapidly and systematically can transform manufacturing practices. We discuss retrosynthetic approaches, text mining, natural language processing, and modern machine learning methods to enable digitalization. Laboratory and multiscale computation automation via active learning are crucial to complement existing literature and expedite discovery and valuable data collection without a human in the loop. Such data can help process simulation and optimization select the most promising processes and molecules according to economic, environmental, and societal metrics. We propose the close integration between bench and process scale models and data to exploit the low dimensionality of the data and transform the manufacturing for renewable feedstocks.Item Ethylene production: process design, techno-economic and life-cycle assessments(Green Chemistry, 2024-01-29) Chen, Yuqiu; Kuo, Mi Jen; Lobo, Raul; Ierapetritou, MarianthiReplacing the steam cracking process with oxidative dehydrogenation for ethylene production offers potential energy and environmental benefits. To evaluate these possibilities, a study combining conceptual process design, techno-economic analysis, and life cycle assessments of the oxidative dehydrogenation of ethane (ODHE) for producing ethylene at an industrial scale is performed. For comparison, the conventional steam cracking process of ethane is also simulated and optimized. The techno-economic analysis results for ODHE with a boron-containing zeolite chabazite (B-CHA) catalyst, as developed in our group, demonstrate that it is economically competitive ($790 per t ethylene production) compared to the steam cracking process ($832 per t ethylene production). However, a “cradle-to-gate” life-cycle assessment shows that the ODHE process emits more greenhouse gases (2.42 kg CO2 equiv. per kg ethylene) compared to the steam cracking counterpart (1.34 kg CO2 equiv. per kg ethylene). The discrepancy between the initial hypothesis and the results arises from the significant refrigerant input required by the ODHE process to recover ethylene from byproducts such as CO, CH4, and unreacted oxygen and ethane. Further scenario analysis reveals that plausible improvements in the C2H6 conversion per pass, the selectivity to ethylene and the ratio of ethane to oxygen in the current ODHE process could render it both economically and environmentally viable as a replacement for the steam cracking process.Item A Life Cycle Greenhouse Gas Model of a Yellow Poplar Forest Residue Reductive Catalytic Fractionation Biorefinery(Environmental Engineering Science, 2022-09-13) Luo, Yuqing; O’Dea, Robert M.; Gupta, Yagya; Chang, Jeffrey; Sadula, Sunitha; Soh, Li Pei; Robbins, Allison M.; Levia, Delphis F.; Vlachos, Dionisios G.; Epps, Thomas H. III; Ierapetritou, MarianthiThe incentive to reduce greenhouse gas (GHG) emissions has motivated the development of lignocellulosic biomass conversion technologies, especially those associated with the carbohydrate fraction. However, improving the overall biomass valorization necessitates using lignin and understanding the impact of different tree parts (leaves, bark, twigs/branchlets) on the deconstruction of lignin, cellulose, and hemicellulose toward value-added products. In this work, we explore the production of chemicals from a yellow poplar-based integrated biorefinery. Yellow poplar (Liriodendron tulipifera L.) is an ideal candidate as a second-generation biomass feedstock, given that it is relatively widespread in the eastern United States. Herein, we evaluate and compare how the different proportions of cellulose, hemicellulose (xylan), and lignin among leaves, bark, and twigs/branchlets of yellow poplar, both individually and as a composite mix, influence the life-cycle GHG model of a yellow poplar biorefinery. For example, the processing GHG emissions were reduced by 1,110 kg carbon dioxide (CO2)-eq, 654 kg CO2-eq, and 849 kg CO2-eq per metric ton of twigs/branchlets, leaves, and bark, respectively. Finally, a sensitivity analysis illustrates the robustness of this biorefinery to uncertainties of the feedstock xylan/glucan ratio and carbon content.Item Process design of a fully integrated continuous biopharmaceutical process using economic and ecological impact assessment(Biotechnology and Bioengineering, 2022-09-15) Ding, Chaoying; Ardeshna, Hiren; Gillespie, Christopher; Ierapetritou, MarianthiContinuous biomanufacturing is a promising alternative to current batch operation as it offers benefits in terms of improved productivity, product quality, and reduced footprint. This study aims to build a fully integrated continuous platform for monoclonal antibody (mAb) production incorporating novel technologies (like intensified seed expansion and continuous high cell density perfusion operations, single-pass tangential flow filtration, and single-use technologies) as well as media and buffer preparation steps. Economic assessment is performed on the basis of the total cost of goods (COGs), which is $102.2/g in the base-case scenario with a bioreactor scale of 500 L. E-factor is used as an environmental indicator and the result shows that 4865.6kg of process water and 11.1 kg of consumables are required to produce 1 kg mAbs. After the development and analysis of the benchmark process, scenario analysis is performed to assess the impacts of the bioreactor scale (60–2000 L) and upstream titers (1.12–2.08 g/L) on the process economics as well as on the environmental footprint. With the increase of bioreactor scale and mAb titer, the operating COGs per unit product decrease. Moreover, increasing the mAb titer is more favorable in terms of the ecological impacts. To investigate the production capacity, the upstream production is increased and the downstream bottlenecks are determined. It is found that only the multicolumn chromatographic (MCC) operations become the process bottleneck and the order of the MCC unit operation that becomes the process bottleneck depends on capacity utilization for that step. Finally, a new platform is built with the integration of membrane chromatography and the two designed processes are compared in terms of economic and ecological impacts.