(402i) Techno Economic and Life Cycle Assessment of Bioproduction of 3-Hydroxypropionic Acid

The growing demand for sustainable chemicals necessitates bio-based alternatives to petrochemicals. With global plastic production exceeding 400 million metric tons annually [1] and carbon emissions from conventional processes contributing significantly to climate change, there is an urgent need for low-carbon chemical manufacturing pathways. 3-Hydroxypropionic acid (3-HP) has emerged as a key platform chemical with applications in biodegradable plastics, acrylates, and specialty esters, offering a potential 50-75% reduction in carbon footprint compared to petroleum-based equivalents [2].

This work evaluates the sustainable production of 3-HP through microbial fermentation using a recombinant Escherichia coli strain, with algae-derived technical grade glycerol (98% purity from lipid hydrogenation) as primary carbon source and arabinose as supplementary substrate. The study combines rigorous techno-economic assessment (TEA) with cradle-to-gate life cycle analysis (LCA). A process model was developed in BioSTEAM, incorporating stoichiometric reaction kinetics, equipment sizing, and energy integration. The system included upstream sterilization, fed-batch fermentation (48-hour residence time, 49% yield), centrifugation, and vacuum distillation. TEA employed a discounted cash flow rate of return analysis with 10% Internal Rate of Return (IRR), while LCA used Intergovernmental Panel on Climate Change's (IPCC) Fourth Assessment Report (AR4) factors for global warming potential (GWP).

Results demonstrated a minimum selling price (MSP) of $2.41/kg 3-HP, with capital investment costs comprising $10.4 million for a 12038 MT/year facility. The GWP of 5.87 kg CO₂ eq/kg 3-HP was dominated by impact of utilities and feedstock production. Sensitivity analysis revealed that reducing arabinose usage by 50% could lower MSP by 18%. 3-HP shows competitive sustainability when considering its biodegradability and potential carbon credits.

This work highlights the economic viability and environmental benefits of bio-based 3-HP, with recommendations for strain optimization to reduce inducer costs and energy integration to further lower emissions. The methodology provides a framework for assessing next-generation bio-chemicals using open-source tools (BioSTEAM), aligning with environmental sustainability goals.

References

[1] Nayanathara Thathsarani Pilapitiya PGC, Ratnayake AS. The world of plastic waste: A review. Cleaner Materials 2024;11:100220. https://doi.org/10.1016/j.clema.2024.100220.

[2] Matsakas L, Hrůzová K, Rova U, Christakopoulos P. Biological Production of 3-Hydroxypropionic Acid: An Update on the Current Status. Fermentation 2018;4:13. https://doi.org/10.3390/fermentation4010013.