The aim of this study is to present and apply a quick screening method and to identify the most promising bioethanol derivatives using an early-stage sustainability assessment method that compares a bioethanol-based conversion route to its respective petrochemical counterpart. The method combines, by means of a multi-criteria approach, quantitative and qualitative proxy indicators describing economic, environmental, health and safety and operational aspects. Of twelve derivatives considered, five were categorized as favorable (diethyl ether, 1,3-butadiene, ethyl acetate, propylene and ethylene), two as promising (acetaldehyde and ethylene oxide) and five as unfavorable derivatives (acetic acid, n-butanol, isobutylene, hydrogen and acetone) for an integrated biorefinery concept.

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Chemical conversions have been a cornerstone of industrial revolution and societal progress. Continuing this progress in a resource constrained world poses a critical challenge which demands the development of innovative chemical processes to meet our energy and material needs in a sustainable way. This challenge forms the basis for this article. We report a method for quick preliminary assessment of chemical processes at the laboratory stage. The proposed method enables a review of chemical processes within a broader sustainability context. It is inspired by green chemistry principles, techno-economic analysis and some elements of environmental life-cycle assessment (LCA). This method evaluates a proposed chemical process against comparable existing processes using a multi-criteria approach that integrates various economic and environmental indicators. An effort has been made to incorporate quantitative and qualitative information about the processes while making the method transparent and easy to implement based on information available at an early stage in process development. The idea is to provide a data-based assessment tool for chemists and engineers to develop sustainable chemistry. This paper describes the method in detail and examines plausibility of the results. A biobased process for the production of but-1,3-diene has been analyzed using this method. This biobased process is compared with a conventional process for the production of but-1,3-diene from petroleum sources. The effects of uncertainty in the underlying model parameters and assumptions are also analyzed, along with the effect of system boundary selection on the assessment outcome. Analysis and testing of the method shows that it can be used as a valuable tool for sustainable process development.

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Pulp and paper industry is facing challenges such as resource scarcity and greenhouse gas (GHG) emissions. The objective of this research is to investigate whether the use of new coatings (micro or nano TiO₂) and different pulp types could bring savings in wood, energy, GHG emissions and other environmental impacts in comparison with conventional printing and writing paper. We studied three types of pulp, namely i) unbleached virgin kraft pulp, ii) recovered fiber, and iii) high yield virgin chemithermo-mechanical pulp (CTMP). A life cycle assessment (LCA) was conducted from cradle to grave.Applying attributional modeling, we found that wood savings amount to 60% for the nanoparticle coated recovered fiber paper and 35% for the micro TiO₂ coated CTMP paper. According to the ReCiPe single score impact assessment method, the new product configurations allow the reduction of the environmental impacts by 10-35% compared to conventional kraft paper.Applying consequential modeling, we found larger energy and GHG emission savings compared to attributional modeling because the saved wood is used for producing energy, thereby replacing fossil fuels. The nanoparticle coated recovered fiber paper offered savings of non-renewable energy use (NREU) by 100% (13GJ/ton paper) and GHG emission reduction by 75% (0.6tonCO₂eq./ton paper). Micro TiO₂ coated CTMP paper offered NREU savings by 25% (3GJ/ton paper) and savings of GHG emissions by 10% (0.1tonCO₂eq./ton paper). The taking into account of all environmental impacts with the ReCiPe single score method leads to comparable results as that of attributional modeling.We conclude that the nanoparticle coated recovered fiber paper offered the highest savings and lowest environmental impacts. However, human toxicity and ecotoxicity impacts of the nanoparticles were not included in this analysis and need further research. If this leads to the conclusion that the toxicity impacts of the nanoparticles are serious, then the CTMP paper with micro TiO₂ coating is the preferred option.

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Background, aim, and scope: Packaging uses nearly 40% of all polymers, a substantial share of which is used for sensitive merchandise such as moisture-sensitive food. To find out if bio-based materials are environmentally advantageous for this demanding application, we compared laminated, printed film across the whole life cycle. Materials and methods: We compared bio-based materials (paper, polylactic acid, bio-based polyethylene, and a bio-based polyester) as well as conventional ones (polypropylene, polyethylene). Data stemmed from 13 companies that produce raw materials, films and/or laminates and which co-operated with us in a project commissioned by a large food producer. The functional unit chosen for this study is 1 m² of packaging film. This is (mostly) laminated, printed film that is delivered on reels to the food industry, where the laminate is cut, sealed and filled. The impact assessment is presented for non-renewable energy use, total energy use, global warming potential, depletion of abiotic resources, photo-oxidant formation, acidification, eutrophication, water use, and land use. Results: For Inner Packs that get in direct contact with food and therefore require certain barrier properties, the environmental performance of many laminates is not better than the reference, petrochemical material. However, our study shows that paper/polypropylene laminates perform equally well as the current material (polypropylene) if the material is landfilled, and better if incinerated with energy recovery. For Outer Packs, bio-based polyethylene film shows a particularly low environmental impact. Paper/bio-based polyester laminates also offer significant savings compared with the current material. For Inner as well as Outer Packs, laminates including polylactic acid offer environmental advantages when accounting for wind credits or when assuming a future technology level for polymer or film production. Discussion: Increased technology maturity of PLA and cellulose in the film production stage offers significant environmental improvement with respect to global warming potential compared with today's technology. Though large, the uncertainty regarding the degree of degradation of paper, cellulose, PLA and bio-based polyester, is not decisive for the conclusions. Conclusions and recommendations: Generally, laminates and films (partly) consisting of bio-based polymers offer opportunities for significantly reducing environmental impacts of food packaging. Large variations in land-use are possible depending on the type of bio-based material that is used. The environmental advantages differ depending on the polymer and the final product (Inner vs. Outer Pack). Lack of experience and investment in converting bio-based polymers into final products and comparatively unfavourable material properties result in lower environmental advantages for some novel bio-based materials than one may expect. However, a) already today, the options with the lowest global warming potential are partly or fully bio-based and b) bio-based materials will benefit more from technological progress than conventional materials, potentially making certain bio-based laminates highly attractive options for the future. Overall, Outer Packs are more promising than Inner Packs when introducing bio-based wrappings to replace the current petrochemical material because a) the opportunities are clearer for this application and b) the product specifications (required barrier properties) are less demanding. Starting with the Outer Packs would also allow bio-based polymer producers and processors to invest and learn, thus offering the opportunity to reduce the environmental impact even further.

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Transitioning towards a sustainable energy system requires the large-scale introduction of novel energy demand and supply technologies. Such novel technologies are often expensive at the point of their market introduction but eventually become cheaper due to technological learning. In order to quantify potentials for price and cost decline, the experience curve approach has been extensively applied to renewable and non-renewable energy supply technologies. However, its application to energy demand technologies is far less frequent. Here, we provide the first comprehensive review of experience curve analyses for energy demand technologies. We find a widespread trend towards declining prices and costs at an average learning rate of 18 ± 9%. This finding is consistent with the results for energy supply technologies and for manufacturing in general. Learning rates for individual energy demand technologies are symmetrically distributed around the arithmetic mean of the data sample. Absolute variation of learning rates within individual technology clusters of 7 ± 4%-points and between technology clusters of 7 ± 5%-points both contribute to the overall variability of learning rates. Our results show that technological learning is as important for energy demand technologies as it is for energy supply technologies. Applying the experience curve approach to forecast technology costs involves, however, unresolved uncertainties, as we demonstrate in a case study for the micro-cogeneration technology.

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Large appliances are major power consumers in households of industrialized countries. Although their energy efficiency has been increasing substantially in past decades, still additional energy efficiency potentials exist. Energy policy that aims at realizing these potentials faces, however, growing concerns about possible adverse effects on commodity prices. Here, we address these concerns by applying the experience curve approach to analyze long-term price and energy efficiency trends of three wet appliances (washing machines, laundry dryers, and dishwashers) and two cold appliances (refrigerators and freezers). We identify a robust long-term decline in both specific price and specific energy consumption of large appliances. Specific prices of wet appliances decline at learning rates (LR) of 29±8% and thereby much faster than those of cold appliances (LR of 9±4%). Our results demonstrate that technological learning leads to substantial price decline, thus indicating that the introduction of novel and initially expensive energy efficiency technologies does not necessarily imply adverse price effects in the long term. By extending the conventional experience curve approach, we find a steady decline in the specific energy consumption of wet appliances (LR of 20-35%) and cold appliances (LR of 13-17%). Our analysis suggests that energy policy might be able to bend down energy experience curves.

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We present and apply a simple bottom-up model for estimating non-energy use of fossil fuels and resulting CO2 (carbon dioxide) emissions. We apply this model for the year 2000: (1) to the world as a whole, (2) to the aggregate of Annex I countries and non-Annex I countries, and (3) to the ten non-Annex I countries with the highest consumption of fossil fuels for non-energy purposes. We find that worldwide non-energy use is equivalent to 1,670 ± 120 Mt (megatonnes) CO2 and leads to 700 ± 90 Mt CO2 emissions. Around 75% of non-energy use emissions is related to industrial processes. The remainder is attributed to the emission source categories of solvent and other product use, agriculture, and waste. Annex I countries account for 51% (360 ± 50 Mt CO2) and non-Annex I countries for 49% (340 ± 70 Mt CO2) of worldwide non-energy use emissions. Among non-Annex I countries, China is by far the largest emitter of non-energy use emissions (122 ± 18 Mt CO2). Our research deepens the understanding of non-energy use and related CO2 emissions in countries for which detailed emission inventories do not yet exist. Despite existing model uncertainties, we recommend NEAT-SIMP to inventory experts for preparing correct and complete non-energy use emission estimates for any country in the world.@en

High costs often prevent the market diffusion of novel and efficient energy technologies. Monitoring cost and price decline for these technologies is thus important in order to establish effective energy policy. Here, we present experience curves and cost-benefit analyses for condensing gas boilers produced and sold in the Netherlands between 1981 and 2006. For the most dominant boiler type on the Dutch market, i.e., condensing gas combi boilers, we identify learning rates of 14±1% for the average price and 16±8% for the additional price relative to non-condensing devices. Economies of scale, competitive sourcing of boiler components, and improvements in boiler assembly are among the main drivers behind the observed price decline. The net present value of condensing gas combi boilers shows an overall increasing trend. Purchasing in 2006 a gas boiler of this type instead of a non-condensing device generates a net present value of 970 EUR (Euro) and realizes CO₂ (carbon dioxide) emission savings at negative costs of -120 EUR per tonne CO₂. We attribute two-thirds of the improvements in the cost-benefit performance of condensing gas combi boilers to technological learning and one-third to a combination of external effects and governmental policies.

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Methane, coal and biomass are being considered as alternatives to crude oil for the production of basic petrochemicals, such as light olefins. This paper is a study on the production costs of 24 process routes utilizing these primary energy sources. A wide range of projected energy prices in 2030-2050 found in the open literature is used. The basis for comparison is the production cost per t of high value chemicals (HVCs or light olefin-value equivalent). A Monte Carlo method was used to estimate the ranking of production costs of all 24 routes with 10,000 trials of varying energy prices and CO₂ emissions costs (assumed to be within $0-100/t CO₂; the total CO₂ emissions, or cradle-to-grave CO₂ emissions, were considered). High energy prices in the first three quarter of 2008 were tested separately. The main findings are:•Production costs: while the production costs of crude oil- and natural gas-based routes are within $500-900/t HVCs, those of coal- and biomass-based routes are mostly within $400-800/t HVCs. Production costs of coal- and biomass-based routes are in general quite similar while in some cases the difference is significant. Among the top seven most expensive routes, six are oil- and gas-based routes. Among the top seven least expensive routes, six are coal and biomass routes.•CO₂ emissions costs: the effect of CO₂ emissions costs was found to be strong on the coal-based routes and also quite significant on the biomass-based routes. However, the effect on oil- and gas-based routes is found to be small or relatively moderate.•Energy prices in 2008: most of the coal-based routes and biomass-based routes (particularly sugar cane) still have much lower production costs than the oil- and gas-based routes (even if international freight costs are included). To ensure the reduction of CO₂ emissions in the long-term, we suggest that policies for the petrochemicals industry focus on stimulating the use of biomass as well as carbon capture and storage features for coal-based routes.

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Non-energy use of fossil fuels accounts for 7% of the Total Primary Energy Supply (TPES) of Germany and represents an important potential source of CO2 (carbon dioxide) emissions. To gain a better understanding of emissions associated with non-energy use in Germany, we conduct a bottom-up carbon flow analysis with the Non-energy use Emission Accounting Tables (NEAT) model for the period of 1990-2003. We calculate average yearly non-energy use emissions to be 25 ± 2 megatonnes (Mt) CO2, of which 77% are related to industrial processes, 17% to solvent and other product use, 2% to fertilizer use in agriculture, and 4% to wastewater treatment. The comparison of NEAT estimates and official data reveals gaps and errors in the German greenhouse gas (GHG) inventory. This research highlights the difficulties associated with non-energy use emissions accounting not only in Germany but in other countries as well. To ensure correct calculation of non-energy use emissions, we recommend that inventory experts (i) obtain detailed insight into the system boundaries of non-energy use data as stated in national energy statistics, (ii) allocate non-energy use emissions accordingly to the relevant emission source categories (i.e., energy, industrial processes, solvent and other product use, agriculture, or waste), (iii) ensure completeness of emission estimates, and (iv) be cautious with the use of default emission factors as given by the Intergovernmental Panel on Climate Change (IPCC).@en

While most olefins (e.g., ethylene and propylene) are currently produced through steam cracking routes, they can also possibly be produced from natural gas (i.e., methane) via methanol and oxidative coupling routes. We reviewed recent data in the literature and then compared the energy use, CO₂ emissions and production costs of methane-based routes with those of steam cracking routes. We found that methane-based routes use more than twice as much process energy than state-of-the-art steam cracking routes do (the energy content of products is excluded). The methane-based routes can be economically attractive in remote, gas-rich regions where natural gas is available at low prices. The development of liquefied natural gas (LNG) may increase the prices of natural gas in these locations. Oxidative coupling routes are currently still immature due to low ethylene yields and other problems. While several possibilities for energy efficiency improvement do exist, none of the natural gas-based routes is likely to become more energy efficient or to lead to less CO₂ emissions than steam cracking routes do.

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A preliminary bottom-up analysis of the energy use in the chemical industry has been performed, using a model containing datasets on production processes for 52 of the most important bulk chemicals as well as production volumes for these chemicals. The processes analysed are shown to cover between 70% and 100% of the total energy use in the chemical sector. Energy use and the heat effects of the reactions taking place are separately quantified. The processes are also compared with energetically-ideal processes following the stoichometric reactions. The comparison shows that there is significant room for process improvements, both in the direction of more selective processes and in the direction of further energy-savings.@en

We prepared energy and carbon balances for 68 petrochemical processes in the petrochemical industry for Western Europe, the Netherlands and the world. We analysed the process energy use in relation to the heat effects of the chemical reactions and quantified in this way the sum of all energy inputs into the processes that do not end up in the useful products of the process, but are lost as waste heat to the environment. We showed that both process energy use and heat effects of reaction contribute significantly to the overall energy loss of the processes studied and recommend addressing reaction effects explicitly in energy-efficiency studies. We estimated the energy loss in Western Europe in the year 2000 at 1620 PJ of final energy and 1936 PJ of primary energy, resulting in a total of 127 Mt CO2. The losses identified can be regarded as good approximations of the theoretical energy-saving potentials of the processes analysed. The processes with large energy losses in relative (per tonne of product) and absolute (in PJ per year) terms are recommended for more detailed analysis taking into account further thermodynamic, economic, and practical considerations to identify technical and economic energy-saving potentials.@en

We studied energy efficiency trends in the Dutch manufacturing industry between 1995 and 2003 using indicators based on publicly available physical production and specific energy consumption data. We estimated annual primary energy efficiency improvements in this period at 1.3% on average, with the individual sub-sectors ranging between -0.1% and 1.5%. Energy efficiency developments with respect to electricity, fuels/heat and non-energy use have been monitored separately and are shown to differ significantly (for the sum of the sectors studied: 1.9% for electricity, 2.6% for fuels/heat and -0.1% for non-energy use). We combined our results with those from a previous, similar study for 1980-1995 and show that over the full time period, efficiency improvements of 1% per year have been achieved on average. Based on comparison with other sources and a detailed uncertainty analysis, we conclude that we developed a reliable top-down monitoring framework for studying energy efficiency trends of the manufacturing industry that can also be applied in other countries where similar data are available. We also showed that substantial differences exist between energy consumption data available from energy statistics and according to the Long Term Agreement monitoring reports, stressing the need for ongoing independent checks of available energy consumption data to avoid problems in future evaluations of energy efficiency policies.@en

Steam cracking for the production of light olefins, such as ethylene and propylene, is the single most energy-consuming process in the chemical industry. This paper reviews conventional steam cracking and innovative olefin technologies in terms of energy efficiency. It is found that the pyrolysis section of a naphtha steam cracker alone consumes approximately 65% of the total process energy and approximately 75% of the total exergy loss. A family portrait of olefin technologies by feedstocks is drawn to search for alternatives. An overview of state-of-the-art naphtha cracking technologies shows that approximately 20% savings on the current average process energy use are possible. Advanced naphtha cracking technologies in the pyrolysis section, such as advanced coil and furnace materials, could together lead to up to approximately 20% savings on the process energy use by state-of-the-art technologies. Improvements in the compression and separation sections could together lead to up to approximately 15% savings. Alternative processes, i.e. catalytic olefin technologies, can save up to approximately 20%.

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Steam cracking for the production of light olefins (e.g. ethylene and propylene) is the single most energy consuming process in the chemical industry. Production of light olefins from natural gas is possible through different routes. This paper compares the cumulative energy use and CO2 emissions of some of these routes (methanol-to-olefins, methanol-to-propylene and oxidative coupling of methane via ethane) with those of naphtha and ethane-based steam cracking. One conclusion is that the most efficient natural gas-to-olefms-via-methanol uses more than twice as much primary energy as state-of-the-art steam cracking to produce one ton of high value chemicals. This is largely due to high energy use in methanol production. Another conclusion is oxidative coupling of methane via ethane routes could have low CO2 emissions if more recycling is used and less electricity is co-generated.@en