Comprehensive techno-economic and environmental assessment for 2,3-butanediol production from bread waste

• Integration of pinch technology reduces the BDO production cost by ∼ 10 %. • Comparable BDO production cost from BW via enzyme ($2.74) and acid ($2.68) hydrolysis. • 82–89% lower global warming for bio-BDO from BW than fossil-based production. • Lower environmental impacts for enzyme hydrolysis than acid one. • Reduction in transportation distance can reduce the overall environmental impacts. Bread waste (BW) is a common food waste in Europe and North America and has enormous potential as a biorefinery substrate for the sustainable synthesis of various platform chemicals. Our previous work made use of BW for the fermentative production of 2,3–butanediol (BDO). The present work evaluated the economic prospects and environmental consequences associated with the overall processes, handling 100 metric tons BW per day. The comprehensive process design using Aspen Plus and integrated techno-economic and environmental assessment was carried out for two different BW hydrolysis scenarios: acid and enzyme hydrolysis, followed by fermentation and extraction-based downstream BDO separation. The optimal heat exchanger network was designed using pinch analysis, which improved the energy efficiency of the processes significantly, with about 10 % savings of BDO production costs. Despite this improvement, the BDO derived from BW was exorbitant (4.2–6.9 $/kg) compared to the market price (3.23 $/kg) due to relatively higher capital investment for the current plant capacity. Further, the process inventory was modelled in SimaPro v9.1.0 to estimate the environmental consequences of these production processes for various impact categories, such as global warming (2.63 – 3.19 kg CO 2 eq.), marine eutrophication (3.55 × 10 -4 – 4.01 × 10 -4 kg N eq.), terrestrial ecotoxicity (6.44 – 7.88 kg 1,4 − DCB), etc. Sensitivity and uncertainty analyses were also conducted to establish the reliability of the results. It was found that the enzyme hydrolysis was associated with lower environmental impacts than acid hydrolysis. This comprehensive study can be used as a guideline for developing sustainable BW-based biorefinery in the future.