Production of nanocellulose from different biomass feedstocks and its economic feasibility using Aspen Plus

Abstract Nanocellulose has garnered significant attention in paper and packaging applications due to its enhanced functionality and sustainability concern. However, the low yield of nanocellulose that can be extracted by acid hydrolysis due to the low initial compositions of cellulose in the biomass poses a significant challenge to the large-scale production of nanocellulose. This study aims to produce 1,000 metric tonnes per year of nanocellulose with more than 80% purity from different lignocellulosic biomass feedstock and evaluate its economic feasibility using Aspen Plus V14. The acid to pulp (A/P) ratios needed for acid hydrolysis are 1:15 and 1:8 (w/v) for oil palm empty fruit bunch (OPEFB) and sugarcane bagasse (SCB), respectively. The process simulation involves sequential stages, including steam explosion, alkaline hydrolysis, and acid hydrolysis. The study discovers that the nanocellulose synthesis route via SCB was more advantageous due to its higher initial cellulose content (39.55%) with higher recovery (84.58%) and purity (86.27%) of cellulose. In comparison, OPEFB with an initial cellulose of 34.18% could recover 77.54% of cellulose with 81.96% purity. Based on the cost breakdown, scenario SCB appears to be more economical with a lower 6.0% total capital investment and 26.5% lower total operating cost compared to OPEFB. It is found that the economic feasibility of nanocellulose synthesis from lignocellulosic biomass is notably influenced by A/P ratio used in the acid hydrolysis process, where OPEFB requires approximately 46% higher A/P ratio than SCB. This higher ratio contributes to the increased H 2 SO 4 consumption and raw material costs, and thus significantly impacts the total operating cost. The study concludes that both feedstocks are feasible options, with SCB offering a more cost-effective and efficient process for nanocellulose production.