Sustainable manufacturing of polymeric materials: A techno-economic analysis of soybean oil-based acrylic monomers production

(Acryloylamino)ethyl soyate is a soybean oil-based acrylic monomer (SBM) with versatile properties for applications in polymeric materials. To explore the economic feasibility of the bio-based monomers as a potential replacement for the commercial petro-counterpart, this study presents a conceptual process design and scale-up of SBMs production. Process simulation was conducted by Aspen Plus through an integrated design consisting of the catalytic transesterification conversion of soybean oil/soybean oil-based biodiesel with N-hydroxyethyl acrylamide (HEAA), followed by product recovery optimization with solvents recycling solutions. The simulation tool estimated mass and energy balances and assessed plant performance under varying process conditions (different renewable content, catalysts, soybean oil-based feedstocks, and scales). The minimum selling price (MSP) of SBM in the base case was estimated to be $78.4/kg using a cash flow analysis, which shows its economic potential compared to stearyl acrylate. The renewable content of the specialty chemical is a key technical parameter for MSP while it contributes to carbon emission reduction as well. Carbon abatement cost analysis indicates trivial economic impact of feedstock and the need for abatement consideration in different environmental profiles for bio-based chemicals. The uncertainty analysis showed the price of the fossil-based component – HEAA has the major impact on the MSP, while feedstock to HEAA ratio, tax rate, interest rate, and capital cost are sensitive parameters. Underlying areas such as wastewater treatment and economy of scale effects in producing specialty polymers were also discussed in this study.