Modelling a biorefinery concept producing carbon fibre-polybutylene succinate composite foam

Abstract In this study, a novel biorefinery concept producing carbon fibre-poly(butylene succinate) composite foam (CPC foam) from lignocellulose and CO2 is modelled. The biodegradable nature of poly(butylene succinate) would allow for easy carbon fibre recovery from the CPC foam for reuse at the end of product lifecycle, thus allowing for a circular materials flow. Technical simulation results show the biorefinery consumes 417 kg of biomass, 33 kg of CO2, 86 kg of methanol, 23 kg of acetic anhydride, 130 kWh of electricity and 1166 kW of heat per hour. The facility generates 72 kg of CPC foam, 82 kg of carbon fibre, 24 kg of tetrahydrofuran and 50 kg of dimethyl ether (DME). DME is used to fulfil parasitic electricity requirement. These results demonstrate the technical viability of this biorefinery although, research is needed to reduce parasitic energy demand. This carbon negative biorefinery avoids carcinogens and halogens for polymeric materials synthesis by utilising green chemistry principles and lignocellulose feedstock.