ABB to automate bioplastics plant
ABB has been awarded a major contract by NatureWorks to automate their new, greenfield plant in Thailand, converting sugar cane to the polylactic acid biopolymer, Ingeo.
The plant will ferment and distill plant-based sugars—in a process similar to making beer or wine—converting the sugars first to lactic acid, then lactide and then polymerize them into Ingeo. In the new site, these three separate production processes will be fully integrated, resulting in improvements in energy and production efficiency. In addition, the integration of the fermentation phase will secure the supply of lactic acid. The Thailand facility will use sugarcane as feedstock and is set to produce 75,000 tpy of sustainable plastic when fully operational. The anticipated projected startup for this greenfield facility is in the second half of 2024.
ABB’s scope of work is a two-part order including a FEED study followed by detailed automation project execution, with ABB acting as the main automation contractor. ABB will deliver the hardware, software, control room design solutions, engineering and site support to fully develop NatureWorks’ greenfield system. ABB’s distributed control system Ability System 800xA will maximize plant efficiency and reliability through automation. Leveraging this technology, ABB will integrate inputs from all key systems into one single user-friendly overview. As a result, operators will be able to utilize data insights from all areas of the plant, delivered in real time, to drive efficiency, reduce risk and ensure production optimization.
The project will apply state based controls, enabling operators to take fewer interactions to start up a unit and reduce risk by having access to the right information at the right time. In addition, ABB’s automated engineering batch application tool will be implemented for this project.
“ABB’s global presence, especially in the U.S. and Thailand, combined with their deep expertise in the chemical industry, leading automation solutions and design optimization approach makes them the obvious choice for a partner to help achieve meaningful progress in our new plant,” said Steven Bray, Vice President of Operations and Project Program Manager at NatureWorks. “We also share a joint vision when it comes to resource efficiency, circular economy and sustainability.”
Part of NatureWorks’ global expansion plan, the plant will help meet the growing global demand for sustainable materials. Bioplastics represent less than 1% of all plastic produced globally but production is expected to grow over 260% between 2020 and 2026.
Ingeo is an eco-friendly, biobased material used in a wide-range of plastic and fiber products from compostable food packaging - coffee capsules, tea bags, food containers – to 3D printing filament, diapers and even refrigerator liners. Compared to traditional fossil-based polymers, manufacturing Ingeo produces approximately 80% less GHGs and uses 52% less non-renewable energy.
“We are proud to support NatureWorks in addressing the increasing demand for sustainable high-performance materials and helping maximize both energy and production efficiency in the new facility,” said Brandon Spencer, President, ABB Energy Industries. “Our project with NatureWorks is perfectly aligned with our 2030 sustainability strategy and driving more sustainable use of our planet’s resources through innovative solutions that help reshape industries and enable a low-carbon society.”
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