Case-study of Neogene Biocatalysis in Sustainable Petrochemicals

Thesis Abstract

The transition to sustainable petrochemicals necessitates a deeper understanding of neogene biocatalysis as a feasible route to replace conventional fossil-based processes in industrial settings. This study addresses the gap in empirical evidence on the operational viability, environmental benefits, and economic implications of integrating neogene biocatalytic pathways within a midstream refinery context, focusing on a case-study of a major petrochemical complex in North America. The aim is to evaluate how neogene biocatalysis can reduce carbon intensity, improve process selectivity, and lower lifecycle costs in the production of ethylene derivatives and propylene oxide through enzyme-enabled transformations. Specific objectives are (i) to quantify process performance gains and energy efficiency of neogene biocatalytic steps relative to conventional catalysis; (ii) to assess environmental impacts using a cradle-to-gate lifecycle assessment (LCA) with a system boundary encompassing feedstock pretreatment, biocatalysis, product separation, and waste treatment; (iii) to analyze economic feasibility via techno-economic analysis (TEA) and sensitivity analyses on capital expenditure (CAPEX), operating expenditure (OPEX), and biocatalyst lifetimes; (iv) to identify operational bottlenecks, catalyst stability concerns, and scale-up challenges; and (v) to develop a decision-support framework linking process parameters, regulatory constraints, and market dynamics to adoption likelihood. The methodology adopts a mixed-methods design anchored in action research within the refinery’s pilot plant and adjacent research facilities. The population comprises process engineers, biocatalyst developers, and sustainability analysts involved in integration projects at the site, with a purposive sample of 24 technicians and 9 senior engineers selected for in-depth interviews, complemented by quantitative data from pilot-scale runs (n = 12) and historical process records (n = 36 months). Data collection instruments include semi-structured interview guides, process performance dashboards, spectroscopic and chromatographic datasets, and lifecycle inventory files. Analytical techniques comprise thematic analysis of qualitative data guided by the Technology Acceptance Model and the Diffusion of Innovations framework, regression analyses to correlate biocatalyst performance with energy consumption, and ANOVA to compare yields across pilot runs. The LCA follows ISO 14040/44 standards, employing SimaPro to model cradle-to-gate impacts, while the TEA employs discounted cash flow analysis with 10-year horizon and Monte Carlo simulations (10,000 iterations) to capture parameter uncertainty. A process optimization model, integrating mass and energy balances with kinetic expressions for neogene enzyme-catalyzed steps, is implemented to estimate optimal operating windows and reactor configurations. Expected findings include demonstrable reductions in process energy intensity by 12–18%, improved selectivity toward target products by 6–14%, and a net lifecycle emission decrease of 15–22% under defined operating conditions, with an initial CAPEX premium offset within 5–7 years under certain feedstock and energy price scenarios. The study anticipates identifying critical stability constraints of neogene biocatalysts under industrial temperatures and solvent environments, and delineates remediation strategies such as enzyme immobilization, co-solvent selection, and in situ product removal. The contribution to knowledge lies in providing an evidence-based, integrative assessment of neogene biocatalysis within a real-world petrochemical complex, offering a transferable framework for feasibility assessment, risk quantification, and staged scale-up of bioengineered catalytic routes in large-scale refining, aligned with theoretical perspectives from the Resource-Based View and Dynamic Capability Theory. The main conclusion posits that, under favorable market conditions and with robust catalyst stabilization strategies, neogene biocatalysis can achieve meaningful environmental and economic benefits without prohibitive CAPEX penalties, enabling progressive decarbonization of petrochemical supply chains. Recommendations include prioritizing catalyst development with enhanced operational stability, investing in modular pilot facilities to de-risk scale-up, implementing comprehensive monitoring to detect performance drift, and cultivating cross-disciplinary collaboration between chemical engineering, biotechnology, and sustainability analytics to inform policy and investment decisions.