ABB automates bioplastics factory

ABB has been awarded a major contract from NatureWorks to provide automation services for its new greenfield plant in Thailand to convert sugarcane into the polylactic acid biopolymer Ingeo
.

The plant will ferment and distill plant sugars (similar to brewing beer or wine), first converting the sugar into lactic acid, which is then polymerized into Ingeo
.
The three separate production processes will be fully integrated at the new site, resulting in increased energy and production efficiency
.
Furthermore, the integration of the fermentation stage will ensure the supply of lactic acid
.
The Thailand factory will use sugarcane as raw material and will achieve a sustainable plastic output of 75,000 tons per year after full production
.
The project is expected to start in the second half of 2024
.

ABB's scope of work consists of two parts, including FEED studies and detailed automation project execution, with ABB as the main automation contractor
.
ABB will provide hardware, software, control room design, engineering and on-site support to fully develop NatureWorks' greenfield system
.
ABB's distributed control system, Ability System 800xA, will maximize plant efficiency and reliability through automation
.
Using this technology, ABB will consolidate all key system inputs into a single user-friendly overview
.
As a result, operators will be able to leverage real-time data from all areas of the plant to increase efficiency, reduce risk and ensure production optimization
.

The project will apply state-based controls, enabling operators to start equipment with less interaction and reducing risk by having the right information at the right time
.
In addition, ABB's automated engineering batch application tools will also be implemented in this project
.

As part of NatureWorks' global expansion plans, the facility will help meet the growing global demand for sustainable materials
.
Bioplastics account for less than 1% of all plastics produced globally, but production is expected to grow by more than 260% between 2020 and 2026
.

Ingeo is an eco-friendly bio-based material that is used in a wide range of plastic and fiber products, from compostable food packaging (coffee capsules, tea bags, food containers) to 3D printed filaments, diapers and even refrigerator liners
.
Compared to traditional fossil-based polymers, manufacturing Ingeo reduces greenhouse gases by about 80 percent and uses 52 percent less non-renewable energy
.