Integrated methods for chemical synthesis

An integrated method of fine-tuning bio-based content of beta-propiolactone derived from bio-based and fossil-based ethylene oxide production systems and bio-based and fossil-based carbon monoxide production systems, the method comprising:

• a) selecting a target bio-based content for beta-propiolactone;
• b) producing a bio-based ethylene oxide stream by a process comprising biomass fermentation or biomass gasification, or both;
• c) producing a fossil-based ethylene oxide stream by a process comprising cracking a fossil-based feedstock;
• d) controlling relative production of the bio-based ethylene oxide stream and the fossil-based ethylene oxide stream to achieve a target bio-based content of ethylene oxide for producing beta-propiolactone with the target bio-based content selected in step (a);
• e) combining the bio-based ethylene oxide stream and the fossil-based ethylene oxide stream to produce a combined ethylene oxide feed stream;
• f) producing a bio-based syngas stream comprising bio-based carbon monoxide and hydrogen by a process comprising biomass gasification, or producing a bio-based carbon monoxide stream by a process comprising electrolysis of carbon dioxide, or both;
• g) producing a fossil-based syngas stream comprising fossil-based carbon monoxide and hydrogen by a process comprising gasification of a fossil-based feedstock;
• h) controlling relative production of the bio-based syngas stream or the bio-based carbon monoxide stream, or both, and the fossil-based syngas stream to achieve a target bio-based content of carbon monoxide for producing beta-propiolactone with the target bio-based content selected in step (a);
• i) combining the bio-based syngas stream or the bio-based carbon monoxide stream, or both, and the fossil-based syngas stream to produce a combined carbon monoxide feed stream;
• and
• j) carbonylating the combined ethylene oxide feed stream using the combined carbon monoxide feed stream in the presence of carbonylation catalyst to produce beta-propiolactone having the target bio-based content selected in step (a).

An integrated system for producing beta-propiolactone having a target bio-based content, the system comprising:

• a bio-based ethylene oxide production system configured to receive biomass, and to produce a bio-based ethylene oxide stream by a process comprising biomass fermentation or biomass gasification, or both;
• a fossil-based ethylene oxide production system configured to receive a fossil-based feedstock, and to produce a fossil-based ethylene oxide stream by a process comprising cracking the fossil-based feedstock;
• a bio-based carbon monoxide production system configured to:
• (i) receive a bio-based syngas stream comprising bio-based carbon monoxide and hydrogen from the biomass gasification, if present, in the bio-based ethylene oxide production system;
• or
• (ii) if the biomass gasification is not present in the bio-based ethylene oxide production system, receive additional biomass, and produce a bio-based syngas stream comprising bio-based carbon monoxide and hydrogen by a process comprising biomass gasification;
• or
• (iii) receive additional biomass, and produce a bio-based carbon monoxide stream by a process comprising electrolysis of carbon dioxide,
• or either (i) or (ii) in combination with (iii);
• a fossil-based carbon monoxide production system configured to receive additional fossil-based feedstock, and to produce a fossil-based syngas stream comprising fossil-based carbon monoxide and hydrogen;
• and
• a carbonylation reactor configured to receive (xl) the bio-based ethylene oxide stream from the bio-based ethylene oxide production system and the fossil-based ethylene oxide stream from the fossil-based ethylene oxide production system, and (x2) the bio-based syngas stream or the bio-based carbon monoxide stream, or both, from the bio-based carbon monoxide production system and the fossil-based syngas stream from the fossil-based ethylene oxide production system, and to produce beta-propiolactone having the target bio-based content by carbonylating the bio-based ethylene oxide stream and the fossil-based ethylene oxide stream using the bio-based syngas stream or the bio-based carbon monoxide stream, or both, and the fossil-based syngas stream in the presence of carbonylation catalyst, wherein the integrated system is configured to control relative production of (y1) the bio-based ethylene oxide stream, (y2) the fossil-based ethylene oxide stream, (y3) the bio-based syngas stream or the bio-based carbon monoxide stream, or both, and (y4) the fossil-based syngas stream to achieve a target bio-based content of ethylene oxide and a target bio-based content of carbon monoxide for producing beta-propiolactone with the target bio-based content.