Acid–hydrolysed furfural production from rice straw bio-waste: Process synthesis, simulation, and optimisation

Finding a way to efficiently utilize this bio-waste resource is a great challenge due to the depletion of traditional fossil fuels and the environmental impact associated to their use. Rice straw is considered as one of the main cereal straws. It is produced in many countries every year in substantial amounts and it has a high ash content and low protein content. Usually, rice straw is burned by farmers causing many adverse effects on the environment and public health. This research investigates the process synthesis of furfural production through the acid-hydrolysis of rice straws. Furfural is a strategic bio-renewable chemical and has gained attention due to its possibility to produce biofuels and bio chemicals. Aspen Plus® simulation package is employed for process simulation, sizing, and analysis. Results of simulations are validated against an experimental work. Optimization through manipulation of several parameters including acid concentration, reaction temperature, acid/rice straw ratio, catalyst concentration, and type of acid to maximize the furfural yield and reaction conversion. A complete flow sheet is synthesized and sensitivity analysis is studied to reach an optimum process concerning environment and economics. The amount of furfural obtained as a final product from the process represents a yield of 73% per 100 kg/hr of rice straw processed.