Dynamic Technoeconomic Analysis for Textile Recycling
Context
Next Rung Technology was tasked with developing a technoeconomic model for a client’s proprietary process for recycling textiles. Through this process we developed a thorough understanding of the lab scale process, which then helped the technology team to conceptualize what type and size of equipment would be needed at commercial scale.
Process
The first phase of the project involved the creation of a dynamic technoeconomic model to forecast costs for the client’s pilot and commercial scale plants, identifying key economic levers and opportunities.
Process Modeling
The project kicked off by mapping the client’s major process parameters including incoming material feed rates, compositions, and wash ratios onto a detailed material balance, tracking all inflows and outflows. Of particular interest to this client was tracking the wash liquid used and recycled throughout the process.
The process model and material balance were used to develop a sized and costed equipment list. Leveraging Next Rung’s internal equipment cost database for most major equipment and conducting vendor outreach for more specialized items, the team was able to arrive at an installed equipment cost estimate, alongside projections for materials, utilities, labor, and other costs of production.
Technoeconomic Analysis
Next Rung presented these insights through a user-friendly dashboard, detailing breakdowns of capital cost (CAPEX) and cost of goods sold (COGS), along with other findings, such as wash usage, wash liquid recovery, and recommended equipment sizes. Major process parameters were included as adjustable inputs, enabling real-time scenario analysis.
Unique to the client’s model was the ability to toggle between modeling their pilot and commercial plants, which would turn on and off specific equipment as needed. This flexibility, combined with the Next Rung TEA’s built-in ability to model processes live across a wide range of production scales, empowered the client to seamlessly analyze economics at both plant scales.
Outcomes
Next Rung continues to partner with the company to design their next plant. Using their technoeconomic model, the client was able to:
Understand the immediate costs of their pre-pilot plant
Strategize their research and development efforts through setting clear priorities
Project costs of their future pilot plant, thus supporting their next round of funding