Renewable energy solutions are appropriate for on-grid and off-grid applications, acting as a supporter for the utility network or rural locations without the need to develop or extend costly and difficult grid infrastructure. As a result, hybrid renewable energy sources have become a popular option for grid-connected or standalone systems. This paper examines hybrid renewable energy power production systems with a focus on energy sustainability, reliability due to irregularities, techno-economic feasibility, and being environmentally friendly. In attaining a reliable, clean, and cost-effective system, sizing optimal hybrid renewable energy sources (HRES) is a crucial challenge. The presenters went further to outline the best sizing approach that can be used in HRES, taking into consideration the key components, parameters, methods, and data. Moreover, the goal functions, constraints from design, system components, optimization software tools, and meta-heuristic algorithm methodologies... [more]

The ambitious CO2 emission reduction targets for the transport sector set in the Paris Climate Agreement require low-carbon energy solutions that can be commissioned rapidly. The production of gasoline, kerosene, and diesel from renewable methanol using methanol-to-olefins (MTO) and Mobil’s Olefins to Gasoline and Distillate (MOGD) syntheses was investigated in this study via process simulation and economic analysis. The current work presents a process simulation model comprising liquid fuel production and heat integration. According to the economic analysis, the total cost of production was found to be 3409 €/tfuels (273 €/MWhLHV), corresponding to a renewable methanol price of 963 €/t (174 €/MWhLHV). The calculated fuel price is considerably higher than the current cost of fossil fuels and biofuel blending components. The price of renewable methanol, which is largely dictated by the cost of electrolytic hydrogen and renewable electricity, was found to be the most significant factor a... [more]

The MixAlco process is a patented biomass conversion technology used to produce valuable chemicals. The basis of this design relies on the use of fermentation, where acidophiles utilize their own enzymatic pathways to convert a variety of biomass, such as organic wastes, into carboxylic acid salts. Unlike previous MixAlco designs in which carboxylate salts are processed further into hydrocarbon fuels, this proposed design simulates the optimization and commercialization of mixed carboxylic acid salts as the final product. Sensitivity analyses identified four critical input factors of the base case process—biomass feed rate, selling price, distribution cost, and biomass composition. Increasing the biomass feed rate or population size has the most pronounced effect on process economics. Overall, the sensitivity analyses of all four critical input factors support that the new design is flexible in its ability to support populations of varying sizes, as well as different biomass feed rates... [more]

The COVID-19 pandemic has motivated the rapid development of numerous vaccines that have proven effective against SARS-CoV-2. Several of these successful vaccines are based on the adenoviral vector platform. The mass manufacturing of these vaccines poses great challenges, especially in the context of a pandemic where extremely large quantities must be produced quickly at an affordable cost. In this work, two baseline processes for the production of a COVID-19 adenoviral vector vaccine, B1 and P1, were designed, simulated and economically evaluated with the aid of the software SuperPro Designer. B1 used a batch cell culture viral production step, with a viral titer of 5 × 1010 viral particles (VP)/mL in both stainless-steel and disposable equipment. P1 used a perfusion cell culture viral production step, with a viral titer of 1 × 1012 VP/mL in exclusively disposable equipment. Both processes were sized to produce 400 M/yr vaccine doses. P1 led to a smaller cost per dose than B1 ($0.15 v... [more]

Biogas is a significant by-product produced in algae processing and may be used for many different applications, not only as a renewable energy carrier but also as a chemical intermediate in integrated algae-based biorefineries. In this work, the reforming of biogas to H2/CO2 mixtures (referred to as SynFeed) as feed for the direct hydrogenation of CO2 to methanol is investigated. Two conventional processes, namely steam methane and autothermal reforming, with upstream CO2 separation from raw biogas are compared to novel concepts of direct biogas bi- and tri-reforming. In addition, downstream CO2 separation from SynFeed using the commercial Selexol process to produce pure H2 and CO2 is considered. The results show that upstream CO2 separation with subsequent steam methane reforming is the most economic process, costing 142.48 €/tSynFeed, and taking into consideration the revenue from excess hydrogen. Bi-reforming is the most expensive process, with a cost of 413.44 €/tSynFeed, due to t... [more]

Kiln is a prime need in the ceramics industry, where energy loss is a major part which consumes about 60% production cost through thermal energy for different applications. Higher density of fired and tunnel kiln refractory material lowers the thermal diffusivity and the proper selection of fired material minimizes the energy loss along the kiln. In particular, this research analysed the results of a heat recovery system comprised of a metallic recuperator which gives around 8% energy savings in natural gas consumption. In this work, detailed power quality analysis of low-power factor motors of a tunnel kiln was carried out and a power factor improvement solution was suggested to save electrical energy with payback period of 0.8 y. The motor operating at a low-power factor consumes more reactive power which does not produce beneficial work. A low-power factor around 0.4 causes network power loss, increases in transformer loss and voltage drops. The solution with accumulative capacitanc... [more]

Methane is the second highest contributor to the greenhouse effect. Its global warming potential is 37 times that of CO2. Flaring-associated natural gas from remote oil reservoirs is currently the only economical alternative. Gas-to-liquid (GtL) technologies first convert natural gas into syngas, then it into liquids such as methanol, Fischer−Tropsch fuels or dimethyl ether. However, studies on the influence of feedstock composition are sparse, which also poses technical design challenges. Here, we examine the techno-economic analysis of a micro-refinery unit (MRU) that partially oxidizes methane-rich feedstocks and polymerizes the syngas formed via Fischer−Tropsch reaction. We consider three methane-containing waste gases: natural gas, biogas, and landfill gas. The FT fuel selling price is critical for the economy of the unit. A Monte Carlo simulation assesses the influence of the composition on the final product quantity as well as on the capital and operative expenses. The Aspen Plu... [more]

Over recent years, the food industry has striven to reduce waste, mostly because of rising awareness of the detrimental environmental impacts of food waste. While the edible oils market (mostly represented by soybean oil) is forecasted to reach 632 million tons by 2022, there is increasing interest to produce non-soybean, plant-based oils including, but not limited to, coconut, flaxseed and hemp seed. Expeller pressing and organic solvent extractions are common methods for oil extraction in the food industry. However, these two methods come with some concerns, such as lower yields for expeller pressing and environmental concerns for organic solvents. Meanwhile, supercritical CO2 and enzyme-assisted extractions are recognized as green alternatives, but their practicality and economic feasibility are questioned. Finding the right balance between oil extraction and phytochemical yields and environmental and economic impacts is challenging. This review explores the advantages and disadvant... [more]

In Germany, enhancing renewable power generation represents a leading step to comply with the requirements of the Energiewende agenda. The geothermal reservoir in Oberhaching is assumed as a case study, with a gross electric power equal to 4.3 MWel. The intent of this work is to design a hybrid binary geothermal power plant and to integrate it into the German energy market. Biogas waste thermal power equal to 1350 kWth is assumed as a secondary source. Two different layouts are defined for the hybrid solution: increasing the geothermal fluid temperature before entering the organic Rankine cycle (ORC) unit and superheating the working fluid after the evaporator. Stationary and quasi-stationary simulations have been performed with Aspen Plus V8.8. Results demonstrate how hybridization allows a maximum electric power increase of about 240 kWel. Off-design conditions are investigated regarding both the switch-off of exhaust gases and the annual ambient temperature fluctuations. In spite of... [more]

Bangladesh is blessed with abundant solar resources. Solar power is considered the most desirable energy source to mitigate the high energy demand of this densely populated country. Although various articles deal with solar energy applications in Bangladesh, no detailed review can be found in the literature. Therefore, in this study, we report on the current scenario of renewable energy in Bangladesh and the most significant potential of solar energy’s contribution among multiple renewable energy resources in mitigating energy demand. One main objective of this analysis was to outline the overall view of solar energy applications in Bangladesh to date, as well as the ongoing development of such projects. The technical and theoretical solar energy potential and the technologies available to harvest solar energy were also investigated. A detailed techno-economic design of solar power applications for the garment industry was also simulated to determine the potential of solar energy for t... [more]

The energy utilization of the transportation industry is increasing tremendously. The battery is one of the primary energy sources for a green and clean mode of transportation, but variations in driving profiles (NYCC, Artemis Urban, WLTP class-1) and higher C-rates affect the battery performance and lifespan of battery electric vehicles (BEVs). Hence, as a singular power source, batteries have difficulty in tackling these issues in BEVs, highlighting the significance of hybrid-source electric vehicles (HSEVs). The supercapacitor (SC) and photovoltaic panels (PVs) are the auxiliary power sources coupled with the battery in the proposed hybrid electric three-wheeler (3W). However, energy management strategies (EMS) are critical to ensure optimal and safe power allocation in HSEVs. A novel adaptive Intelligent Hybrid Source Energy Management Strategy (IHSEMS) is proposed to perform energy management in hybrid sources. The IHSEMS optimizes the power sources using an absolute energy-sharin... [more]

This paper examines a novel approach to activated carbon (AC) production that uses pea waste (PW) and to what extent it is economically competitive with current production methods. Additionally, the outcome is to provide a detailed economic analysis to understand whether this process is viable. The focus of this production route and the economic analysis will be on a United Kingdom (UK) basis. The plant will be located within the north UK to minimise storage and transportation costs. It also has extensive links to other clusters of nearby industries that would produce from this process in air pollution control or wastewater treatments. The overall production process is detailed, and detailed equipment specifications, including the sizing of equipment and utility requirements, were also given. Material balance calculations are carried out to assess the performance and improve process design. An economic analysis is performed to study the potential of biomass-to-AC conversion costs and c... [more]

In order to increase the typically low equilibrium CO2 conversion to methanol using commercially proven technology, the addition of two intermediate condensation units between reaction steps is evaluated in this work. Detailed process simulations with heat integration and techno-economic analyses of methanol synthesis from green H2 and captured CO2 are presented here, comparing the proposed process with condensation steps with the conventional approach. In the new process, a CO2 single-pass conversion of 53.9% was achieved, which is significantly higher than the conversion of the conventional process (28.5%) and its equilibrium conversion (30.4%). Consequently, the total recycle stream flow was halved, which reduced reactant losses in the purge stream and the compression work of the recycle streams, lowering operating costs by 4.8% (61.2 M€·a−1). In spite of the additional number of heat exchangers and flash drums related to the intermediate condensation units, the fixed investment cos... [more]

The over-enrichment of phosphorus in waste streams can lead to eutrophication and oxygen limitations for aquatic life. To understand the release of phosphorus from a soybean processing facility, it is imperative to track the flow of phosphorus in different streams during the processing of soybeans. The objective of the study is to develop process simulation models to study the flow of phosphorus in the soy-biodiesel process and evaluate strategies to mitigate phosphorus release by recovering phosphorous from soapstock and wastewater. Since most of the P is found in soybean meal, the processing of which releases phosphorus, a third case of lecithin recovery was also studied to reduce the amount of phosphorous in soybean meal. It was observed that phosphorus can be economically recovered from the soapstock, as well as the wastewater stream, with an estimated operating cost of USD 1.65 and 3.62 per kg of phosphorous recovered, respectively. The phosphorus recovered from both streams can b... [more]

Recycling of waste plastics has become vital due to the threat to the environment the huge piles of those wastes represent, with research revealing High-Density Polyethylene (HDPEs) as the most dominant waste plastics. Because of their dominance and significant environmental impact, this paper reports the economic potential of recycling HDPE waste plastic into liquid fuels via pyrolysis. A risk and benefit assessment are presented to highlight whether the process has reasonable potential prior to the analysis of its corresponding finances. Aspen HYSYS simulation models were used as the basis for the analysis. From this, preliminary cost estimations for the net present value (NPV) of the process, its economic viability, were determined. It is shown that 100 kg/h of waste is not financially sustainable. Retailing the fuel product at a competitive price of £60/barrel would ultimately bankrupt the business. This is a consequence of the extremely high production cost of £198.40/barrel induc... [more]

Hyaluronic acid (HA) is a polysaccharide of alternating d-glucuronic acid and N-acetyl-d-glucosamine residues present in the extracellular matrix of connective, epithelial, and nervous tissues. Due to its singular hydrating, rheological and adhesive properties, HA has found numerous cosmetic and medical applications. However, techno-economic analyses of high value-added bioproducts such as HA are scarce in the literature. Here, we present a techno-economic analysis of a process for producing HA using Streptococcus zooepidemicus, simulated in SuperPro Designer. In the baseline scenario, HA is produced by batch fermentation, reaching 2.5 g/L after 24 h. It is then centrifuged, diafiltered, treated with activated carbon and precipitated with isopropanol. The product is suitable for topical formulations and its production cost was estimated as 1115 $/kg. A similar scenario, based on fed-batch culture and assuming a titer of 5.0 g/L, led to a lower cost of 946 $/kg. Moreover, in two additio... [more]

Models and codes that were used in this work. Please read the simulation instruction.

Carbon capture, transport, and storage (CCS) is an essential technology to mitigate global CO2 emissions from power and industry sectors. Despite the increasing recognition and interest in both the scientific community and stakeholders, current CCS deployment is far behind targeted ambitions. A key reason is that CCS is often perceived as too expensive to reduce CO2 emissions. The costs of CCS have however traditionally been looked at from the industrial plant point of view which does not necessarily reflect the end-user’s perspective. This paper addresses the incomplete view by investigating the impact of implementing CCS in industrial facilities on the overall costs and CO2 emissions of end-user products and services. As an example, this work examines the extent to which an increase in costs of raw materials (cement and steel) due to CCS impact the costs of building a bridge. Our results show that although CCS significantly increases the cost of cement and steel, the subsequent incre... [more]

This is supplemental data for a paper submitted to the PSE 2021+ conference. It includes values used to calculate emissions reductions and financial value of biomass pyrolysis by-product utilization.

As part of efforts to reduce carbon emissions in the iron and steel industry, which are especially pertinent in Canada due to rising carbon taxes, Canadian producers have been investigating the effects of replacing coal used in pulverized coal injection with biochar. Although there has been research into the economic value and effect on net life cycle emissions of using the biochar product itself, there are no comprehensive techno-economic analyses which investigate the value and potential uses of the by-products of biomass pyrolysis. These by-products include volatile organic compounds, known collectively as tar or bio-oil, and light gases, which are mainly hydrogen, carbon monoxide, carbon dioxide, and methane. Since only 20-30% of the mass of pyrolyzed biomass is actually converted to char, with the rest converted to the by-products, [1] usage of these by-products is likely the key to increasing the value of biochar to a degree that makes up for the market price of biochar currently... [more]

While pipeline transport traditionally has been regarded as the best option for CO2 transport due to its low cost over short distances and important economies of scale, interest in vessel-based transport of CO2 is growing. While virtually all recent literature has focused on low pressure transport (at 7 barg and -46°C), the issue of optimal transport conditions, in terms of pressure, temperature and gas composition, is becoming more relevant as carbon capture and storage chains based on ship transport move closer towards implementation.
This study focuses on an in-depth comparison of the two primary and relevant transport pressures, 7 and 15 barg, for annual volumes up to 20 MtCO2/y and transport distances up to 2000 km. We also address the impact of a number of key factors on optimal transport conditions, including (a) transport between harbours versus transport to an offshore site, (b) CO2 pressure prior to conditioning, (c) the presence of impurities and of purity constraints, and... [more]

Transitioning to a renewable energy economy requires the widespread integration of solar and wind power, which are intermittent, into the electricity grid. To this goal, it is paramount to develop cost-competitive, reliable, location-independence, and large-scale energy storage technologies. The hydrogen bromine flow battery (HBFB) is a promising technology given the abundant material availability and its high power density. Here, the aim is to perform a comprehensive techno-economic analysis of a 500 kW nominal power/5 MWh HBFB storage system, based on the levelized cost of storage approach. Then, we systematically analyze stack and system components costs for both the current base and a future scenario (2030). We find that, for the base case, HBFB capital investments are competitive to Li-ion battery technology, highlighting the potential of large-scale HBFB market introduction. Improving the stack performance and reducing the stack and system costs are expected to result in ~62% red... [more]

Hybrid Renewable Energy Systems (HRESs) have been touted as an appropriate way for supplying electricity to remote and off-grid areas in developing countries, especially in sub-Saharan Africa (SSA), where rural electrification challenges are the most pronounced. This study proposes a two-step methodology for optimizing and analyzing a stand-alone photovoltaic/wind/battery/diesel hybrid system to meet the electricity needs of Fanisua, an off-grid and remote village of northern Nigeria. In the first step, the MATLAB environment was used to run simulations and optimize the system via the genetic algorithm. Then, techno-economic and emissions analysis was carried out in the second step to compare the proposed system to the existing traditional modes of rural electrification in sub-Saharan Africa, namely, the grid-extension and diesel generator. The break-even distance parameter was adopted in the comparison with grid-extension. Besides, the hypothetical project of replacing the diesel gene... [more]

There is a growing awareness of the need to mitigate greenhouse gas emissions and the inevitable depletion of fossil fuel. With the market pull for the growth in sustainable and renewable alternative energy, the challenge is to develop cost-effective, large-scale renewable energy alternatives for all energy sectors, of which transport fuels are one significant area. This work presents a summary of novel methods for integrating kraft mills with a hydrothermal liquefaction process. The application of these methods has resulted in a proposed kraft mill-integrated design that produces a liquid fuel and could provide net mitigation of 64.6 kg CO2-e/GJ, compared to conventional petrol and diesel fuels, at a minimum fuel selling price of 1.12−1.38 NZD/LGE of fuel, based on the case study. This paper concludes that a hydrothermal liquefaction process with product upgrading has promising economic potential and environmental benefits that are significantly amplified by integrating with an existi... [more]

SuperPro Designer® is a process simulator software used for analyzing the techno-economic feasibility of large-scale bioprocesses. Its predetermined built-in features allow for easy implementation by non-experts, but a lack of examples limits its appropriation. This study aims to validate the implementation of SuperPro Designer® by non-experts for the techno-economic analysis of anaerobic digestion in Colombia, using vinasse as feedstock. These results demonstrate the financial feasibility of such a process when a processing flow rate of 25 m3/h is ensured. Additionally, this study validates the manageability of the tool for assessing the economic feasibility of a technology, a key practice during technology development regardless of the area of expertise.