A novel mathematical modelling platform for evaluation of a novel biorefinery design with Green hydrogen recovery to produce renewable aviation fuel

Abstract

A novel integrated biorefinery system consists of (1) pyrolysis of biomass into gas, bio-oil and char; (2) bio-oil hydrodeoxygenation and hydrocracking (hydroprocessing) producing renewable jet fuel and small chain alkanes; (3) alkane steam reforming and pressure swing adsorption (PSA) producing green hydrogen and carbon monoxide; (4) mixed ionic electronic conducting membrane (MIEC) splitting high pressure superheated steam (HPSS) into green hydrogen and oxygen; and (5) combined heat and power generation (CHP) using pyrolysis gas and carbon monoxide from PSA as fuel with oxygen from MIEC, to fulfil the demand for HPSS and electricity. Comprehensive mathematical models are shown for the design simulation of the integrated system: (1) kinetic model of biomass pyrolysis at temperature 300−500 °C, (2) stoichiometric chemical reaction model of hydroprocessing, (3) renewable aviation fuel property correlations from its chemical compositions for the ASTM D7566 standard, (4) mass and energy balance analyses of the integrated biorefinery system. Economic value and overall avoided environmental and social impacts have been analysed for sustainability. The ratios of mass and energy flows between biomass, bio-oil, renewable jet fuel, CHP-fuel, char and hydrogen are 1.33:1:0.45:0.3:0.16:0.05 and 1:0.82:0.7:0.41:0.14:0.22, respectively. For 10tph bio-oil processing, the capital cost of the plant is $13.7 million, the return on investment is 19% and the cost of production of renewable jet fuel is $0.07/kg, which is lower than its market price, $0.27/kg. This production can curb 108 kt CO2 equivalent and 1.44 PJ fossil energy per annum. To enable the biorefinery simulation, user-friendly open-source TESARREC™ https://tesarrec.web.app/sustainability/bio-jet-fuel has been developed.