Cogeneration Research Articles

Principal parameters of thermoelectric generator module design for effective industrial waste heat recovery

In the sustainable energy agenda, thermoelectric generators (TEG) can be a central technology for low-cost combined heat and power (CHP) systems. TEG module (TEM) is the combination of TEG cells, heat pipes, heat sinks and copper blocks that produce electrical power and thermal energy for low temperature heating simultaneously. Two TEG cells were used in each TEM for CHP in a bakery factory with a reference waste heat temperature of 250°C. Different designs of TEM affect the heat transfer mechanics through the components. However, actual testing of each design requires high cost and time consuming. Identifying the principal parameters affecting the desired output is indeed important before investing in actual design fabrication. One-dimensional model is developed in this manuscript to evaluate the fundamental interactions between each component. Parametric variation for nine main parameters characterized the steady-state response of each parameter under four novel heat sink configurations. The parameter sweeps approach benefits in designing a novel TEM for optimum system output. An improved TEM with 6 TEG cells was designed and it increased the heat recovery ratio from an initial 14% to 38%. The Reynolds number of streams are the major operating parameter as it influences the heat sink effectiveness. Large heat exchanger frontal area and copper block housing surface area are also significant parameters. Identification of these principle parameters would assist in effective designs of TEM systems for industrial CHP.

Synergistic Effects of Amine Functional Groups and Enriched-Atomic-Iron Sites in Carbon Dots for Industrial-Current-Density CO2 Electroreduction.

Metal phthalocyanine molecules with Me-N4 centers have shown promise in electrocatalytic CO2 reduction (eCO2R) for CO generation. However, iron phthalocyanine (FePc) is an exception, exhibiting negligible eCO2R activity due to a higher CO2 to *COOH conversion barrier and stronger *CO binding energy. Here, amine functional groups onto atomic-Fe-rich carbon dots (Af-Fe-CDs) are introduced via a one-step solvothermal molecule fusion approach. Af-Fe-CDs feature well-defined Fe-N4 active sites and an impressive Fe loading (up to 8.5wt%). The synergistic effect between Fe-N4 active centers and electron-donating amine functional groups in Af-Fe-CDs yielded outstanding CO2-to-CO conversion performance. At industrial-relevant current densities exceeding 400mA cm-2 in a flow cell, Af-Fe-CDs achieved >92% selectivity, surpassing state-of-the-art CO2-to-CO electrocatalysts. The in situ electrochemical FTIR characterization combined with theoretical calculations elucidated that Fe-N4 integration with amine functional groups in Af-Fe-CDs significantly reduced energy barriers for *COOH intermediate formation and *CO desorption, enhancing eCO2R efficiency. The proposed synergistic effect offers a promising avenue for high-efficiency catalysts with elevated atomic-metal loadings.

Techno-economic analysis of vacuum pressure swing adsorption process for a sustainable upgrading of biogas

Vacuum pressure swing adsorption (VPSA) has demonstrated promising features for the upgrading of biogas to biomethane. In this study, a biogas upgrading plant, comprised of a hybrid of an N-column VPSA unit (2 ≤N ≤ 6) with a combined heat and power (CHP) engine, was developed and its techno-economic characteristics were assessed via a mathematical approach. Moreover, the techno economic analysis was used for the state-of-the-art VPSA configuration (a sophisticated configuration) and compared with the developed hybrid process. The prominent parameters including feedstock transport, biogas production, desulfurization, drying, upgrading, combustion, and grid injection were considered in the analyses of the plant for the upgrading capacity in the range of 100–6500 Nm3/h. Sensitivity analysis of the most influencing parameters, i.e., electricity price, gas price, and feed processing revenues, was conducted for the developed models. Beside comparing upgrading cost of the sophisticated VPSA with other upgrading technologies, a detailed comparison with the best available membrane unit for biogas upgrading was conducted. The limitations of adsorption process and VPSA in reducing the upgrading cost were also investigated. The results showed that in the absence of subsidies and requirements for CO2 capture, the hybrid plant outperforms the sophisticated VPSA units. Also, higher market price of natural gas or feedstock processing revenues were necessary in order to render the plant profitable. The results showed that, at flowrates larger than 175 Nm3/h, the sophisticated VPSA unit required a lower investment cost than the membrane unit for identical outputs. The results also show that even at the most idealistic conditions in the adsorption process, the upgrading is not economically favorable without subsidies. The findings of this study shed light on the importance of process design for biogas upgrading.

Operational Strategies of Two-Spool Micro Gas Turbine With Alternative Fuels: A Performance Assessment

Abstract Micro gas turbines (mGT) have not yet succeeded in conquering the small-scale combined heat and power (CHP) market. One reason is that their electrical efficiency is not high enough to maintain a cost-effective operation. A two-shaft intercooled mGT has the potential to meet the current market demand. This technology maintains a high electrical efficiency even at part-load and coupled with its fuel-flexible combustion chamber, it is an ideal candidate for CHP concepts in a renewable future. In this paper, performance analysis on two-spool mGT is carried out with various fuel blends. Attention is given to the low-pressure and high-pressure compressors and the variation of surge margin by adding hydrogen and syngas. Two control strategies for the mGT are adopted. In the first scenario, the two shafts have equal rotational speeds while in the second, the speeds are controlled independently. As the engine is operated at equal speeds, the maximum performance with 100 vol. % of syngas is observed at 85% of the nominal load while 100 vol. % of hydrogen shows maximum efficiency at a load of 63.7%. At electric power lower than 60% and for high amounts of syngas in natural gas, the low-pressure compressor (LPC) operates closely to surge line. In the second scenario, the efficiency increases as the load decreases and the LPC runs in an efficient and safe operating region. Additionally, the amount of nitrogen in syngas affects the part-load performance of the two-spool mGT.

Modulating selectivity in CO2 Methanation through Rhodium catalysts supported on Zirconia-Chemically grafted SBA-15

This study presents the impact of ZrO2 incorporation on Rh-supported SBA-15 catalysts for CO2 hydrogenation. ZrO2 was chemically grafted onto the SBA-15 surface, varying concentrations of ZrO2 from 5 to 20 wt.%. The ZrO2-free catalyst favored CO production, leaning towards the reverse water gas shift reaction. The addition of ZrO2 notably enhanced catalytic activity and led to a significant shift in selectivity towards methane production. The selectivity modulation is linked with the modified surface of SBA-15, covered with a ZrO2 phase. The FTIR characterization under reaction conditions evidenced Rh-carbonyls formation in all samples. However, in catalysts materials with ZrO2, formate species are also formed, probably promoted by the Zr-OH groups. A linear relation between formate species and the CH4 selectivity suggests that the methane formation could be associated with the hydrogenation of formate species, while the desorption of carbonyls on Rh can explain the CO generation.

Thermal and environmental analysis of an infectious medical waste-to-energy

This work presents an infectious medical waste-to-energy (IMWtE) thermal and environmental analysis using combined heat and power (CHP) technology. Steam sterilization can be operated with an infectious medical waste (IMW) of 375 kg/h⋅unit, a maximum per day of 12,000 kg/day for double sterilization units, and a running time of 16 h/day. The CHP system uses a dried IMW of 797 kg/h, generating a power output of 128.98 kWe, providing a drying heat of 382.91 kW, and achieving an overall system efficiency of 8.45 %. Results are obtained for a life cycle assessment (LCA) of the IMWtE by CHP system technology. The endpoint effectiveness comprises considerations of human health: 2.83E+01 DALY, ecosystem quality is represented value of: 9.32E+00 Species⋅y, and natural resource value of: 1.08E+06 USD, all of these are fundamentally linked to the utilization of steel, copper, paint, and gypsum. The LCA impacts are primarily due to the operation phase (93 %), with the smaller contribution of the decommissioning phase (4 %), and the construction phase (3 %), respectively.

The disaster-causing characteristics of CO and CO2 rapid generation in coal’s high-temperature oxidation: the effect law of oxygen concentration

The disaster-causing characteristics of CO and CO2 rapid generation in coal’s high-temperature oxidation: the effect law of oxygen concentration

Physically 100 % renewable electricity supply through hybrid electricity storage – A top-down modelling study for the case of Austria

A top-down model calculation based on real generation and demand data is presented for the hypothetical case of 100 % renewable electricity generation combined with hybrid electricity storage infrastructure in the Austrian control area (9 million inhabitants, electric demand ∼70 TWh per year). To reach 100 % physical coverage by renewables, the actual wind and photovoltaic generation curves in the selected reference year of 2022 were scaled by a factor of 2.8 and 30, respectively. In the scope of the presented system are lithium-ion battery storage (cyclic efficiency 90 %), pumped hydro storage (70 %) and power-to-gas storage with subsequent re-electrification in gas turbine combined cycle plants operated as combined heat and power (CHP) system (30 %). Our core aspect lies in the optimized operation of the hybrid storage system, where the charging and discharging of the storage technology with higher cyclic efficiency is given priority. A straightforward cascading control algorithm is applied with individual elements functioning as simple proportional controllers. The results show how a 100 % renewable electricity system in Austria could be configured, partially building upon existing electricity generation infrastructure (pumped hydro and gas turbine combined cycle plants) and on the implementation of new lithium-ion battery storage with a total capacity of 100 GWh and new electrolysis infrastructure with a power of 5 to 10 GW. To overcome existing limitations of the presented model, an extension to a more complex model with spatial differentiation and consideration of electricity grid characteristics and constraints is recommended.

Reduced graphene oxide decorated two-dimensional FeSiCr nanosheets for improving flame-retardancy, electromagnetic wave absorption, and thermal conduction of ethylene vinyl acetate composites

Ball milling introduced graphene oxide onto FeSiCr, followed by radiation reduction to convert it to reduced graphene oxide (rGO). The materials, FeSiCr-rGO and FeSiCr-GO, were blended with Ethylene-Vinyl Acetate (EVA) to create composites. Compared to pure EVA, EVA/FeSiCr-rGO composites showed significant reductions in peak heat release rate (71.3 %), total heat release (33.0 %), and total smoke production (18.3 %). CO and CO2 generation rates decreased, enhancing overall fire resistance. FeSiCr-rGO significantly improved thermal conductivity with minimal impact on mechanical properties compared to FeSiCr-GO. In electromagnetic absorption, FeSiCr-rGO notably enhanced low-frequency and X-band absorption for EVA composites. At 2 mm thickness, EVA/FeSiCr-rGO achieved a maximum reflection loss of -24.8 dB in the X-band, surpassing FeSiCr and FeSiCr-GO. At 3 mm thickness, it effectively absorbed electromagnetic waves in the 6–8 GHz range.

Cerium doped dibismuthoxysulfide flowers for boosting CO2 photoreduction

Photocatalytic CO2 conversion is one of the major ways to simultaneously decelerate the greenhouse effect and the energy crisis. In this work, cerium doped dibismuthoxysulfide (Ce–Bi2O2S) photocatalysts were fabricated via a hydrothermal method, and the influence of Ce doping on their photocatalytic CO2 reduction was evaluated under simulated solar irradiation. It was found that Ce4+/Ce3+ ions were successfully incorporated into the crystal lattice of Bi2O2S. The Ce–Bi2O2S with CO and CH4 generation rates of 5.11 μmol/g/h and 1.41 μmol/g/h, which was more than 1.9 and 2.0 times greater than those obtained for pure Bi2O2S, respectively. The enhanced CO2 reduction performance of Ce–Bi2O2S is ascribed to the acceleration of the charge separation in the presence of Ce4+/Ce3+. Therefore, this work provides a promising direction for design high-active Ce doped bismuth-containing photocatalysts for solar fuel generation.

Performance evaluation and operation optimization of a combined heat and power plant integrated with molten salt heat storage system

Combined heat and power is an effective way to enhance the energy efficiency of thermal power plants. The solar and wind power are intermittent, and dispatchable power sources are critical to balance the supply and demand sides. To facilitate the high penetration of renewable energy, combined heat and power (CHP) plants should provide more and more peak shaving services for the power grid. The thermal energy can be stored in and released from the molten salt heat storage system (MSHSS). The integration of MSHSS can enlarge the adjustable range of the power load of CHP plants, so it is a potential way to enhance the operational flexibility of CHP plants supplying industrial steam and power. In this study, the MSHSS integrated within CHP plants are proposed, which store a part of sensible heat energy carried by extraction steam before supplying to industrial users. The heat storage capacity dominates the flexibility enhancement, and indicators to evaluate energy performances of the proposed system are defined. Moreover, models for the operation optimization of CHP plants integrated with the MSHSS are developed, and a case study of a 350 MW CHP unit is conducted. When the reheat steam is extracted to supply to industrial steam, the maximum and minimum adjustable power loads can be increased and decreased by 17.13 and 12.01 MW, respectively with the integration of the MSHSS. Moreover, during the peak, flat, valley time of reference day, the heat supply coal consumption rates are 73.94, 74.19 and 81.03 kg t−1,respectively. With the operation scheduling of CHP plant integrated with MSHSS, the MSHSS with reheat steam as heat source show the lowest coal consumption rate as 1553.79 ton/day.

Experimental Study on Flame Chemical Composition of Coal and Ammonia Gas-Solid Jet in Flat Flame Burner.

Ammonia as a fuel to partially or completely replace fossil fuels is one of the effective ways to reduce carbon dioxide, and the research on ammonia coal cocombustion is of great significance. The combustion characteristics of ammonia are very different from those of pulverized coal, resulting in the ignition and emission characteristics of ammonia and pulverized coal gas flow that is different from traditional pulverized coal flame. In this paper, the effect of pulverized coal concentration in coal and ammonia mixed combustion jet on the ignition distance and gas-phase components at different positions of the jet flame were studied experimentally on the flat flame burner, and the conditions of ignition and ignition stability of coal and ammonia gas-solid fuel were expounded. It was found that the ammonia mixed with pulverized coal changed the temperature field of the flat flame burner and therefore the ignition characteristics of the jet were changed. The ignition delay time at the same jet speed was positively correlated with the pulverized coal concentration, but when the pulverized coal concentration continued to decrease, the influence on the ignition delay time gradually became smaller. The composition of coal ammonia gas-solid fuel changed the heat transfer path and share during combustion, and finally, the flame temperature was negatively correlated with the concentration of pulverized coal. Therefore, the reduction of the pulverized coal concentration was conducive to the stable combustion of coal ammonia mixed fuel. When HAB = 100 mm, the conversion rate of fuel N to NOx per unit mass of coal ammonia mixture increased with the increase of pulverized coal concentration. The NOx production amount first increased and then decreased with the increase of pulverized coal concentration, and the amount of N2O and NO2 decreased rapidly with the increase of HAB. The proportion of NOx in NO exceeded 94%, which was conducive to achieving low nitrogen combustion of coal and ammonia gas-solid fuel. In general, the O2 concentration in the ammonia coal jet flame decreased, the flue gas temperature, and NOx and CO generation increased after mixing ammonia, and the optimal pulverized coal concentration in this experiment was 0.41 kgc/kga (mass ratio of pulverized coal to the sum of N2 and NH3).

Photokatalytische CO2 Reduktion mit CO2‐bindenden Enzymen

AbstractNeuartige Konzepte zur Nutzung von Kohlendioxid sind erforderlich, um eine kreislauforientierte Kohlenstoffwirtschaft zu erreichen und Umweltprobleme zu minimieren. Um diese Ziele zu erreichen, sind Photo‐, Elektro‐, thermische und Biokatalyse die Schlüsselwerkzeuge, die vorzugsweise in wässrigen Lösungen eingesetzt werden. Dennoch gibt es nur wenige katalytische Systeme, die in Wasser effizient arbeiten. Hier stellen wir eine allgemeine Strategie zur Identifizierung von Enzymen vor, die für die CO2‐Reduktion geeignet sind und zwar auf der Grundlage von Strukturanalysen für potenzielle Kohlendioxid‐Bindungsstellen und anschließenden Mutationen. Wir entdeckten, dass die Phenolsäure‐Decarboxylase aus Bacillus subtilis (BsPAD) die wässrige photokatalytische CO2‐Reduktion in Gegenwart eines Ruthenium‐Photosensibilisators und Natriumascorbat selektiv zu Kohlenmonoxid‐Bildung ermöglicht. Mit modifizierten Varianten von BsPAD wurden TONs von bis zu 978 und Selektivitäten von bis zu 93 % (wobei die gewünschte CO‐ gegenüber der H2‐Erzeugung bevorzugt wurde) erreicht. Durch Mutationen im Bereich des aktiven Zentrums von BsPAD wurden die Umsatzzahlen für die CO‐Erzeugung weiter verbessert. Dabei zeigte sich, dass der Elektronentransfer geschwindigkeitsbegrenzend ist und durch mehrstufiges Tunneln erfolgt. Die Allgemeingültigkeit dieses Ansatzes wurde durch die Verwendung von acht anderen Enzymen bewiesen, die alle die gewünschte Aktivität zeigten, was unterstreicht, dass eine Reihe von Proteinen zur photokatalytischen CO2‐Reduktion in der Lage ist.

Photocatalytic CO2 Reduction Using CO2-Binding Enzymes.

Novel concepts to utilize carbon dioxide are required to reach a circular carbon economy and minimize environmental issues. To achieve these goals, photo-, electro-, thermal-, and biocatalysis are key tools to realize this, preferentially in aqueous solutions. Nevertheless, catalytic systems that operate efficiently in water are scarce. Here, we present a general strategy for the identification of enzymes suitable for CO2 reduction based on structural analysis for potential carbon dioxide binding sites and subsequent mutations. We discovered that the phenolic acid decarboxylase from Bacillus subtilis (BsPAD) promotes the aqueous photocatalytic CO2 reduction selectively to carbon monoxide in the presence of a ruthenium photosensitizer and sodium ascorbate. With engineered variants of BsPAD, TONs of up to 978 and selectivities of up to 93 % (favoring the desired CO over H2 generation) were achieved. Mutating the active site region of BsPAD further improved turnover numbers for CO generation. This also revealed that electron transfer is rate-limiting and occurs via multistep tunneling. The generality of this approach was proven by using eight other enzymes, all showing the desired activity underlining that a range of proteins is capable of photocatalytic CO2 reduction.

Multi-objective scheduling and optimization for smart energy systems with energy hubs and microgrids

This paper introduces a novel model for optimizing microgrid systems by integrating multi-purpose renewable energy (MEM) and cutting-edge technologies, including electric vehicles (EVs). The proposed MEM demand response programs encompass various energy sources such as wind energy, multi-carrier energy storage technologies, boilers, combined heat and cooling units, EVs, P2G (power-to-gas), and demand response capabilities. The primary objective is to minimize the total operational cost of the microgrid system. A distinctive aspect of the proposed method lies in considering the prices of all energy carriers as unknown variables. Market prices are integrated into the modeling process, incorporating scenarios with reasonable probabilities and taking into account demand-side management programs. Moreover, the model allows for customizable programming of different parts of the multi-energy microgrids, with a focus on maintaining convexity principles for the operating area of each CHP (combined heat and power) unit. To tackle the unique complexity of this optimization problem, a developed blue whale optimization algorithm is proposed. This algorithm builds upon the main whale optimization algorithm (WOA), a promising population-based optimization approach. However, the effectiveness of WOA heavily relies on the careful setting of exploration and exploitation parameters, which may lead to being trapped in local optima. To address this challenge, the paper introduces a self-adaptation modification based on wavelet theory to enhance the WOA's performance. The proposed model and optimization method are thoroughly evaluated through simulation studies for different scenarios, showcasing their efficacy in achieving cost-efficient and sustainable microgrid operation. The combination of MEM and emerging technologies like EVs, along with the improved optimization algorithm, marks a significant contribution to advancing the planning and operation of microgrid systems towards low-cost, reliable, and environmentally-friendly energy solutions.

Optimal bidding strategy for integrated CHP system by modified heuristic algorithm considering CO2 emission in energy and reserve markets

Purpose This study aims to solve optimal pricing and power bidding strategy problem for integrated combined heat and power (CHP) system by using a modified heuristic optimization algorithm. Design/methodology/approach In electricity markets, generation companies compete according to their bidding parameters; therefore, optimal pricing and bidding strategy are solved. Recently, CHP units are significantly operated by generation companies to meet power and heat, simultaneously. Findings For validation, it is shown that profit is improved by 0.04%–48.02% for single and 0.02%–31.30% for double-sided auctions. As heat price curve is extracted, the simulation results show that when CHP system is integrated with other units results in profit increase and emission decrease by 3.04%–3.18% and 2.23%–4.13%, respectively. Also, CHP units significantly affect bidding parameters. Originality/value The novelties are pricing and bidding strategy of integrated CHP system is solved; local heat selling is considered in pricing and bidding strategy problem and heat price curve is extracted; the effects of CHP utilization on bidding parameters are investigated; a modified heuristic and deterministic optimization algorithm is presented.

Multi-timescale available flexibility assessment of integrated energy systems considering different proportions of wind power installations

The available flexibility capacity of the integrated energy system can be used as one of the indicators of proportions of system wind power installations, which, in turn, affects the maximum installed capacity of the system wind power, and this paper proposes a method for assessing the available flexibility of the integrated energy system at multiple timescales considering different proportions of system wind power installations. First, the framework of the integrated energy system is constructed, and based on the coupling relationship between the electrical and thermal systems, the mathematical models of the P2G, combined heat and power (CHP), energy storage equipment, and wind power generation equipment within the integrated energy system are established, and the Monte Carlo method is used to predict the wind power output in a typical scenario. Second, an integrated energy system optimization model is constructed to obtain the optimal dispatch operation of the system; the empirical mode decomposition (EMD) algorithm is used to decompose the flexibility demand curve of the system in multiple timescales. The flexibility supply capacity model of different types of flexibility resources in the system at different timescales is established, and through the comparative analysis of flexibility supply and demand at the same timescale, the upward and downward flexibility shortage probability and shortage expectation indexes at each timescale can be intuitively calculated and then weighted to constitute a comprehensive index of system flexibility assessment. Finally, the available flexibility analysis of the integrated energy system under different installed wind power capacities shows that the proposed methodology can more comprehensively assess the available flexibility capacity of the integrated energy system under different timescales, and the maximum installed wind power capacity that the system can withstand can be obtained while guaranteeing sufficient available flexibility capacity.

A Novel Layout for Combined Heat and Power Production for a Hospital Based on a Solid Oxide Fuel Cell

This paper addresses the problem of the reduction in the huge energy demand of hospitals and health care facilities. The sharp increase in the natural gas price, due to the Ukrainian–Russian war, has significantly reduced economic savings achieved by combined heat and power (CHP) units, especially for hospitals. In this framework, this research proposes a novel system based on the integration of a reversible CHP solid oxide fuel cell (SOFC) and a photovoltaic field (PV). The PV power is mainly used for balancing the hospital load. The excess power production is exploited to produce renewable hydrogen. The SOFC operates in electrical tracking mode. The cogenerative heat produced by the SOFC is exploited to partially meet the thermal load of the hospital. The SOFC is driven by the renewable hydrogen produced by the plant. When this hydrogen is not available, the SOFC is driven by natural gas. In fact, the SOFC is coupled with an external reformer. The simulation model of the whole plant, including the reversible SOFC, PV, and hospital, is developed in the TRNSYS18 environment and MATLAB. The model of the hospital is calibrated by means of measured data. The proposed system achieves very interesting results, with a primary energy-saving index of 33% and a payback period of 6.7 years. Therefore, this energy measure results in a promising solution for reducing the environmental impact of hospital and health care facilities.

Optimal Design and Techno-Economic Analysis of a Hybrid System to Supply a Remote Fishpond with Electricity and Heat

This paper deals with the design of a hybrid system for the generation of electricity and heat that will supply a remote fishpond in eastern Serbia. The proposed hybrid system consists of a micro-hydro power plant (MHPP), a photovoltaic (PV) generator, a combined heat and power (CHP) unit with one diesel generator, batteries, a converter, a thermal load controller (TLC), and a boiler. A comprehensive techno-economic analysis is performed in the HOMER Pro software, which evaluated and compared 12 possible configurations with different combinations of system components. The results show that the optimal system has the lowest total net present cost (NPC) and the lowest levelized cost of energy (COE) amounting to 284421.0 $ and 0.178 $/kWh, respectively. Compared to a diesel/batteries/converter/boiler hybrid system, the proposed system produces 65.4 % less greenhouse gas (GHG) emissions, while the shares of electricity, heat, and renewable energy generation are increased by 31.1 %, 5.0 %, and 51.2 %, respectively. It is shown that covering the demand for heat by regenerating the waste heat from the diesel generator and excess electricity from renewables contributes to reducing the total cost of the system and the GHG emissions. This finding finally emphasised the necessity of applying TLCs in off-grid hybrid systems.

Energy recovery and waste valorization in a frozen food processing facility: a case study from Lazio, Italy

AbstractFood and Agriculture Organization of the United Nations (FAO) estimates that food, beverage, and tobacco sector is currently responsible for about 30% of total world energy consumption and approximately the same percentage of food is wasted during its industrial transformation. Improving the sustainability of food processing is fundamental to reduce the environmental impact of this sector as well as to lower the disposal cost of industrial waste. The objective of this work is to propose an efficient and technically feasible solution for the management and energy recovery of residual biomasses and industrial processing by-products, such as sewage sludge produced by industrial wastewater treatment. The above solution is developed for a real frozen food factory operating in Lazio region (Italy) introducing a sewage sludge dryer and a gasifier to produce syngas. The software Aspen Plus is adopted to numerically simulate the gasification process, using a literature validated model, while the dryer and the already present combined heat and power (CHP) plant are dynamically modelled in TRNSYS environment. The results demonstrate that the proposed solution is feasible and attractive from both an environmental and an economic perspective. The Simple Pay Back of the investment is less than 3 years, while the Net Present Value stands at about 2.4 M€. Furthermore, the CO2 proposed system allows to save 179 t of equivalent CO2 emissions compared to the current system.