Process Simulation Analysis Research Articles

Comparative techno-economic assessment of renewable diesel production integrated with alternative hydrogen supply

The hydrodeoxygenation of triglycerides and fatty acids (HEFA) represents a well-established technological pathway for producing renewable drop-in fuels, such as renewable diesel, aviation fuel, or renewable light ends, like naphtha and LPG. A hydrogen supply is required, and the conventional method involves steam methane reforming (SMR) from natural gas. Both HEFA and SMR processes have been investigated in the literature separately. In this context, the goal of this work is to assess the hydrodeoxygenation process (HDO) of triglycerides/fatty acids integrated with hydrogen production. Two scenarios are compared by process simulation, equipment sizing, and economic analysis: one with traditional SMR (SC-A) and another with electrified SMR (SC–B), which is a recent alternative for hydrogen production with no natural gas. The HDO capacity was 6220 BPSD (38000 kg/h) of soybean oil, and the average yields for renewable diesel, naphtha, and LPG were 71.23 %-wt, 1.80 %-wt, and 5.87 %-wt, accordingly. Both scenarios were technical feasible and may be economically attractive. However, the grey hydrogen source was more profitable per its plant simplicity — although the CO2 taxation may impact its profitability.

Process simulation and techno-economic analysis of CO2 capture by coupling calcium looping with concentrated solar power in coal-fired power plant

The calcium looping (CaL) cycle is an effective high-temperature CO2 capture technology, its primary energy consumption arises from the calcination process, which limits the development of CaL technology. Utilizing concentrated solar power (CSP) instead of combustion for the calcination process in the CaL cycle can significantly reduce the energy penalty associated with CO2 capture of coal-fired power plants. Currently, the application of coupling CaL with concentrated solar power (CaL-CSP) systems in coal-fired power plants is still in its infancy, and there is limited research on its thermal performance and techno-economic analysis. In this study, a process simulation model of a 660 MW supercritical coal-fired power plant is developed as a reference. Subsequently, four different heat transfer routes are integrated into the design of CaL-CSP systems. The results indicate that the coupled power plant achieves a CO2 capture rate of 90 % compared to the reference coal-fired power plant, and reduces annual CO2 emissions by 93 % to only 58.2 g CO2/kWh. The CO2 capture energy penalty is 0.24 MJ/kg CO2. A sensitivity analysis of power generation cost reveals that if the cost of solar concentrator components is halved, the power generation cost will decrease to just 25 % higher than the reference power plant. Given the rapid advancements in CSP technology, this reduction is likely to be realized soon. Moreover, with the increase in carbon taxes and carbon prices, the power generation cost is expected to further decrease.

Optimization of travel requests with process simulation analysis

Efficient travel request management is crucial in the modern corporate landscape, impacting decision-making, budget control, and overall operational efficiency. This study delves into the intricacies of the travel request management process with process mining and process simulation, aiming to assess the cost structure and efficiency. Three research questions were examined and tested statistically. Using a comprehensive dataset encompassing timestamps, personnel roles, and cost details, the research uncovers significant insights. The findings reveal substantial cost variations across different stages of the travel request process. Role-based analysis highlights variations in costs and processing times associated with distinct personnel roles. Additionally, delays, bottlenecks, and process variability emerge as key contributors to elevated process costs. Furthermore, process mining and simulation were instrumental in quantifying the impact of process optimizations. The simulations demonstrated that a 20% reduction in response times for Unit Leaders, a 40% reduction for Project Managers, and a 30% reduction for both roles collectively yielded the most significant cost savings. On average, a 0.45% cost improvement was observed for each percentage reduction in response times, reinforcing the importance of efficiency enhancements. These numerical results not only validate the critical role of response time reduction in cost control but also provide actionable insights for organizations to streamline their travel request management processes, improve budget allocation, and enhance operational efficiency in the corporate landscape.

Upcycling potential of hazardous tannery sludge to value-added products: Process modelling, simulation, and 3E analysis

The sustainability of the tannery sector largely depends on the eco-friendly management of its solid and liquid wastes. Unfortunately, the global tannery sector is strappingly suffering a significant challenge to meet environmental standards towards sustainability due to a lack of tannery sludge (TS) management facilities as well as lacking research on hazardous TS upcycling facilities to value-added products. Hence, TS from leather processing generally undergoes open dumping, responsible for environmental pollution, including water, soil, and air pollution. To ensure the sustainability of tannery sector, pioneeringly, this study attempts to conceptually design gasification based on four novel upcycling potentials of TS-to-value added products such as (i) TS to syngas with steam generation (TS-SS), (ii) TS to hydrogen with power generation (TS-HP), (iii) TS to power generation with carbon capture (TS-PCC), and (iv) TS to methanol production with power production (TS-MPP) using ASPEN Plus® simulator. Further, this research offers a comprehensive techno-economic analysis to evaluate the economic feasibility of the proposed four TS upcycling processes. The TS-PCC and TS-HP processes outperformed for their net energy efficiencies of 72.80 % and 50.22 %, correspondingly, compared to TS-HP (39.13 %) and TS-MPP (40.38 %). Regarding exergy efficiency, the TS upcycling processes coded TS-MPP and TS-HP demonstrated better net exergy efficiencies of 34.34 % and 27.20 %, respectively, compared to TS-SS and TS-PCC upcycling processes. These results confirm that TS-HP is much more efficient in terms of exergy. Furthermore, techno-economic analysis has confirmed that the developed processes, namely TS-SS and TS-PCC, are economically viable at a 70 % plant efficiency, whereas other processes, such as TS-HP and TS-MPP, are financially viable only if a subsidy of $33/ton subsidy is provided. The study findings have a significant impact on the development of circular economy-based industrial-scale TS management facilities in developing countries, which can ensure the sustainability of the leather sector.

Effect of flip-chip ball grid array structure on capillary underfill flow

During the capillary underfill (CUF) process in flip-chip packaging, issues like incomplete filling, voids, wire sweeping, and overflow can impact product reliability and the relatively long filling time required. Therefore, finding ways to improve filling efficiency is a critical challenge. Conducting experiments to address these issues can be costly. As a result, the industry often relies on simulation software to simulate the actual manufacturing process, predict potential problems, compare results with experimental data, and analyze ways to improve the process. This approach helps enhance the package yield and further improves production efficiency.This study investigates the capillary underfill (CUF) process through simulation. Firstly, the viscosity and reaction kinetics of the underfill material are measured to establish the necessary data for the simulation. Then, Moldex3D, a mold flow simulation software, is used to create the model, generate the mesh, and perform the process simulation analysis. The effects of material properties and process parameters on the capillary underfill process are considered. The simulation results are compared with experimental data to validate the feasibility of the simulation. Subsequently, different flip-chip package structures and CUF process parameters are analyzed through simulation to explore the impact of these parameters on the flow pattern and filling efficiency of the adhesive material during the filling process.According to the simulation results, the filling speed is faster when the bump pitch and gap height are larger. However, the required filling time still has a considerable relationship with the volume of the filling region. Dispensing from the side with lower bump density can shorten the filling time when the bump distribution is uneven.

Process simulation, optimization, and cost analysis of a proposed sulfur recovery unit by applying modified Claus technology

Removing sour gas from any suitable gas sweetening technology in a cost-effective and environmentally responsible manner is a major challenge. This paper discusses how to safely and economically dispose of small amounts of acid gases resulting from the amine sweetening process. A two-stage Claus desulfurization unit was studied and simulated to treat acid gases resulting from natural gas sweetening operations in Ras Gharib oil fields (Egypt). These acid gases are used as feedstock for the proposed plant to produce a valuable product, such as elemental sulfur, which is used as a raw material in many industries. Although many sulfur recovery techniques are available for various conditions and applications, the Claus process is a critical and widely used method for recovering elemental sulfur from gaseous hydrogen sulfide. This work represents the potential benefits of treating acid gases with high hydrogen sulfide content. In addition, operational variables that could affect sulfur production and sulfur recovery efficiency of the studied Claus unit were studied and optimized. Aspen HYSYS simulation software (version 9) was used to evaluate the economic aspects and optimize the operational parameters of the unit for producing sulfur from acid background gases. The results showed that the maximum sulfur production was achieved at a catalytic converter reactor temperature of 270 °C and 210 °C for the first and second catalytic reactor, respectively, with an air flow rate of 933.3 kg mol/h. The economic study of the proposed desulfurization unit showed that the Claus unit would be economically acceptable with an expected return on investment of approximately 10% and an average payback period of 10 years. Moreover, the introduced plant has a positive impact on the environment by reducing the concentration of hydrogen sulfide in the gas from 69.58 to 0.16%.

Using low-shear aerated and agitated bioreactor for producing two specific laccases by trametes versicolor cultures induced by 2,5-xylidine: Process development and economic analysis

Laccase isoforms from basidiomycetes exhibit a superior redox potential compared to commercially available laccases obtained from ascomycete fungi, rendering them more reactive toward mono-substituted phenols and polyphenolic compounds. However, basidiomycetes present limitations for large-scale culture in liquid media, restraining the current availability of laccases from this fungal class. To advance laccase production from basidiomycetes, a newly designed 14-L low-shear aerated and agitated bioreactor provided enzyme titers up to 23.5 IU/mL from Trametes versicolor cultures. Produced enzymes underwent ultrafiltration and LC/MS-MS characterization, revealing the predominant production of only two out of the ten laccases predicted in the T. versicolor genome. Process simulation and economic analysis using SuperPro designer® suggested that T. versicolor laccase could be produced at US$ 3.60/kIU in a 200-L/batch enterprise with attractive economic parameters and a payback period of 1.7 years. The study indicates that new bioreactors with plain design help to produce low-cost enzymes from basidiomycetes.

Processing of metal-free end-of-life tyres (EOLTs) to fuels and products: an experimental study with process simulation and economic analysis from an Australian perspective

AbstractThe aim of this experimental study, process simulation and economic analysis is to assess the applicability of pyrolysis technology for processing end-of-life tyres and to evaluate the economic viability of a 60 ton/day EOLT processing facility: a case-specific study within Australia. The experimental work and characterization of feedstock and products were carried out in-house. Capital costs for major equipment were collected from suppliers. The running cost of the processing facility is calculated on the basis of the current labour and utility costs. An economic model is developed based on the information generated from the experimental program and those obtained from suppliers. From the analysis, it is evident that the pyrolysis process for processing EOLT promises a significant upside in economic terms. A conservative conclusion of 20% light oil, ~ 65% furnace oil and 7% carbon black, generated as pyrolysis products, depicts a cash-flow positivity for a 60 tonne per day (TPD) plant that can be run using the generated fuel gas for under 4 years. This is in addition to the benefit of the zero landfill requirement. Apart from the base calculations, the sensitivity of six different scenarios is analysed by mainly changing the land cost and bank investment. Depending on the scenario, the calculated internal rate of return varies between 15 and 35%. While Australia generates significant quantities of EOLT, the techno-economic results confirm that pyrolysis technology for processing EOLT is a viable solution in Australia. However, a dedicated supply chain needs to exist to make pyrolysis plants an attractive investment at defined locations. Graphical abstract

Simulation analysis of the entire construction process of the sunflower shaped continuous arch bridge

At present, there is a lot of research on the structural system of the completion stage of the Kuihua arch bridge in China, but there is a lack of research on the risks existing in each stage of the construction of the Kuihua arch bridge. Therefore, it is necessary to conduct a full process simulation analysis of the construction process of the sunflower shaped continuous arch bridge. The following conclusions were drawn from this study: (1) After analysis, the construction method of first removing the support below the main arch ring and then pouring the main beam can ensure the safety of construction. (2) The maximum axial force of the support pole below the main arch is -17.67kN, located in rows 10 and 50. The maximum vertical displacement of the main arch is -4.998mm, which is much smaller than the allowable deflection. Therefore, the shape of the main arch is within the safe range. (3) The tensile stress of the main arch and continuous longitudinal beam are both less than the design value of C40 concrete tensile strength of 1.71MPa, so the main arch and continuous longitudinal beam have not cracked, and are in a safe state throughout the construction process.

Comparative study on process simulation and performance analysis in two pressurized oxy-fuel combustion power plants for carbon capture

Process simulation and analysis are demonstrated to provide significant benefits for pressurized oxy-fuel combustion systems. This study compares the performance of pressurized oxy-fuel combustion systems and a first-generation oxy-combustion system under the same standard conditions. On this basis, the increase in efficiency of pressurized oxy-fuel combustion systems is evaluated. Process simulation and analysis are carried out for the first-generation oxy-combustion system in a 600 MW supercritical primary intermediate reheat power plant without heat integration (Base Case) and with heat integration (Case A). The validity of the simulation results is then verified. Considering Case A as a benchmark model, the process simulations of a pressurized oxy-coal combustion system and a staged pressurized oxy-combustion system are performed. The simulation results are compared with results in other literature studies. Compared with the benchmark model, the results indicate that the gross generation efficiency of the pressurized oxy-coal combustion system is improved by 1.12 % (LHV), and the net generation efficiency is improved by 0.47 % (LHV). In addition, the gross generation efficiency of the staged pressurized oxy-combustion system is enhanced by 1.78 % (LHV), and the net generation efficiency is improved by 2.4 % (LHV) compared with the benchmark model.

Plant fiber‐reinforced composites based on injection molding process: Manufacturing, service life, and remanufacturing

AbstractResource depletion and environmental degradation have become important issues affecting the human development process. Plant fiber‐reinforced composites (PFRCs) are characterized by high natural availability, good mechanical properties, low density, recyclability, and eco‐friendliness. Expanding human applications of plant fibers is an important measure to combat resource and environmental problems. The injection molding process has the characteristics of strong product size adaptability, high molding precision, and high production efficiency. It is suitable for large‐scale production in the industry and is one of the main molding methods of PFRCs. Currently, there are still challenges and opportunities for high‐performance manufacturing of PFRCs based on the injection molding process. This article reviews the complete process of manufacturing‐service life‐remanufacturing of PFRCs based on the injection molding process. Emphasis is placed on the pretreatment technology and selection strategy of multi‐phase blended raw materials, the molding process conditions, functional applications, and simulation analysis, the aging and degradation characteristics during service, and the remanufacturing characteristics of the composites. Finally, the future research focus is summarized and prospected. The research in this paper will help promote the continuous progress of key technologies in the production process of PFRCs and help the industry to truly realize high‐performance green manufacturing in the future.Highlights Plant fibers exhibit variability in morphology and properties. The link between the structure and performance of PFRCs is unclear. The degradability and durability of PFRCs are contradictory. The functionality and mechanical properties of PFRCs are contradictory. PFRCs have good characteristics for remanufacturing.

Pilot scale production of biodiesel from Azolla oil via heterogeneous catalysis and diesel engine analysis: kinetic and techno-economic analysis considerations

ABSTRACT The use of Azolla pinnata oil for the production of biodiesel, coupled with the use of industrial waste dolomite as a catalyst, represents a novel approach with significant potential. This innovative process offers several key advantages, such as utilizing a non-edible feedstock, reducing waste generation, and providing an alternative to fossil fuels. This research aims to investigate the viability of creating biodiesel using Azolla pinnata oil and evaluate its technical and economic appropriateness for large-scale manufacturing. A pilot plant reactor with a 10 L biodiesel capacity carries out the transesterification reaction, using dolomite from industrial waste as a heterogeneous catalyst. The reaction was conducted for 4 h at a temperature of 70°C, and biodiesel yielded approximately 99.14%. Aspen Plus is employed to simulate and design a biodiesel plant, with the reaction kinetics derived from the pilot plant reaction and inputted into Aspen Plus. Plant optimization and economic analysis are performed using the Aspen Economic Analyzer. The biodiesel blends (Azolla 20, Azolla 40, and Azolla 60) were tested in a CI engine and compared with diesel results. Based on the engine test results, the Azolla 20 blend provides less HC (12.9%), CO (13.07%), and smoke (10%) emissions; therefore, it can serve as a better alternative to neat diesel. The primary units of the proposed plant have been designed, and the process’s economic viability was determined. It was discovered that the total capital investment needed is approximately 5.054 million USD, which will be repaid within 1.97 years of operation. This research encompasses pilot plant experiments, process simulation, engine testing, and economic analysis, demonstrating the novelty, technical feasibility, and potential socio-economic impact of this biodiesel production process.

Process design, kinetics, simulation, and techno-economic analysis of biodiesel production from Pongamia pinnata seed oil using a magnetically recyclable acidic ionic liquid catalyst

A magnetically recyclable polymeric acidic ionic liquid nanocatalyst was fabricated in response to the demand for economical and eco-friendly one-pot conversion of inexpensive oils to biodiesel. To achieve this, Fe3O4–SiO2 nanocomposites with Fe3O4 as the core and SiO2 as the shell were prepared, and polymeric acidic ionic liquid (PAIL) was grafted over the core–shell nanocomposite (Fe3O4-SiO2) to produce Fe3O4–SiO2–PAIL nanocatalyst. The characterization results demonstrated that Fe3O4–SiO2–PAIL nanocatalyst had a strong saturation magnetization of 19.16 emu/g, a large surface area of 13.067 m2/g, and a high acid loading of 6.1 mmol/g. The Fe3O4–SiO2–PAIL was used as a heterogeneous catalyst to transesterify Pongamia pinnata seed oil (PPO) into fatty acid methyl esters (FAME). The biodiesel yield was 94.89% under optimized reaction conditions of 6.14 % (w/w) catalyst loading, methanol:oil molar ratio of 12:12, 57.37 °C, and 1.67 h. The produced FAME complied with the ASTM specifications for biodiesel. The transesterification reaction exhibited a low activation energy of 28.298 KJ/mol with pseudo-first-order kinetics. The positive values of ΔH° and ΔG° indicated that the transesterification reaction was endothermic, endergonic, and non-spontaneous. The negative value of ΔS° illustrated that the reaction is less disordered. Furthermore, the reusability studies of the heterogeneous nanocatalyst was investigated. The Fe3O4-SiO2-PAIL nanocatalyst was successfully retrieved swiftly by magnetic force, with no discernible mass loss, and employed at least six additional times without significantly losing its catalytic activity. The techno-economic analysis was executed to investigate the technical and economical feasibility of 15 metric tonne/batch biodiesel production from Pongamia pinnata seed oil using the Fe3O4–SiO2–PAIL nanocatalyst. The economic reports demonstrated a positive NPV of 20,736,000 $/year, a gross margin of 9.41%, and a biodiesel minimum selling price of 0.926 $ with a payback period of 1.88 years. This work paves the way for the sustainable use of P. pinnata as a feedstock for biodiesel production using the Fe3O4–SiO2–PAIL nanocatalyst under specified circumstances.

Implementation Process Simulation and Performance Analysis for the Multi-Timescale Lookup-Table-Based Maximum Power Point Tracking under Variable Irregular Waves

The efficacy of the multi-timescale lookup-table-based maximum power point tracking (MLTB MPPT) in capturing energy at various fixed sea states has already been demonstrated. However, it remains imperative to conduct a more comprehensive evaluation of the MPPT tracking performance under varying sea states in practical scenarios. Additionally, it is crucial to engage in an in-depth analysis of the dynamic process and energy loss/consumption associated with MLTB MPPT implementations. This paper focuses on the implementation process simulation and performance analysis for the MLTB MPPT under variable irregular waves. Firstly, the structure of the wave power controller based on a MLTB MPPT algorithm is described in detail, as well as that of a controlled plant, known as a novel inverse-pendulum wave energy converter (NIPWEC). Secondly, mathematical models for the MLTB MPPT are developed, taking into account the efficiency of each link. In this paper, we present simplified modelling methods for both permanent magnet synchronous generator (PMSG) vector control and permanent magnet synchronous motor (PMSM) servo control. Finally, the tracking performance of the MLTB MPPT in the presence of variable irregular waves is comprehensively analyzed by simulating the implementation process and comparing it with two other MPPT algorithms, i.e., the frequency- and amplitude-control-based MPPT and the lookup-table-based internal mass position adjustment combined with the optimal fixed damping search. Results show that the MLTB MPPT (Method 2) is a competitive algorithm. Besides, a significant portion (>12%) of the time-averaged absorbed power is actually lost during the power generation process. On the other hand, the power required for a mass-position-adjusting mechanism is relatively small (approximately 0.2 kW, <1.5%). The research findings can offer theoretical guidance for optimizing the operation of NIPWEC engineering prototypes under actual sea conditions.

Dynamics of Hydrogen Storage through Adsorption: Process Simulation and Energy Analysis

The mass and energy balances of a zero-dimensional model for hydrogen storage by adsorption is studied. The model is solved with an in-house MATLAB code and validated with three experimental case studies from the literature, obtained with cryogenic lab-scale reservoirs using different adsorbents and dynamic operating conditions. The results of the simulations agree well with reported measured temperature and pressure profiles. The hydrogen adsorption process is described assuming instantaneous thermodynamic equilibrium. In accordance with the potential theory, variations in the adsorbed phase volumes filling the adsorbent pores were described applying the revisited Dubinin–Astakhov (rev-D-A) equation and accounting for gas phase non-ideality. The simulation model was used to assess the energy requirements of a variety of adsorption-based hydrogen storage processes and compared with other conventional hydrogen storage modes such as compression and liquefaction. Thus, whatever different adsorbent materials are considered, this technology appears relatively energy intensive due to the reservoir cooling duty at cryogenic temperature.

Process simulation and reaction performance evaluation of CO2 chemical looping conversion based on modified bauxite residue oxygen carriers

A large number of greenhouse gas emissions have brought a series of environmental problems, so it is urgent to realize efficient conversion of CO2. The multistage regeneration process of CO2 chemical looping conversion was established and the process simulation analysis carried out with Aspen Plus. The system’s feasibility was verified by simulation and the process needed to provide additional energy input, and the sensitivity analysis of different operating conditions was carried out to provide guidance for subsequent experimental design. Oxygen carrier bauxite residue was modified by acid washing and CeO2 impregnation, and the reaction characteristics were evaluated via a fixed-bed reactor and on-line mass spectrometry, and the kinetic parameters of the reaction were solved by gas-solid reaction kinetics. The results showed that 12 wt% CeO2 loading oxygen carrier had the highest yield and average formation rate of CO, which were 6.22 mmol·g−1 and 388.71 μmol·g−1·min−1, respectively. The oxygen carrier conversion (oxygen vacancy utilization) was close to 100% after modification, while that of single bauxite residue oxygen carrier was only 60%. The reaction system conformed to the first-order reaction model, and the activation energy was 33.90 kJ·mol−1. This study provided new insight into chemical looping conversion of CO2.

Comparative techno-economic analysis of CO2 capture processes using blended amines

Blended amines synthesize the absorption characteristics of different amine solvents and show a great potential in carbon capture. However, a comprehensive techno-economic analysis (TEA) of the CO2 absorption process using blended amines is still lacking. In this study, we investigated three blended amine solvents: MEA/MDEA, PZ/MEA, and PZ/MDEA, with commercially available amine MEA used as the benchmark. Rigorous process simulation and techno-economic analysis were applied to evaluate the performance of the carbon capture process in a steel plant. CO2 molar loading in the lean solvent (αlean) and stripper pressure (P) were optimized to minimize the total annualized cost (TAC). The results demonstrated that PZ/MDEA-based process is most cost-effective (31.43$/tCO2) under the operating conditions of αlean = 0.15 and P = 1.25 bar. The cost breakdown analysis revealed that αlean and P significantly impact the TAC through the regeneration heat, equipment investment, and amines make-up cost. Furthermore, the energy analysis indicated that using a solvent with a low reaction enthalpy and heat capacity as well as high reactivity and absorption capacity could minimize the energy consumption of the process.

A novel moving bed chemical looping process with integration of combustor heat exchangers for hydrogen production: Process simulation and techno-economic analysis

In this study, using natural gas as the feedstock, a new scheme – a chemical looping combustion system with a moving bed reducer, coupled with the steam methane reforming (MCLC-SMR), is proposed and simulated for hydrogen production. This suggested process configuration is compared with other hydrogen production systems including the fluidized bed chemical looping combustion system coupled with the steam methane reforming (FCLC-SMR), the chemical looping partial oxidation system combined with the water-gas-shift reaction (CLPO-WGS), the 3-reactor chemical looping system for hydrogen generation (CLHG-3R), the conventional steam methane reforming (SMR) and auto-thermal reforming (ATR) systems with CO2 capture. The simulation results indicate that the particle circulation rate in MCLC-SMR is 64% less than in FCLC-SMR. MCLC-SMR also shows the best system performance regarding cold gas efficiency (79%) and effective thermal efficiency (75%). The economic assessment indicates that MCLC-SMR can achieve the lowest levelized cost of hydrogen (LCOH) of $1.34/kg at 30 ton/hr H2 production capacity, and CLHG-3R can achieve the lowest LCOH of $2.06/kg at 1 ton/hr H2 production capacity among the six hydrogen production methods. At 30 ton/hr H2 production capacity, the chemical looping reactors in MCLC-SMR are 37% cheaper than in FCLC-SMR. The sensitivity analysis also indicates that MCLC-SMR remains the most economical hydrogen production method over a wide range of price parameters (the prices of particles, chemical looping reactors, natural gas, and electricity).

Enhancing Sustainable Production of Fatty Acid Methyl Ester from Palm Oil Using Bio-Based Heterogeneous Catalyst: Process Simulation and Techno-Economic Analysis.

A new sustainable solid carbon catalyst has been developed for biodiesel synthesis using pyrolytic coconut shell ash (CSA). The CSA support was loaded with various amounts of potassium carbonate (K2CO3), and response surface methodology with a central composite design was used to optimize the transesterification process. The best-performing catalyst was the 30 wt % K2CO3/CSA catalyst. The optimal conditions included a catalyst loading of 3.27 wt %, methanol:oil molar ratio of 9.98:1, reaction time of 74 min, and temperature of 65 °C, resulting in an obtained biodiesel yield of 97.14%. This catalyst was reusable for up to four cycles, but a reduction in the biodiesel yield was observed due to potassium ion leaching during the recovery process. A techno-economic analysis to assess the financial viability of the project revealed a net present value of 5.16 million USD for a project lifetime of 20 years, a payback period time of 2.49 years, and an internal rate of return of 44.2%. An environmental assessment to evaluate the impact of global warming potential from the production of biodiesel revealed a lower level of carbon dioxide emission (1401.86 ton/y) than in the conventional process (1784.6 ton/y).

Process simulation and multi-aspect analysis of methanol production through blast furnace gas and landfill gas

This paper presents a novel process for methanol production from blast furnace gas (BFG) and landfill gas (LFG). The process is evaluated using the energy, exergy, economic, and environmental (4E) analyses. The process consists of a power plant fueled by LFG, carbon dioxide (CO2) chemisorption using 30% (wt.) solution of monoethanolamine, methanol synthesis and separation, and power and steam plants. Thermodynamic analysis shows that the total energy and exergy efficiencies for the proposed process are 59% and 63.2%, respectively. The carbon efficiency for this method is 42%. Environmental analysis shows that the total CO2 emission is 2614.85 kg/h. Based on the simulation results, this process produces 18,200 kg/h methanol, which results in a CO2 emission intensity of 0.144 kg CO2/kg MeOH. Economic evaluation determines that the proposed scheme has a capital cost of $100, 315, 128.9 with a payback period of 1.94 years. In addition, methanol production's annual profit is $4,798,088.309, and the minimum selling price of the produced methanol is $0.388/kg. The proposed process is a promising alternative for methanol production from BFG and LFG. It has high energy and exergy efficiencies, low CO2 emission intensity, and a short payback period. The economic analysis shows that the process is profitable.