Search Results (408)

The non-thermal plasma-driven cascade process for CO₂-to-methanol conversion shows significant potential in the field of green methanol synthesis. This process innovatively couples a plasma activation module with a catalytic synthesis module via a multi-stage pressurization device, establishing an efficient two-step pathway that converts CO₂ into methanol via a CO intermediate. Such an arrangement establishes an energy conversion system characterized by both low carbon emissions and high efficiency. This work involved an initial technical evaluation employing a custom-built, lab-scale apparatus. The optimum parameters determined through this assessment were a plasma input voltage of 40 V combined with a subsequent reaction temperature of 240 °C. Operation at these specified parameters yielded a CO₂ conversion of 48%, with the methanol selectivity and production rate reaching 40% and 502 g_MeOH${·\mathrm{kg}}_{\mathrm{cat}}^{-1}$·h⁻¹, respectively. Furthermore, industrial-scale process design and scale-up were performed, accompanied by process simulation using Aspen Plus and a subsequent techno-economic evaluation. The results indicate that, compared to the conventional direct CO₂ hydrogenation process, the proposed cascade route can reduce the capital investment by approximately 17%. Full article

Carbon capture is an essential technology for reducing industrial CO₂ emissions, particularly in the power and cement sectors. Among the various capture methods, solvent-based absorption systems are widely used due to their efficiency and scalability, making the selection of the right solvent critical for near-term applications. This study analyzes several solvents for use in an absorption-based CO₂ capture system, emphasizing identifying the most suitable solvent for 2025–2030. The research methodology involves process modeling in Aspen Plus, sensitivity analysis, and evaluation of the regeneration duty for each solvent. The objective is to achieve at least 90% CO₂ capture and 95% CO₂ purity. The flue gas composition considered in this analysis is 19.8% CO₂, 9.3% O₂, 63% N₂, 7.5% H₂O, and other trace gases. Various solvents are evaluated to determine their effectiveness in capturing CO₂ while minimizing the energy consumption during solvent regeneration. A sensitivity analysis was conducted to optimize the system’s performance based on the solvent type, operating conditions, and regeneration duty. The results showed that amine blends demonstrated a CO₂ capture rate of 92% and a CO₂ purity of 96%, with regeneration energy requirements of around 3.2 GJ/ton of CO₂, significantly lower than those of traditional MEA systems, which typically require around 4.0 GJ/ton. In contrast, ionic liquids showed a CO₂ capture rate of 89% and a purity of 95%, with a regeneration energy of 2.8 GJ/ton, though their current cost is higher, limiting their immediate large-scale application. Annual capital expenditure (CAPEX) calculation revealed that amine blends could potentially reduce the CAPEX by 15–20% compared to MEA, while amino acid salts showed similar CAPEX reductions with a capture efficiency of 90%. Overall, the results indicate that hybrid amine solvents are the most cost-effective and practical solution for 2025–2030, with ionic liquids and amino acid salts emerging as promising alternatives as their costs decrease. Full article

The increasing atmospheric concentration of carbon dioxide (CO₂) poses a critical threat to global climate stability, highlighting the need for efficient carbon capture technologies. While amine-based solvents such as monoethanolamine (MEA) are widely used for industrial CO₂ capture, they are subject to limitations such as high energy requirements for regeneration, solvent degradation, and environmental concerns. This study investigates potassium carbonate/bicarbonate system as an alternative solution for CO₂ absorption. The absorption mechanism and reaction kinetics of potassium carbonate in the presence of bicarbonates were reviewed. A rate-based model was developed in Aspen Plus, using literature kinetics, to simulate CO₂ absorption using 20 wt% potassium carbonate (K₂CO₃) solution with 10% carbonate-to-bicarbonate conversion under different industrial conditions. Three flue gas compositions were evaluated: cement industry, biomass combustion, and anaerobic digestion, each at 3000 m³/h flow rate. The simulation was conducted to determine minimum column height and solvent loading requirements with a target output of 90% CO₂ removal from the gas streams. Results demonstrated that potassium carbonate systems successfully achieved the target removal efficiency across all scenarios. Column heights ranged from 18 to 25 m, with molar K₂CO₃/CO₂ ratios between 1.41 and 4.00. The biomass combustion scenario proved most favorable due to lower CO₂ concentration and effective heat integration. While requiring higher column heights (18–25 m) compared to MEA systems (6–12 m) and greater solvent mass flow rates, potassium carbonate demonstrated technical feasibility for CO₂ capture. The findings of this study provide a foundation for technoeconomic evaluation of potassium carbonate systems versus amine-based technologies for industrial carbon capture applications. Full article

Amidst the ongoing global energy crisis, environmental deterioration, and the exacerbation of climate change, the development of renewable energy, particularly solar energy, has become a central topic in the global energy transition. This study investigates a solar photovoltaic thermal (PVT) heat pump system that utilizes an expanded honeycomb-channel PVT module to enhance the comprehensive utilization efficiency of solar energy. A simulation platform for the solar PVT heat pump system was established using Aspen Plus software (V12), and the system’s performance impact mechanisms and engineering applications were researched. The results indicate that solar irradiance and the circulating water temperature within the PVT module are the primary factors affecting system performance: for every 100 W/m² increase in solar irradiance, the coefficient of performance for heating (COP_h) increases by 13.7%, the thermoelectric comprehensive performance coefficient (COP_co) increases by 14.9%, and the electrical efficiency of the PVT array decreases by 0.05%; for every 1 °C increase in circulating water temperature, the COP_h and COP_co increase by 11.8% and 12.3%, respectively, and the electrical efficiency of the PVT array decreases by 0.03%. In practical application, the system achieves an annual heating capacity of 24,000 GJ and electricity generation of 1.1 million kWh, with average annual COP_h and COP_co values of 5.30 and 7.60, respectively. The Life Cycle Cost (LCC) is 13.2% lower than that of the air-source heat pump system, the dynamic investment payback period is 4–6 years, and the annual carbon emissions are reduced by 94.6%, demonstrating significant economic and environmental benefits. This research provides an effective solution for the efficient and comprehensive utilization of solar energy, utilizing the low-global-warming-potential refrigerant R290, and is particularly suitable for combined heat and power applications in regions with high solar irradiance. Full article

Although technologies used in non-fossil methane and fossil resources to produce blue hydrogen are relatively mature, a system-integrated approach to reference system (RS)-based purification of H₂, CO₂ capture and storage, and UHS is relatively unexplored and requires research to fill gaps in the literature regarding balanced permutations and geological viability for net-zero requirements. This research proposes a system-integrated process for H₂ production through a PSA-based purification technique coupled with amine-based CO₂ capture and underground hydrogen storage (UHS). The intellectual novelty of the research is its first quantitative treatment of synergistic effects such as heat recovery and pressure-matching across units. Additionally, a site separation technique is applied, where H₂ and CO₂ reservoirs are selected based on the permeability of rock formations and fluids. On a research methodology front, a base case of a steam methane reforming process with the production of 99.99% pure H₂ at a production rate of 5932 kg/h is modeled and simulated using Aspen Plus™ to create a balanced permutation of mass and energy across units. As per the CO₂ capture requirements of this research, a capture of 90% of CO₂ is accomplished from the production of 755 t/d CO₂ within the model. The compressed CO₂ is permanently stored at specifically identified rock strata separated from storage reservoirs of H₂ to avoid empirically identified hazards of rock–fluid interaction at high temperatures and pressures. The lean amine cooling of CO₂ to 60 °C and elimination of tail-gas recompression simultaneously provides 5.4 MW_th of recovered heat. The integrated design achieves a net primary energy penalty of 18% of hydrogen’s LHV, down from ~25% in a standalone configuration. This corresponds to an energy saving of 8–12 MW, or approximately 15–18% of the primary energy demand. The research computes a production cost of H₂ of 0.98 USD per kg of H₂ within a production atmosphere of a commercialized WGS and non-fossil methane-based production of H₂. Additionally, a sensitivity analysis of ±23% of the energy requirements of the reference system shows no marked sensitivity within a production atmosphere of a commercially available WGS process. Full article

To improve traditional cement manufacturing, which generates a large amount of greenhouse gases, blending calcareous green algae and fly ash as cement replacement materials is expected to achieve nearly zero carbon emissions. As a calcareous green alga, Halimeda macroloba is a significant producer of biogenic calcium carbonate (CaCO₃), sequestering approximately 440 kg of carbon dioxide (CO₂) per 1000 kg of CaCO₃, with CaCO₃ production reported in relation to algal biomass. To assess the new low-carbon/low-waste cement production process, the proposed scenarios (2 and 3) are validated via Python-based modeling (Python 3.12) and Aspen Plus^® simulation (Aspen V14). The core technology is the pre-calcination of algae-derived CaCO₃ and fly ash from coal combustion, which are added to a rotary kiln to enhance the proportions of tricalcium silicate (C₃S) and dicalcium silicate (C₂S) for forming the desired silicate phases in clinker. Through the lifecycle assessment (LCA) of all scenarios using SimaPro^® (SimaPro 10.2.0.3), the proposed Scenario 2 achieves the GWP at approximately 0.906 kg CO₂-eq/kg clinker, lower than the conventional cement production process (Scenario 1) by 47%. If coal combustion is replaced by natural gas combustion, the fly ash additive is reduced by 74.5% in the cement replacement materials, but the proposed Scenario 3 achieves the GWP at approximately 0.753 kg CO₂-eq/kg clinker, lower than Scenario 2 by 16.9%. Moreover, the LCA indicators show that Scenario 3 has lower environmental impacts on human health, ecosystem, and resources than Scenario 1 by 24.5%, 60.0% and 68.6%, respectively. Full article

The increasing penetration of variable renewable energy sources intensifies grid imbalance and challenges the reliability of small-scale power systems. This study addresses these challenges by developing and analyzing a fully integrated hybrid energy system that combines biogas upgrading to biomethane, photovoltaic (PV) generation, hydrogen production via alkaline electrolysis, hydrogen storage, and a gas-steam combined cycle (CCGT). The system is designed to supply uninterrupted electricity to a small municipality of approximately 4500 inhabitants under predominantly self-sufficient operating conditions. The methodology integrates high-resolution, full-year electricity demand and solar resource data with detailed process-based simulations performed using Aspen Plus, Aspen HYSYS, and PVGIS-SARAH3 meteorological inputs. Surplus PV electricity is converted into hydrogen and stored, while upgraded biomethane provides dispatchable backup during periods of low solar availability. The gas-steam combined cycle enables flexible and efficient electricity generation, with hydrogen blending supporting dynamic turbine operation and further reducing fossil fuel dependency. The results indicate that a 10 MW PV installation coupled with a 2.9 MW CCGT unit and a hydrogen storage capacity of 550 kg is sufficient to ensure year-round power balance. During winter months, system operation is sustained entirely by biomethane, while in high-solar periods hydrogen production and storage enhance operational flexibility. Compared to a conventional grid-based electricity supply, the proposed system enables near-complete elimination of operational CO₂ emissions, achieving an annual reduction of approximately 8800 tCO₂, corresponding to a reduction of about 93%. The key novelty of this work lies in the simultaneous and process-level integration of biogas, hydrogen, photovoltaic generation, energy storage, and a gas-steam combined cycle within a single operational framework, an approach that has not been comprehensively addressed in the recent literature. The findings demonstrate that such integrated hybrid systems can provide dispatchable, low-carbon electricity for small communities, offering a scalable pathway toward resilient and decentralized energy systems. Full article

The European Union’s enhanced greenhouse gas (GHG) reduction targets for 2030 make the large-scale deployment of carbon capture and storage (CCS) technologies essential to achieve deep decarbonization goals. Within this context, this study aims to advance CCS research by developing and testing a pilot-scale system that integrates gasification for syngas and power production with CO₂ absorption and solvent regeneration. The work focuses on improving and validating the operability of a pilot plant section designed for CO₂ capture, capable of processing up to 40 kg CO₂ per day through a 6 m absorber and stripper column. Experimental campaigns were carried out using different amine-based absorbents under varied operating conditions and liquid-to-gas (L/G) ratios to evaluate capture efficiency, stability, and regeneration performance. The physical properties of regenerated and CO₂-saturated solvents (density, viscosity, pH, and CO₂ loading) were analyzed as potential indicators for monitoring solvent absorption capacity. In parallel, a process simulation and optimization study was developed in Aspen Plus, implementing a split-flow configuration to enhance energy efficiency. The combined experimental and modeling results provide insights into the optimization of solvent-based CO₂ capture processes at pilot scale, supporting the development of next-generation capture systems for low-carbon energy applications. Full article

Membrane separation is a promising, low-energy technology for purifying turquoise hydrogen from methane pyrolysis streams. However, there is a critical knowledge gap between the performance of membrane materials and the practical application of large-scale modules under realistic process conditions. This study evaluates commercial polyimide and polysulfone hollow fiber membranes for H₂/CH₄ separation. The effect of feed composition and pressure on the membrane separation performance were studied, revealing that the separation efficiency is overwhelmingly dominated by concentration polarization, which reduced the H₂/CH₄ separation factor by up to 80% compared to ideal values. Despite this, by optimizing process conditions, we successfully achieved a permeate purity of 99.3% H₂ at 85% recovery. Furthermore, Aspen Plus simulations of an integrated pyrolysis reactor with the membrane unit and a recycle stream demonstrate significant process benefits. The integration increased the H₂ production rate from 10.3 to 17.6 kmol/h and substantially reduced the specific energy consumption from 40.3 to 24.9 kJ/g H₂ compared to non-integrated systems. This work shows that a membrane process can improve not only the product H₂ purity but also the overall energy efficiency of a turquoise hydrogen production process. Full article

The sustainable management of sewage sludge (SS) requires comparative evaluations that capture both environmental impacts and the trade-offs associated with emerging and established treatment routes. This study applies life cycle assessment (LCA) to compare hydrothermal carbonization (HTC), rotary kiln pyrolysis, and incineration using SS from the Salitre WWTP in Bogotá, Colombia, based on a life cycle inventory that integrates experimental characterization, Aspen Plus simulations, and Ecoinvent datasets modeled in EASETECH. Thirteen ILCD midpoint impact categories were assessed, and uncertainty was evaluated through global sensitivity analysis (GSA) and Monte Carlo simulations. The results show that the three technologies distribute their impacts differently across categories, as follows: HTC yields reductions in several categories due to carbon storage and fertilizer substitution but presents toxicity-related impacts linked to heavy metal transfer to soils; pyrolysis produces a pyrochar with metal retention and nutrient recovery potential that influences climate and resource-related categories while remaining sensitive to sludge composition; and incineration influences climate categories without the potential toxic effects of using chars in soils, reduces sludge volume, and facilitates subsequent nutrient recovery processes from ash, with lower uncertainty due to its technological stability. These results support circular economy strategies in low- and middle-income countries by clarifying the environmental conditions under which carbonized materials or ash-derived recovery pathways can be incorporated into sludge treatment systems. Full article

Industrial effluents often contain azeotropic mixtures that are difficult to separate by conventional distillation. An illustrative case is the methanol/methyl acetate/ethyl acetate (MA/ME/EA) mixture. To address these challenges, this work studies the conceptual design and optimization of the reactive distillation-based hybrid processes for separating the MA/ME/EA mixture with an EA-rich feed composition (0.25/0.20/0.55 mol fraction). An improved triple-column extractive–reactive distillation with a side-draw product (TCERD-SP) and its heat-integrated variant (TCERD-SP-HI) have been developed. In the TCERD-SP process, EA is strategically withdrawn as a side product, reconfiguring the extractive column into integrated pre-separation and entrainer-recovery sections, thereby reducing entrainer and energy demands. A four-step process design methodology is applied, including thermodynamics analysis, conceptual design, rigorous optimization via Aspen Plus integrated with the genetic algorithm to minimize total annual cost (TAC), and comparative evaluation of economic and environmental performance. The results show that the basic double-column pre-separation-reactive distillation (DCPSRD) process, optimal for a previous feed composition, exhibits unsatisfactory TAC performance for this EA-rich feed composition. Among the configurations studied, the TCERD-SP process exhibits superior performance, saving TAC by 8.4% and 14.4% compared to the TCERD and DCPSRD processes, respectively. In addition, based on the advantage of convenient heat integration between the side reboiler and the reactive distillation column condenser, the heat-integrated TCERD-SP-HI process achieves a further 10.7% TAC reduction. Thus, for this EA-rich feed examined in this work, the TCERD-SP and TCERD-SP-HI processes are demonstrated as effective solutions for recovering these valuable chemicals. Full article

Simulation studies of adsorption in complex effluents are challenging due to nonlinear interactions between sorbents, adsorbates and carrying flows. This study investigates effluents from oil and textile industries, characterised by their heavy metal content and chemical oxygen demand. It examines the process in a continuous-flow laboratory-scale adsorption system. Results were validated using process modelling based on mass and energy conservation, applied to an industrial adsorber. The model described surface sorption mechanisms on bioactivated carbon at the molecular level and predicted breakthrough curve profiles, integrated with Aspen Plus ^® adsorption simulation under industrially relevant conditions. Experimental data and model predictions showed good agreement, with relative deviations ranging from 0.2% to 24.6%. Differences in adsorption capacities between oily and textile effluents highlighted the influence of coexisting constituents. At the same time, the varied behaviour of identical components supported the hypothesis of multifactorial effects in complex mixtures. The optimisation study, using Response Surface Methodology with a Central Composite design, evaluated factors such as bed height, feed rate, and adsorption cycle time, achieving enhanced removal efficiencies of 62% for chemical oxygen demand and 25% for suspended solids. Full article

Biomass gasification serves as a key carbon-neutral technology. To effectively address the challenge of tar treatment during biomass gasification, the National Institute of Clean and low-carbon Energy developed a fluidized bed coupled with an entrained-flow bed. A steady-state Aspen Plus V12 model was designed to assess the compatibility between the two beds and optimize operating parameters. The model divides the process into three main zones: fluidized bed gasification, entrained-flow bed gasification, and bottom slag treatment, employing a reaction-restricted equilibrium assumption. Simulation results indicate that an increase in pressure leads to a reduction in the concentration of syngas components (CO and H₂), an insignificant rise in gas low heating value (LHV), and a notable decline in cold gas efficiency (η). A higher equivalence ratio (ER) results in decreased syngas components, along with a significant reduction in both LHV and η. The introduction of carbon dioxide reduces syngas components and lowers LHV. Similarly, the addition of steam reduces the CO content of the syngas and decreases its LHV. When the fluidized bed temperature exceeds 900 °C, changes in LHV and gas yield become negligible, while variations remain minimal when the entrained-flow bed temperature exceeds 1200 °C. Full article

The transition toward a circular bioeconomy requires efficient conversion of biogenic wastes and biomass into renewable fuels. This study explores the gasification potential of wastewater sludge (WWS) and food waste (FW), representing high moisture-content biowastes, compared with softwood (SW), a lignocellulosic biomass reference. An Aspen Plus equilibrium model incorporating the drying stage was developed to evaluate the performance of air and steam gasification. The effects of temperature (400–1200 °C), equivalence ratio (ER = 0.1–1), and steam-to-biomass ratio (S/B = 0.1–1) on gas composition and energy efficiency (EE) were examined. Increasing temperature enhanced H₂ and CO generation but reduced CH₄, resulting in a maximum EE at intermediate temperatures, after which it declined due to the lower heating value of the gases. Although EE followed the order SW > FW > WWS, both biowastes maintained robust efficiencies (60–80%) despite high drying energy requirements. Steam gasification increased H₂ content up to 53% (WWS), 54% (FW), and 51% (SW) near S/B = 0.5–0.6, while air gasification achieved 23–27% H₂ and 70–80% EE at ER ≈ 0.1–0.2. The results confirm that wet bio-wastes such as WWS and FW can achieve performance comparable to lignocellulosic biomass, highlighting their suitability as sustainable feedstocks for waste-to-syngas conversion and supporting bioenergy integration into waste management systems. Full article

Integrating electrochemical fuel cells and internal combustion engines can enhance the total efficiency and sustainability of power systems. This study presents a promising solution by integrating a Proton Exchange Membrane Fuel Cell (PEMFC) with a mini gas turbine, forming a hybrid system called the “Oya System.” This approach aims to mitigate the efficiency losses of gas turbines during high ambient temperatures. The hybrid model was designed using Aspen Plus for modelling and the EES simulation program for solving mathematical equations. The primary objective of this research is to enhance the efficiency of gas turbine systems, particularly under elevated ambient temperatures. The results demonstrate a notable increase in efficiency, rising from 37.97% to 43.06% at 10 °C (winter) and from 31.98% to 40.33% at 40 °C (summer). This improvement, ranging from 5.09% in winter to 8.35% in summer, represents a significant achievement aligned with the goals of the Oya System. Furthermore, integrating PEMFC contributes to environmental sustainability by utilising hydrogen, a clean energy source, and reducing greenhouse gas emissions. The system also enhances efficiency through waste heat recovery, further optimising performance and reducing energy losses. This research highlights the critical role of interface engineering in the hybrid system, particularly the interaction between the PEMFC and the gas turbine. Integrating these two systems involves complex interfaces that facilitate the transfer of electrochemistry, energy, and materials, optimising the overall performance. This aligns with the conference session’s focus on green technologies and resource efficiency. The Oya System exemplifies how innovative hybrid systems can enhance performance while promoting environmentally friendly processes. Full article