Emission factors of industrial boilers burning biomass-derived fuels.

Boilers are combustion devices that provide process heat and are integral to many industrial facilities. Historically, outside of the pulp and paper industry, most boilers burned fossil fuels, although interest in decarbonization has been leading to an increased use of renewable fuels in boilers. These boilers, including those in the biorefineries, are often large sources of air pollutant emissions, and the characterization of these emissions is critical to obtaining air permits and ensuring protection of the surrounding air quality. Several industrial boilers and new biorefineries allow utilization of biomass-derived fuels (e.g. wastewater sludge, lignin, etc.) produced during their operation as a fuel for the boiler to meet process energy needs. However, there is limited empirical data on emission factors for the burning of unconventional fuels, such as solid-gas mixtures containing biomass residues. To fill this gap, we carry out a comprehensive data survey, collecting information on emission factors for boilers burning either a single or a mixture of solid and gaseous biomass-derived fuels. We review multiple hard-to-obtain and unconventional data sources, such as air permit applications, stack test data, and industry-sponsored data collection efforts, to compile emission factors for biomass-derived fuels. We then compare this data with wood residue emission factors from the U.S. Environmental Protection Agency's AP-42 emission factor database. Our results indicate that the emission factors for boilers burning unconventional fuels vary widely depending on the fuel composition, boiler type, and fuel characteristics. Overall, we find that median emission factors of selected biomass-derived fuels are typically lower than those of wood residue boilers in AP-42. The information collected herein could be useful to permitting agencies and industries utilizing boilers who may want to reduce the carbon impact of their facilities by combusting biomass-derived wastes for process energy needs, for more accurate emission estimation for permitting.Implications: Emission factors are often used for air permitting, specifically for emission estimation purposes. This study carries out a comprehensive data survey of emission factors burning unconventional biomass-derived fuels from underutilized sources such as air permits, stack test data, and industry-led efforts, and compare the results to EPA's wood residue emission factor database. The results from this study can be used can be used by multiple stakeholders such as air permitting agencies, industries burning biomass-derived fuels, and biorefineries, that utilize more advanced boiler technologies. The findings can help mitigate risks to industry owners and operators and helps to avoid delays in obtaining the required air permits that arise due to inappropriate emission estimates in permit applications.

Characterization factors and other air quality impact metrics: Case study for PM2.5-emitting area sources from biofuel feedstock supply.

In this paper, we develop a framework and metrics for estimating the impact of emission sources on regulatory compliance and human health for applications in air quality planning and life cycle impact assessment (LCIA). Our framework is based on a pollutant's characterization factor (CF) and three new metrics: Available Regulatory Capacity for Incremental Emissions (ARCIE), Source CF Ratio, and Activity Health Impact (AHI) Ratio. ARCIE can be used to assess whether a receptor location has capacity to accommodate additional source emissions while complying with regulatory limits. We present CF as a midpoint indicator of health impacts per unit mass of emitted pollutant. Source CF Ratio enables comparison of potential new-source locations based on human health impacts. The AHI Ratio estimates the health impacts of a pollutant in relation to the utilization of the source for each unit of product or service. These metrics can be applied to any pollutant, energy source sector (e.g., agriculture, electricity), source type (point, line, area), and spatial modeling domain (nation, state, city, region). We demonstrate these metrics through a case study of fine particulate (PM2.5) emissions from U.S. corn stover harvesting and local processing at various scales, representing steps in the biofuel production process. We model PM2.5 formation in the atmosphere using a novel reduced-complexity chemical transport model called the Intervention Model for Air Pollution (InMAP). Through this case study, we present the first area-source PM2.5 CFs that address the recommendations of several LCIA studies to establish spatially explicit CFs specific to an energy source sector or type. Overall, the framework developed in this work provides multiple new ways to consider the potential impacts of air emissions through spatially differentiated metrics.

Techno-economic analysis and life cycle assessment of a biorefinery utilizing reductive catalytic fractionation.

Reductive catalytic fractionation (RCF) is a promising approach to fractionate lignocellulose and convert lignin to a narrow product slate. To guide research towards commercialization, cost and sustainability must be considered. Here we report a techno-economic analysis (TEA), life cycle assessment (LCA), and air emission analysis of the RCF process, wherein biomass carbohydrates are converted to ethanol and the RCF oil is the lignin-derived product. The base-case process, using a feedstock supply of 2000 dry metric tons per day, methanol as a solvent, and H2 gas as a hydrogen source, predicts a minimum selling price (MSP) of crude RCF oil of $1.13 per kg when ethanol is sold at $2.50 per gallon of gasoline-equivalent ($0.66 per liter of gasoline-equivalent). We estimate that the RCF process accounts for 57% of biorefinery installed capital costs, 77% of positive life cycle global warming potential (GWP) (excluding carbon uptake), and 43% of positive cumulative energy demand (CED). Of $563.7 MM total installed capital costs, the RCF area accounts for $323.5 MM, driven by high-pressure reactors. Solvent recycle and water removal via distillation incur a process heat demand equivalent to 73% of the biomass energy content, and accounts for 35% of total operating costs. In contrast, H2 cost and catalyst recycle are relatively minor contributors to operating costs and environmental impacts. In the carbohydrate-rich pulps, polysaccharide retention is predicted not to substantially affect the RCF oil MSP. Analysis of cases using different solvents and hemicellulose as an in situ hydrogen donor reveals that reducing reactor pressure and the use of low vapor pressure solvents could reduce both capital costs and environmental impacts. Processes that reduce the energy demand for solvent separation also improve GWP, CED, and air emissions. Additionally, despite requiring natural gas imports, converting lignin as a biorefinery co-product could significantly reduce non-greenhouse gas air emissions compared to burning lignin. Overall, this study suggests that research should prioritize ways to lower RCF operating pressure to reduce capital expenses associated with high-pressure reactors, minimize solvent loading to reduce reactor size and energy required for solvent recovery, implement condensed-phase separations for solvent recovery, and utilize the entirety of RCF oil to maximize value-added product revenues.

Economic Perspectives of Biogas Production via Anaerobic Digestion.

As the demand for utilizing environment-friendly and sustainable energy sources is increasing, the adoption of waste-to-energy technologies has started gaining attention. Producing biogas via anaerobic digestion (AD) is promising and well-established; however, this process in many circumstances is unable to be cost competitive with natural gas. In this research, we provide a technical assessment of current process challenges and compare the cost of biogas production via the AD process from the literature, Aspen Plus process modeling, and CapdetWorks software. We also provide insights on critical factors affecting the AD process and recommendations on optimizing the process. We utilize four types of wet wastes, including wastewater sludge, food waste, swine manure, and fat, oil, and grease, to provide a quantitative assessment of theoretical energy yields of biogas production and its economic potential at different plant scales. Our results show that the cost of biogas production from process and economic models are in line with the literature with a potential to go even lower for small-scale plants with technological advancements. This research illuminates potential cost savings for biogas production using different wastes and guide investors to make informed decisions, while achieving waste management goals.

Value Proposition of Untapped Wet Wastes: Carboxylic Acid Production through Anaerobic Digestion.

Although traditional anaerobic digestion (AD) process to produce methane-rich biogas from wet waste is deep-rooted, high carbon footprint and its low value as compared with other renewable sources demand advanced strategies to avoid its production. An emerging conversion pathway to arrest methanogenesis for producing value-added fuels and chemicals instead of biogas is sought as a sustainable alternative. This research provides a comprehensive analysis on current technology development, process challenges, applications, and economics for producing high-value short-chain carboxylic acids from AD of wet wastes. We show that (1) the theoretical energy yields of acids equal or exceed biogas, and (2) the cost of these acids is competitive with those produced from chemical markets, making this economically viable for mass production. With global abundance of wet waste feedstocks, this process of short-chain acid production provides a promising alternative to conventional biogas production technology, while achieving waste management and carbon mitigation goals.

Potential Air Pollutant Emissions and Permitting Classifications for Two Biorefinery Process Designs in the United States.

Advanced biofuel production facilities (biorefineries), such as those envisioned by the United States (U.S.) Renewable Fuel Standard and U.S. Department of Energy's research and development programs, often lack historical air pollutant emissions data, which can pose challenges for obtaining air emission permits that are required for construction and operation. To help fill this knowledge gap, we perform a thorough regulatory analysis and use engineering process designs to assess the applicability of federal air regulations and quantify air pollutant emissions for two feasibility-level biorefinery designs. We find that without additional emission-control technologies both biorefineries would likely be required to obtain major source permits under the Clean Air Act's New Source Review program. The permitting classification (so-called "major" or "minor") has implications for the time and effort required for permitting and therefore affects the cost of capital and the fuel selling price. Consequently, we explore additional technically feasible emission-control technologies and process modifications that have the potential to reduce emissions to achieve a minor source permitting classification. Our analysis of air pollutant emissions and controls can assist biorefinery developers with the air permitting process and inform regulatory agencies about potential permitting pathways for novel biorefinery designs.