Sewage-water treatment with bio-energy production and carbon capture and storage.

Typical large-scale sewage-water treatments consume energy, occupy space and are unprofitable. This work evaluates a conceivable two-staged sewage-water treatment at 40,000 m3/d of sewage-water with sewage-sludge (totaling 10kgCOD/m3) that becomes a profitable bioenergy producer exporting reusable water and electricity, while promoting carbon capture. The first stage comprises microbial anaerobic digesters reducing the chemical oxygen demand (COD) by 95% and producing 60%mol methane biogas. The effluent waters enter the subsequent aerobic stage comprising microbial air-fed digesters that extend COD reduction to 99.7%. To simulate the process, up-to-date anaerobic/aerobic digester models were implemented. A biogas-combined-cycle power plant with/without post-combustion carbon capture is designed to match the biogas production, supplying electricity to the process and to the grid. Results comprehend electricity exportation of 13.21 MW (7.92 kWh/tReusable-Water) with -9.957tCO2/h of negative carbon emission (-0.6 kgCO2-Emitted/kgCOD-Removed). The biogas-combined-cycle without carbon capture achieves 21.08 MW of power exportation, while a 37.3% energy penalty arises if carbon capture is implemented. Configurations with/without carbon capture reach feasibility at 125 USD/MWh of electricity price, with respective net present values of 6.86 and 85.07 MMUSD and respective payback-times of 39 and 12 years. These results demonstrate that large-scale sewage-water treatment coupled to biogas-fired combined-cycles and carbon capture can achieve economically feasible bioenergy production with negative carbon emissions.

Screening biorefinery pathways to biodiesel, green-diesel and propylene-glycol: A hierarchical sustainability assessment of process.

Plant design implies the best choice among a set of feedstock-to-product process pathways. Multiple sustainability performance indicators can blur the decision, and existing sustainability assessment methods usually focus only on environmental life-cycle performance and corporate metrics or solely on the gate-to-gate process. It is relevant to incorporate integrated system analysis to address sustainability comprehensively. To this end, the Sustainable Process Systems Engineering (S-PSE) method was previously introduced to select the most sustainable feedstock-process-product configuration via four-dimensional indicators (environment, efficiency, health-&-safety, and economic), and then pinpoint the sustainability hotspots of the best design to unveil possible improvements. This work expands S-PSE by adding new features: (i) cradle-to-gate environmental assessment; (ii) composition of flowsheets; (iii) new indicators; (iv) statistical screening of indicators; and (v) 2030 Agenda compliance. A biorefinery case-study demonstrates S-PSE: to select the best pathway from soybean-oil, palm-oil, and microalgae-oil to biodiesel, green-diesel, and propylene-glycol. Firstly, statistical screening reduces the indicator set by 62%. Results evince all routes from microalgae-oil as economically unfeasible due to oil cost, despite superior environmental performance. S-PSE evinces palm-oil-to-biodiesel as the most sustainable due to lower cradle-to-gate emissions and manufacturing cost, with sustainability hotspots associated to hazardous methanol input and energy-intensive distillations. 2030 Agenda analysis also outlines palm-oil-to-biodiesel as best for 5 out of 10 Sustainable Development Goals linked to the reduced indicator set.

Novel ethylene oxide production with improved sustainability: Loss prevention via supersonic separator and carbon capture.

Sustainability must be always assured in process design. Not rarely, multiple sustainability criteria point oppositely, entailing a need for more systematic and coherent assessments. The Sustainable Process Systems Engineering method is introduced as a two-level hierarchical evaluation of process designs. The first level selects the best design via four-dimensional indicators (environment, efficiency, health-&-safety, and economic), while in the second level, sustainability hotspots of the best design are pinpointed to unveil possible improvements. The method is applied for sustainability assessment of two ethylene oxide processes: the conventional and a novel route employing supersonic separator to prevent ethylene oxide losses using liquid-water injection. Supersonic separator route reduces oxide losses by 83.33 kg/h, representing +0.9% greater ethylene oxide production, 95% less ethylene oxide losses, entailing 2.5% higher net value for 20 operation years despite 0.11% higher investment, and consequently exhibiting the best environmental, technical, health-&-safety and economic performances. Photochemical-oxidation and aquatic-ecotoxicity are environmental indicators with highest improvement due to supersonic separator inclusion. Ethylene oxidation reactor, carbon dioxide stripping-column and cooling-water tower are the main unit-operations with sustainability hotspots.

Economic leverage affords post-combustion capture of 43% of carbon emissions: Supersonic separators for methanol hydrate inhibitor recovery from raw natural gas and CO2 drying.

Offshore oil/gas productions are power intensive and CO2 emitters from gas-fired power generation. This work investigates supersonic separator as a strategy for affording post-combustion capture backed up by cost reductions. Conventional offshore gas processing usually loses thermodynamic hydrate inhibitor methanol in processing and exported gas. This work analyses a supersonic separator variant gas processing simultaneously reducing methanol losses. Such process dramatically improves gas-plant profitability via cost-reduction of methanol make-up and power-consumption, simultaneously increasing revenues from liquefied-petroleum-gas by-product. This economic leverage affords post-combustion carbon capture, including subsequent CO2 dehydration and compression for exportation of high-pressure liquid CO2. This corresponds to abate 43% of CO2 emissions boosting revenues via enhanced oil recovery. Moreover, CO2 is dehydrated via another supersonic separator operating with minimum head-loss, minimizing compression costs. Despite its much higher investment, the new process with carbon capture presents higher net value (865.63 MMUSD) than the conventional processing without carbon capture (829.31 MMUSD), being economically feasible and more environmentally adequate with cleaner natural gas production and successful CO2 management. The new process is superior in several scenarios and particularly favored by oil prices above 55 USD/bbl. Rising oil price from 40 to 100 USD/bbl, the new process net value rises 29%, whereas the conventional counterpart rises only 7.5%. In addition, as a plausible future scenario, CO2 taxation favors the new process, which always has superior economic performance, even without CO2 taxation. In summary, implementing supersonic separators in offshore natural gas processing aiming at anti-hydrate recovery and CO2 dehydration for enhanced oil recovery creates economic leverage sustaining Carbon Capture & Storage without loss of competitiveness. This result, backed up by rigorous thermodynamic simulations and economic-environmental assessments, configure an original achievement to the literature.

Carbon dioxide utilization in a microalga-based biorefinery: Efficiency of carbon removal and economic performance under carbon taxation.

Coal-fired power plants are major stationary sources of carbon dioxide and environmental constraints demand technologies for abatement. Although Carbon Capture and Storage is the most mature route, it poses severe economic penalty to power generation. Alternatively, this penalty is potentially reduced by Carbon Capture and Utilization, which converts carbon dioxide to valuable products, monetizing it. This work evaluates a route consisting of carbon dioxide bio-capture by Chlorella pyrenoidosa and use of the resulting biomass as feedstock to a microalgae-based biorefinery; Carbon Capture and Storage route is evaluated as a reference technology. The integrated arrangement comprises: (a) carbon dioxide biocapture in a photobioreactor, (b) oil extraction from part of the produced biomass, (b) gasification of remaining biomass to obtain bio-syngas, and (c) conversion of bio-syngas to methanol. Calculation of capital and operational expenditures are estimated based on mass and energy balances obtained by process simulation for both routes (Carbon Capture and Storage and the biorefinery). Capital expenditure for the biorefinery is higher by a factor of 6.7, while operational expenditure is lower by a factor of 0.45 and revenues occur only for this route, with a ratio revenue/operational expenditure of 1.6. The photobioreactor is responsible for one fifth of the biorefinery capital expenditure, with footprint of about 1000 ha, posing the most significant barrier for technical and economic feasibility of the proposed biorefinery. The Biorefinery and Carbon Capture and Storage routes show carbon dioxide capture efficiency of 73% and 48%, respectively, with capture cost of 139$/t and 304$/t. Additionally, the biorefinery has superior performance in all evaluated metrics of environmental impacts.

Cultivation of Spirulina maxima in medium supplemented with sugarcane vinasse.

The feasibility of sugarcane vinasse as supplement in growth medium of Spirulina maxima was investigated. The cell was cultivated under autotrophic (no vinasse, 70 µmol photons m(-2) s(-1)), heterotrophic (no light, culture medium supplemented with vinasse at 0.1% v/v and 1.0% v/v) and mixotrophic conditions (70 µmol photons m(-2) s(-1), vinasse at 0.1% v/v and 1.0% v/v). These preliminary results suggested a cyclic two-stage cultivation - CTSC, with autotrophic condition during light phase of the photoperiod (12 h, 70-200 µmol photons m(-2) s(-1)) and heterotrophic condition during dark phase (12h, 3.0% v/v vinasse). The adopted CTSC strategy consisted in three cycles with 75% withdrawal of suspension and reposition of medium containing 3.0% v/v vinasse, separated by autotrophic rest periods of few days between cycles. Results show an increase of biomass concentration between 0.495 g L(-1) and 0.609 g L(-1) at the 7th day of each cycle and high protein content (between 74.3% and 77.3% w/w).

Effects of CO2 enrichment and nutrients supply intermittency on batch cultures of Isochrysis galbana.

Aiming at enhanced performance to increase economic feasibility of microalgae based processes, Isochrysis galbana was grown in three modes of cultivation: batch, intermittent fed batch and semi-continuous. The batch mode was conducted under two regimes of aeration: conventional aeration and CO2 enriched aeration (5% v/v in air). Increased biomass productivity without significant impact on lipid accumulation was observed for CO2 enriched aeration relatively to cultivation aerated with air only. The intermittent fed batch cultivation policy was proven to be useful for lipid accumulation, increasing the lipid content by 19.8%. However, the semi-continuous mode resulted in higher productivity due to increased biomass concentration; the biomass productivity reached 0.51 g/(Ld). Fluorescence measurements were performed; the calculated low electron transport rate showed the need to increase the irradiance. The results showed that I. galbana can be grown in semi-continuous condition at high levels of biomass productivity.