An integrated approach to energy recovery from biomass and waste: Anaerobic digestion-gasification-water treatment

Thermal Analysis and Energy Efficiency Improvements in Tunnel Kiln for Sustainable Environment

Kiln is a prime need in the ceramics industry, where energy loss is a major part which consumes about 60% production cost through thermal energy for different applications. Higher density of fired and tunnel kiln refractory material lowers the thermal diffusivity and the proper selection of fired material minimizes the energy loss along the kiln. In particular, this research analysed the results of a heat recovery system comprised of a metallic recuperator which gives around 8% energy savings in natural gas consumption. In this work, detailed power quality analysis of low-power factor motors of a tunnel kiln was carried out and a power factor improvement solution was suggested to save electrical energy with payback period of 0.8 y. The motor operating at a low-power factor consumes more reactive power which does not produce beneficial work. A low-power factor around 0.4 causes network power loss, increases in transformer loss and voltage drops. The solution with accumulative capacitance power of 148.05 uF was installed to achieve the power factor to 0.9. Flu gas analyzer was installed to monitor the range of O2 in pre-heating, oxidation, and firing zones of the kiln which should be ≥8% and 3%, respectively. Regression analysis for thermal energy consumption of a tunnel kiln is done to find the forecast thermal energy consumption. This analysis can be used to find operational efficiency, supporting decisions regarding dependent variable of thermal energy consumption and independent variable of production. This research is very helpful for the ceramics industry to mitigate the energy loss at SMEs as well as in mass production level.

An analytical study on municipal wastewater to energy generation, current trends, and future prospects in South Asian developing countries (an update on Pakistan scenario)

The water scarcity and energy crises are major challenges, particularly for South Asian developing countries. Wastewater resource recovery always remained an untapped potential for South Asian countries, especially in Pakistan. Globally, municipal wastewater's global generation rate is about 331 km3/year; only a small proportion is treated and safely reused. Wastewater also has high energy content and can be greatly productive, whereas most of the wastewater treatment plants currently employed in developing regions are non-functional or taking high energy inputs. Many global level studies are being conducted for energy use reduction and the production of renewable energy from wastewater. In this review, installation of wastewater treatment plants is suggested in the context of economic and environmental feasibility for South Asian developing countries. Multiple factors showed the need for and high potential to installation of wastewater treatment plants for providing clean water under sustainable development goals and further to recover valuable contents from municipal wastewater. The tremendous need for infrastructure development became obvious to deliver clean water to communities that are using wastewater directly or indirectly for various purposes. Based on technical grounds, economic, social, and environmental challenges can be tackled with viable wastewater treatment plant design options in each country context. With each step of wastewater treatment, control strategies would minimize energy use and enhanced resource recovery will reduce pressure on the current natural resource base. Overall, the cost assessment, funding opportunities, research and development, and social acceptability remained the big factors to energy generation from municipal wastewater in South Asia. Graphical presentation of the study.

Anaerobic Digestion for Producing Renewable Energy-The Evolution of This Technology in a New Uncertain Scenario

Anaerobic digestion is a well-known technology with wide application in the treatment of high-strength organic wastes. The economic feasibility of this type of installation is usually attained thanks to the availability of fiscal incentives. In this review, an analysis of the different factors associated with this biological treatment and a description of alternatives available in literature for increasing performance of the process were provided. The possible integration of this process into a biorefinery as a way for producing energy and chemical products from the conversion of wastes and biomass also analyzed. The future outlook of anaerobic digestion will be closely linked to circular economy principles. Therefore, this technology should be properly integrated into any production system where energy can be recovered from organics. Digestion can play a major role in any transformation process where by-products need further stabilization or it can be the central core of any waste treatment process, modifying the current scheme by a concatenation of several activities with the aim of increasing the efficiency of the conversion. Thus, current plants dedicated to the treatment of wastewaters, animal manures, or food wastes can become specialized centers for producing bio-energy and green chemicals. However, high installation costs, feedstock dispersion and market distortions were recognized as the main parameters negatively affecting these alternatives.

Valorization of OFMSW Digestate-Derived Syngas toward Methanol, Hydrogen, or Electricity: Process Simulation and Carbon Footprint Calculation

This paper explores a possible waste-based economy transition strategy. Digestate from the organic fraction of municipal solid waste (OFMSW) is considered, as well as a low-added value product to be properly valorized. In this regard, air gasification may be used to produce syngas. In this work, the production of methanol, hydrogen, or electricity from digestate-derived syngas was assessed by ChemCAD process simulation software. The process scheme of methanol production comprises the following parts: water gas shift (WGS) with carbon capture and storage units (CCS), methanol synthesis, and methanol purification. In the case of hydrogen production, after WGS-CCS, hydrogen was purified from residual nitrogen by pressure swing absorption (PSA). Finally, for electricity production, the digestate-derived syngas was used as fuel in an internal combustion engine. The main objective of this work is to compare the proposed scenarios in terms of CO2 emission intensity and the effect of CO2 storage. In particular, CCS units were used for methanol or hydrogen production with the aim of obtaining high equilibrium yield toward these products. On the basis of 100 kt/year of digestate, results show that the global CO2 savings were 80, 71, and 69 ktCO2eq/year for electricity, methanol, and hydrogen production, respectively. If carbon storage was considered, savings of about 105 and 99 ktCO2eq/year were achieved with methanol and hydrogen production, respectively. The proposed scenarios may provide an attractive option for transitioning into methanol or hydrogen economy of the future.

Techno-Economic Assessment of a Scaled-Up Meat Waste Biorefinery System: A Simulation Study

While exports from the meat industry in New Zealand constitute a valuable source of foreign exchange, the meat industry is also responsible for the generation of large masses of waste streams. These meat processing waste streams are largely biologically unstable and are capable of leading to unfavourable environmental outcomes if not properly managed. To enable the effective management of the meat processing waste streams, a value-recovery based strategy, for the complete valorisation of the meat processing waste biomass, is proposed. In the present study therefore, a biorefinery system that integrates the biomass conversion technologies of hydrolysis, esterification, anaerobic digestion and hydrothermal liquefaction has been modelled, simulated and optimized for enhanced environmental performance and economic performance. It was determined that an initial positive correlation between the mass feed rate of the waste to the biorefinery system and its environmental performance exists. However, beyond an optimal total mass feed rate of the waste stream there is a deterioration of the environmental performance of the biorefinery system. It was also determined that economies of scale ensure that any improvement in the economic performance of the biorefinery system with increasing total mass feed rate of the waste stream, is sustained. The present study established that the optimized meat waste biorefinery system facilitated a reduction in the unit production costs of the value-added products of biodiesel, biochar and biocrude compared the literature-obtained unit production costs of the respective aforementioned products when generated from stand-alone systems. The unit production cost of biogas was however shown to be comparable to the literature-obtained unit production cost of biogas. Finally, the present study showed that the optimized meat processing waste biorefinery could achieve enhanced economic performance while simultaneously maintaining favourable environmental sustainability.

Innovative operational strategies for biogas plant including temperature and stirring management

Finding the optimum operational conditions (mainly temperature and stirring) inside the fermenters is crucial in the field of anaerobic digestion. This study was conducted to contribute to the research area of anaerobic digestion process optimization and is an example for other biogas plants to improve efficiency. The research aimed at finding the optimum operational conditions in a large-scale biogas plant located in Lower Saxony, Germany, which started operation in 2011. The optimization activities were performed by operating the fermenters under different operational conditions: the temperature inside the fermenters ranged between 40°C and 43°C, while applying several stirring scenarios. These changes led to an increase in specific electricity yield of 11.7% and a decrease in internal energy consumption of 10.4%. The total internal energy consumption of the biogas plant was in the range of 6.3-7.2% (the average monthly internal energy consumption was 6.7% in 2013 and 6.0% in 2014) from their own production, and 28% of this energy consumption was used by the stirrers before optimization. Therefore, finding the optimum operational conditions leads to high energy harvesting and lower internal energy consumption.

Design and commissioning of a multi-mode prototype for thermochemical conversion of human faeces

This article describes the design and commissioning of a micro-combustor for energy recovery from human faeces, which can operate both in updraft and downdraft modes. Energy recovery from faecal matter via thermochemical conversion has recently been identified as a feasible solution for sanitation problems in low income countries and locations of high income countries where access to sewage infrastructures is difficult or not possible. This technology can be applied to waterless toilets with the additional outcome of generating heat and power that can be used to pre-treat the faeces before their combustion and to ensure that the entire system is self-sustaining. The work presented here is framed within the Nano Membrane Toilet (NMT) project that is being carried out at Cranfield University, as part of the Reinvent the Toilet Challenge of the Bill and Melinda Gates Foundation. For this study, preliminary trials using simulant faeces pellets were first carried out to find out the optimum values for the main operating variables at the scale required by the process, i.e. a fuel flowrate between 0.4 and 1.2 g/min of dry faeces. Parameters such as ignition temperature, residence time, and maximum temperature reached, were determined and used for the final design of the bench-scale combustor prototype. The prototype was successfully commissioned and the first experimental results, using real human faeces, are discussed in the paper.

Numerical analysis of an entire ceramic kiln under actual operating conditions for the energy efficiency improvement

The paper focuses on the analysis of an industrial ceramic kiln in order to improve the energy efficiency and thus the fuel consumption and the corresponding carbon dioxide emissions. A lumped and distributed parameter model of the entire system is constructed to simulate the performance of the kiln under actual operating conditions. The model is able to predict accurately the temperature distribution along the different modules of the kiln and the operation of the many natural gas burners employed to provide the required thermal power. Furthermore, the temperature of the tiles is also simulated so that the quality of the final product can be addressed by the modelling. Numerical results are validated against experimental measurements carried out on a real ceramic kiln during regular production operations. The developed numerical model demonstrates to be an efficient tool for the investigation of different design solutions for the kiln's components. In addition, a number of control strategies for the system working conditions can be simulated and compared in order to define the best trade off in terms of fuel consumption and product quality. In particular, the paper analyzes the effect of a new burner type characterized by internal heat recovery capability aimed at improving the energy efficiency of the ceramic kiln. The fuel saving and the relating reduction of carbon dioxide emissions resulted in the order of 10% when compared to the standard burner.