Two-stage thermal pyrolysis of plastic solid waste: Set-up and operative conditions investigation for gaseous fuel production.

In response to the escalating global challenge of mounting plastic waste and the imperative to adopt more sustainable practices for resource utilization, our study focuses on the utilization of plastic solid waste (PSW) through a two-stage thermal pyrolysis process. This aims to demonstrate its potential as a high-performance alternative to existing two-stage catalytic pyrolysis methods. The experimentation involved processing real scrap PSW material in a lab-scale batch set-up, emphasizing optimizing residence time in the cracking reactor to maximize gas yield and its lower heating value (LHV). The study underscores the advantages of the employed two-stage thermal pyrolysis apparatus through a comparative analysis with established set-up dedicated to maximizing gas yield. Once the operative conditions were explored, resulting pyrolysis products underwent detailed characterization to assess their suitability as a sustainable fuel source. The study also presents a practical application of the produced gaseous fuel, envisioning its combustion in an internal combustion engine (ICE), known for its flexibility regarding fuel properties. This application is demonstrated through a simulation conducted in Unisim Design©. The successful processing of real PSW material in the two-stage lab-scale experimental set-up showcased optimal gas yield achievements (>65 % w/w) with an LHV (∼41 MJ/kg), comparable to that of natural gas. This emphasizes the potential of these sustainable alternatives to replace fossil fuels, especially in the context of ICE applications. The integration of the pyrolysis plant with an ICE demonstrated promising prospects for generating electricity in the transportation sector and facilitating thermal power for heat integration in pyrolysis reactors.

Influence of Torrefaction on Biomass Devolatilization.

The present study investigated the effect of torrefaction on the devolatilization characteristics of three lignocellulosic biomass feedstocks with different degrees of torrefaction together with their parent fuel, palm kernel shell, a residue of palm oil production. Thermogravimetric (TG) analysis was employed for the study of the devolatilization process. A kinetic model based on three parallel reactions corresponding to biomass chemical components was applied to TG data and used for the evaluation of reaction kinetics. The results obtained indicated that the torrefaction process led to a significant reduction of the hemicellulose content of the investigated biofuels. The characterization of volatile products evolved during biofuel devolatilization was performed by TG analysis coupled with Fourier transform infrared spectroscopy. The emission characteristics and the yields of the main volatile products were assessed. Specific linear correlations between volatile yields and the torrefaction degree could be observed.

Evaluation of Mussel Shells Powder as Reinforcement for PLA-Based Biocomposites.

The use of biopolyesters, as polymeric matrices, and natural fillers derived from wastes or by-products of food production to achieve biocomposites is nowadays a reality. The present paper aims to valorize mussel shells, 95% made of calcium carbonate (CaCO3), converting them into high-value added products. The objective of this work was to verify if CaCO3, obtained from Mediterranean Sea mussel shells, can be used as filler for a compostable matrix made of Polylactic acid (PLA) and Poly(butylene adipate-co-terephthalate) (PBAT). Thermal, mechanical, morphological and physical properties of these biocomposites were evaluated, and the micromechanical mechanism controlling stiffness and strength was investigated by analytical predictive models. The performances of these biocomposites were comparable with those of biocomposites produced with standard calcium carbonate. Thus, the present study has proved that the utilization of a waste, such as mussel shell, can become a resource for biocomposites production, and can be an effective option for further industrial scale-up.

Biomethane from Short Rotation Forestry and Microalgal Open Ponds: System Modeling and Life Cycle Assessment.

Gasification of Short Rotation Forestry (SRF) poplar wood chips and anaerobic digestion of the microalga Chlorella vulgaris have been analyzed as alternative supply chains for the production of biomethane. Life Cycle Assessment (LCA) was performed from the biomass cultivation to the upgrading stages. Process simulation of gasification and upgrading was carried out, environmental impacts of the entire supply chains have been estimated and discussed. The highest CO2 removal has been reached by absorption on monoethanolamine. Electricity requirements heavily affect the SRF chain, while productions of carbon dioxide and fertilizers are the main sources of impact of the microalgae cultivation. The recycle of non-absorbed fertilizers, as well as integration of microalgae digestion in wastewater plants, are recommended. Capture and re-injection of the CO2 lost during the upgrading stages would result, simultaneously, in an 8.53% reduction of the atmospheric emission, and in a minor demand to promote algal growth.

Development of a bi-equilibrium model for biomass gasification in a downdraft bed reactor.

This work proposes a simple and accurate tool for predicting the main parameters of biomass gasification (syngas composition, heating value, flow rate), suitable for process study and system analysis. A multizonal model based on non-stoichiometric equilibrium models and a repartition factor, simulating the bypass of pyrolysis products through the oxidant zone, was developed. The results of tests with different feedstocks (corn cobs, wood pellets, rice husks and vine pruning) in a demonstrative downdraft gasifier (350kW) were used for validation. The average discrepancy between model and experimental results was up to 8 times less than the one with the simple equilibrium model. The repartition factor was successfully related to the operating conditions and characteristics of the biomass to simulate different conditions of the gasifier (variation in potentiality, densification and mixing of feedstock) and analyze the model sensitivity.

Gasification of agricultural residues in a demonstrative plant: Vine pruning and rice husks.

Tests with vine pruning and rice husks were carried out in a demonstrative downdraft gasifier (350 kW), to prove the reactor operability, quantify the plant efficiency, and thus extend the range of potential energy feedstocks. Pressure drops, syngas flow rate and composition were monitored to study the material and energy balances, and performance indexes. Interesting results were obtained for vine pruning (syngas heating value 5.7 MJ/m(3), equivalent ratio 0.26, cold gas efficiency 65%, power efficiency 21%), while poorer values were obtained for rice husks (syngas heating value 2.5-3.8 MJ/m(3), equivalent ratio 0.4, cold gas efficiency 31-42%, power efficiency 10-13%). The work contains also a comparison with previous results (wood pellets, corn cobs, Miscanthus) for defining an operating diagram, based on material density and particle size and shape, and the critical zones (reactor obstruction, bridging, no bed buildup, combustion regime).

Gasification of agricultural residues in a demonstrative plant: corn cobs.

Biomass gasification couples the high power efficiency with the possibility of valuably using the byproducts heat and biochar. The use of agricultural wastes instead of woody feedstock extends the seasonal availability of biomasses. The downdraft type is the most used reactor but has narrow ranges of feedstock specifications (above all on moisture and particle size distribution), so tests on a demonstrative scale are conducted to prove the versatility of the gasifier. Measurements on pressure drops, syngas flow rate and composition are studied to assess the feasibility of such operations with corn cobs. Material and energy balances, and performance indexes are compared for the four tests carried out under different biomass loads (66-85 kg/h). A good operability of the plant and interesting results are obtained (gas specific production of 2 m3/kg, gas heating value 5.6-5.8 MJ/m3, cold gas efficiency in the range 66-68%, potential net power efficiency 21.1-21.6%).

Assessment of syngas composition variability in a pilot-scale downdraft biomass gasifier by an extended equilibrium model.

A new simplified approach based on equilibrium modeling is proposed in this work to describe the correlations among syngas species experimentally observed in a pilot scale downdraft biomass gasifier operated with different feedstocks (biomass pellets and vine prunings). The modeling approach is based on experimental evidence on the presence of devolatilization products in the syngas and fluctuations of syngas composition during stationary operation, accounted for by introducing two empirical parameters, a by-pass index and a permeability index. The simplified model correctly reproduces the correlations among the main syngas species (including methane and ethylene) resulting from experimental data of pilot tests with different feedstocks and under a wide range of operating conditions.

Numerical and experimental investigation of downdraft gasification of woody residues.

A pilot scale throated downdraft gasifier was operated with vine prunings as feedstock to assess the effect of biomass loading rate on process performance. A distributed 1D model of mass and heat transfer and reactions was applied to aid the interpretation of experimental evidence. The model takes into account peculiar gasifier design features (air inlets and throat) and it reproduces satisfactorily the temperature profiles and the mass fluxes of gaseous species at different biomass loading rates. The integration of pilot-scale experiments and numerical simulations provides sound indications for the gasifier operation. In particular, simulations performed at different loading rates and feedstock humidity show that steady state operation and stable performance of the gasifier rely on the thermal balance between the enthalpy of cold biomass moving downward and the counter-current radiative heat fluxes moving upward from the oxidation zone. This balance can be destabilized by high loading rate and moisture contents.

Gasification of pelletized biomass in a pilot scale downdraft gasifier.

This work presents a pilot-scale investigation aimed at assessing the feasibility and reliability of biomass pellet gasification. Wood sawdust and sunflower seeds pellets were tested in a 200 kW downdraft gasifier operating with air as gasifying agent. The gasification of pelletized biomass led to rather high and unstable pressure drops, reducing the gasifier productivity and stability. Furthermore the generation of fine residues compromised the operation of wet ash removal systems. On the other hand, good syngas compositions (H(2) 17.2%, N(2) 46.0%, CH(4) 2.5%, CO 21.2%, CO(2) 12.6%, and C(2)H(4) 0.4%), specific gas production (2.2-2.4 N m(3) kg(-1)) and cold gas efficiency (67.7-70.0%) were achieved. For these reasons pelletized biomass should be considered only as complementary fuel in co-gasification with other feedstock.

Comparative study of thermochemical processes for hydrogen production from biomass fuels.

Different thermochemical configurations (gasification, combustion, electrolysis and syngas separation) are studied for producing hydrogen from biomass fuels. The aim is to provide data for the production unit and the following optimization of the "hydrogen chain" (from energy source selection to hydrogen utilization) in the frame of the Italian project "Filiera Idrogeno". The project focuses on a regional scale (Tuscany, Italy), renewable energies and automotive hydrogen. Decentred and small production plants are required to solve the logistic problems of biomass supply and meet the limited hydrogen infrastructures. Different options (gasification with air, oxygen or steam/oxygen mixtures, combustion, electrolysis) and conditions (varying the ratios of biomass and gas input) are studied by developing process models with uniform hypothesis to compare the results. Results obtained in this work concern the operating parameters, process efficiencies, material and energetic needs and are fundamental to optimize the entire hydrogen chain.