Process design and techno‐economic analysis of ethyl levulinate production from carbon dioxide and 1,4‐butanediol as an alternative biofuel and fuel additive

Carbon dioxide capture, utilization, and storage (CCUS) is one of the promising negative emission technologies (NET). Within various CCUS routes available, CO₂ conversion into fuels is one of the attractive options. Currently, most of CO₂ conversion into fuels requires hydrogen, which is expensive and consume large energy to produce. Hence, a different route of producing fuel from CO₂ by utilizing 1,4‐butanediol as the raw material is proposed and evaluated in this study. This alternative route comprises production of levulinic acid from the reaction between CO₂ and 1,4‐butanediol and production of ethyl levulinate, an alternative biofuel and biofuel additive, via an esterification reaction of levulinic acid with ethanol. The process is designed and simulated according to the available data and evaluated in terms of its technical features. Because of the unavailability of reaction data for synthesis of levulinic acid from 1,4‐butanediol and CO₂, several assumptions were taken, which may implicate the accuracy of the studied design. This technical evaluation is followed by cost estimations and sensitivity analysis. Because of the free CO₂, the profitability of the plant depends strongly on the prices of the other chemicals and the price difference between 1,4‐butanediol (raw material) and ethyl levulinate (product). Monte Carlo simulation indicates that the proposed plant will always be profitable if the ethyl levulinate is slightly more expensive than the 1,4‐butanediol, highlighting that the process of producing ethyl levulinate from CO₂ is economically profitable. Future research should be directed towards a catalytic system that can effectively convert CO₂ into levulinic acid, by‐products produced from the two reaction steps, and reduce the excess ethanol used in the second reaction.     

Integrated free‐form method for aerostructural optimization of wind turbine blades

A typical approach to optimize wind turbine blades separates the airfoil shape design from the blade planform design. This approach is sequential, where the airfoils along the blade span are preselected or optimized and then held constant during the blade planform optimization. In contrast, integrated blade design optimizes the airfoils and the blade planform concurrently and thereby has the potential to reduce cost of energy (COE) more than sequential design. Nevertheless, sequential design is commonly performed because of the ease of precomputation, or the ability to compute the airfoil analyses prior to the blade optimization. This research compares 2 integrated blade design approaches. The precomputational method combines precomputation with the ability to change the airfoil shapes in limited ways during the optimization. The free‐form method allows for a complete range of airfoil shapes, but without precomputation. The airfoils are analyzed with a panel method (XFOIL) and a Reynolds‐averaged Navier‐Stokes computational fluid dynamics method (RANS CFD). Optimizing the NREL 5‐MW reference turbine showed COE reductions of 2.0%, 4.2%, and 4.7% when using XFOIL and 2.7%, 6.0%, and 6.7% when using RANS CFD for the sequential, precomputational, and free‐form methods, respectively. The precomputational method captures most of the benefits of integrated design for minimal additional computational cost and complexity, but the free‐form method provides modest additional benefits if the extra effort is made in computational cost and development time.     

Performance analysis and optimization design of an axial‐flow vane separator for supercritical CO2 (sCO2)‐water mixtures from geothermal reservoirs

Supercritical CO₂ (sCO₂) has been proven to be a promising working fluid for geothermal heat mining, and the produced hot sCO₂ can be directly used for power generation. However, the sCO₂ produced from a brine‐based reservoir may contain a certain amount of water, preventing direct power‐cycle utilization. In this paper, an axial vane separator was designed to address the separation problem of sCO₂ and water produced from geothermal reservoirs. First, the influences of operational and structural parameters on the separation performance were analyzed through numerical simulations. Five factors were selected to develop separation performance regression models by the response‐surface method (RSM). Finally, geometrical parameter optimization was applied to these RSM models. The results show that the guide vane area and the exhaust inlet are the main locations impacting the system pressure drop. The separation performance can be affected by many factors, including the guide blade outlet angle, number of vanes, hub diameter, length of the vortex tube, droplet size, and inlet velocity. The water‐droplet size and the number of vanes are the most critical factors affecting the separation efficiency. The inlet velocity, the number of vanes, and the hub diameter have a larger influence on the pressure drop of the separator. The optimization results indicate that the separation efficiency can reach 100% under certain operating conditions with a pressure drop no greater than 100 kPa.     

Aerodynamic shape optimization of wind turbine blades using a Reynolds‐averaged Navier–Stokes model and an adjoint method

Computational fluid dynamics (CFD) is increasingly used to analyze wind turbines, and the next logical step is to develop CFD‐based optimization to enable further gains in performance and reduce model uncertainties. We present an aerodynamic shape optimization framework consisting of a Reynolds‐averaged Navier Stokes solver coupled to a numerical optimization algorithm, a geometry modeler, and a mesh perturbation algorithm. To efficiently handle the large number of design variables, we use a gradient‐based optimization technique together with an adjoint method for computing the gradients of the torque coefficient with respect to the design variables. To demonstrate the effectiveness of the proposed approach, we maximize the torque of the NREL VI wind turbine blade with respect to pitch, twist, and airfoil shape design variables while constraining the blade thickness. We present a series of optimization cases with increasing number of variables, both for a single wind speed and for multiple wind speeds. For the optimization at a single wind speed performed with respect to all the design variables (1 pitch, 11 twist, and 240 airfoil shape variables), the torque coefficient increased by 22.4% relative to the NREL VI design. For the multiple‐speed optimization, the torque increased by an average of 22.1%. Depending on the CFD mesh size and number of design variables, the optimization time ranges from 2 to 24h when using 256 cores, which means that wind turbine designers can use this process routinely. Copyright © 2016 John Wiley & Sons, Ltd.     

Parametric techno‐economic studies of coal/biomass co‐gasification for IGCC plants with carbon capture using various coal ranks,fuel‐feeding schemes,and syngas cooling methods

Because of biomass's limited supply (as well as other issues involving its feeding and transportation), pure biomass plants tend to be small, which results in high production and capital costs (per unit power output) compared with much larger coal plants. Thus, it is more economically attractive to co‐gasify biomass with coal. Biomass can also make an existing plant carbon‐neutral or even carbon‐negative if enough carbon dioxide is captured and sequestered (CCS). As a part of a series of studies examining the thermal and economic impact of different design implementations for an integrated gasification combined cycle (IGCC) plant fed with blended coal and biomass, this paper focuses on investigating various parameters, including radiant cooling versus syngas quenching, dry‐fed versus slurry‐fed gasification (particularly in relation to sour‐shift and sweet‐shift carbon capture systems), oxygen‐blown versus air‐blown gasifiers, low‐rank coals versus high‐rank coals, and options for using syngas or alternative fuels in the duct burner for the heat recovery steam generator (HRSG) to achieve the desired steam turbine inlet temperature. Using the commercial software, Thermoflow^®, the case studies were performed on a simulated 250‐MW coal IGCC plant located near New Orleans, Louisiana, and the coal was co‐fed with biomass using ratios ranging from 10% to 30% by weight. Using 2011 dollars as a basis for economic analysis, the results show that syngas coolers are more efficient than quench systems (by 5.5 percentage points), but are also more expensive (by $500/kW and 0.6 cents/kW h). For the feeding system, dry‐fed is more efficient than slurry‐fed (by 2.2–2.5 points) and less expensive (by $200/kW and 0.5 cents/kW h). Sour‐shift CCS is both more efficient (by 3 percentage points) and cheaper (by $600/kW or 1.5 cents/kW h) than sweet‐shift CCS. Higher‐ranked coals are more efficient than lower‐ranked coals (2.8 points without biomass, or 1.5 points with biomass) and have lower capital cost (by $600/kW without using biomass, or $400/kW with biomass). Finally, plants with biomass and low‐rank coal feedstock are both more efficient and have lower costs than those with pure coal: just 10% biomass seems to increase the efficiency by 0.7 points and reduce costs by $400/kW and 0.3 cents/kW h. However, for high‐rank coals, this trend is different: the efficiency decreases by 0.7 points, and the cost of electricity increases by 0.1 cents/kW h, but capital costs still decrease by about $160/kW. Copyright © 2016 John Wiley & Sons, Ltd.     

Single and multi‐objective optimization for the performance enhancement of lead–acid battery cell

Electric energy storage systems are used considerably in industries and daily applications. The demand for batteries with high energy content has increased because of their use in hybrid vehicles. Lead–acid batteries have wide applications because of their advantages such as high safety factor and low cost of production. The major shortcoming of lead–acid batteries is low energy content and high dimension and weight. Nowadays, a common method to increase the energy content of lead–acid battery is the experimental method with trial and error, which is time consuming and expensive. In this paper, non‐isothermal one‐dimensional numerical simulation of lead–acid battery with finite volume method is performed. In addition, a cell with higher energy content and lower thickness is designed by using particle swarm optimization algorithm based on developed simulation code. The results of single objective optimization show that an optimal battery that has 27.6% higher energy can be made with the same cell dimension. The results also show that an optimum cell battery can be obtained with a decrease of 24% in thickness while keeping the energy the same. Moreover, a multi‐objective optimization algorithm is utilized to find Pareto optimal solutions while considering the energy content and thickness objectives simultaneously. Copyright © 2016 John Wiley & Sons, Ltd.     

Techno‐economic analysis of biomass/coal Co‐gasification IGCC systems with supercritical steam bottom cycle and carbon capture

In recent years, integrated gasification combined cycle technology has been gaining steady popularity for use in clean coal power operations with carbon capture and sequestration (CCS). This study focuses on investigating two approaches to improve efficiency and further reduce the greenhouse gas (GHG) emissions. First, replace the traditional subcritical Rankine steam cycle portion of the overall plant with a supercritical steam cycle. Second, add different amounts of biomass as feedstock to reduce emissions. Employing biomass as a feedstock has the advantage of being carbon neutral or even carbon negative if CCS is implemented. However, due to limited feedstock supply, such plants are usually small (2–50 MW), which results in lower efficiency and higher capital and production costs. Considering these challenges, it is more economically attractive and less technically challenging to co‐combust or co‐gasify biomass wastes with low‐rank coals. Using the commercial software, Thermoflow®, this study analyzes the baseline plants around 235 MW and 267 MW for the subcritical and supercritical designs, respectively. Both post‐combustion and pre‐combustion CCS conditions are considered. The results clearly show that utilizing a certain type of biomass with low‐rank coals up to 50% (wt.) can, in most cases, not only improve the efficiency and reduce overall emissions but may be economically advantageous, as well. Beyond a 10% Biomass Ratio, however, the efficiency begins to drop due to the rising pretreatment costs, but the system itself still remains more efficient than from using coal alone (between 0.2 and 0.3 points on average). The CO₂ emissions decrease by about 7000 tons/MW‐year compared to the baseline (no biomass), making the plant carbon negative with only 10% biomass in the feedstock. In addition, implementing a supercritical steam cycle raises the efficiency (1.6 percentage points) and lowers the capital costs ($300/kW), regardless of plant layout. Implementing post‐combustion CCS consistently causes a drop in efficiency (at least 7–8 points) from the baseline and increases the costs by $3000–$4000/kW and In recent years, integrated gasification combined cycle technology has been gaining steady popularity for use in clean coal power operations with carbon capture and sequestration (CCS). This study focuses on investigating two approaches to improve efficiency and further reduce the greenhouse gas (GHG) emissions. First, replace the traditional subcritical Rankine steam cycle portion of the overall plant with a supercritical steam cycle. Second, add different amounts of biomass as feedstock to reduce emissions. Employing biomass as a feedstock has the advantage of being carbon neutral or even carbon negative if CCS is implemented. However, due to limited feedstock supply, such plants are usually small (2–50 MW), which results in lower efficiency and higher capital and production costs. Considering these challenges, it is more economically attractive and less technically challenging to co‐combust or co‐gasify biomass wastes with low‐rank coals. Using the commercial software, Thermoflow®, this study analyzes the baseline plants around 235 MW and 267 MW for the subcritical and supercritical designs, respectively. Both post‐combustion and pre‐combustion CCS conditions are considered. The results clearly show that utilizing a certain type of biomass with low‐rank coals up to 50% (wt.) can, in most cases, not only improve the efficiency and reduce overall emissions but may be economically advantageous, as well. Beyond a 10% Biomass Ratio, however, the efficiency begins to drop due to the rising pretreatment costs, but the system itself still remains more efficient than from using coal alone (between 0.2 and 0.3 points on average). The CO₂ emissions decrease by about 7000 tons/MW‐year compared to the baseline (no biomass), making the plant carbon negative with only 10% biomass in the feedstock. In addition, implementing a supercritical steam cycle raises the efficiency (1.6 percentage points) and lowers the capital costs ($300/kW), regardless of plant layout. Implementing post‐combustion CCS consistently causes a drop in efficiency (at least 7–8 points) from the baseline and increases the costs by $3000–$4000/kW and $0.06–$0.07/kW‐h. The SO_x emissions also decrease by about 190 tons/year (7.6 × 10^?6 tons/MW‐year). Finally, the CCS cost is around $65–$72 per ton of CO₂. For pre‐combustion CCS, sour shift appears to be superior both economically and thermally to sweet shift in the current study. Sour shift is always cheaper, (by a difference of about $600/kW and $0.02‐$0.03/kW‐h), easier to implement, and also 2–3 percentage points more efficient. The economic difference is fairly marginal, but the trend is inversely proportional to the efficiency, with cost of electricity decreasing by 0.5 cents/kW‐h from 0% to 10% biomass ratio (BMR) and rising 2.5 cents/kW‐h from 10% to 50% BMR. Pre‐combustion CCS plants are smaller than post‐combustion ones and usually require 25% less energy for CCS due to their compact size for processing fuel flow only under higher pressure (450 psi), versus processing the combusted gases at near‐atmospheric pressure. Finally, the CO₂ removal cost for sour shift is around $20/ton, whereas sweet shift's cost is around $30/ton, which is much cheaper than that of post‐combustion CCS: about $60–$70/ton. Copyright © 2014 John Wiley & Sons, Ltd.