Process Analysis of Flexible Gasification Based Thermochemical Conversion Concepts of Biogenic Residues and Wastes into Biomethane and Biochar

This study provides the main performance estimates for new concepts, using flexible gasification operation modes, adaptable to prevailing market conditions, for the production of bio-synthetic natural gas (bio-SNG) and biochar from biogenic residues and waste, such as bark, straw, and Solid Recovered Fuel (SRF). Dedicated integrated process models were developed in Aspen Plus based on and validated against data from experimental campaigns in a gasification and gas cleaning pilot plant. Simulation runs show that the proposed concepts convert biomass to bio-SNG 10% more efficiently than the reference case, mainly due to the considerably reduced oxygen demand at the Autothermal Reformer (ATR) enabled by the improved catalyst. The co-production mode schemes showed promising results in terms of overall plant efficiency, at 76.5–78.2%, and total carbon utilisation, at 41–55.3%. The hybrid cases require an electrolyser with a power capacity almost 70% of the biomass thermal input to the gasifier, resulting in a total electricity consumption of up to 0.769 kWhe/kWh of biofuel. In return, they achieve over 50% utilisation of the carbon contained in the feedstock for biofuel production and a 70.1–76.5% total plant energy efficiency. Efficient biofuel and biochar production unlock negative emission potential, further strengthening the value of these flexible concepts.