Integration of post-combustion capture and storage into a pulverized coal-fired power plant

Post-combustion CO₂ capture and storage (CCS) presents a promising strategy to capture, compress, transport and store CO₂ from a high volume–low pressure flue gas stream emitted from a fossil fuel-fired power plant. This work undertakes the simulation of CO₂ capture and compression integration into an 800 MW_e supercritical coal-fired power plant using chemical process simulators. The focus is not only on the simulation of full load of flue gas stream into the CO₂ capture and compression, but also, on the impact of a partial load. The result reveals that the energy penalty of a low capture efficiency, for example, at 50% capture efficiency with 10% flue gas load is higher than for 90% flue gas load at the equivalent capture efficiency by about 440 kWh_e/tonne CO₂. The study also addresses the effect of CO₂ capture performance by different coal ranks. It is found that lignite pulverized coal (PC)-fired power plant has a higher energy requirement than subbituminous and bituminous PC-fired power plants by 40.1 and 98.6 MW_e, respectively. In addition to the investigation of energy requirement, other significant parameters including energy penalty, plant efficiency, amine flow rate and extracted steam flow rate, are also presented. The study reveals that operating at partial load, for example at half load with 90% CO₂ capture efficiency, as compared with full load, reduces the energy penalty, plant efficiency drop, amine flow rate and extracted steam flow rate by 9.9%, 24.4%, 50.0% and 49.9%, respectively. In addition, the effect of steam extracted from different locations from a series of steam turbine with the objective to achieve the lowest possible energy penalty is evaluated. The simulation shows that a low extracted steam pressure from a series of steam turbines, for example at 300 kPa, minimizes the energy penalty by up to 25.3%.     

CO2 capture from power plants: Part II. A parametric study of the economical performance based on mono-ethanolamine

While the demand for reduction in CO₂ emission is increasing, the cost of the CO₂ capture processes remains a limiting factor for large-scale application. Reducing the cost of the capture system by improving the process and the solvent used must have a priority in order to apply this technology in the future. In this paper, a definition of the economic baseline for post-combustion CO₂ capture from 600 MW_e bituminous coal-fired power plant is described. The baseline capture process is based on 30% (by weight) aqueous solution of monoethanolamine (MEA). A process model has been developed previously using the Aspen Plus simulation programme where the baseline CO₂-removal has been chosen to be 90%. The results from the process modelling have provided the required input data to the economic modelling. Depending on the baseline technical and economical results, an economical parameter study for a CO₂ capture process based on absorption/desorption with MEA solutions was performed.Major capture cost reductions can be realized by optimizing the lean solvent loading, the amine solvent concentration, as well as the stripper operating pressure. A minimum CO₂ avoided cost of € 33 tonne⁻¹ CO₂ was found for a lean solvent loading of 0.3 mol CO₂/mol MEA, using a 40 wt.% MEA solution and a stripper operating pressure of 210 kPa. At these conditions 3.0 GJ/tonne CO₂ of thermal energy was used for the solvent regeneration. This translates to a € 22 MWh⁻¹ increase in the cost of electricity, compared to € 31.4 MWh⁻¹ for the power plant without capture.     

Maintaining a neutral water balance in a 450 MWe NGCC-CCS power system with post-combustion carbon dioxide capture aimed at offshore operation

A post-combustion CO₂ capture process intended for offshore operations has been designed and optimised for integration with a natural gas-fired power plant on board a floating structure developed by the Norway-based company Sevan Marine ASA—designated Sevan GTW (gas-to-wire). The concept is constrained by the structure of the floater carrying a SIEMENS modular power system rated at 450 MW_e, with a capture rate of 90% and CO₂ compression (1.47 Mtpa) for pipeline pressure at 12 MPa. A net efficiency of 45% (based on a lower heating value) is estimated for the system with CO₂ capture, thus suggesting that the post-combustion CO₂ capture system is accountable for a fuel penalty of nine percentage points.The rationale behind the technology selection is the urgency of replacing the dispersed aero-derivative gas turbines which power the offshore oil and gas production units in Norwegian waters with near-zero emission power.As (inherently) fresh water usually constitutes a limiting factor in sea operations, efforts are made to obtain a neutral water balance to obtain an optimal design. This is primarily achieved by controlling the cleaned flue gas temperature at the top of the absorber column.     

The value of post-combustion carbon dioxide capture and storage technologies in a world with uncertain greenhouse gas emissions constraints

By analyzing how the largest CO₂ emitting electricity-generating region in the United States, the East Central Area Reliability Coordination Agreement (ECAR), responds to hypothetical constraints on greenhouse gas emissions, the authors demonstrate that there is an enduring role for post-combustion CO₂ capture technologies. The utilization of pulverized coal generation with carbon dioxide capture and storage (PC + CCS) technologies is particularly significant in a world where there is uncertainty about the future evolution of climate policy and in particular uncertainty about the rate at which the climate policy will become more stringent. The paper's analysis shows that within this one large, heavily coal-dominated electricity-generating region, as much as 20–40 GW of PC + CCS could be operating before the middle of this century. Depending upon the state of PC + CCS technology development and the evolution of future climate policy, the analysis shows that these CCS systems could be mated to either pre-existing PC units or PC units that are currently under construction, announced and planned units, as well as PC units that could continue to be built for a number of decades even in the face of a climate policy. In nearly all the cases analyzed here, these PC + CCS generation units are in addition to a much larger deployment of CCS-enabled coal-fueled integrated gasification combined cycle (IGCC) power plants. The analysis presented here shows that the combined deployment of PC + CCS and IGCC + CCS units within this one region of the U.S. could result in the potential capture and storage of between 3.2 and 4.9 Gt of CO₂ before the middle of this century in the region's deep geologic storage formations.     

Assessment of the different parameters affecting the CO2 purity from coal fired oxyfuel process

The oxyfuel process is one of the most promising options to capture CO₂ from coal fired power plants. The combustion takes place in an atmosphere of almost pure oxygen, delivered from an air separation unit (ASU), and recirculated flue gas. This provides a flue gas containing 80–90 vol% CO₂ on a dry basis. Impurities are caused by the purity of the oxygen from the ASU, the combustion process and air ingress. Via liquefaction a CO₂ stream with purity in the range from 85 to 99.5 vol% can be separated and stored geologically. Impurities like O₂, NO_X, SO_X, and CO may negatively influence the transport infrastructure or the geological storage site by causing geochemical reactions. Therefore the maximum acceptable concentrations of the impurities in the separated CO₂ stream must be defined regarding the requirements from transportation and storage. The main objective of the research project COORAL therefore is to define the required CO₂ purity for capture and storage.     

A comparison of on-site nutrient and energy recycling technologies in algal oil production

Research on biofuel production pathways from algae continues because among other potential advantages they avoid key consequential effects of terrestrial oil crops, such as competition for cropland. However, the economics, energetic balance, and climate change emissions from algal biofuels pathways do not always show great potential, due in part to high fertilizer demand. Nutrient recycling from algal biomass residue is likely to be essential for reducing the environmental impacts and cost associated with algae-derived fuels. After a review of available technologies, anaerobic digestion (AD) and hydrothermal liquefaction (HTL) were selected and compared on their nutrient recycling and energy recovery potential for lipid-extracted algal biomass using the microalgae strain Scenedesmus dimorphus. For 1 kg (dry weight) of algae cultivated in an open raceway pond, 40.7 g N and 3.8 g P can be recycled through AD, while 26.0 g N and 6.8 g P can be recycled through HTL. In terms of energy production, 2.49 MJ heat and 2.61 MJ electricity are generated from AD biogas combustion to meet production system demands, while 3.30 MJ heat and 0.95 MJ electricity from HTL products are generated and used within the production system.Assuming recycled nutrient products from AD or HTL technologies displace demand for synthetic fertilizers, and energy products displace natural gas and electricity, the life cycle greenhouse gas reduction achieved by adding AD to the simulated algal oil production system is between 622 and 808 g carbon dioxide equivalent (CO₂e)/kg biomass depending on substitution assumptions, while the life cycle GHG reduction achieved by HTL is between 513 and 535 g CO₂e/kg biomass depending on substitution assumptions. Based on the effectiveness of nutrient recycling and energy recovery, as well as technology maturity, AD appears to perform better than HTL as a nutrient and energy recycling technology in algae oil production systems.     

Modeling the impacts of climate policy on the deployment of carbon dioxide capture and geologic storage across electric power regions in the United States

This paper summarizes the results of a first-of-its-kind holistic, integrated economic analysis of the potential role of carbon dioxide (CO₂) capture and storage (CCS) technologies across the regional segments of the United States (U.S.) electric power sector, over the time frame 2005–2045, in response to two hypothetical emissions control policies analyzed against two potential energy supply futures that include updated and substantially higher projected prices for natural gas. This paper's detailed analysis is made possible by combining two specialized models developed at Battelle: the Battelle CO₂-GIS to determine the regional capacity and cost of CO₂ transport and geologic storage; and the Battelle Carbon Management Electricity Model, an electric system optimal capacity expansion and dispatch model, to examine the investment and operation of electric power technologies with CCS against the background of other options. A key feature of this paper's analysis is an attempt to explicitly model the inherent heterogeneities that exist in both the nation's current and future electricity generation infrastructure and in its candidate deep geologic CO₂ storage formations. Overall, between 180 and 580 gigawatts (GW) of coal-fired integrated gasification combined cycle with CCS (IGCC + CCS) capacity is built by 2045 in these four scenarios, requiring between 12 and 41 gigatonnes of CO₂ (GtCO₂) storage in regional deep geologic reservoirs across the U.S. Nearly all of this CO₂ is from new IGCC + CCS systems, which start to deploy after 2025. Relatively little IGCC + CCS capacity is built before that time, primarily under unique niche opportunities. For the most part, CO₂ emissions prices will likely need to be sustained at over $20/tonne CO₂ before CCS begins to deploy on a large scale within the electric power sector. Within these broad national trends, a highly nuanced picture of CCS deployment across the U.S. emerges. Across the four scenarios studied here, power plant builders and operators within some North American Electric Reliability Council (NERC) regions do not employ any CCS while other regions build more than 100 GW of CCS-enabled generation capacity. One region sees as much as 50% of its geologic CO₂ storage reservoirs’ total theoretical capacity consumed by 2045, while most of the regions still have more than 90% of their potential storage capacity available to meet storage needs in the second half of the century and beyond. A detailed presentation of the results for power plant builds and operation in two key regions: ECAR in the Midwest and ERCOT in Texas, provides further insight into the diverse set of economic decisions that generate the national and aggregate regional results.     

Flue gas desulphurization for hot recycle Oxyfuel combustion: Experiences from the 30 MWth Oxyfuel pilot plant in Schwarze Pumpe

Significant differences exist in the flue gas composition in hot recycle Oxyfuel conditions as e.g. the high CO₂ partial pressure (>90 vol%, dry), the very high SO₂ concentration and the high water content (approx. 30 vol%). Therefore certain design and operation criteria have to be observed for the flue gas desulphurization with forced oxidation under Oxyfuel combustion conditions. Several performance tests have been executed at the 30 MW_th Oxyfuel pilot plant in Schwarze Pumpe to evaluate the main performance parameters and to assess the influence of the major operation parameters. The results show that there are no fundamental problems for the operation of the flue gas desulphurization unit under Oxyfuel combustion conditions. High removal rates could be reached and no negative impact of the high CO₂ partial pressure was observed under the tested operating conditions. No major differences in the gypsum quality have been observed between air firing and Oxyfuel conditions.     

Study of Hg and SO3 behavior in flue gas of oxy-fuel combustion system

Oxy-fuel combustion systems have been under development to reduce CO₂ emissions from coal-fired power plants. In oxy-fuel combustion system, Hg in the flue gas causes corrosion in CO₂ purification and compression units. Also, SO₃ in the flue gas corrodes the equipment and ducts of oxy-fuel combustion system. Therefore, Hg and SO₃ need to be removed.Babcock-Hitachi conducted tests using a 1.5 MWth Combustion & Air Quality Control System (AQCS) test facility which consists of oxygen supply unit, furnace, Selective Catalytic Reduction (SCR) catalyst, Clean Energy Recuperator (CER), Dry Electrostatic Precipitator (DESP), flue gas recirculation system, Wet Flue Gas Desulfurization (WFGD), and CO₂ Compression and Purification Unit (CPU). In both cases of air and oxy-fuel combustion, the Hg removal across the DESP could be improved, and SO₃ concentration at the DESP outlet could be reduced to less than 1 ppm by installing a CER upstream of the DESP and reducing the gas temperature at the DESP inlet. Hg was not dissolved in the drain recovered from CO₂ compressor, and may be adsorbed at an inner part of CO₂ compressor. This indicated that Hg needs to be removed at a location upstream of the CO₂ compressor to prevent corrosion of the compressor.     

Integration and evaluation of a power plant with a CaO-based CO2 capture system

This paper explores the integration and evaluation of a power plant with a CaO-based CO₂ capture system. There is a great amount of recoverable heat in the CaO-based CO₂ capture process. Five cases for the possible integration of a 600 MW power plant with CaO-based CO₂ capture process are considered in this paper. When the system is configured so that recovered heat is used to replace part of the boiler heat load (Case 2), modelling not only shows that this is the system recovering the most heat of 1008.8 MW but also results in the system with the lowest net power output of 446 MW and the second lowest of efficiency of 34.1%. It is indicated that system performance depends both on the amount of heat recovery and the type of heat utilization. When the system is configured so that a 400 MW power plant is built using the recovered heat (Case 4), modelling shows that this is the system with the most net power output of 846 MW, the highest efficiency of 36.8%, the lowest cost of electricity of 54.3 €/MWh and the lowest cost of CO₂ avoided of 28.9 €/tCO₂. This new built steam cycle will not affect the operation of the reference plant which vents its CO₂ to the atmosphere, highly reducing the connection between the CO₂ capture process and the reference plant which vents its CO₂ to the atmosphere. The average cost of electricity and the cost of CO₂ avoided of the five cases are about 58.9 €/kWh and 35.9 €/tCO₂, respectively.     

Pulverized coal stream ignition delay under conventional and oxy-fuel combustion conditions

The coal stream ignition process is critical to the performance of modern pulverized coal burners, particularly when operating under novel conditions such as experienced in oxy-fuel combustion. However, experimental studies of coal stream ignition are lacking, and recent modeling efforts have had to rely on comparisons with a single set of experiments in vitiated air. To begin to address this shortfall, we have conducted experiments on the ignition properties of two U.S. and two Chinese coals in a laminar entrained flow reactor. Most of the measurements focused on varying the coal feed rate for furnace temperatures of 1230–1320 K and for 12–20 vol.% O₂ in nitrogen. The influence of coal feed rate on ignition with a carbon dioxide diluent was also measured for 20 vol.% O₂ at 1280 K. A second set of measurements was performed for ignition of a fixed coal feed rate in N₂ and CO₂ environments at identical furnace temperatures of 1200 K, 1340 K, and 1670 K. A scientific CCD camera equipped with a 431 nm imaging filter was used to interrogate the ignition process. Under most conditions, the ignition delay decreased with increasing coal feed rate until a minimum was reached at a feed rate corresponding to a particle number density of approximately 4 × 10⁹ m^?3 in the coal feed pipe. This ignition minimum corresponds to a cold flow group number, G, of ～0.3. At higher coal feed rates the ignition delay increased. The ignition delay time was shown to be very sensitive to (a) the temperature of the hot coflow into which the coal stream is introduced, and (b) the coal particle size. The three high volatile bituminous coals showed nearly identical ignition delay as a function of coal feed rate, whereas the subbituminous coal showed slightly greater apparent ignition delay. Bath gas CO₂ content was found to have a minor impact on ignition delay.     

Kinetic studies on the adsorption of phenol, 4-chlorophenol,and 2,4-dichlorophenol from water using activated carbons

This study uses rate parameters in pseudo-first-order (PFO) and pseudo-second-order (PSO) equations (k₁ and k₂q_e, respectively) to judge the extent for approaching equilibrium in an adsorption process. Out of fifty-six systems collected from the literature, the adsorption processes with a k₂q_e value between 0.1 and 0.8 min^?1 account for as much as 70% of the total. These are classified as fast processes. This work compares the validity of PFO and PSO equations for the adsorption of phenol, 4-chlorophenol (4-CP), and 2,4-dichlorophenol (2,4-DCP) on activated carbons prepared from pistachio shells at different NaOH/char ratios. The activated carbons, recognized as microporous materials, had a surface area ranging from 939 to 1936 m²/g. Findings show that the adsorption of phenol, 4-CP, and 2,4-DCP on activated carbons had a k₂q_e value of 0.15–0.58 min^?1, reflecting the fast process. Evaluating the operating time by rate parameters revealed that k₂q_e was 1.6–1.8 times larger than k₁. These findings demonstrate the significance of using an appropriate kinetic equation for adsorption process design.     

Effect of gas composition in Chemical-Looping Combustion with copper-based oxygen carriers: Fate of light hydrocarbons

Chemical-Looping Combustion (CLC) is an emerging technology for CO₂ capture because separation of this gas from the other flue gas components is inherent to the process and thus no energy is expended for the separation. Natural or refinery gas can be used as gaseous fuels and they may contain different amounts of light hydrocarbons. This paper presents the combustion results obtained with a Cu-based oxygen carrier using mixtures of CH₄ and light hydrocarbons (LHC) (C₂H₆ and C₃H₈) as fuel. The effect on combustion efficiency of the fuel reactor temperature, solid circulation flow rate and gas composition was studied in a continuous CLC plant (500 W_th). Full combustions were reached at 1073 and 1153 K working at oxygen to fuel ratios, ? higher than 1.5 and 1.2 respectively. Unburnt hydrocarbons were never detected at any experimental conditions at the fuel reactor outlet. Carbon formation can be avoided working at 1153 K or at ? values higher than 1.5 at 1073 K. After 30 h of continuous operation, the oxygen carrier exhibited an adequate behavior regarding attrition and agglomeration. It can be concluded that no special measures should be taken in a CLC process with Cu-based OC with respect to the presence of LHC in the fuel gas.     

Pathways towards large-scale implementation of CO2 capture and storage: A case study for the Netherlands

We sketch four possible pathways how carbon dioxide capture and storage (CCS) (r)evolution may occur in the Netherlands, after which the implications in terms of CO₂ stored and avoided, costs and infrastructural requirements are quantified. CCS may play a significant role in decarbonising the Dutch energy and industrial sector, which currently emits nearly 100 Mt CO₂/year. We found that 15 Mt CO₂ could be avoided annually by 2020, provided some of the larger gas fields that become available the coming decade could be used for CO₂ storage. Halfway this century, the mitigation potential of CCS in the power sector, industry and transport fuel production is estimated at maximally 80–110 Mt CO₂/year, of which 60–80 Mt CO₂/year may be avoided at costs between 15 and 40 €/t CO₂, including transport and storage. Avoiding 30–60 Mt CO₂/year by means of CCS is considered realistic given the storage potential represented by Dutch gas fields, although it requires planning to assure that domestic storage capacity could be used for CO₂ storage. In an aggressive climate policy, avoiding another 50 Mt CO₂/year may be possible provided that nearly all capture opportunities that occur are taken. Storing such large amounts of CO₂ would only be possible if the Groningen gas field or large reservoirs in the British or Norwegian part of the North Sea will become available.     

The challenge in understanding the corrosion mechanisms under oxyfuel combustion conditions

Basic research on the corrosive effect of flue gases has been performed at the BAM Federal Institute for Materials Research and Testing (Germany). Conditions at both high and low temperatures were simulated in specially designed experiments. Carburization occured in flue gases with high CO₂ content and temperatures higher than 500 °C. In SO₂ containing flue gases sulphur was detected in the oxide scale. At lower temperatures no corrosion was observed when gases with low humidity were investigated. Humidity higher than 1500 ppm was corrosive and all steels with Cr contents lower than 12% revealed corroded surfaces. At low temperatures below 10 °C a mixture of sulphuric and nitric acid condensed on metal surfaces. Acid condensation caused severe corrosion. Humidity, CO₂, O₂, and SO₂ contents are the important factors determining corrosion. Below 300 °C acid condensation is the primary reason for corrosion. Low humidity and low temperatures are conditions which can be expected in the CO₂ separation and treatment process. This work includes major conditions of the flue gas and CO₂ stream in CCS plants and CCS technology.     

Kinetics of sulfur dioxide- and oxygen-induced degradation of aqueous monoethanolamine solution during CO2 absorption from power plant flue gas streams

Studies of the kinetics of sulfur dioxide (SO₂)- and oxygen (O₂)-induced degradation of aqueous monoethanolamine (MEA) during the absorption of carbon dioxide (CO₂) from flue gases derived from coal- or natural gas-fired power plants were conducted as a function of temperature and the liquid phase concentrations of MEA, O₂, SO₂ and CO₂. The kinetic data were based on the initial rate which shows the propensity for amine degradation and obtained under a range of conditions typical of the CO₂ absorption process (3–7 kmol/m³ MEA, 6% O₂, 0–196 ppm SO₂, 0–0.55 CO₂ loading, and 328–393 K temperature). The results showed that an increase in temperature and the concentrations of MEA, O₂ and SO₂ resulted in a higher MEA degradation rate. An increase in CO₂ concentration gave the opposite effect. A semi-empirical model based on the initial rate, ?r_MEA = {6.74 × 10⁹ e^?(29,403/RT)[MEA]^0.02([O]^2.91 + [SO₂]^3.52)}/{1 + 1.18[CO₂]^0.18} was developed to fit the experimental data. With the higher order of reaction, SO₂ has a higher propensity to cause MEA to degrade than O₂. Unlike previous models, this model shows an improvement in that any of the parameters (i.e. O₂, SO₂, and CO₂) can be removed without affecting the usability of the model.     

Techno-economic evaluation of biogas upgrading process using CO2 facilitated transport membrane

The biogas upgrading by membrane separation process using a highly efficient CO₂-selective polyvinylamine/polyvinylalcohol (PVAm/PVA) blend membrane was investigated by experimental study and simulation with respect to process design, operation optimization and economic evaluation. This blend membrane takes advantages of the unique CO₂ facilitated transport from PVAm and the robust mechanical properties from PVA, exhibits both high CO₂/CH₄ separation efficiency and very good stability. CO₂ transports through the water swollen membrane matrix in the form of bicarbonate. CO₂/CH₄ selectivity up to 40 and CO₂ permeance up to 0.55 m³(STP)/m² h bar at 2 bar were documented in lab with synthesized biogas (35% CO₂ and 65% CH₄). Membrane performances at varying feed pressures were recorded and used as the simulation basis in this work. The process simulation of an on-farm scale biogas upgrading plant (1000 Nm³/h) was conducted. Processes with four different membrane module configurations with or without recycle were evaluated technically and economically, and the 2-stage in cascade with recycle configuration was proven optimal among the four processes. The sensitivity of the process to various operation parameters was analyzed and the operation conditions were optimized.     

Application of polyacrylamide to reduce phosphorus losses from a Chinese purple soil: A laboratory and field investigation

Use of anionic polyacrylamide (PAM) to control phosphorus (P) losses from a Chinese purple soil was studied in both a laboratory soil column experiment and a field plot experiment on a steep slope (27%). Treatments in the column study were a control, and PAM mixed uniformly into the soil at rates of 0.02, 0.05, 0.08, 0.10, and 0.20%. We found that PAM had an important inhibitory effect on vertical P transport in the soil columns, with the 0.20% PAM treatment having the greatest significant reduction in leachate soluble P concentrations and losses resulting from nine leaching periods. Field experiments were conducted on 5 m wide by 21 m long natural rainfall plots, that allowed collection of both surface runoff and subsurface drainage water. Wheat was planted and grown on all plots with typical fertilizer applied. Treatments included a control, dry PAM at 3.9 kg ha^?1, dry PAM at 3.9 kg ha^?1 applied together with lime (CaCO₃ at 4.9 t ha^?1), and dry PAM at 3.9 kg ha^?1 applied together with gypsum (CaSO₄·2H₂O at 4 t ha^?1). Results from the field plot experiment in which 5 rainfall events resulted in measurable runoff and leachate showed that all PAM treatments significantly reduced runoff volume and total P losses in surface runoff compared to the control. The PAM treatments also all significantly reduced water volume leached to the tile drain. However, total P losses in the leachate water were not significantly different due to the treatments, perhaps due to the low PAM soil surface application rate and/or high experimental variability. The PAM alone treatment resulted in the greatest wheat growth as indicated by the plant growth indexes of wheat plant height, leaf length, leaf width, grain number per head, and dried grain mass. Growth indexes of the PAM with Calcium treatments were significantly lesser. These results indicate that the selection and use of soil amendments need to be carefully determined based upon the most important management goal at a particular site (runoff/nutrient loss control, enhanced plant growth, or a combination).     

Environmental resource footprinting of drug manufacturing: Effects of scale-up and tablet dosage

The formulation and scale-up of batch processes is one of the major challenges in the development of pharmaceutical dosage forms and at the same time a significant resource demanding process which is generally overlooked in environmental sustainability assessments. First, this paper proposes general trends in the experience curve of cumulative resource consumption of pharmaceutical tablet manufacturing of PREZISTA^® 800 mg through wet granulation (WG) at four consecutive scales in both R&D and manufacturing environments (resp. WG1 = 1 kg/h, WG5 = 5 kg/h, WG30 = 30 kg/h and WG240 = 240 kg/h). Second, the authors aim at evaluating the environmental impact from a life cycle perspective of a daily consumption of PREZISTA^® 2× 400 mg tablets versus the bioequivalent PREZISTA^® 800 mg tablet which was launched to enhance patient compliance. Environmental sustainability assessment was conducted at three different system boundaries, which enables identification, localization and eventually reduction of burdens, in this case natural resource extraction. Exergy Analysis (EA) was used at process level (α) and plant level (β) while a cradle-to-gate Exergetic Life Cycle Assessment (ELCA) was conducted at the overall industrial level (γ) by means of the CEENE method (Cumulative Exergy Extraction from the Natural Environment). Life cycle stages taken into account are Active Pharmaceutical Ingredient (API) production, Drug Product (DP) production and Packaging. At process level (α), the total resource extraction for the manufacturing of one daily dose of PREZISTA^® (800 mg tablet) amounted up to 0.44 MJ_ex at the smallest scale (WG1) while this amount proved to be reduced by 58%, 79% and 83% at WG5, WG30 and WG240 respectively. Expanding the boundaries to the overall industrial level (γ) reveals that the main resource demand is at the production of the Active Pharmaceutical Ingredient (API), excipients, packaging materials and cleaning media used in DP production. At the largest scale (WG240) the use of cleaning media during DP production contributes considerably less to the total resource extraction. Overall, the effect of scale-up and learning on resource consumption during DP production showed to possess a power-law experience curve y = 2.40 * x^−0.57 when shifting from WG1 (smallest lab scale) to WG240 (industrial manufacturing). Tablet dosage (2× 400 mg versus 1× 800 mg) did not significantly affect the absolute environmental burden. However, the relative contribution of resource categories did change due to the different production technology. It could be concluded that in meeting social and economic demands by launching the PREZISTA^® 800 mg tablet, no trade-off in environmental burden occurred. On the long term, future research should strive to take into account R&D processes and all services related to pipeline activities taking place prior to market launch and eventually to allocate impacts to the final product.     

Energy balances,greenhouse gas emissions and economics of biochar production from palm oil empty fruit bunches

This paper presents results from a gate-to-gate analysis of the energy balance, greenhouse gas (GHG) emissions and economic efficiency of biochar production from palm oil empty fruit bunches (EFB). The analysis is based on data obtained from EFB combustion in a slow pyrolysis plant in Selangor, Malaysia. The outputs of the slow pyrolysis plant are biochar, syngas, bio-oil and water vapor. The net energy yield of the biochar produced in the Selangor plant is 11.47 MJ kg⁻¹ EFB. The energy content of the biochar produced is higher than the energy required for producing the biochar, i.e. the energy balance of biochar production is positive. The combustion of EFB using diesel fuel has the largest energy demand of 2.31 MJ kg⁻¹ EFB in the pyrolysis process. Comparatively smaller amounts of energy are required as electricity (0.39 MJ kg⁻¹ EFB) and for transportation of biochar to the warehouse and the field (0.13 MJ kg⁻¹ EFB). The net greenhouse gas emissions of the studied biochar production account for 0.046 kg CO₂-equiv. kg⁻¹ EFB yr⁻¹ without considering fertilizer substitution effects and carbon accumulation from biochar in the soil. The studied biochar production is profitable where biochar can be sold for at least 533 US-$ t⁻¹. Potential measures for improvement are discussed, including higher productivity of biochar production, reduced energy consumption and efficient use of the byproducts from the slow pyrolysis.