Aspen Plus simulation of biomass integrated gasification combined cycle systems at corn ethanol plants

Biomass integrated gasification combined cycle (BIGCC) systems and natural gas combined cycle (NGCC) systems are employed to provide heat and electricity to a 0.19 hm3 y−1 (50 million gallon per year) corn ethanol plant using different fuels (syrup and corn stover, corn stover alone, and natural gas). Aspen Plus simulations of BIGCC/NGCC systems are performed to study effects of different fuels, gas turbine compression pressure, dryers (steam tube or superheated steam) for biomass fuels and ethanol co-products, and steam tube dryer exhaust treatment methods. The goal is to maximize electricity generation while meeting process heat needs of the plant. At fuel input rates of 110 MW, BIGCC systems with steam tube dryers provide 20–25 MW of power to the grid with system thermal efficiencies (net power generated plus process heat rate divided by fuel input rate) of 69–74%. NGCC systems with steam tube dryers provide 26–30 MW of power to the grid with system thermal efficiencies of 74–78%. BIGCC systems with superheated steam dryers provide 20–22 MW of power to the grid with system thermal efficiencies of 53–56%. The life-cycle greenhouse gas (GHG) emission reduction for conventional corn ethanol compared to gasoline is 39% for process heat with natural gas (grid electricity), 117% for BIGCC with syrup and corn stover fuel, 124% for BIGCC with corn stover fuel, and 93% for NGCC with natural gas fuel. These GHG emission estimates do not include indirect land use change effects. -- Highlights: •BIGCC and natural gas combined cycle systems at corn ethanol plants are simulated. •The best performance results in 25–30 MW power to grid. •The best performance results in 74–78% system thermal efficiencies. •GHG reduction for corn ethanol with BIGCC systems compared to gasoline is over 100%