Sustainable industrial process design for derived CO2 adsorbent from municipal solid wastes: Scale-up, techno-economic and parametric assessment

Climate change and carbon emissions attributed to anthropogenic activities is getting alarming dimensions. On the other hand, the overwhelming progress of industrialization and urbanization contributed to an explosion in the municipal solid waste (MSW), as one of the other global challenges. However, developing a cost-effective adsorbent with appealing textural properties for CO₂ capture is still one of the main challenges. Lately, carbon-based solid waste materials of biogenic origin have received a major interest to this end, owing to the renewability, availability and low-cost. Routinely, academic research mainly focuses on lab-scale development of activated carbons derived from waste materials. However, there is a significant gap concerning the industrial production of activated carbon from such materials. Accordingly, in this work, an industrial plant has been designed for producing activated carbon derived from digestate of MSWs in the industrial scale by presenting all scale-up details, engineering assumptions and process specifications. The results indicated that the plant has a potential to process 90,273 ton MSW annually, which consumes 1367.8 MWh net electricity and 20,134.4 GJ net heat, also produces 4788.10 ton CO₂ adsorbent, per year. The economic assessment specified that the plant capital cost is around $14.112 million with the net price of 0.61 $/kg for produced activated carbon. Further, the sensitivity analysis and parametric study determined that the sample level in the drum is the determinative parameter on the energy consumption and net price of adsorbent. Finally, Response Surface Methodology was employed to maximize the plant profitability concerning the designing factors.