In this paper, a hydrothermal carbonization (HTC) process is designed and modeled on the basis of experimental data previously obtained for two representative organic waste materials: off-specification compost and grape marc. The process accounts for all the steps and equipment necessary to convert raw moist biomass into dry and pelletized hydrochar. By means of mass and thermal balances and based on common equations specific to the various equipment, thermal energy and power consumption were calculated at variable process conditions: HTC reactor temperature T: 180, 220, 250 °C; reaction time θ: 1, 3, 8 h. When operating the HTC plant with grape marc (65% moisture content) at optimized process conditions (T = 220 °C; θ = 1 h; dry biomass to water ratio = 0.19), thermal energy and power consumption were equal to 1170 kWh and 160 kWh per ton of hydrochar produced, respectively. Correspondingly, plant efficiency was 78%. In addition, the techno-economical aspects of the HTC process were analyzed in detail, considering both investment and production costs. The production cost of pelletized hydrochar and its break-even point were determined to be 157 €/ton and 200 €/ton, respectively. Such values make the use of hydrochar as a CO₂ neutral biofuel attractive.

Hydrothermal carbonization (HTC) is an emerging path to give a new life to organic waste and residual biomass. Fulfilling the principles of the circular economy, through HTC “unpleasant” organics can be transformed into useful materials and possibly energy carriers. The potential applications of HTC are tremendous and the recent literature is full of investigations. In this context, models capable to predict, simulate and optimize the HTC process, reactors, and plants are engineering tools that can significantly shift HTC research towards innovation by boosting the development of novel enterprises based on HTC technology. This review paper addresses such key-issue: where do we stand regarding the development of these tools? The literature presents many and simplified models to describe the reaction kinetics, some dealing with the process simulation, while few focused on the heart of an HTC system, the reactor. Statistical investigations and some life cycle assessment analyses also appear in the current state of the art. This work examines and analyzes these predicting tools, highlighting their potentialities and limits. Overall, the current models suffer from many aspects, from the lack of data to the intrinsic complexity of HTC reactions and HTC systems. Therefore, the emphasis is given to what is still necessary to make the HTC process duly simulated and therefore implementable on an industrial scale with sufficient predictive margins.Graphic