This study focuses on the modeling, simulation, and optimization of an integrated biomass gasification and methanation process to produce bio-synthetic natural gas (Bio-SNG) as part of the AIRE project. The process was simulated using Aspen Plus^® software (V14), incorporating experimental results from pilot-scale gasification setups. Key steps involved syngas production in a dual fluidized bed gasifier and its subsequent conversion to Bio-SNG in a methanation section. Heat integration strategies were implemented to enhance system results demonstrate that optimized heat recovery, achieved by utilizing exothermic methanation reactions to preheat gasification inputs, eliminates the need for auxiliary fuel in the gasification process. The optimized system achieved a thermal recovery rate of 80%, a cold gas efficiency of 79%, a Bio-SNG production rate of 0.4 Nm³/kg_Biom, and a methane content of 85 vol.%. These optimizations reduced CO₂ emissions by 10% while increasing overall energy efficiency. This work highlights the potential of integrating biomass gasification and methanation processes with heat recovery for sustainable methane production. The findings provide a basis for scaling up the process and further exploring syngas utilization pathways to produce renewable energy carriers.

This study presents a fully integrated process for the flexible conversion of biogenic waste into synthetic natural gas (bio-SNG) and electricity centred on a 100 kWth dual concentric bubbling fluidised bed steam gasifier. The raw syngas is processed in a high-temperature gas cleaning section, and the resulting clean, H₂-rich syngas is directed to three alternative downstream configurations: (i) conventional methanation, (ii) enhanced methanation with external H₂ supplied by a reversible solid oxide cell (rSOC), and (iii) electricity generation via the same rSOC operating in fuel cell mode. The overall process is modelled in Aspen Plus, in which the gasification section is constrained by experimentally derived syngas data, while downstream units are described through thermodynamic and kinetics-based models. Methanation is simulated using a plug-flow reactor model based on validated kinetic expressions, while the rSOC operating in electrolysis and fuel cell mode is modelled using performance parameters of commercial stacks. A plant-wide heat integration strategy based on composite curve analysis is implemented to maximise internal heat recovery and minimise external utilities. The enhanced methanation configuration enables the production of bio-SNG with high methane content (up to 93.3 vol.% dry, N₂-free), with a yield 0.72 kg/kg_Biomass and a fuel efficiency of 70.1%. In electricity production mode, the system reaches an electrical efficiency of 43.1% with complete elimination of auxiliary fuel through thermal integration. These results demonstrate the capability of a single integrated plant to flexibly switch between fuel synthesis and power generation, enhancing adaptability to fluctuating electricity and methane market conditions while maintaining high efficiency.

This work presents a techno-economic assessment of hydrogen production via sorption-enhanced gasification (SEG) of hazelnut shells across three plant scales (100 kWth, 1 MWth, and 10 MWth). The overall model is developed through the integration of Aspen Plus^® process simulation, coupled with MATLAB^®-based kinetic reactor modelling, enabling the assessment of the entire process chain. The kinetic SEG model, validated against experimental literature data, was implemented to describe the fluidized bed gasifier behaviour at the three scales. The resulting process streams were subsequently integrated into Aspen Plus^® for downstream upgrading and overall system analysis. The simulations show that the SEG process produces a hydrogen-rich syngas with H₂ contents around 80 vol.%_dry-basis, which is further upgraded to a hydrogen purity of 99.95% with a recovery of 90% via pressure swing adsorption. The process exhibits stable performance across scales, with Cold Gas Efficiency values around 60% and hydrogen yields close to 1 Nm³/kg_Biomass. The economic analysis highlights a decrease in the Levelized Cost of Hydrogen (LCOH) from 41.3 €/kg at 100 kWth to 6.8 €/kg at 10 MWth. These results indicate that SEG represents a promising pathway for low-carbon hydrogen production, while enabling the valorisation of biogenic residues within a sustainable energy framework.