Co-Hydrothermal Carbonization (Co-HTC) is a thermochemical process, where coal and biomass were treated simultaneously in subcritical water, resulting in bulk-homogenous hydrochar that is carbon-rich and a hydrophobic solid fuel with combustion characteristics like coal. In this study, technoeconomic analysis of Co-HTC was performed for a scaled-up Co-HTC plant that produces fuel for 110 MWe coal-fired power plant using Clarion coal #4a and miscanthus as starting feedstocks. With precise mass and energy balance of the Co-HTC process, sizing of individual equipment was conducted based on various systems equations. Cost of electricity was calculated from estimated capital, manufacturing, and operating and maintenance costs. The breakeven selling price of Co-HTC hydrochar was $117 per ton for a 110 MWe. Sensitivity analysis indicates that this breakeven selling price could be as low as $106 per ton for a higher capacity plant. Besides plant size, the price of solid fuel is sensitive to the feedstock costs and hydrochar yield.

Each year the pulp and paper industries generate enormous amounts of effluent treatment sludge. The sludge is made up of various fractions including primary, secondary, deinked, fiber rejects sludge, etc. The goal of this study was to evaluate the fuel properties of the hydrochars produced from various types of paper mill sludges (PMS) at 180 °C, 220 °C, and 260 °C. The hydrochars, as well as the raw feedstocks, were characterized by means of ultimate analysis, proximate analysis, moisture, ash, lignin, sugar, and higher heating value (HHV_daf) measurements. Finally, combustion indices of selected hydrochars were evaluated and compared with bituminous coal. The results showed that HHV_daf of hydrochar produced at 260 °C varied between 11.4 MJ/kg and 31.5 MJ/kg depending on the feedstock. This implies that the fuel application of hydrochar produced from PMS depends on the quality of feedstocks rather than the hydrothermal carbonization (HTC) temperature. The combustion indices also showed that when hydrochars are co-combusted with coal, they have similar combustion indices to that of coal alone. However, based on the energy and ash contents in the produced hydrochars, Primary and Secondary Sludge (PPS₂) could be a viable option for co-combustion with coal in an existing coal-fired power plant.