IDEAS home Printed from https://ideas.repec.org/a/eee/energy/v322y2025ics036054422501415x.html

Optimization of bischofite pyrolysis furnace system based on orthogonal experiments and exergy analysis with assessment of its green economy

Author

Listed:
  • Xu, Hanlu
  • Kong, Yating
  • Cheng, Daokuan
  • Zhao, Liang
  • Dong, Hui
  • Zhang, Menghui

Abstract

Spray pyrolysis technology has the potential for valorization of industrial waste bischofite in a sustainable and environmentally friendly manner. This study utilizes Aspen Plus® to simulate and optimize the pyrolysis furnace system for bischofite. Through orthogonal experimental design, key parameters, including the air-fuel ratio, the ratios of primary and secondary air, the solids content of the bischofite precursor, and the temperature of the combustion-supporting air were determined to improve chemical recovery rate, net profit, and energy efficiency, thereby achieving sustainable and clean production. Additionally, the optimized pyrolysis process was compared with the traditional precipitation process in three dimensions: energy consumption, carbon emissions, and economic performance. The results indicate that the optimized operating conditions reduce the total exergy destruction per ton of bischofite from 2211.580 MW (127,190 kWh/t) to 1967.095 MW (113,129 kWh/t) while increasing the system exergy efficiency by 8.15 %. Specifically, the exergy destruction in the subareas of CH4 combustion, pyrolysis, and dehydration combustion is reduced by 66.01 %, 6.13 %, and 8.99 %, respectively. Compared with the current ammonia and lime precipitation methods, this optimized pyrolysis process can reduce CO2 emissions by 6.38 % and 6.28 %, respectively, while the net profit can be improved by 38.39 % and 26.54 %, respectively. The results confirm that the spray pyrolysis process has a broad application prospect in the bischofite valorization and is expected to become the preferred technical scheme in the industry.

Suggested Citation

  • Xu, Hanlu & Kong, Yating & Cheng, Daokuan & Zhao, Liang & Dong, Hui & Zhang, Menghui, 2025. "Optimization of bischofite pyrolysis furnace system based on orthogonal experiments and exergy analysis with assessment of its green economy," Energy, Elsevier, vol. 322(C).
    • Handle: RePEc:eee:energy:v:322:y:2025:i:c:s036054422501415x
    DOI: 10.1016/j.energy.2025.135773
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S036054422501415X
    Download Restriction: Full text for ScienceDirect subscribers only
    File URL: https://libkey.io/10.1016/j.energy.2025.135773?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    As the access to this document is restricted, you may want to

    for a different version of it.

    References listed on IDEAS

    as
    1. Azarpour, Abbas & Mohamadi-Baghmolaei, Mohamad & Hajizadeh, Abdollah & Zendehboudi, Sohrab, 2022. "Systematic energy and exergy assessment of a hydropurification process: Theoretical and practical insights," Energy, Elsevier, vol. 239(PC).
    2. Mohamadi-Baghmolaei, Mohamad & Hajizadeh, Abdollah & Zahedizadeh, Parviz & Azin, Reza & Zendehboudi, Sohrab, 2021. "Evaluation of hybridized performance of amine scrubbing plant based on exergy, energy, environmental, and economic prospects: A gas sweetening plant case study," Energy, Elsevier, vol. 214(C).
    3. Bai, Wengang & Li, Hongzhi & Zhang, Lei & Zhang, Yifan & Yang, Yu & Zhang, Chun & Yao, Mingyu, 2021. "Energy and exergy analyses of an improved recompression supercritical CO2 cycle for coal-fired power plant," Energy, Elsevier, vol. 222(C).
    4. Zhao, Ruixin & Liu, Shanjian & Li, Zhihe & Liu, Yinjiao & Li, Ning & Xu, Pan, 2024. "Exergy, exergoeconomic and carbon emission analysis of a novel biomass pyrolysis system with self-heating and torrefaction," Energy, Elsevier, vol. 313(C).
    5. Arslan, Muhammed & Yılmaz, Ceyhun, 2022. "Thermodynamic Optimization and Thermoeconomic Evaluation of Afyon Biogas Plant assisted by organic Rankine Cycle for waste heat recovery," Energy, Elsevier, vol. 248(C).
    6. Rosha, Pali & Ibrahim, Hussameldin, 2022. "Technical feasibility of biomass and paper-mill sludge co-gasification for renewable fuel production using Aspen Plus," Energy, Elsevier, vol. 258(C).
    7. Utlu, Zafer & Hepbasli, Arif, 2007. "A review and assessment of the energy utilization efficiency in the Turkish industrial sector using energy and exergy analysis method," Renewable and Sustainable Energy Reviews, Elsevier, vol. 11(7), pages 1438-1459, September.
    8. Zhu, Jun & Chen, Wu, 2014. "Energy and exergy performance analysis of a marine rotary desiccant air-conditioning system based on orthogonal experiment," Energy, Elsevier, vol. 77(C), pages 953-962.
    9. Morris, David R. & Szargut, Jan, 1986. "Standard chemical exergy of some elements and compounds on the planet earth," Energy, Elsevier, vol. 11(8), pages 733-755.
    10. Razi, Faran & Dincer, Ibrahim & Gabriel, Kamiel, 2021. "Exergoenvironmental analysis of the integrated copper-chlorine cycle for hydrogen production," Energy, Elsevier, vol. 226(C).
    11. Sevinchan, Eren & Dincer, Ibrahim & Lang, Haoxiang, 2019. "Energy and exergy analyses of a biogas driven multigenerational system," Energy, Elsevier, vol. 166(C), pages 715-723.
    12. Lim, Jonghun & Kim, Junghwan, 2022. "Optimizing ash deposit removal system to maximize biomass recycling as renewable energy for CO2 reduction," Renewable Energy, Elsevier, vol. 190(C), pages 1006-1017.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Zhao, Liang & Wang, Zeye & Dong, Hui & Yu, Zitao, 2025. "Thermodynamic and carbon reduction analysis of a novel magnesite decomposition system with hydrogen," Energy, Elsevier, vol. 339(C).

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Azarpour, Abbas & Mohamadi-Baghmolaei, Mohamad & Hajizadeh, Abdollah & Zendehboudi, Sohrab, 2022. "Systematic energy and exergy assessment of a hydropurification process: Theoretical and practical insights," Energy, Elsevier, vol. 239(PC).
    2. Tera, Ibrahim & Zhang, Shengan & Liu, Guilian, 2024. "A conceptual hydrogen, heat and power polygeneration system based on biomass gasification, SOFC and waste heat recovery units: Energy, exergy, economic and emergy (4E) assessment," Energy, Elsevier, vol. 295(C).
    3. Shabruhi Mishamandani, Arian & Asfand, Faisal & Fadlallah, Sulaiman O., 2025. "Energetic, exergetic, economic and environmental (4E) assessment of power cycles integrated with anaerobic digester," Energy, Elsevier, vol. 340(C).
    4. Chen, Chih-Hao & Hsu, Chien-Yeh & Chen, Chih-Chieh & Chiang, Yuan-Ching & Chen, Sih-Li, 2016. "Silica gel/polymer composite desiccant wheel combined with heat pump for air-conditioning systems," Energy, Elsevier, vol. 94(C), pages 87-99.
    5. Bejan, Adrian, 2018. "Thermodynamics today," Energy, Elsevier, vol. 160(C), pages 1208-1219.
    6. Anvari, Simin & Mahian, Omid & Taghavifar, Hadi & Wongwises, Somchai & Desideri, Umberto, 2020. "4E analysis of a modified multigeneration system designed for power, heating/cooling, and water desalination," Applied Energy, Elsevier, vol. 270(C).
    7. Kim, Dohee & Kim, Taehyun & Kim, Yungeon & Park, Jinwoo, 2025. "Integration of biomass gasification and water electrolysis: Importance of sweep gas selection," Applied Energy, Elsevier, vol. 393(C).
    8. Chen, B. & Chen, G.Q., 2007. "Modified ecological footprint accounting and analysis based on embodied exergy--a case study of the Chinese society 1981-2001," Ecological Economics, Elsevier, vol. 61(2-3), pages 355-376, March.
    9. Raúl Arango-Miranda & Robert Hausler & Rabindranarth Romero-López & Mathias Glaus & Sara Patricia Ibarra-Zavaleta, 2018. "An Overview of Energy and Exergy Analysis to the Industrial Sector, a Contribution to Sustainability," Sustainability, MDPI, vol. 10(1), pages 1-19, January.
    10. Bai, Wengang & Li, Hongzhi & Zhang, Xuwei & Qiao, Yongqiang & Zhang, Chun & Gao, Wei & Yao, Mingyu, 2022. "Thermodynamic analysis of CO2–SF6 mixture working fluid supercritical Brayton cycle used for solar power plants," Energy, Elsevier, vol. 261(PB).
    11. Hao, Xiaoqing & An, Haizhong & Qi, Hai & Gao, Xiangyun, 2016. "Evolution of the exergy flow network embodied in the global fossil energy trade: Based on complex network," Applied Energy, Elsevier, vol. 162(C), pages 1515-1522.
    12. Sun, Xue & Li, Xiaofei & Zeng, Jingxin & Song, Qiang & Yang, Zhen & Duan, Yuanyuan, 2023. "Energy and exergy analysis of a novel solar-hydrogen production system with S–I thermochemical cycle," Energy, Elsevier, vol. 283(C).
    13. Kim, Yungeon & Kim, Taehyun & Lee, Inkyu & Park, Jinwoo, 2025. "Liquid air energy storage system with oxy-fuel combustion for clean energy supply: Comprehensive energy solutions for power, heating, cooling, and carbon capture," Applied Energy, Elsevier, vol. 379(C).
    14. Chen, G.Q. & Qi, Z.H., 2007. "Systems account of societal exergy utilization: China 2003," Ecological Modelling, Elsevier, vol. 208(2), pages 102-118.
    15. Peters, Jens F. & Petrakopoulou, Fontina & Dufour, Javier, 2015. "Exergy analysis of synthetic biofuel production via fast pyrolysis and hydroupgrading," Energy, Elsevier, vol. 79(C), pages 325-336.
    16. Utlu, Zafer, 2015. "Investigation of the potential for heat recovery at low, medium, and high stages in the Turkish industrial sector (TIS): An application," Energy, Elsevier, vol. 81(C), pages 394-405.
    17. Mohammadpour, Mohammadreza & Houshfar, Ehsan & Ashjaee, Mehdi & Mohammadpour, Amirreza, 2021. "Energy and exergy analysis of biogas fired regenerative gas turbine cycle with CO2 recirculation for oxy-fuel combustion power generation," Energy, Elsevier, vol. 220(C).
    18. Sogut, M. Ziya & Seçgin, Ömer & Ozkaynak, Süleyman, 2019. "Investigation of thermodynamics performance of alternative jet fuels based on decreasing threat of paraffinic and sulfur," Energy, Elsevier, vol. 181(C), pages 1114-1120.
    19. Costantini, Michele & Provolo, Giorgio & Bacenetti, Jacopo, 2024. "The effects of incorporating renewable energy into the environmental footprint of beef production," Energy, Elsevier, vol. 289(C).
    20. Ezzat, M.F. & Dincer, I., 2019. "Development and exergetic assessment of a new hybrid vehicle incorporating gas turbine as powering option," Energy, Elsevier, vol. 170(C), pages 112-119.

    More about this item

    Keywords

    ;
    ;
    ;
    ;
    ;
    ;

    Statistics

    Access and download statistics

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:eee:energy:v:322:y:2025:i:c:s036054422501415x. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Catherine Liu (email available below). General contact details of provider: http://www.journals.elsevier.com/energy .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.