Techno-economic analysis of small-scale ammonia production via sorption-enhanced gasification of biomass

Biomass gasification is a green and efficient pathway for lowering the carbon footprint of ammonia production. Decentralized, small-scale biomass gasification plants (<150 t NH3/day output) are more practical than large plants due to sustainable large-scale biomass supply constraints. Small-scale biomass gasification for ammonia production faces the challenges of high energy consumption and production costs. Process intensification through sorption-enhanced gasification (SEG) integrates steam gasification and in-situ CO2 separation using regenerable CaO sorbents, directly producing hydrogen-rich syngas (∼70 vol%), which streamlines syngas conditioning and increases cost-effectiveness. Two SEG process configurations for small-scale biomass-to-ammonia (∼45000 t of agricultural residues/year) were proposed: SEG process A, which produced low-carbon ammonia without air separation, and SEG process B, which employed an air separation unit to deliver carbon-negative ammonia by capturing CO2. The two processes were compared against a dual fluidized bed gasification (DFBG) process, which generated green ammonia without an air separation, like SEG process A. Of the three cases, SEG process B showed the lowest biomass (2.14 t biomass/t NH3) and water consumption (0.47 t H2O/t NH3) and avoided 2.8 t CO2/t NH3, making it carbon-negative. While the DFBG process and SEG process A had higher energy efficiencies, SEG process B posted the lowest net energy consumption (36.6 GJ/t NH3). Furthermore, SEG process B had the lowest ammonia production cost ($692/t NH3) and payback time (9.4 years), making it the most economically viable. Sensitivity analysis showed that favorable carbon credit policies could boost the economics of SEG process B to match large-scale plants.