Presentation Information
[P02-289]Process design and Techno-Economic Assessment (TEA) of biochar production from yellow mealworm frass
○Qing zhang Cai1, Yu Shen Cheng1 (1. National Yunlin University of Science and Technology (Taiwan))
Keywords:
Pyrolysis,Mealworm frass,Biochar production,Resource recovery,Process simulation
This study aims to evaluate the pyrolysis of mealworm frass for biochar production and resource recovery, combined with process simulation using SuperPro Designer. With increasing interest in sustainable waste management and circular economy, insect frass has gained attention as a promising biomass resource due to its rich carbon content and inherent nutrient value. However, direct application of raw frass may lead to potential environmental concerns, highlighting the need for controlled conversion and resource recovery strategies.
In this study, a simple leaching step was applied as a pretreatment to reduce soluble inorganic components. The main focus was placed on pyrolysis, which was conducted at 400–450 °C with residence times of 4, 6, and 8 hours to investigate product distribution and material properties. The results showed that biochar yield decreased from approximately 22% to 19% with increasing pyrolysis time, while bio-oil yield reached its maximum at 6 hours and then decreased due to secondary cracking reactions at longer residence times.
Surface characterization revealed that the highest BET surface area (about 90 m²/g) was obtained at 4 hours, indicating a more developed pore structure. In contrast, extended pyrolysis time (6–8 hours) led to structural changes and did not further improve surface area performance. Elemental analysis further indicated continuous changes in material composition during thermal conversion.
Based on both yield and surface characteristics, 4 hours was identified as the optimal pyrolysis condition. In addition, process simulation using SuperPro Designer has been completed to evaluate mass balance, energy consumption, and economic feasibility. The simulation results demonstrated the technical feasibility and scalability of the process.
Overall, this study highlights the potential of mealworm frass as a feedstock for biochar production and demonstrates that the integrated system can support both material conversion and resource recovery, contributing to sustainable waste utilization and circular economy development.
In this study, a simple leaching step was applied as a pretreatment to reduce soluble inorganic components. The main focus was placed on pyrolysis, which was conducted at 400–450 °C with residence times of 4, 6, and 8 hours to investigate product distribution and material properties. The results showed that biochar yield decreased from approximately 22% to 19% with increasing pyrolysis time, while bio-oil yield reached its maximum at 6 hours and then decreased due to secondary cracking reactions at longer residence times.
Surface characterization revealed that the highest BET surface area (about 90 m²/g) was obtained at 4 hours, indicating a more developed pore structure. In contrast, extended pyrolysis time (6–8 hours) led to structural changes and did not further improve surface area performance. Elemental analysis further indicated continuous changes in material composition during thermal conversion.
Based on both yield and surface characteristics, 4 hours was identified as the optimal pyrolysis condition. In addition, process simulation using SuperPro Designer has been completed to evaluate mass balance, energy consumption, and economic feasibility. The simulation results demonstrated the technical feasibility and scalability of the process.
Overall, this study highlights the potential of mealworm frass as a feedstock for biochar production and demonstrates that the integrated system can support both material conversion and resource recovery, contributing to sustainable waste utilization and circular economy development.
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