Abstract
The growing demand for sustainable biomass valorisation and low-cost adsorbents has intensified interest in scalable systems for producing activated biochar (ABC) from agricultural residues. While extensive research has demonstrated the high adsorption performance of lignocellulosic waste-derived biochars, their industrial scalability remains insufficiently explored. This study addresses that gap by simulating full-scale production of ABC from apple pruning waste using a one-step thermochemical activation process (1S), integrating carbonization and activation to reduce energy use and operational complexity. The process model was developed in Aspen Plus® V14 and fed with experimentally measured yields, gas compositions, and reactant consumption obtained from previous laboratory work. Experimentally produced 1S-ABC showed a high fixed-carbon content and outstanding adsorption performance, achieving >95% methylene blue (MB) removal within 4 h, supported by its well-developed porosity and enhanced surface chemistry. These results validated the suitability of apple-pruning-derived ABC as a competitive sorbent. Building on this, a techno-economic analysis was conducted to evaluate full-scale feasibility, including capital investment, operating costs, and utilities. The estimated Total Capital Investment was USD 2.23 million, with operating costs dominated by KOH consumption and energy demands. Economic indicators confirmed the profitability of the process, yielding a positive Net Present Value of USD 29,055 over a 20-year lifetime.
