Integration of energy-efficient empty fruit bunch drying with gasification/combined cycle systems

•Novel integrated drying, gasification and combined cycle for empty fruit bunch.•Application of enhanced process integration to achieve high total energy efficiency.•The technology covers exergy recovery and process integration.•High overall energy efficiency can be achieved (about 44% including drying). A high-energy-efficient process for empty fruit bunch drying with integration to gasification and combined cycle processes is proposed. The enhancement is due to greater exergy recovery and more efficient process integration. Basically, the energy/heat involved in a single process is recovered as much as possible, leading to minimization of exergy destruction. In addition, the unrecoverable energy/heat is utilized for other processes through process integration. During drying, a fluidized bed dryer with superheated steam is used as the main evaporator. Exergy recovery is performed through exergy elevation via compression and effective heat coupling in a dryer and heat exchangers. The dried empty fruit bunches are gasified in a fluidized bed gasifier using air as the fluidizing gas. Furthermore, the produced syngas is utilized as fuel in the combined cycle module. From process analysis, the proposed integrated processes can achieve a relatively high energy efficiency. Compared to a standalone drying process employing exergy recovery, the proposed integrated drying can reduce consumed energy by about 1/3. In addition, the overall integrated processes can reach a total power generation efficiency of about 44%.