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<p>Molasses-based bioethanol plants face challenges in meeting zero liquid discharge (ZLD) norms and delivering favorable returns. This study performed a gate-to-gate life cycle assessment (LCA) using the IMPACT World+midpoint method and ReCipe 2016 endpoint method, coupled with discounted cash flow economics. It quantifies environmental and economic performance for a 105&#xa0;kl per day (KLPD) bioethanol plant, serving as a conventional baseline and in combination with wastewater treatment schemes, resolving the resulting trade-offs through multicriteria analysis. The six wastewater treatment schemes include Bio-methanation, Bio-methanation coupled with Reverse osmosis (RO), Multiple effect evaporation (MEE), RO followed by MEE, MEE with incineration, and Composting. The baseline scheme exhibited a climate change impact of 8.86E+04&#xa0;kg CO₂-eq/day. Bio-methanation with RO halved this burden to 4.43E+04&#xa0;kg CO<sub>2</sub>-eq/day, whereas incineration recovered energy equivalent to 3 tons of steam per m<sup>3</sup> of concentrate. Financially, MEE with incineration achieved the highest return (IRR 20.8%, static payback 3.6&#xa0;years), while Bio-methanation alone remained modest at 15.7% IRR. With carbon credit revenues of $2.35/tCO<sub>2</sub>-eq, IRR increased by 4 to 6% points, and payback periods shortened by up to two years in these schemes. In multi-criteria decision analysis (MCDA), Bio-methanation with RO and MEE+incineration are the most balanced options, offering optimal environmental and economic benefits. These findings demonstrate that decision frameworks integrating LCA, economics and MCDA offer robust guidance for sustainably scaling ZLD options in the bioethanol sector. These options become more favorable by incorporating carbon credits.</p>

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Integrating zero liquid discharge options in molasses-based bioethanol plant: comparative life cycle and economic analysis

  • 期刊论文

  • 发表日期：

    2026年7月4日

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  • Anita Kokate,
  • Surendra Singh Kachhwaha,
  • Pravin Kodgire,
  • Jeffrey S. Cross

摘要

Molasses-based bioethanol plants face challenges in meeting zero liquid discharge (ZLD) norms and delivering favorable returns. This study performed a gate-to-gate life cycle assessment (LCA) using the IMPACT World+midpoint method and ReCipe 2016 endpoint method, coupled with discounted cash flow economics. It quantifies environmental and economic performance for a 105 kl per day (KLPD) bioethanol plant, serving as a conventional baseline and in combination with wastewater treatment schemes, resolving the resulting trade-offs through multicriteria analysis. The six wastewater treatment schemes include Bio-methanation, Bio-methanation coupled with Reverse osmosis (RO), Multiple effect evaporation (MEE), RO followed by MEE, MEE with incineration, and Composting. The baseline scheme exhibited a climate change impact of 8.86E+04 kg CO₂-eq/day. Bio-methanation with RO halved this burden to 4.43E+04 kg CO2-eq/day, whereas incineration recovered energy equivalent to 3 tons of steam per m3 of concentrate. Financially, MEE with incineration achieved the highest return (IRR 20.8%, static payback 3.6 years), while Bio-methanation alone remained modest at 15.7% IRR. With carbon credit revenues of $2.35/tCO2-eq, IRR increased by 4 to 6% points, and payback periods shortened by up to two years in these schemes. In multi-criteria decision analysis (MCDA), Bio-methanation with RO and MEE+incineration are the most balanced options, offering optimal environmental and economic benefits. These findings demonstrate that decision frameworks integrating LCA, economics and MCDA offer robust guidance for sustainably scaling ZLD options in the bioethanol sector. These options become more favorable by incorporating carbon credits.