Conversion of Spirulina platensis into methanol via gasification: Process simulation modeling and economic evaluation

• Spirulina platensis can be converted into methanol, offering a sustainable alternative. • Aspen Plus v10® used for the development of integrated steam gasification and methanol model • Increasing temperature (650-950°C) boosts H 2 and CO, increasing methanol yield from 6500 to 9500 kg/h. • Economic analysis shows the optimum case has higher methanol output 7.2 vs. 6.7 tonnes/h). • The optimum scenario generates more income ($9.76M/y) and reduces CO 2 emissions (4.918 vs. 5.72 tonnes CO2-e/y). The conversion of bioresources like Spirulina platensis (SP) into value-added chemicals, such as methanol, offers a sustainable replacement of fossil fuels and contributes to greenhouse gas mitigation. This study presents an integrated process simulation model, developed using Aspen Plus v10®, for the steam gasification of SP and subsequent methanol production. Process parameters, including temperature range from 650-950°C, steam/feed ratio from 0.5-2, and recycle ratio from 0-9, were investigated to optimize syngas composition and methanol yield. Results demonstrated that increasing temperature enhances H 2 and CO production while reducing CO 2 and CH 4 , significantly increasing methanol production from 6500 to 9500 kg/h. The steam/feed ratio also influences syngas composition and methanol yield, with higher ratios promoting H 2 and CO 2 production and reducing CO and CH 4 . The economic evaluation of two scenarios, a base case and an optimum case, shows that the capital expenditure (Capex) and operating expenditure (Opex) are 19.3M$ and 9.07M$ for the base case, and 20.018M$ and 10.21M$ for the optimum case. The analysis also reveals that the optimum case, with higher methanol production (7.2 tonnes/h compared to 6.7 tonnes/h in the base case), generates a higher net income (9.76 M$/y) and reduces CO 2 emissions (4.918 tonnes CO 2 -e/y compared to 5.72 tonnes CO 2 -e/y). The energy flow indicates the input energy requirement, the energy carried by methanol, and the surplus energy, totalling 26740 kW to meet the major system's energy demands. This study provides valuable insights for researchers, policymakers, and commercial entities seeking to develop sustainable and economically viable biofuel production processes.