A new strategy to produce calcium carbide-acetylene from integrated multi-level low carbon construction driven by biomass11The short version of the paper was presented at ICAE2023, Doha, Qatar, Dec 3–5, 2023. This paper is a substantial extension of the short version of the conference paper

A highly efficient and clean biomass energy-based calcium carbide-acetylene production system, including low-carbon energy supply, solid waste recycling and cascade utilization of waste heat, has been developed for the conventional energy-intensive and highly polluting fossil fuel-dependent calcium carbide industry. This system supplies the carbide-acetylene production plant with energy from the gasification of biomass and converts the plant's solid waste carbide slag into the calcium feedstock required by the plant. The waste heat from the plant's high-temperature exhaust gases is recycled and used via the multi-stage heat exchange, so that the energy cascade conversion and utilization is achieved. A simulation model of the plant is created in Aspen Plus, and a mathematical model for the biomass gasification process and cycle compensation of the calcium source through the Fortran language is written and embedded. When calculating the carbon consumption and CO2e emissions of the system, it was found that the carbon consumption and CO2e emissions of the conventional process were 5.43 t Coal·t−1C2H2 and 2.25 t CO2e·t−1C2H2, respectively. However, the carbon consumption of the new process was reduced by 65.19%, and carbon emissions by 27.24% in comparison. The energy analysis shows that the energy efficiency of the system is 36.21% for the conventional process and 44.82% for the new processes. The exergy analysis of the effective energy shows that the exergy efficiency of the new process is 73.20%, which is 52.98% better than that of the conventional process. Introduction of an index, the levelized income of acetylene product (LIOA), to characterize the product income of the system. When the price of acetylene is between 2.23 $/kg and 4.19 $/kg, the LIOA for the conventional and the new processes are 1.41 $/kg to 3.38 $/kg and − 1.28 $/kg to 0.68 $/kg, respectively. It is worth noting that the critical price (PCC2H2) for products generating net revenue from the new process is 3.17 $/kg. This study is of great importance for the development of a low-carbon biomass-coupled calcium carbide-acetylene process.