Energy Recovery and Techno-Economic Analysis of Hydrothermal Carbonization and Anaerobic Digestion of Food Waste

The sustainable valorization of food waste is essential for advancing the circular bioeconomy and reducing the environmental impacts of organic waste disposal. This study presents an integrated approach combining hydrothermal carbonization (HTC) and anaerobic digestion (AD) to recover renewable energy and valuable resources from food waste. The process was simulated in Aspen Plus® version 14.1 using thermochemical and biochemical reaction models to evaluate the effects of feed moisture (60–85%) and HTC temperature (180–280 °C) on performance. Integration of HTC and AD increased overall energy recovery by 26–38% compared to standalone AD, with a feed moisture of 85%, organic loading of 4 kg VS m−3 d−1, and mesophilic/thermophilic temperatures of 35 and 55 °C. Improvements resulted from higher methane yield (0.42 m3 CH4 kg−1 VS) from HTC liquor and energy-rich hydrochar (25–29 MJ kg−1). The techno-economic assessment indicated a net energy ratio of 2.3, an Internal Rate of Return (IRR) of 18.6%, and a 4.8-year payback period, confirming economic viability. Sensitivity analysis highlighted energy prices and feedstock costs as key drivers, while Monte Carlo simulation demonstrated stability under ±20% uncertainty. Optimal conditions (HTC at 220 °C, 65% moisture, and 100 kg h−1 solid loading) significantly enhanced profitability and carbon efficiency. Overall, the integrated HTC–AD process offers a technically, economically, and environmentally sustainable route for converting food waste into renewable energy and biochar, supporting circular bioeconomy and net-zero energy goals.