Carbon Capture Modeling and Simulation Platform: A Coupled Microalgal Bioreactor-Yeast Fermentation Approach for Bioethanol

Abstract

This article presents the development of an advanced modeling and simulation platform for carbon capture systems, with a focus on integrated process analysis from upstream CO2 capture through to bioethanol production. The platform supports the evaluation of CO2 mitigation technology by coupling mathematical bioprocess models with an interactive desktop application. The biological system employs Chlorella vulgaris microalgae to fix CO2 through photosynthesis and generate carbohydrate substrates, which are subsequently converted to bioethanol by Saccharomyces cerevisiae yeast via fermentation. The simulation integrates three established kinetic models--the Monod, Logistic, and Luedeking-Piret models--to predict biomass growth, substrate consumption, and ethanol yield under varying operational conditions. A closed-loop CO2 recycling subsystem captures fermentation off-gases and reintroduces them into the bioreactor, enhancing overall carbon utilization efficiency. Three representative simulation scenarios demonstrated process efficiencies ranging from 1.09% to 93.78% of the theoretical maximum CO2-to-ethanol conversion efficiency, confirming the platforms capacity to evaluate a wide operational envelope. The Electron/React-based desktop application provides real-time visualization, interactive 3D bioreactor models, and a simulation history module, making it accessible to researchers, engineers, and students. The platform serves as a digital twin that bridges rigorous bioprocess mathematics with intuitive user interaction, providing a cost-effective tool for designing and optimizing sustainable carbon capture and biofuel production systems.