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

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 CO ₂ capture through to bioethanol production. The platform supports the evaluation of CO ₂ mitigation technology by coupling mathematical bioprocess models with an interactive desktop application. The biological system employs Chlorella vulgaris microalgae to fix CO ₂ 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 CO ₂ 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 CO ₂ -to-ethanol conversion efficiency, confirming the platform’s 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.