Design of value chains for microalgal biorefinery at industrial scale : process integration and techno-economic analysis

The objective of this work was to identify industrial scenarios for the most promising microalgal biorefinery value chains on the basis of product selection, yields, and techno-economic performance, using biological characteristics of algae species. The development, value creation, and validation of several new processing routes with applications in food, aquafeeds and non-food products were particularly considered in this work. The techno-economic performance of various single product value chains (SP) and multiproduct value chains (MP) was evaluated for four industrial microalgal strains. Cost-revenue optimization was done for a 10 kton microalgal dry weight y–1 simulated biorefinery plant, using flow sheeting software for equipment sizing, mass and energy flow modeling, and subsequent techno-economic evaluation. Data on yield, material and energy consumption were based on pre- and pilot size production plants (TRL 5–6). Revenue optimization was accomplished by first analyzing the performance of single product value chains of the microalgal strains. Subsequently, a strategy was developed to exploit almost all biomass based on the most promising microalgal strains. The cultivation costs are most of the time the major costs of the value chains. For the single product value chains common process bottlenecks are low product yields, especially for soluble proteins where only a small fraction of the biomass is leading to economic value. The biorefinery costs (excluding cultivation) vary significantly for various species, due to the species-specific operating conditions as well as differences in product yields. For the evaluated single product value chain scenarios the costs for utilities and other inputs were in general the highest contributing expenses. A biorefinery approach significantly increases the biomass utilization potential to marketable products from 7–28% to more than 97%. Although the cascading approach increases the total production costs of the multiproduct value chains significantly, this is more than compensated by the increased overall biomass revenue. For all selected multiproduct chains there is a significant potential to become profitable at a relevant industrial scale of 10 kton per year. Additional insights in the product functionality, quality, and their market size are needed to narrow down the wide range of foreseen product revenues and resulting profits.publishedVersio

Design of value chains for microalgal biorefinery at industrial scale : process integration and techno-economic analysis

The objective of this work was to identify industrial scenarios for the most promising microalgal biorefinery value chains on the basis of product selection, yields, and techno-economic performance, using biological characteristics of algae species. The development, value creation, and validation of several new processing routes with applications in food, aquafeeds and non-food products were particularly considered in this work. The techno-economic performance of various single product value chains (SP) and multiproduct value chains (MP) was evaluated for four industrial microalgal strains. Cost-revenue optimization was done for a 10 kton microalgal dry weight y–1 simulated biorefinery plant, using flow sheeting software for equipment sizing, mass and energy flow modeling, and subsequent techno-economic evaluation. Data on yield, material and energy consumption were based on pre- and pilot size production plants (TRL 5–6). Revenue optimization was accomplished by first analyzing the performance of single product value chains of the microalgal strains. Subsequently, a strategy was developed to exploit almost all biomass based on the most promising microalgal strains. The cultivation costs are most of the time the major costs of the value chains. For the single product value chains common process bottlenecks are low product yields, especially for soluble proteins where only a small fraction of the biomass is leading to economic value. The biorefinery costs (excluding cultivation) vary significantly for various species, due to the species-specific operating conditions as well as differences in product yields. For the evaluated single product value chain scenarios the costs for utilities and other inputs were in general the highest contributing expenses. A biorefinery approach significantly increases the biomass utilization potential to marketable products from 7–28% to more than 97%. Although the cascading approach increases the total production costs of the multiproduct value chains significantly, this is more than compensated by the increased overall biomass revenue. For all selected multiproduct chains there is a significant potential to become profitable at a relevant industrial scale of 10 kton per year. Additional insights in the product functionality, quality, and their market size are needed to narrow down the wide range of foreseen product revenues and resulting profits

Bioenergy II: Biomass Valorisation by a Hybrid Thermochemical Fractionation Approach

The need for green renewable sources is adamant because of the adverse effects of the increasing use of fossil fuels on our society. Biomass has been considered as a very attractive candidate for green energy carriers, chemicals and materials. The development of cheap and efficient fractionation technology to separate biomass into its main constituents is highly desirable. It enables treatment of each constituent separately, using dedicated conversion technologies to get specific target chemicals. The synergistic combination of aquathermolysis (hot pressurised water treatment) and pyrolysis (thermal degradation in the absence of oxygen) is a promising thermolysis option, integrating fractionation of biomass with production of valuable chemicals. Batch aquathermolysis in an autoclave and subsequent pyrolysis using bubbling fluidised bed reactor technology with beech, poplar, spruce and straw indicate the potential of this hybrid concept to valorise lignocellulosic biomass. Hemicellulose-derived furfural was obtained in yields that ranged from 2 wt% for spruce to 8 wt% for straw. Hydroxymethylfurfural from hemicellulose was obtained in yields from 0.3 wt% for poplar to 3 wt% for spruce. Pyrolysis of the aquathermolised biomass types resulted in 8 wt% (straw) to 11 wt% (spruce) of cellulose-derived levoglucosan. Next to the furfurals and levoglucosan, appreciable amounts of acetic acid were obtained as well from the aquathermolysis step, ranging from 1 wt% for spruce to 5 wt% for straw. To elucidate relations between the chemical changes occurring in the biomass during the integrated process and type and amount of the chemical products formed, a 13C-solid state NMR study has been conducted. Main conclusions are that aquathermolysis results in hemicellulose degradation to lower molecular weight components. Lignin ether bonds are broken, but apart from that, lignin is hardly affected by the aquathermolysis. Cellulose is also retained, although it seems to become more crystalline, probably due to a higher ordering of amorphous cellulose when the samples are cooled down after aquathermolysis. These NMR results are in agreement with thermogravimetric analyses results.