Search Results (19)

A comprehensive techno-economic assessment was undertaken to determine the viability of bioethanol production from sugarcane bagasse in Thailand through organosolv fractionation, incorporating three distinct catalytic systems: sulfuric acid, formic acid, and sodium methoxide. Rigorous process simulations were executed using Aspen Plus, facilitating the derivation of detailed mass and energy balances, which served as the foundational input for downstream cost modeling. Economic performance metrics, including the total annualized cost and minimum ethanol selling price, were systematically quantified for each scenario. Among the evaluated configurations, the formic acid-catalyzed organosolv system exhibited superior techno-economic attributes, achieving the lowest unit production costs of 1.14 USD/L for ethanol and 1.84 USD/kg for lignin, corresponding to an estimated ethanol selling price of approximately 1.14 USD/L. This favorable outcome was attained with only moderate capital intensity, indicating a well-balanced trade-off between operational efficiency and investment burden. Conversely, the sodium methoxide-based process configuration imposed the highest economic burden, with a TAC of 15.27 million USD/year, culminating in a markedly elevated MESP of 5.49 USD/kg (approximately 4.33 USD/L). The sulfuric acid-driven system demonstrated effective delignification performance. Sensitivity analysis revealed that reagent procurement costs exert the greatest impact on TAC variation, highlighting chemical expenditure as the key economic driver. These findings emphasize the critical role of solvent choice, catalytic performance, and process integration in improving the cost-efficiency of lignocellulosic ethanol production. Among the examined options, the formic acid-based organosolv process stands out as the most economically viable for large-scale implementation within Thailand’s bioeconomy. Full article

One of the key guidelines in the European waste management policy is the diversion of waste from landfills, preventing harmful effects on human health and the environment and ensuring that economically valuable waste materials are efficiently recycled and reused through proper management. The organic fraction of municipal waste is abundant and contains biodegradable ingredients such lignocellulose, starch, lipids, pectin, and proteins, making it suitable for biotechnological production. Taking into account that a large amount of organic waste is disposed of in landfills, within this work, the amount of organic waste disposed of in the landfill in Banja Luka was considered. Four simulation model scenarios of the integrated production of bioethanol and biogas are generated, and their process and economic aspects are discussed. In the first two modelled scenarios, the pretreatment conditions (1% sulfuric acid and a different neutralization agent) were varied, while in the other two, the share of the amount of raw material used for the production of bioethanol, i.e., biogas, was varied (split factor: 10–90%). The modelled plant, with a designed capacity of 6 tons/h of organic waste, is a significant bioethanol producer, generating 5,000,000 L/year. The profitability indicators, when examined, revealed that dedicating a portion of the organic municipal waste input exclusively to biogas production leads to decreased process efficiency. Based on the modeled process parameters, ethanol’s minimum feasible selling price is $0.6616 per liter, while regarding the composition of organic municipal waste, carbohydrates have the most significant impact on the viability of the process. The developed model represents an excellent basis for further development of this integrated bioprocess in such a way that it can be modified with new process parameters or economic or ecological indicators and used at all levels of bioprocess design. Additionally, the obtained sustainable integrated bioethanol and biogas production plant models could support forthcoming steps in municipal waste management by providing reliable data on the conditions under which the integrated process of bioethanol and biogas production would take place, as well as the technical feasibility and economic profitability of such organic municipal waste utilization. Full article

The development of sustainable biofuels can help to reduce the reliance on fossil fuels and mitigate the impact of climate change. This study analyzes bioethanol production from agro-forestry residual biomass, namely eucalyptus residues and corn stover. The study includes process simulation using Aspen Plus software, followed by economic analysis and life cycle assessment (LCA) with the help of SimaPro software and by applying the environmental footprint (EF) 3.0 method. The economic analysis on the biorefinery’s economic viability, equipment, and production costs reveals a positive decision for bioethanol production from eucalyptus residues due to logistical and transportation costs. The minimum ethanol selling price (MESP) obtained was 2.19 €/L and 2.45 €/L for eucalyptus residues and corn stover, respectively. From the LCA with a functional unit of 1 MJ of ethanol, bioethanol production from eucalyptus residues results in a single score impact of 37.86 µPt, whereas for corn stover, it is 33.47 µPt. In the climate change impact category, the eucalyptus residues scenario has an impact of 0.264 kg CO₂ eq/MJ ethanol while corn stover leads to 0.254 kg CO₂ eq/MJ ethanol. In-situ enzyme production, heat integration, and the use of renewable energy sources were also analyzed. Combining in situ enzyme production with renewable energy sources lowers CO₂ equivalent emissions by 89% for both feedstocks, in comparison to the base-case scenario. Full article

Decarbonization of the aviation sector relies on deployment of sustainable aviation fuels (SAF) at commercial scale. Hydrothermal liquefaction (HTL) has been recognized as a promising technology to help supply the increasing projected SAF demand. High availability of agro-industrial residues, combined with a well-established biorefinery system, makes the sugarcane industry in Brazil a good option for HTL technology deployment. Moreover, challenges regarding the economic feasibility of SAF from HTL could be partially addressed by the RenovaBio policy, a market-driven incentive mechanism of carbon credits implemented in Brazil. This study investigated both the techno-economic and life cycle assessment of SAF production from sugarcane lignocellulosic residues, considering HTL integrated to a first-generation ethanol distillery and a HTL stand-alone facility. The evaluated scenarios showed great climate mitigation potential, reaching a reduction of up to 73–82% when compared to fossil jet fuel. The minimum fuel selling price of SAF at 15.4 USD/GJ indicated potential of economic competitiveness with fossil jet fuel in the best integrated scenario. The economic benefits obtained from carbon credits are not enough to enable feasibility of HTL in the stand-alone scenarios, even with carbon prices projected at 125 USD/tonne CO₂-eq avoided. Full article

Methanol is considered to be a viable option for reducing greenhouse gas (GHG) emissions in shipping, the second-highest emitter after road freight. However, the use of fossil methanol is insufficient to meet climate change targets, while renewable methanol is yet unavailable on a commercial scale. This paper presents a novel biorefinery concept based on biomass solvolysis to produce crude lignin oil (CLO) from forest residues, a drop-in biofuel for methanol-propelled ships, and evaluates its environmental and economic profiles. In the base scenario, CLO can achieve emission saving of 84% GHG compared to fossil alternatives, and a minimum selling price (MSP) of $821 per ton of methanol equivalent (ME), i.e., within the range of the current bio-methanol production costs. The emission of GHGs of co-produced ethanol can be reduced by 67% compared to fossil analogues. The increase of renewable electricity share to 75% is capable of shrinking emissions by 1/5 vs. the base case, while fossil methanol losses, e.g., of that in cellulose pulp, can boost emissions by 63%. Low-pressure steam use in the biomass pretreatment, as well as biorefinery capacity increase by a factor of 2.5, have the greatest potential to reduce MSP of CLO to $530 and $614 per ton of ME, respectively. Full article

There is global pressure to make advanced biofuels profitable. For cellulosic ethanol, three aspects remain as bottlenecks: collection of feedstocks, pretreatment methods, and enzyme production. In this paper, the first aspect is investigated, by addressing the main challenges for the logistics of agricultural residues. A logistic supply chain of corn stover collection and utilization for cellulosic ethanol production in Mexico is proposed, and a cost structure is designed for its estimation. By applying a value chain methodology, seven links and a set of three minimum selling prices (MSPs) of agricultural residues were determined. Furthermore, the harvest index (HI), crop residue index (CRI), nutrient substitution by extraction of agricultural residues, and harvest costs of corn stover were also calculated for a case study. The main results were a HI of 0.45, a CRI of 1.21, and nutrient substitution potential of 7 kg N, 2.2 kg P₂O₅, and 12.2 kg K₂O per ton of corn stover. The set of the three estimated MSPs for corn stover was: $28.49 USD/ton (for delivery to the biorefinery’s gate), $31.15 USD/ton (for delivery and storage), and $48.14 USD/ton (for delivery, storage, and nutrient replenishment). Given the impact of the feedstock cost on the profitability of cellulosic ethanol, knowing details of the logistical information and its costs is critical to advancing the field of biofuels in Mexico. We also found that only 20% of farmers currently sell their residues; however, 65% of farmers would be willing to do so, a significant percentage for cellulosic ethanol production. Full article

Co-production is a process based on the biorefinery concept that maximizes the benefit of biomass by reusing residue from the production of one product to produce others. In this regard, biogas is one of the most researched second products for the production of ethanol from cellulosic biomass. However, operating this scheme requires additional investment in biogas processing equipment. This review compiles data from research studies on the co-production of bioethanol and biogas from lignocellulosic biomass to determine which is more worthwhile: leaving the residue or investing more to benefit from the second product. According to previous research, ethanol stillage can be converted to biogas via anaerobic digestion, increasing energy output by 2–3 fold. Techno-economic studies demonstrated that the co-production process reduces the minimum ethanol selling price to a level close to the market price of ethanol, implying the possibility of industrializing cellulosic ethanol production through this scheme. Full article

This work presents a strategy for optimizing the production process of ethanol via integrated gasification and syngas fermentation, a conversion platform of growing interest for its contribution to carbon recycling. The objective functions (minimum ethanol selling price (MESP), energy efficiency, and carbon footprint) were evaluated for the combinations of different input variables in models of biomass gasification, energy production from syngas, fermentation, and ethanol distillation, and a multi-objective genetic algorithm was employed for the optimization of the integrated process. Two types of waste feedstocks were considered, wood residues and sugarcane bagasse, with the former leading to lower MESP and a carbon footprint of 0.93 USD/L and 3 g CO₂eq/MJ compared to 1.00 USD/L and 10 g CO₂eq/MJ for sugarcane bagasse. The energy efficiency was found to be 32% in both cases. An uncertainty analysis was conducted to determine critical decision variables, which were found to be the gasification zone temperature, the split fraction of the unreformed syngas sent to the combustion chamber, the dilution rate, and the gas residence time in the bioreactor. Apart from the abovementioned objectives, other aspects such as water footprint, ethanol yield, and energy self-sufficiency were also discussed. Full article

This research studied the commercial exploitation of an indigenous African crop in order to formulate high value products, with a potential significant impact on the local economy. More specifically, the present work investigated the extraction of polysaccharides from baobab in a bench-scale unit, focusing on the overall yield and the techno-economic assessment of the extraction process. Preliminary technoeconomic analysis for two scenarios (with and without ethanol recycling) was performed to determine the economic viability of the process and the development of the baobab market both in Nigeria and the UK. A full economic analysis was undertaken for each of the two scenarios, considering all operating and capital costs, and the production cost of baobab polysaccharides was estimated based on a constant return on investment. Combining the operating cost with the average polysaccharide yield, the minimum profitable selling price in the UK was estimated to be between £23 and £35 per 100 g of polysaccharide, which is comparable to the commercial selling price of high purity polysaccharides. An assessment of a scaled-up plant was also performed under Nigerian conditions and the results showed that such an investment is potentially viable and profitable, with a minimum profitable selling price of £27 per 100 g, a value comparable to the UK-based scenarios. Full article

For international civil aviation to be able to significantly reduce its greenhouse gas (GHG) emissions, the use of Sustainable Aviation Fuels (SAF) needs to be made feasible. This paper presents the results of an assessment of the feasibility of production of SAF in Brazil, considering three certified routes, based on the dedicated production of eucalyptus, soy, sugarcane and corn. The results presented here refer to the production of biomass in selected locations, aiming to reduce GHG emissions and minimise production costs. Considering that the opportunity costs of feedstocks were not observed, the minimum selling price (MSP) of SAF in the reference case was estimated at 13.4 EUR·GJ⁻¹ for the production based on soybean oil (HEFA-SPK route), 21.0 EUR·GJ⁻¹ for the production based on ethanol from sugarcane and corn (ATJ-SPK) and 32.0 EUR·GJ⁻¹ from eucalyptus (FT-SPK). These values refer to SAF’s nth industrial plant and biomass costs that are compatible with the current agricultural yields in Brazil but which are also the highest. The MSP results are relatively low compared to the estimates available in the literature, but they do not show the strict economic viability of SAFs in the short- to medium-term, mainly because of the low prices of fossil fuels. Full article

While the production costs and logistical benefits of biomass pelleting have been widely discussed in the literature, the downstream economic and environmental benefits of processing pelleted biomass have been largely neglected. To investigate those benefits, we performed a comparative techno-economic analysis and life cycle assessment of producing ethanol using loose and pelleted forms of biomass. Analyses of a 2000 metric tons (dry)/d biorefinery showed that using pelleted biomass is more economical than using loose or baled biomass. The lowest minimum ethanol selling price (MESP) for pelleted biomass was USD 0.58/gal less than the lowest MESP for loose biomass. Among all processing conditions analyzed, MESP for ethanol produced with pelleted biomass was always lower than when produced with loose biomass. Shorter pretreatment and hydrolysis times, higher pretreatment solids loadings, lower ammonia requirements, and reduced enzyme loadings were the primary factors contributing to lower MESP with pelleted biomass. Similarly, pelleted biomass also demonstrated a 50% lower life cycle greenhouse gas emission compared to loose biomass. Emissions from higher pelleting energy were offset by downstream advantage in lower chemical needs. Full article

Oil palm empty fruit bunch (OPEFB) is a potential raw material abundantly available for bioethanol production. However, the second-generation bioethanol is still not yet economically feasible. The COVID-19 pandemic increases the demand for ethanol as the primary ingredient of hand sanitisers. This study evaluates the techno-economic feasibility of hand sanitiser production using OPEFB-based bioethanol. OPEFB was alkaline-pretreated, and simultaneous saccharification and fermentation (SSF) was then performed by adding Saccharomyces cerevisiae and cellulose enzyme. The cellulose content of the OPEFB increased from 39.30% to 63.97% after pretreatment. The kinetic parameters of the OPEFB SSF at 35 °C, which included a µ max, ks, and kd of 0.018 h⁻¹, 0.025 g/dm³, and 0.213 h⁻¹, respectively, were used as input in SuperPro Designer^® v9.0. The total capital investment (TCI) and annual operating costs (AOC) of the plant were $645,000 and $305,000, respectively, at the capacity of 2000 kg OPEFB per batch. The batch time of the modelled plant was 219 h, with a total annual production of 32,506.16 kg hand sanitiser. The minimum hand sanitiser selling price was found to be $10/L, achieving a positive net present value (NPV) of $108,000, showing that the plant is economically feasible. Full article

Biofuels are still too costly to compete in the energy market and it has been suggested that low-value feedstocks could provide an opportunity for the production of low-cost biofuels; however, the lower quality of these feedstocks requires the introduction of a conditioning step in the biorefinery process. The aim of this study was to evaluate whether feedstock savings cover the cost of conditioning in the case of animal bedding. The BioSTEAM software was used to simulate a wheat straw biorefinery and an animal bedding biorefinery, whose economic performance was compared. The wheat straw biorefinery could deliver ethanol at a minimum selling price of USD 0.61 per liter, which is similar to prices in the literature. The cost of producing ethanol in the animal bedding biorefinery without water recycling was almost 40% higher, increasing the minimum selling price to USD 1.1 per liter of ethanol. After introducing water recycling in the conditioning step, the animal bedding biorefinery could deliver ethanol at a minimum selling price of USD 0.38 per liter, which is 40% lower than in the case of the wheat straw biorefinery. This demonstrates that low-value feedstocks can be used to reduce the biofuel price, as feedstock savings easily cover the additional conditioning cost. Full article

Worldwide, there are various feedstocks such as straws, corn stover, sugarcane bagasse, sweet sorghum bagasse (SSB), grasses, leaves, whey permeate, household organic waste, and food waste (FW) that can be converted to valuable biofuels such as butanol. For the present studies, an economic analysis was performed to compare butanol production from three feedstocks (SSB; FW; and yellow top presscake, YTP or YT) using a standard process and an advanced integrated process design. The total plant capacity was set at 170,000–171,000 metric tons of total acetone butanol ethanol (ABE) per year (99,300 tons of just butanol per year). Butanol production from SSB typically requires pretreatment, separate hydrolysis, fermentation, and product recovery (SHFR). An advanced process was developed in which the last three steps were combined into a single unit operation for simultaneous saccharification, fermentation, and recovery (SSFR). For the SHFR and SSFR plants, the total capital investments were estimated as $213.72 × 10⁶ and $198.16 × 10⁶, respectively. It was further estimated that the minimum butanol selling price (using SSB as a feedstock) for the two processes were $1.14/kg and $1.05/kg. Therefore, SSFR lowered the production cost markedly compared to that of the base case. Butanol made using FW had an estimated minimum selling price of only $0.42/kg. This low selling price is because the FW to butanol process does not require pretreatment, hydrolysis, and cellulolytic enzymes. For this plant, the total capital investment was projected to be $107.26 × 10⁶. The butanol selling price using YTP as a feedstock was at $0.73/kg and $0.79/kg with total capital investments for SSFR and SHFR of $122.58 × 10⁶ and $132.21 × 10⁶, respectively. In the Results and Discussion section, the availability of different feedstocks in various countries such as Brazil, the European Union, New Zealand, Denmark, and the United States are discussed. Additionally, the use of various microbial strains and product recovery technologies are also discussed. Full article

Ethanol is a material that has a high demand from different industries such as fuel, beverages, and other industrial applications. Commonly, ethanol has been produced from yeast fermentation using sugar crops as a feedstock. However, food waste (FW) was found to be one of the promising resources to produce ethanol because it contained a higher amount of glucose. Generally, column distillation has been used to separate ethanol from the fermentation broth, but this operation is considered an energy-intensive process. On the contrary, membrane distillation is expected to be more practical and cost-effective because of its lower energy requirement. Therefore, this study aims to make a comparison of economic performance on FW fermentation with membrane distillation and a conventional distillation system using techno-economy analysis (TEA) method. A commercial-scale FW fermentation plant was modeled using SuperPro Designer V9.0 Modeling. Discounted cash flow analysis was employed to determine ethanol minimum selling price (MSP) for both distillation systems at 10% of the internal rate of return. Results from this analysis showed that membrane distillation has a higher MSP than a conventional process, $6.24 and $2.41 per gallon ($1.65 and $0.64 per liter) respectively. Hence, this study found that membrane distillation is not economical to be implemented in commercial-scale ethanol production. Full article