Integrated algal biorefineries from process systems engineering aspects: A review

Removal of organic and inorganic contaminants from the air, soil, and water by algae

Rapid increases in human populations and development has led to a significant exploitation of natural resources around the world. On the other hand, humans have come to terms with the consequences of their past mistakes and started to address current and future resource utilization challenges. Today's primary challenge is figuring out and implementing eco-friendly, inexpensive, and innovative solutions for conservation issues such as environmental pollution, carbon neutrality, and manufacturing effluent/wastewater treatment, along with xenobiotic contamination of the natural ecosystem. One of the most promising approaches to reduce the environmental contamination load is the utilization of algae for bioremediation. Owing to their significant biosorption capacity to deactivate hazardous chemicals, macro-/microalgae are among the primary microorganisms that can be utilized for phytoremediation as a safe method for curtailing environmental pollution. In recent years, the use of algae to overcome environmental problems has advanced technologically, such as through synthetic biology and high-throughput phenomics, which is increasing the likelihood of attaining sustainability. As the research progresses, there is a promise for a greener future and the preservation of healthy ecosystems by using algae. They might act as a valuable tool in creating new products.

Energy recovery by anaerobic digestion of algal biomass from integrated microalgae/constructed wetland wastewater treatment

The present study evaluated the potential for biogas generation from microalgae (MA) biomass and macrophytes used in vertical flow constructed wetlands (VFCW). The samples were obtained by separation and collection of MA after a hydraulic retention time of 14 days, frozen and taken to the laboratory, while the macrophytes of VFCW were obtained, by pruning, every 6 months. The obtained results presented reductions of 63.22% and 61.18% for COD and BOD₅, respectively, and removal efficiencies of 53.91% for TP and 99.98% de N-NH₃. Average biogas generation was 2322.51 NmL-gSV^-1 with 54.61% CH₄ (winter/2019), 4491.47 Nml-gSV^-1 with 57.17% CH₄ (spring/2019), 680.78 NmL-gSV^-1 with 16.04% CH₄ (summer/2020), and 681.0 NmL-gSV^-1 with 19.86% CH₄ (autumn/2020) for MA biomass and generation of biogas of 3826.70 NmL-gSV^-1 with 44.26% CH₄ for VFCW biomass in winter and spring/2019 and of 829.68 NmL-gSV^-1 with 17.06% CH₄ in summer and autumn/2020. Regarding electricity generation, the present work obtained 1.50 kWh/m³, therefore reaching similar values to other studies that used more traditional biomass sources.

Advances and opportunities in integrating economic and environmental performance of renewable products

There is a growing global need to transition from a fossil-based to a bio-based economy to produce fuels, chemicals, food, and materials. In the specific context of industrial biotechnology, a successful transition toward a sustainable development requires not only steering investment toward a bioeconomy, but also responsibly introducing bio-based products with lower footprints and competitive market prices. A comprehensive sustainability assessment framework applied along various research stages to guide bio-based product development is urgently needed but currently missing. To support holistic approaches to strengthen the global bioeconomy, the present study discusses methodologies and provides perspectives on the successful integration of economic and environmental performance aspects to guide product innovation in biotechnology. Efforts on quantifying the economic and environmental performance of bio-based products are analyzed to highlight recent trends, challenges, and opportunities. We critically analyze methods to integrate Techno-Economic Assessment (TEA) and Life Cycle Assessment (LCA) as example tools that can be used to broaden the scope of assessing biotechnology systems performance. We highlight the lack of social assessment aspects in existing frameworks. Data need for jointly applying TEA and LCA of succinic acid as example commodity chemical are assessed at various Technology readiness levels (TRLs) to illustrate the relevance of the level of integration and show the benefits of the use of combined assessments. The analysis confirms that the implementation of integrated TEA and LCA at lower TRLs will provide more freedom to improve bio-based product's sustainability performance. Consequently, optimizing the system across TRLs will guide sustainability-driven innovation in new biotechnologies transforming renewable feedstock into valuable bio-based products.

Algal biorefinery culminating multiple value-added products: recent advances, emerging trends, opportunities, and challenges

Algal biorefinery is rising as a prominent solution to economically fulfill the escalating global requirement for nutrition, feed, fuel, and medicines. In recent years, scientific productiveness associated with microalgae-based studies has elaborated in multiplied aspects, while translation to the commercial level continues to be missing. The present microalgal biorefinery has a challenge in long-term viability due to escalated market price of algal-mediated biofuels and bioproducts. Advancements are required in a few aspects like improvement in algae processing, energy investment, and cost analysis of microalgae biorefinery. Therefore, it is essential to recognize the modern work by understanding the knowledge gaps and hotspots driving business scale up. The microalgae biorefinery integrated with energy-based products, bioactive and green compounds, focusing on a circular bioeconomy, is urgently needed. A detailed investigation of techno-economic analysis (TEA) and life cycle assessment (LCA) is important to increase the market value of algal products. This review discusses the valorization of algal biomass for the value-added application that holds a sustainable approach and cost-competitive algal biorefinery. The current industries, policies, technology transfer trends, challenges, and future economic outlook are discussed. This study is an overview through scientometric investigation attempt to describe the research development contributing to this rising field.

Life cycle assessment of microalgal biorefinery: A state-of-the-art review

Microalgal biorefineries represent an opportunity to economically and environmentally justify the production of bioproducts. The generation of bioproducts within a biorefinery system must quantitatively demonstrate its viability in displacing traditional fossil-based refineries. To this end, several works have conducted life cycle analyses on microalgal biorefineries and have shown technological bottlenecks due to energy-intensive processes. This state-of-the-art review covers different studies that examined microalgal biorefineries through life cycle assessments and has identified strategic technologies for the sustainable production of microalgal biofuels through biorefineries. Different metrics were introduced to supplement life cycle assessment studies for the sustainable production of microalgal biofuel. Challenges in the comparison of various life cycle assessment studies were identified, and the future design choices for microalgal biorefineries were established.

A Scoping Review on Environmental, Economic, and Social Impacts of the Gasification Processes

In recent years, computer-based simulations have been used to enhance production processes, and sustainable industrial strategies are increasingly being considered in the manufacturing industry. In order to evaluate the performance of a gasification process, the Life Cycle Thinking (LCT) technique gathers relevant impact assessment tools to offer quantitative indications across different domains. Following the PRISMA guidelines, the present paper undertakes a scoping review of gasification processes’ environmental, economic, and social impacts to reveal how LCT approaches coping with sustainability. This report categorizes the examined studies on the gasification process (from 2017 to 2022) through the lens of LCT, discussing the challenges and opportunities. These studies have investigated a variety of biomass feedstock, assessment strategies and tools, geographical span, bioproducts, and databases. The results show that among LCT approaches, by far, the highest interest belonged to life cycle assessment (LCA), followed by life cycle cost (LCC). Only a few studies have addressed exergetic life cycle assessment (ELCA), life cycle energy assessment (LCEA), social impact assessment (SIA), consequential life cycle assessment (CLCA), and water footprint (WLCA). SimaPro® (PRé Consultants, Netherlands), GaBi® (sphere, USA), and OpenLCA (GreenDelta, Germany) demonstrated the greatest contribution. Uncertainty analysis (Monte Carlo approach and sensitivity analysis) was conducted in almost half of the investigations. Most importantly, the results confirm that it is challenging or impossible to compare the environmental impacts of the gasification process with other alternatives since the results may differ based on the methodology, criteria, or presumptions. While gasification performed well in mitigating negative environmental consequences, it is not always the greatest solution compared to other technologies.

The role of bioprocess systems engineering in extracting chemicals and energy from microalgae

In this study, the role of process systems engineering in enhancing the algae economy is highlighted. First, basic characteristics of the various strains of microalgae are presented. In addition, the beneficial extracted bioproducts and their applications are reviewed. Then, an overview of the various technologies available in each step of biorefinery to produce added-value products and biofuels from microalgae is provided. These technologies are compared in terms of required energy and efficiency. Different perspectives of the algae industry, from molecule to enterprises scale where process systems engineering can have a role, are addressed. Subsequently, the roles of process systems engineering in process and product design, process control, and supply chain of the algae biorefinery are discussed. It is found that process systems engineering can play an important role in the biobased economy, especially by applying sustainability and economic concepts in the decision-making process for selecting the best feedstock, processing pathways, and desired products. Tools such as market analysis, techno-economic analysis, life cycle assessment (LCA), and supply chain (SC) analysis can be applied to design sustainable algae biorefinery. There are, however, several challenges such as the lack of data, the complexity of optimization, and validation that should be addressed before using these tools.

Biochemical biorefinery: A low-cost and non-waste concept for promoting sustainable circular bioeconomy

The transition from a fossil-based linear economy to a circular bioeconomy is no longer an option but rather imperative, given worldwide concerns about the depletion of fossil resources and the demand for innovative products that are ecocompatible. As a critical component of sustainable development, this discourse has attracted wide attention at the regional and international levels. Biorefinery is an indispensable technology to implement the blueprint of the circular bioeconomy. As a low-cost, non-waste innovative concept, the biorefinery concept will spur a myriad of new economic opportunities across a wide range of sectors. Consequently, scaling up biorefinery processes is of the essence. Despite several decades of research and development channeled into upscaling biorefinery processes, the commercialization of biorefinery technology appears unrealizable. In this review, challenges limiting the commercialization of biorefinery technologies are discussed, with a particular focus on biofuels, biochemicals, and biomaterials. To counteract these challenges, various process intensification strategies such as consolidated bioprocessing, integrated biorefinery configurations, the use of highly efficient bioreactors, simultaneous saccharification and fermentation, have been explored. This study also includes an overview of biomass pretreatment-generated inhibitory compounds as platform chemicals to produce other essential biocommodities. There is a detailed examination of the technological, economic, and environmental considerations of a sustainable biorefinery. Finally, the prospects for establishing a viable circular bioeconomy in Nigeria are briefly discussed.

Continuous design and economic analysis of a Sargassum muticum biorefinery process

This work assesses scale effects in designing a biorefinery from Sargassum muticum seaweed by applying a detailed process modeling methodology. Two process conversion units were simulated: one considering anaerobic digestion steps for producing biogas and generating electricity (base project), and the other with residual seaweed solids sold as fertilizer (alternative project). A comprehensive economic analysis was performed to estimate the minimum selling price of the process's main product (fucoidan extract). Results indicated that capital expenditures are up to 12.7% times higher in the base project. Minimum selling prices of the fucoidan extract product demonstrate the biorefinery's economies of scale for both projects. Seaweed's low methane potential reduces the economic attractiveness of electricity generation from biogas in the base project. Conversely, organic fertilizer price was more influential in the alternative project. Nonetheless, risk analyses show similar results for both scenarios, mainly due to fucoidan extract selling price and CAPEX estimates uncertainties.

Sustainable valorization of algae biomass via thermochemical processing route: An overview

Biofuels have become an attractive energy source because of the growing energy demand and environmental issues faced by fossil fuel consumption. Algal biomass, particularly microalgae, has excellent potential as feedstock to be converted to bio-oil, biochar, and combustible syngas via thermochemical conversion processes. Third-generation biofuels from microalgal feedstock are the promising option, followed by the first-generation and second-generation biofuels. This paper provides a review of the applications of thermochemical conversion techniques for biofuel production from algal biomass, comprising pyrolysis, gasification, liquefaction, and combustion processes. The progress in the thermochemical conversion of algal biomass is summarized, emphasizing the application of pyrolysis for its benefits over other processes. The review also encompasses the challenges and perspectives associated with the valorization of microalgae to biofuels ascertaining the potential opportunities and possibilities of extending the research into this area.

Life cycle and techno-economic assessment of source-separated wastewater-integrated microalgae biofuel production plant: A nutrient organization approach

Microalgae cultivating in wastewater enabling nutrient uptake for biomass and biofuel generation is regarded as a promising pathway to increase sustainability of microalgae biofuel production process. A source-separated nutrient organization approach for the process of wastewater-based microalgae biofuel is proposed in this study. Comparative life cycle assessment (LCA) method and Techno-economic analysis (TEA) approach are employed to assess sustainability and economic performance of the proposed nutrient approach. Two scenarios are used to validate our study. Scenario 1 is based on the source-separated nutrient delivery approach with microalgae integrated wastewater in tertiary treatment. Scenario 2 is based on non-separated-point nutrient delivery policy and microalgae integrated with secondary wastewater treatment. The results show that the source-separated nutrient approach is effective for reducing the environmental impacts and increasing commercial potential of microalgae biofuel.

Sustainable, Decentralized Sanitation and Reuse with Hybrid Nature-Based Systems

Nature (ecosystem) based processes for wastewater treatment include constructed wetlands (CWs), waste stabilization ponds, vegetated drainage ditches, buffer zones, instream or bankside river techniques, and mixotrophic systems, where light and CO2 are utilized, in addition to organic carbon compounds, by algal cultures. Algae-based systems can simultaneously remove organic matter, N, and P and may offer substantial energetic advantages compared to traditional biological treatment systems, require small spatial footprint, and contribute to biofuels production and CO2 emissions mitigation. Bioelectrochemical systems (BES) such as microbial fuel cells (MFCs) present characteristics compatible with the use in isolated realities for water and wastewater treatment with contextual energy recovery and may be combined with other nature-based process technologies to achieve good treatment and energy efficiencies. Despite that their application in real-scale plants has not been assessed yet, the most probable outcome will be the in situ/on site treatment (or pretreatment) of wastes for small “in house” plants not connected to the sewerage network. This paper focuses on the current practices and perspectives of hybrid nature-based systems, such as constructed wetlands and microalgae integrated phytoremediation plants, and their possible integration with microbial electrochemical technologies to increase recovery possibilities from wastes and positively contribute to a green economy approach.

A Multi-Objective Life Cycle Optimization Model of an Integrated Algal Biorefinery toward a Sustainable Circular Bioeconomy Considering Resource Recirculation

Biofuel production from microalgae biomass has been considered a viable alternative to harmful fossil fuels; however, challenges are faced regarding its economic sustainability. Process integration to yield various high-value bioproducts is implemented to raise profitability and sustainability. By incorporating a circular economy outlook, recirculation of resource flows is maximized to yield economic and environmental benefits through waste minimization. However, previous modeling studies have not looked into the opportunity of integrating productivity reduction related to the continuous recirculation and reuse of resources until it reaches its end of life. In this work, a novel multi-objective optimization model is developed centered on an algal biorefinery that simultaneously optimizes cost and environmental impact, adopts the principle of resource recovery and recirculation, and incorporates the life cycle assessment methodology to properly account for the environmental impacts of the system. An algal biorefinery involving end-products such as biodiesel, glycerol, biochar, and fertilizer was used for a case study to validate the optimization model. The generated optimal results are assessed and further analyzed through scenario analysis. It was seen that demand fluctuations and process unit efficiencies have significant effect on the optimal results.

Multi-Objective Optimization of an Integrated Algal and Sludge-Based Bioenergy Park and Wastewater Treatment System

Given increasing energy demand and global warming potential, the advancements in bioenergy production have become a key factor in combating these issues. Biorefineries have been effective in converting biomass into energy and valuable products with the added benefits of treating wastewater used as a cultivation medium. Recent developments enable relationships between sewage sludge and microalgae that could lead to higher biomass and energy yields. This study proposes a multi-objective optimization model that would assist stakeholders in designing an integrated system consisting of wastewater treatment systems, an algal-based bioenergy park, and a sludge-based bioenergy park that would decide which processes to use in treating wastewater and sludge while minimizing cost and carbon emissions. The baseline run of the model showed that the three plants were utilized in treating both sludge and water for the optimal answer. Running the model with no storage prioritizes water disposal, while having storage can help produce more energy. Sensitivity analysis was performed on storage costs and demand. Results show that decreasing the demand is directly proportional to the total costs while increasing it can help reduce expected costs through storage and utilizing process capacities. Costs of storage do not cause a huge overall difference in costs and directly follow the change.

Biorefinery of Chlorella sorokiniana using ultra sonication assisted liquid triphasic flotation system

The aim of this work was to study the ultrasonication-assisted Liquid Tri-phasic Flotation (LTF) System to obtain lipid and protein from microalgae Chlorella sorokiniana in a single step as a novel process. In the current study, biorefinery of Chlorella sorokiniana was performed using LTF system in a single step. The highest protein recovery of 97.43 ± 1.67% and lipid recovery of 69.50 ± 0.54% were obtained. The corresponding parameters were microalgae biomass loading of 0.5 w/v%, ammonium sulphate concentration of 40 w/v%, volume ratio of 1:1.5 (salt:alcohol), ultrasonication pulse mode of 20 s ON/20 s OFF at 20% amplitude for 5 mins, flotation air flowrate of 100 mL/min. Additionally, recycling of alcohol phase to study the circular nature of proposed biorefinery was investigated. The proposed LTF system for extraction of proteins and lipid reduces the number of operation units required in this biorefinery approach.

Deoiled algal biomass derived renewable sugars for bioethanol and biopolymer production in biorefinery framework

The present study is designed to evaluate the potential of deoiled algal biomass (DAB) residue as an alternative resource for the production of bioethanol and biopolymers in a biorefinery approach. Hybrid pretreatment method resulted in higher sugar solubilization (0.590 g/g DAB) than the corresponding individual physicochemical (0.481 g/g DAB) and enzymatic methods (0.484 g/g DAB). Subsequent utilization of sugars from hybrid pretreatment for bioethanol using Saccharomyces cerevisiaeresulted in maximum bioethanol production at pH 5.5 (0.145 ± 0.008 g/g DAB) followed by pH 5.0 (0.122 ± 0.004 g/g DAB) and pH 6.0 (0.102 ± 0.002 g/g DAB). The experiments for biopolymer (PHB: polyhydroxybutyrate) production resulted in 0.43 ± 0.20 g PHB/g DCW. Extracted polymer on NMR and FT-IR analysis showed the presence of PHB. Exploration of DAB as an alternative renewable resource for multiple biobased products supports sustainability and also enables entirety use of DAB by addressing the DAB-residue allied disposal issues.

Optimizing Multimodal Transportation Routes Considering Container Use

This study focuses on the route selection problem of multimodal transportation: When facing a shortage of containers, a transport plan must be designed for freight forwarders that realizes the optimal balance between transportation time and transportation cost. This problem is complicated by two important characteristics: (1) The use of containers is related to transport routes, and they interact with each other; and (2) Different types of containers should be used in different time ranges for different modes of transportation. To solve this problem, we establish a multi-objective optimization model for minimizing the total transportation time, transportation cost and container usage cost. To solve the multi-objective programming model, the normalized normal constraint method (NNCM) is used to obtain Pareto solutions. We conducted a case study considering the transportation of iron ore in Panzhihua City, Sichuan Province. The results demonstrate that using railway containers and railway transportation as much as possible in route selection can effectively solve the problem of container shortage and balance transportation time and transportation cost.