High-Resolution Lipidomics Reveals Influence of Biomass and Pretreatment Process on the Composition of Extracted Algae Oils As Feedstock for Sustainable Aviation Fuels

The increasing demand for sustainable aviation fuel (SAF) creates a need for innovative biomass and lipid sources with compositions that are compatible with refineries. Algae-derived oils present an opportunity to supply a process-compatible lipid feedstock at yields higher than those of conventional oilseed crops. With few documented reports on chemical composition, the process readiness remains elusive. We present data on extraction efficiency, yield, and purity of lipids from algae with and without the application of a low-concentration sulfuric acid pretreatment of the biomass. The pretreatment process increased the oil yield and positively impacted the quality of the extracted oils. Results from fatty acid and lipidomics analysis revealed that the low-lipid biomass sources extracted 70-80% of the available lipids, and the non-fatty acid co-extractants exceeded 40% of the extracted oils. For a high-lipid algae sample, derived from a genetically engineered strain, we show >90% extraction yield with >85% FAME purity. This work provides insights into the composition of algae-derived oils and quality metrics that are essential to determining the viability of lipid hydroprocessing to SAF.

Enabling Production of Algal Biofuels by Techno-Economic Optimization of Co-Product Suites

Recent techno-economic analysis (TEA) has underscored that for algal biofuels to be cost competitive with petroleum fuels, co-products are necessary to offset the cost of fuel production. The co-product suite must scale with fuel production while also maximizing value from the non-fuel precursor components. The co-product suite also depends on algal biomass composition, which is highly dynamic and depends on environmental conditions during cultivation. Intentional shifts in composition during cultivation are often associated with reduced biomass productivity, which can increase feedstock production costs for the algae-based biorefinery. The optimal algae-based biorefinery configuration is thus a function of many factors. We have found that comprehensive TEA, which requires the construction of process models with detailed mass and energy balances, along with a complete accounting of capital and operating expenditures for a commercial-scale production facility, provides invaluable insight into the viability of a proposed biorefinery configuration. This insight is reflected in improved viability for one biorefining approach that we have developed over the last 10 years, namely, the Combined Algal Processing (CAP) approach. This approach fractionates algal biomass into carbohydrate-, lipid-, and protein-rich fractions, and tailors upgrading chemistry to the composition of each fraction. In particular, transitioning from valorization of only the lipids to a co-product suite from multiple components of high-carbohydrate algal biomass can reduce the minimum fuel selling price (MFSP) from more than $8/gallon of gasoline equivalent (GGE) to $2.50/GGE. This paper summarizes that progress and discusses several surprising implications in this optimization approach.

Key Targets for Improving Algal Biofuel Production

A number of technological challenges need to be overcome if algae are to be utilized for commercial fuel production. Current economic assessment is largely based on laboratory scale up or commercial systems geared to the production of high value products, since no industrial scale plant exits that are dedicated to algal biofuel. For macroalgae (‘seaweeds’), the most promising processes are anaerobic digestion for biomethane production and fermentation for bioethanol, the latter with levels exceeding those from sugar cane. Currently, both processes could be enhanced by increasing the rate of degradation of the complex polysaccharide cell walls to generate fermentable sugars using specifically tailored hydrolytic enzymes. For microalgal biofuel production, open raceway ponds are more cost-effective than photobioreactors, with CO2 and harvesting/dewatering costs estimated to be ~50% and up to 15% of total costs, respectively. These costs need to be reduced by an order of magnitude if algal biodiesel is to compete with petroleum. Improved economics could be achieved by using a low-cost water supply supplemented with high glucose and nutrients from food grade industrial wastewater and using more efficient flocculation methods and CO2 from power plants. Solar radiation of not <3000 h·yr−1 favours production sites 30° north or south of the equator and should use marginal land with flat topography near oceans. Possible geographical sites are discussed. In terms of biomass conversion, advances in wet technologies such as hydrothermal liquefaction, anaerobic digestion, and transesterification for algal biodiesel are presented and how these can be integrated into a biorefinery are discussed.