Increasing Profits in Food Waste Biorefinery—A Techno-Economic Analysis

Recent progress and prospects for chain elongation of transforming biomass waste into medium-chain fatty acids

Chain elongation technology utilises microorganisms in anaerobic digestion to transform waste biomass into medium-chain fatty acids that have greater economic value. This innovative technology expands upon traditional anaerobic digestion methods, requiring abundant substrates that serve as electron donors and acceptors, and inoculating microorganisms with chain elongation functions. While this process may result in the production of by-products and elicit competitive responses, toxicity suppression of microorganisms by substrates and products remains a significant obstacle to the industrialisation of chain elongation technology. This study provides a comprehensive overview of existing research on widely employed electron donors and their synthetic reactions, competitive reactions, inoculum selection, toxicity inhibition of substrates and products, and increased chain elongation approaches. Additionally, it presents actionable recommendations for future research and development endeavours in this domain, intending to inspire and guide researchers in advancing the frontiers of chain elongation technology.

Characterizing the Opportunity Space for Sustainable Hydrothermal Valorization of Wet Organic Wastes

Resource recovery from wet organic wastes can support circular economies by creating financial incentives to produce renewable energy and return nutrients to agriculture. In this study, we characterize the potential for hydrothermal liquefaction (HTL)-based resource recovery systems to advance the economic and environmental sustainability of wastewater sludge, FOG (fats, oils, and grease), food waste, green waste, and animal manure management through the production of liquid biofuels (naphtha, diesel), fertilizers (struvite, ammonium sulfate), and power (heat, electricity). From the waste management perspective, median costs range from -193 $·tonne-1 (FOG) to 251 $·tonne-1 (green waste), and median carbon intensities range from 367 kg CO2 eq·tonne-1 (wastewater sludge) to 769 kg CO2 eq·tonne-1 (green waste). From the fuel production perspective, the minimum selling price of renewable diesel blendstocks are within the commercial diesel price range (2.37 to 5.81 $·gal-1) and have a lower carbon intensity than petroleum diesel (101 kg CO2 eq·MMBTU-1). Finally, through uncertainty analysis and Monte Carlo filtering, we set specific targets (i.e., achieve wastewater sludge-to-biocrude yield >0.440) for the future development of hydrothermal waste management system components. Overall, our work demonstrates the potential of HTL-based resource recovery systems to reduce the costs and carbon intensity of resource-rich organic wastes.

Socio-economic sustainability with circular economy - An alternative approach

As the global population and living standards rise, it pushes the demand for basic amenities like food, health, and energy resources. Additionally, manufacturing automation has led to mass production and consumption, triggering waste production. The existing linear economy approach has led to increasing waste production and resource depletion, posing significant environmental and public health threats. To overcome these impediments, an alternative model called the circular economy concept has gained popularity in the global industry community. This closed-loop, restorative, waste-free concept has the potential to protect the environment and improve economics by reducing energy and resource consumption. Thus, major impetus should be given to strengthening the backbone of the economy where tools such as green technologies, decarbonization strategies, bio refinery processes, material flow analysis, life cycle assessment, ecological footprints (water, carbon, and material), substance flow analysis, circularity index, eco-designing, bioresource management, new business models, and policy play an essential role in the areas of socio-economic sustainability, ecological facts, and industrial aspects to enhance socio-economic growth in a sustainable manner. Sectoral awareness, collaborations, and partnerships among the Government, stakeholders, policymakers, and competent authorities are also essential to enabling circularity within the eco-systems.

Lactic acid production from food waste at an anaerobic digestion biorefinery: effect of digestate recirculation and sucrose supplementation

Low lactic acid (LA) yields from direct food waste (FW) fermentation restrict this production pathway. However, nitrogen and other nutrients within FW digestate, in combination with sucrose supplementation, may enhance LA production and improve feasibility of fermentation. Therefore, this work aimed to improve LA fermentation from FWs by supplementing nitrogen (0-400 mgN·L^-1) as NH₄Cl or digestate and dosing sucrose (0-150 g·L^-1) as a low-cost carbohydrate. Overall, NH₄Cl and digestate led to similar improvements in the rate of LA formation (0.03 ± 0.02 and 0.04 ± 0.02 h^-1 for NH₄Cl and digestate, respectively), but NH₄Cl also improved the final concentration, though effects varied between treatments (5.2 ± 4.6 g·L^-1). While digestate altered the community composition and increased diversity, sucrose minimised community diversion from LA, promoted Lactobacillus growth at all dosages, and enhanced the final LA concentration from 25 to 30 g·L^-1 to 59-68 g·L^-1, depending on nitrogen dosage and source. Overall, the results highlighted the value of digestate as a nutrient source and sucrose as both community controller and means to enhance the LA concentration in future LA biorefinery concepts.

Catalytic conversion of waste corrugated cardboard into lactic acid using lanthanide triflates

The efficient strategy for waste conversion and resource recovery is of great interest in the sustainable bioeconomy context. This work reports on the catalytic upcycling of waste corrugated cardboard (WCC) into lactic acid using lanthanide triflates catalysts. WCC, a primary contributor to municipal solid wastes, has been viewed as a feedstock for producing a wide range of renewable products. Hydrothermal conversion of WCC was carried out in the presence of several lanthanide triflates. The reaction with erbium(III) triflate (Er(OTf)₃) and ytterbium(III) triflate (Yb(OTf)₃) resulted in high lactic acid yields, 65.5 and 64.3 mol%, respectively. In addition, various monomeric phenols were readily obtained as a co-product stream, opening up opportunities in waste management and resource recovery. Finally, technoeconomic analysis was conducted based on the experimental results, which suggests a significant economic benefit of chemocatalytic upcycling of WCC into lactic acid.

Modification of wheat straw to improve the caproate production in a cell immobilized system

Wheat straw is a favorable cell carrier in the caproate fermentation system, yet its smooth surface limits the biofilm formation. In this study, the modification of wheat straw was conducted using three different chemical methods and the influence of its modified surface on the caproate fermentation was investigated. Results showed that the sodium hydroxide was the optimum reagent for modification of wheat straw, where both the external and internal surfaces were effectively modified, resulting in 34.4% increased specific surface area. The highest caproate production of 21.1 g/L was obtained in fed-batch fermentation, which was ascribed to the formation of a thick biofilm on the modified carrier. Moreover, the crystallinity index of the carrier increased during the fed-batch fermentation, implying that the modified wheat straw was a stable matrix for cell immobilization. This study provides an effective way for efficient caproate production through modification of wheat straw.

A novel cascade biorefinery approach to transform food waste into valuable chemicals and biogas through thermal pretreatment integration

A novel biorefinery platform integrating thermal pretreatment and solid-liquid separation unit is here proposed to fully exploit food waste (FW) potential for production of valuable chemicals and energy through semi-continuous anaerobic bioconversion. The liquid fraction deriving from raw or pretreated FW, was fermented into volatile fatty acids (VFAs, from acetic to caproic acid) while the residual fraction was converted into biomethane. Thermal pretreatment effectively extracted a portion of the macromolecular organics, especially starch, to the liquid phase, promoting acidogenic fermentation and chain elongation pathways (0.43 gVFA g^-1VS_fed and 0.58 gVFA g^-1VS_fed with raw and pretreated extract, respectively). In parallel, anaerobic digestion of solid residue in 10 L reactors showed process stability and higher conversion rate for the pretreated residue (0.31 against 0.26 Nm³CH₄ kg^-1VS_fed). The mass-transfer balance coupled with the economic assessment, calculated in terms of direct gross added value, indicated promising revenues by integrating the thermal upstream treatment.

Organic-waste-derived butyric acid-to-biodiesel supply-chain network: Strategic planning design using a deterministic snapshot model

An integrated optimization model for an organic-waste-derived butyric acid-to-butanol supply-chain network (BABSCN) is proposed to minimize the total network cost by simultaneously optimizing both strategic biodiesel production and waste management planning decisions. This model is useful for ensuring effective organic-waste provision for large-scale biodiesel production and waste management. The proposed mixed-integer linear-programming model optimizes the activities ranging from organic-waste preprocessing to butyric acid (BA), transportation of BA to biorefinery, butanol (BuOH) production and mixing with diesel to the distribution of biodiesel. This model is useful for forecasting organic-waste management biodiesel supply chains in South Korea in 2030. The case study results show that a total network cost of $US 3.16/gallon of B3 contains 3% BuOH from organic waste products combined with diesel. The biorefinery-related cost accounts for 98.3% of the total network cost, followed by the organic waste procurement cost (1.1%) and biodiesel distribution cost (0.6%). A scenario-based analysis shows that a 7%-BuOH increase in biodiesel increases the total network cost by 18.8%.

Volatile Fatty Acid Production from Organic Waste with the Emphasis on Membrane-Based Recovery

In recent years, interest in the biorefinery concept has emerged in the utilization of volatile fatty acids (VFAs) produced by acidogenic fermentation as precursors for various biotechnological processes. This has attracted substantial attention to VFA production from low-cost substrates such as organic waste and membrane based VFA recovery techniques to achieve cost-effective and environmentally friendly processes. However, there are few reviews which emphasize the acidogenic fermentation of organic waste into VFAs, and VFA recovery. Therefore, this article comprehensively summarizes VFA production, the factors affecting VFA production, and VFA recovery strategies using membrane-based techniques. Additionally, the outlook for future research on VFA production is discussed.

Recent Developments in Microbial Electrolysis Cell-Based Biohydrogen Production Utilizing Wastewater as a Feedstock

Carbon constraints, as well as the growing hazard of greenhouse gas emissions, have accelerated research into all possible renewable energy and fuel sources. Microbial electrolysis cells (MECs), a novel technology able to convert soluble organic matter into energy such as hydrogen gas, represent the most recent breakthrough. While research into energy recovery from wastewater using microbial electrolysis cells is fascinating and a carbon-neutral technology that is still mostly limited to lab-scale applications, much more work on improving the function of microbial electrolysis cells would be required to expand their use in many of these applications. The present limiting issues for effective scaling up of the manufacturing process include the high manufacturing costs of microbial electrolysis cells, their high internal resistance and methanogenesis, and membrane/cathode biofouling. This paper examines the evolution of microbial electrolysis cell technology in terms of hydrogen yield, operational aspects that impact total hydrogen output in optimization studies, and important information on the efficiency of the processes. Moreover, life-cycle assessment of MEC technology in comparison to other technologies has been discussed. According to the results, MEC is at technology readiness level (TRL) 5, which means that it is ready for industrial development, and, according to the techno-economics, it may be commercialized soon due to its carbon-neutral qualities.

Review and perspectives of enhanced volatile fatty acids production from acidogenic fermentation of lignocellulosic biomass wastes

Lignocellulosic biomass wastes are abundant resources that are usually valorized for methane-rich biogas via anaerobic digestion. Conversion of lignocellulose into volatile fatty acids (VFA) rather than biogas is attracting attention due to the higher value-added products that come with VFA utilization. This review consolidated the latest studies associated with characteristics of lignocellulosic biomass, the effects of process parameters during acidogenic fermentation, and the intensification strategies to accumulate more VFA. The differences between anaerobic digestion technology and acidogenic fermentation technology were discussed. Performance-enhancing strategies surveyed included (1) alkaline fermentation; (2) co-digestion and high solid-state fermentation; (3) pretreatments; (4) use of high loading rate and short retention time; (5) integration with electrochemical technology, and (6) adoption of membrane bioreactors. The recommended operations include: mesophilic temperature (thermophilic for high loading rate fermentation), C/N ratio (20-40), OLR (< 12 g volatile solids (VS)/(L·d)), and the maximum HRT (8-12 days), alkaline fermentation, membrane technology or electrodialysis recovery. Lastly, perspectives were put into place based on critical analysis on status of acidogenic fermentation of lignocellulosic biomass wastes for VFA production.

Microbial Electrolysis Cells for Decentralised Wastewater Treatment: The Next Steps

Traditional wastewater treatment methods have become aged and inefficient, meaning alternative methods are essential to protect the environment and ensure water and energy security worldwide. The use of microbial electrolysis cells (MEC) for wastewater treatment provides an innovative alternative, working towards circular wastewater treatment for energy production. This study evaluates the factors hindering industrial adoption of this technology and proposes the next steps for further research and development. Existing pilot-scale investigations are studied to critically assess the main limitations, focusing on the electrode material, feedstock, system design and inoculation and what steps need to be taken for industrial adoption of the technology. It was found that high strength influents lead to an increase in energy production, improving economic viability; however, large variations in waste streams indicated that a homogenous solution to wastewater treatment is unlikely with changes to the MEC system specific to different waste streams. The current capital cost of implementing MECs is high and reducing the cost of the electrodes should be a priority. Previous pilot-scale studies have predominantly used carbon-based materials. Significant reductions in relative performance are observed when electrodes increase in size. Inoculation time was found to be a significant barrier to quick operational performance. Economic analysis of the technology indicated that MECs offer an attractive option for wastewater treatment, namely greater energy production and improved treatment efficiency. However, a significant reduction in capital cost is necessary to make this economically viable. MEC based systems should offer improvements in system reliability, reduced downtime, improved treatment rates and improved energy return. Discussion of the merits of H2 or CH4 production indicates that an initial focus on methane production could provide a stepping-stone in the adoption of this technology while the hydrogen market matures.

Economically-feasible production of a nylon monomer using RANEY® catalysts

This research was aimed at developing an economically-feasible process to produce a value-added chemical used to synthesize nylon, hexamethylenediamine (HMDA), by hydrogenating adiponitrile (ADN) using an inexpensive catalyst such as RANEY® Ni or RANEY® Co.

Towards a bio-based circular economy in organic waste management and wastewater treatment - The Polish perspective

Bio-based solutions are expected to ensure technological circularity in priority areas such as agriculture, biotechnology, ecology, green industry or energy. Although Poland, unlike the other EU member states, has not yet adopted a precise political strategy to promote bioeconomy, it has taken several actions to enable smart, sustainable and inclusive growth. This goal can be achieved by developing selected bioeconomy-related areas such as the biogas industry together with novel technologies implemented to optimize treatment of municipal sewage and management of organic solid waste. Here, the relatively strong status of the Polish biogas sector is presented. The widely used practice of sewage sludge biomethanation has led to construction of numerous complex installations combining biological wastewater treatment plants with anaerobic digesters. Based on physico-chemical processing of biostabilized sludges, a novel method for efficient granulated soil fertilizer production is elaborated, in line with the concept of circular economy and the notion of "waste-to-product". It is also shown that anaerobic fermentation of sewage sludges can be optimized by co-digestion with properly selected co-substrates to increase bioprocess yield and improve the resultant digestate fertilizer quality. The problem of post-fermentation eutrophic sludge liquors, environmentally hazardous waste effluents requiring proper treatment prior to discharge or field application, is addressed. Attempts to optimize biological treatment of digestate liquors with complex microbial consortia are presented. The Polish innovations described show that the "zero waste" path in circular bioeconomy may bring advantageous results in terms of transformation of waste materials into commercial, added-value products together with recovery of water resources.

Concurrent use of methanol and ethanol for chain-elongating short chain fatty acids into caproate and isobutyrate

Microbial chain elongation (MCE) is a bioprocess that could utilise a mixed-culture fermentation to valorise organic waste. MCE converting ethanol and short chain fatty acids (SCFA; derived from organic waste) to caproate has been studied extensively and implemented. Recent studies demonstrated the conversion of SCFAs and methanol or ethanol into isomerised fatty acids as novel products, which may expand the MCE application and market. Integrating caproate and isomerised fatty acid production in one reactor system is theoretically feasible given the employment of a mixed culture and may increase the economic competence of MCE; however, the feasibility of such has never been demonstrated. This study investigated the feasibility of using two electron donors, i.e. methanol and ethanol, for upgrading SCFAs into isobutyrate and caproate concurrently in MCE Results show that supplying methanol and ethanol in MCE simultaneously converted acetate and/or butyrate into caproate and isobutyrate, by a mixed-culture microbiome. The butyrate supplement stimulated the caproate production rate from 1.5 to 2.6 g/L.day and induced isobutyrate production (1.5 g/L.day). Further increasing ethanol feeding rate from 140 to 280 mmol carbon per litre per day enhanced the direct use of butyrate for caproate production, which improved the caproate production rate to 5.9 g/L.day. Overall, the integration of two electron donors, i.e. ethanol and methanol, in one chain-elongation reactor system for upgrading SCFAs was demonstrated. As such, MCE could be applied to valorise organic waste (water) streams into a wider variety of value-added biochemical.

Biorefineries in circular bioeconomy: A comprehensive review

Biorefinery is a sustainable means of generating multiple bioenergy products from various biomass feedstocks through the incorporation of relevant conversion technologies. With the increased attention of circular economy in the past half-decade with the emphasis of holistically addressing economic, environmental, and social aspects of the industrial-sector, biorefinery acts as a strategic mechanism for the realization of a circular bioeconomy. This study presents a comprehensive review of different biorefinery models used for various biomass feedstocks such as lignocelluloses, algae, and numerous waste-types. The review focuses on how biorefinery is instrumental in the transition of various biomass-based industries in a circular bioeconomy. The results reveal that the social-economic aspect of the industrial sector has a major influence on the full adoption of biorefineries in circular bioeconomy. Biomass wastes have played a major role in the implementation of biorefinery in circular bioeconomy. The current challenges are also presented along with future perspectives.

Techno-Economic Analysis of Bio-Based Lactic Acid Production Utilizing Corn Grain as Feedstock

Lactic acid is an important chemical with numerous commercial applications that can be fermentatively produced from biological feedstocks. Producing lactic acid from corn grain could complement the use of already existing infrastructure for corn grain-based ethanol production with a higher value product. The objective of this study was to evaluate the techno-economic feasibility of producing 100,000 metric tons (t) of lactic acid annually from corn grain in a biorefinery. The study estimated the resources (equipment, raw materials, energy, and labor) requirements and costs to produce lactic acid from bacteria, fungi and yeast-based fermentation pathways. Lactic acid production costs were $1181, $1251 and $844, for bacteria, fungi and yeast, respectively. Genetically engineered yeast strains capable of producing lactic acid at low pH support significantly cheaper processes because they do not require simultaneous neutralization and recovery of lactic acid, resulting in lower requirements for chemical, equipment, and utilities. Lactic acid production costs were highly sensitive to sugar-to-lactic-acid conversion rates, grain price, plant size, annual operation hours, and potential use of gypsum. Improvements in process efficiencies and lower equipment and chemical costs would further reduce the cost of lactic acid production from corn grain.

Techno-economic assessment of non-sterile batch and continuous production of lactic acid from food waste

Non-sterile lactic acid (LA) fermentation of highly viscous food waste was demonstrated in batch and continuous flow fermentations. With Streptococcus sp., an indigenous consortium, and/or applied glucoamylase, food waste was fermented without addition of external carbon or nitrogen sources. Experimental results were used for economic and energy evaluations under consideration of different catchment area sizes from 50,000 to 1,000,000 inhabitants. During batch mode, addition of glucoamylase resulted in a titer (after 24 h), yield, and productivity of 50 g L^-1, 63%, and 2.93 g L^-1h^-1, respectively. While titer and yield were enhanced, productivity was lower during continuous operation and 69 g L^-1, 86%, and 1.27 g L^-1h^-1 were obtained at a dilution rate of 0.44 d^-1 when glucoamylase was added. Both batch and continuous flow fermentations were found economically profitable with food waste from 200,000 or more inhabitants.

Inhibitory effects of free propionic and butyric acids on the activities of hydrogenotrophic methanogens in mesophilic mixed culture fermentation

The aim of this work was to study the inhibitory of free propionic acid (FPA) and free butyric acid (FBA) on enriched hydrogenotrophic methanogens. It demonstrated that concentrations of FPA and FBA were correlated well with the specific methanogenic activity. Coenzyme M concentrations also agreed well with the trends of FPA and FBA. Two fators of C_50% (concentration at 50% inhibition) and C_RC (recoverable concentration from inhibition) were used to quantitively analyze the inhibitory order using the former result of free acetic acid (FAA) and the results of FBA and FPA. The order according to C_50% was FAA (5.2 mM) > FBA (8.3 mM) > FPA (8.5 mM), while for C_RC it was FPA (9.3 mM) > FAA = FBA (13.5 mM). After comparing with literatue, it suggests that the toxicities of these three organic acids are similar. Thus, accumulating free organic acid offers a cost-effective method to inhibit methanogenesis.

Energy Efficiency of Biorefinery Schemes Using Sugarcane Bagasse as Raw Material

The use of biomass to obtain value-added products has been a good alternative for reducing their environmental impacts. For this purpose, different studies have been carried out focused on the use of agro-industrial waste. One of the most commonly used raw materials has been bagasse obtained from the processing of sugarcane in high quantities in countries like Brazil, India, China, Thailand, Pakistan, Mexico, Colombia, Indonesia, Philippines, and the United States. From 1 ton of sugarcane, 280 kg of bagasse can be obtained. Sugarcane bagasse (SCB) is a waste that is rich in polysaccharides, which makes it a promising raw material for obtaining products under biorefinery concept. The objective of this work was to analyze from the energetic point of view, different biorefinery schemes in which SCB is employed as a raw material. The design and simulation of the different biorefinery schemes is performed in Aspen Plus software. From this software, it was possible to obtain the different mass and energy balances, which are used in the technical and energetic analysis. Exergy is used as a comparison tool for the energy analysis. These analyses allowed for the selection of the best biorefinery configuration from SCB.

BioEnergy and BioChemicals Production from Biomass and Residual Resources

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