Biochar production and its environmental applications: Recent developments and machine learning insights

Biochar production through thermochemical processing is a sustainable biomass conversion and waste management approach. However, commercializing biochar faces challenges requiring further research and development to maximize its potential for addressing environmental concerns and promoting sustainable resource management. This comprehensive review presents the state-of-the-art in biochar production, emphasizing quantitative yield and qualitative properties with varying feedstocks. It discusses the technology readiness level and commercialization status of different production strategies, highlighting their environmental and economic impacts. The review focuses on integrating machine learning algorithms for process control and optimization in biochar production, improving efficiency. Additionally, it explores biochar's environmental applications, including soil amendment, carbon sequestration, and wastewater treatment, showcasing recent advancements and case studies. Advances in biochar technologies and their environmental benefits in various sectors are discussed herein.

Production, characterization and techno-economic evaluation of Aspergillus fusant L-asparaginase

Protoplast fusion is one of the most reliable methods of introducing desirable traits into industrially-promising fungal strains. It harnesses the entire genomic repertoire of fusing microorganisms by routing the natural barrier and genetic incompatibility between them. In the present study, the axenic culture of a thermo-halotolerant strain of Aspergillus candidus (Asp-C) produced an anti-leukemic L-asparaginase (L-ASNase) while a xylan-degrading strain of Aspergillus sydowii (Asp-S) produced the acrylamide-reduction type. Protoplast fusion of the wild strains generated Fusant-06 with improved anti-leukemic and acrylamide reduction potentials. Submerged fed-batch fermentation was preferred to batch and continuous modes on the basis of impressive techno-economics. Fusant-06 L-ASNase was purified by PEG/Na⁺ citrate aqueous two-phase system (ATPS) to 146.21-fold and global sensitivity analysis report revealed polymer molecular weight and citrate concentration as major determinants of yield and purification factor, respectively. The enzyme was characterized by molecular weight, amino acid profile, activity and stability to chemical agents. Michaelis-Menten kinetics, evaluated under optimum conditions gave K_m, V_max, K_cat, and K_cat/K_m as 6.67 × 10^-5 M, 1666.67 µmolmin^-1 mg^-1 protein, 3.88 × 10⁴ min^-1 and 5.81 × 10⁸ M^-1.min^-1 respectively. In-vitro cytotoxicity of HL-60 cell lines by Fusant-06 L-ASNase improved significantly from their respective wild strains. Stability of Fusant-06 L-ASNase over a wide range of pH, temperature and NaCl concentration, coupled with its micromolar K_m value, confers commercial and therapeutic value on the product. Free-radical scavenging and acrylamide reduction activities were intermediate and the conferred thermo-halo-stability could be exploited for sustainable clinical and food industry applications.

Organic solid waste: Biorefinery approach as a sustainable strategy in circular bioeconomy

Waste generation is associated with numerous environmental consequences, making it a point of discussion in the environmental arena. Efforts have been made around the world to develop a systematic management approach coupled with a sustainable treatment technology to maximize resource utilization of organic solid waste. Biorefineries and bio-based products play a critical role in lowering total emissions and supporting energy systems. However, economic viability of biorefineries, on the other hand, is a stumbling hurdle to their commercialization. This communication provides a thorough study of the concept of biorefinery in waste management, as well as technological advancements in this field. In addition, the notion of techno-economic assessment, as well as challenges and future prospects have been covered. To find the most technologically and economically viable solution, further techno-economic study to the new context is required. Overall, this communication would assist decision-makers in identifying environmentally appropriate biorefinery solutions ahead of time.

Techno-economic feasibility assessment of bacterial cellulose biofilm production during the Kombucha fermentation process

Bacterial cellulose produced during Kombucha fermentation has recently received lots of attention owing to its desirable mechanical and physicochemical properties and is exploited for different food, textiles and environmental applications. However, lack of information on process feasibility often hinders large-scale manufacturing of Kombucha-based cellulose. Therefore, the current study assesses techno-economic feasibility of a 60-ton annual capacity Kombucha-based cellulose production facility using SuperPro designer. Economic feasibility analysis showed an estimation of 13.72 million US$ as total investment and 3.8 million US$ as operating costs with 89% expenses associated with facility dependent and labour costs. The process feasibility is revealed with a payback time of 4.23 years, 23.64% return on investment and 16.48% internal rate of return. Sensitivity analysis presented that increased volume of fermentation units and automating the process can significantly reduce input costs. Such research is necessary to aid policymakers in facilitating the commercialization of Kombucha-based cellulose at field scale.

Techno-economic assessment of various hydrogen production methods - A review

Hydrogen is a clean fuel that could provide energy incentives and reduce environmental impacts, if production platform is carefully selected and optimized. In specific, techno-economic and sensitivity analysis of the existing hydrogen production platforms and processes is need for an hour to boost the future hydrogen economical aspects. This will have greater impact on future hydrogen production project designs and developing new approaches to reduce the overall production costs to make it as cheaper fuel. The sensitivity analysis of various hydrogen production process such as pyrolysis, gasification, steam reforming of natural gas, dark fermentation, photobiolysis, water electrolysis and renewable liquid reforming were reviewed to evaluate their merits and demerits along with cost-effectiveness. On economic view point, steam reforming of natural gas is efficient, low cost and best methods for hydrogen production. A future research is required to reduce energy input and trapping carbon dioxide emission using membrane models.

A feasibility assessment of the production of char using the slow pyrolysis process

There is a growing need for the production and use of sustainable biofuels worldwide. One noteworthy approach is the production of biofuels via the thermochemical conversion of lignocellulose biomass. This work studied the production of char via the slow pyrolysis of corn-stover as a suitable supplement or replacement of coal in industrial processes. The char quality was assessed according to the ASTM D388 (American Standard Testing Method), which ranks coals according to their higher heating value (HHV), volatile matter and fixed carbon. Furthermore, an evaluation of the techno-economic feasibility of an industrial scale 30 t/day slow pyrolysis plant was conducted. The techno-economic study was conducted at a char baseline price of $100/ton. A two-level three-factor central composite design (CCD), with response surface methodology (RSM) was used to study the slow-pyrolysis process conditions. Optimisation experiments were conducted at bench-scale gram-level to study the influences of the process condition of char higher heating value (HHV) and yield. Furthermore, this study assessed the techno-economic feasibility of a 30t/day processing plant. The results showed process temperature had the most significant influence on char HHV and yield. Optimal conditions for char production were at a reactor temperature of 453 °C, and 5 °C/min and 29 min for heating rate and holding time respectively. Under these conditions char with HHV of 26.25 ± 1.5 MJ/kg and yield of 34.5% were produced. These chars are comparable to sub-bituminous A coals. A high energy efficiency of ~82% was also associated with the process. The economic feasibility of the plant is highly sensitive to the cost of CS feedstock. The process had a net present value (NPV) of -$1.17 million at the $20/ton CS baseline assumption. A cost sensitivity analysis showed that when the cost of CS was lowered to $3/ton, the NPV was zero. Uncertainties in the price estimation of the volatile by-products remained a concern.

A comparative account of glucose yields and bioethanol production from separate and simultaneous saccharification and fermentation processes at high solids loading with variable PEG concentration

A process strategy to aid in optimal enzymatic hydrolysis through the addition of polyethylene glycol (PEG6000) was tested for separate hydrolysis and fermentation (SHF) and simultaneous saccharification and fermentation (SSF). Pretreated wheat straw at 30% solids (w/w) loading was enzymatically hydrolyzed with 0, 0.5, 1, 1.5, 2 and 2.5% of PEG6000 through SHF and SSF. During SHF, bioethanol concentration of 107.5 g/L (2.5% PEG6000) was achieved. SSF ethanol concentration were about 113 g/L at 1.5% PEG6000 addition. A technoeconomic feasibility showed a return on investment (ROI) of 8.13% using 0.5% PEG6000 for SHF (96 h) and 12.25% ROI for SSF control (72 h). Life cycle assessment for the various scenarios indicated higher environmental gains for best cases of SSF over SHF. The study shows the SSF approach (0% PEG6000; 72 h) facilitates higher process efficiencies; technoeconomic gains and high environmental sustainability for future scale-up and commercial realization.

Improving techno-economics of bioproduct glycolic acid by successive recycled-cell catalysis of ethylene glycol with Gluconobacter oxydans

Bioconversion of ethylene glycol (EG) to glycolic acid (GA) by the whole-cell of Gluconobacter oxydans in an aired stirred tank reactor (ASTR) with continuous substrate feeding yielded over 220 g/L of GA. However, the bioreactor productivity declined to an unfavorable level of 0.63 g/L/h due to negative feed-back by GA which inhibited the reaction. To overcome this problem, based on results obtained from techno-economic comparative analysis, we set up a successive recycled-cell catalytic bioprocessing ASTR, and carried out five consecutive cycles stably during 240 h. At the end of this process, total 490.7 g GA was accumulated with over 90% yield, and an average bioreactor productivity of 2.04 g/L/h. The twin strategies of end-product titer control and cell-recycling successfully demonstrated the large scale applicability of EG bioconversion to GA.

Experimental and feasibility assessment of biogas production by anaerobic digestion of fruit and vegetable waste from Joburg Market

Substrate-induced instability of anaerobic digestion from fruit and vegetable waste (FVW) results in low biogas yield. In this study, substrate management through fruit to vegetable mix ratio in a two-stage semi-continuous digester was investigated as a pathway for optimality of yield. The experiment conducted over 105 days with 62.52 kg of FVWs sourced from Joburg Market, South Africa showed that a stable process was achieved at a fruit to vegetable waste mix ratio of 2.2:2.8. At this ratio, optimal organic loading rate ranged between 2.68 and 2.97 kg VS/m³-d which resulted in a specific biogas yield of 0.87 Nm³/kg VS with 57.58% methane on average. The results of the experimental study were used as a feasibility assessment for a full-scale 45 tonnes/d plant for Joburg Market considering three energy pathways. The plant will produce 1,605,455 Nm³/y of biogas with the potential for offsetting 15.2% of the Joburg Market energy demand. Conversion of all biogas to biomethane was the most economically attractive energy pathway with a net present value of $2,428,021, an internal rate of return of 16.90% and a simple payback period of 6.17 years. This route avoided the greenhouse gas emission of 12,393 tonnes CO₂, eq. The study shows that the anaerobic digestion of FVWs as sole substrate is possible with financial and environmental attractiveness.

Process design and economics of a flexible ethanol-butanol plant annexed to a eucalyptus kraft pulp mill

This work proposes a strategy, from a process design standpoint, for pulp companies to enter the Brazilian ethanol market. The flexible plant converts eucalyptus-derived glucose to either ethanol or butanol (according to market conditions) and xylose only to butanol production. Depending on the biomass pretreatment technology, Monte Carlo simulations showed that the Net Present Value (NPV) of the flexible plant increases by 20-28% in relation to an ethanol-dedicated plant. Whereas the lower costs of the steam explosion technology turns the investment more attractive (NPV = 184 MMUSD; IRR = 29%), the organosolv technology provides better flexibility to the plant. This work also shows that excessive power consumption is a hurdle in the development of flash fermentation technology chosen for the flexible plant. These results indicate that conventional batch fermentation is preferable if the enzymatic hydrolysis step operates with solids loading up to 20 wt%.

Universal model of slow pyrolysis technology producing biochar and heat from standard biomass needed for the techno-economic assessment

Biochar as a soil amendment and carbon sink becomes in last period one of the vast, interesting product of slow pyrolysis. Simplest and most used industrial process arrangement is a production of biochar and heat at the same time. Proposed mass and heat balance model consist of heat consumers (heat demand side) and heat generation-supply side. Direct burning of all generated uncondensed volatiles from biomass provides heat. Calculation of the mass and heat balance of both sides reveals the internal distribution of masses and energy inside process streams and units. Thermodynamic calculations verified not only the concept but also numerical range of the results. The comparisons with recent published scientific and vendors data prove its general applicability and reliability. The model opens the possibility for process efficiency innovations. Finally, the model was adapted to give more investors favorable results and support techno-economic assessments entirely.

Hydrocarbon bio-jet fuel from bioconversion of poplar biomass: techno-economic assessment

BACKGROUND

Infrastructure compatible hydrocarbon biofuel proposed to qualify as renewable transportation fuel under the U.S. Energy Independence and Security Act of 2007 and Renewable Fuel Standard (RFS2) is evaluated. The process uses a hybrid poplar feedstock, which undergoes dilute acid pretreatment and enzymatic hydrolysis. Sugars are fermented to acetic acid, which undergoes conversion to ethyl acetate, ethanol, ethylene, and finally a saturated hydrocarbon end product. An unfermentable lignin stream may be burned for steam and electricity production, or gasified to produce hydrogen. During biofuel production, hydrogen gas is required and may be obtained by various methods including lignin gasification.

RESULTS

Both technical and economic aspects of the biorefinery are analyzed, with different hydrogen sources considered including steam reforming of natural gas and gasification of lignin. Cash operating costs for jet fuel production are estimated to range from 0.67 to 0.86 USD L^-1 depending on facility capacity. Minimum fuel selling prices with a 15 % discount rate are estimated to range from 1.14 to 1.79 USD L^-1. Capacities of 76, 190, and 380 million liters of jet fuel per year are investigated. Capital investments range from 356 to 1026 million USD.

CONCLUSIONS

A unique biorefinery is explored to produce a hydrocarbon biofuel with a high yield from bone dry wood of 330 L t^-1. This yield is achieved chiefly due to the use of acetogenic bacteria that do not produce carbon dioxide as a co-product during fermentation. Capital investment is significant in the biorefinery in part because hydrogen is required to produce a fully de-oxygenated fuel. Minimum selling price to achieve reasonable returns on investment is sensitive to capital financing options because of high capital costs. Various strategies, such as producing alternative, intermediate products, are investigated with the intent to reduce risk in building the proposed facility. It appears that producing and selling these intermediates may be more profitable than converting all the biomass into aviation fuel. With variability in historical petroleum prices and environmental subsidies, a high internal rate of return would be required to attract investors.