Economic and environmental assessment of cellulosic ethanol production scenarios annexed to a typical sugar mill

Review of methodological decisions in life cycle assessment (LCA) of biorefinery systems across feedstock categories

The application of life cycle assessment (LCA) to biorefineries is a necessary step to estimate their environmental sustainability. This review explores contemporary LCA biorefinery studies, across different feedstock categories, to understand approaches in dealing with key methodological decisions which arise, including system boundaries, consequential or attributional approach, allocation, inventory data, land use changes, product end-of-life (EOL), biogenic carbon storage, impact assessment and use of uncertainty analysis. From an initial collection of 81 studies, 59 were included within the final analysis, comprising 22 studies which involved dedicated feedstocks, 34 which involved residue feedstocks (including by-products and wastes), and a further 3 studies which involved multiple feedstocks derived from both dedicated and secondary sources. Many studies do not provide a comprehensive LCA assessment, often lacking detail on decisions taken, omitting key parts of the value chain, using generic data without uncertainty analyses, or omitting important impact categories. Only 28% of studies included some level of primary data, while 39% of studies did not undertake an uncertainty or sensitivity analysis. Just 8% of studies included data related to dLUC with a further 8% including iLUC, and only 14% of studies considering product end of life within their scope. The authors recommend more transparency in biorefinery LCA, with justification of key methodological decisions. A full value-chain approach should be adopted, to fully assess burdens and opportunities for biogenic carbon storage. We also propose a more prospective approach, taking into account future use of renewable energy sources, and opportunities for increasing circularity within bio-based value chains.

Ethanol Production from the Mixture of Waste French Fries and Municipal Wastewater via Separate Hydrolysis and Fermentation

The potential of bioethanol generation using the mixture of waste French fries (WFF) and municipal wastewater (MWW) via separate hydrolysis and fermentation (SHF) was evaluated in this study. The effect of WFF substrate loading (SL, 10%, 16%, and 20%, w/v) on the SHF was also examined. Both glucose production and hydrolysis efficiency increased with increasing of SL from 10 to 16% and the maximum glucose yield of 0.236 g glucose/g WFF and hydrolysis efficiency of 91.9% were obtained at SL of 16%. However, the glucose production and hydrolysis efficiency decreased when the SL further increased to 20% due to the inhibition on enzyme caused by higher glucose production. The mixture hydrolysate was then used as feedstock for ethanol fermentation. The maximum ethanol production of 22.69 g/L was obtained from SL of 16%. The highest rate of glucose conversion to ethanol was 84.2%. The results demonstrated that the mixture of WFF and MWW could be used for ethanol production by the SHF.

Effects of Enzyme Volumes on Hydrolysis and Fermentation for Ethanol Production From Leftover Cooked Rice

This study aimed to utilize the enzymatic hydrolysis of leftover cooked rice (LCR) for fermentative ethanol production. Effect of glucoamylase volumes (V1: 5 U/g, V2: 25 U/g, and V3: 50 U/g) on the performance of LCR hydrolysis was also evaluated. It was found that the highest chemical oxygen demand (COD) of 77.5 g/L and reducing sugar (RS) of 34.6 g/L were achieved at V3. The LCR hydrolyzate obtained from enzymatic hydrolysis was then used as feedstock for ethanol fermentation. Higher ethanol production was obtained when RS increased from 18.7 g/L (V1) to 23.2 g/L (V2). However, lower ethanol production was found when RS further increased to 34.6 g/L (V3) probably because too high RS concentration led to the inhibition on the yeast. The maximum ethanol production and yield were 21.1 g/L and 0.3 g ethanol/g LCR, respectively. The LCR could be a promising substrate for fermentative ethanol production for industrial application.

Status of Life Cycle Assessment (LCA) in Africa

Life cycle assessment (LCA) has received attention as a tool to evaluate the environmental impacts of products and services. In the last 20 years, research on the topic has increased, and now more than 25,000 articles are related to LCA in scientific journals databases such as the Scopus database; however, the concept is relatively new in Africa, where the number of networks has been highlighted to be very low when compared to the other regions. This paper focuses on a review of life cycle assessments conducted in Africa over the last 20 years. It aims at highlighting the current research gap for African LCA. A total of 199 papers were found for the whole continent; this number is lower than that for both Japan and Germany (more than 400 articles each) and nearly equal to developing countries such as Thailand. Agriculture is the sector which received the most attention, representing 53 articles, followed by electricity and energy (60 articles for the two sectors). South Africa (43), Egypt (23), and Tunisia (19) were the countries where most of the research was conducted. Even if the number of articles related to LCA have increased in recent years, many steps still remain. For example, establishing a specific life cycle inventory (LCI) database for African countries or a targeted ideal life cycle impact assessment (LCIA) method. Several African key sectors could also be assessed further.

Life Cycle Analysis of the Bioethanol Production from Food Waste—A Review

Food Waste (FW) because of its composition is considered as an ideal feedstock for the production of biofuels and in particular bioethanol. The production of bioethanol from lignocellulosic materials has been studied over a long time. The process consists of the stages of pretreatment, enzymatic hydrolysis, fermentation and product recovery. However, the legal framework regarding biofuels has established specific environmental criteria for their production which are regularly updated. The most common tool for the assessment of the environmental performance of a process or product is the Life Cycle Analysis (LCA). In the present review, the results of LCA studies on the production of bioethanol from food waste are presented. Significant differences are observed among the studies in terms of the methodological choices made. Despite the high heterogeneity observed which does not allow a direct comparison among them, there is strong evidence that the production of bioethanol from food waste is an eco-friendly process which can substantially contribute to Green House Gas (GHG) emissions savings.

A Review of Landfill Microbiology and Ecology: A Call for Modernization With 'Next Generation' Technology

Engineered and monitored sanitary landfills have been widespread in the United States since the passage of the Clean Water Act (1972) with additional controls under RCRA Subtitle D (1991) and the Clean Air Act Amendments (1996). Concurrently, many common perceptions regarding landfill biogeochemical and microbiological processes and estimated rates of gas production also date from 2 to 4 decades ago. Herein, we summarize the recent application of modern microbiological tools as well as recent metadata analysis using California, USEPA and international data to outline an evolving view of landfill biogeochemical/microbiological processes and rates. We focus on United States landfills because these are uniformly subject to stringent national and state requirements for design, operations, monitoring, and reporting. From a microbiological perspective, because anoxic conditions and methanogenesis are rapidly established after daily burial of waste and application of cover soil, the >1000 United States landfills with thicknesses up to >100 m form a large ubiquitous group of dispersed 'dark' ecosystems dominated by anaerobic microbial decomposition pathways for food, garden waste, and paper substrates. We review past findings of landfill ecosystem processes, and reflect on the potential impact that application of modern sequencing technologies (e.g., high throughput platforms) could have on this area of research. Moreover, due to the ever evolving composition of landfilled waste reflecting transient societal practices, we also consider unusual microbial processes known or suspected to occur in landfill settings, and posit areas of research that will be needed in coming decades. With growing concerns about greenhouse gas emissions and controls, the increase of chemicals of emerging concern in the waste stream, and the potential resource that waste streams represent, application of modernized molecular and microbiological methods to landfill ecosystem research is of paramount importance.

Sustainable valorization of sugar industry waste: Status, opportunities, and challenges

Sugarcane processing in sugar industry results in generation of vast amounts of wastes, which can be valorized to biofuels and value-added chemicals based on the concept of circular bioeconomy. For successful commercialization, economic and technological bottlenecks must be clearly identified. In this review, the state of the art of various valorization routes are discussed for each waste stream. Subsequently, studies quantifying the environmental impacts and performing techno-economic assessment are reviewed. The scope and bottlenecks involved in the commercialization of these routes are identified and discussed. The review shows that electricity production from bagasse has matured as a technology but the production of value-added chemicals is still lagging. Here, downstream separation and purification are the major hurdles needing technological innovation. Moreover, indirect environmental and human health benefits due to waste valorization are not adequately accounted for. Further, strong trade-offs between economic and environmental performance exist, necessitating systematic and region-specific decision-making framework.

An Environmental and Economic Analysis of Flocculation Technology Applied to a Corn-Based Ethanol Plant

The stimulation of renewable fuel production is related to the environmental issues resulting from the extraction and utilization of fossil fuels. Although corn-based ethanol is one of the leading renewable fuels and promises to mitigate these environmental impacts, it generates large volumes of wastewater with high concentrations of organic material (CODcr > 30,000 mg/L) and low pH (3.5–4.5), which leads to serious environmental concerns. A common method of treatment of distillery wastewater is the Dry Distilled Grain Soluble (DDGS) process, which separates liquid and solid fractions; however, a disadvantage of this process is its high energy consumption. Other commonly implemented methods are often costly and not environmentally safe. To minimize these problems, a flocculation process can be applied as a potential lower energy consumption process utilizing bioflocculants, which have been proven harmless to the environment. Therefore, the main goal of this study was to analyze the economic and environmental impacts of using bioflocculants instead of evaporation process in a corn-based ethanol plant. The procedures were evaluated by analyzing the Life Cycle Assessment (LCA) and Techno-Economic Analysis (TEA). From the results, it can be seen that the flocculation system can be an alternative process for effectively minimizing energy consumption during the production of DDGS, Distilled Wet Grains with Solubles (DWGS), and corn oil. The flocculation process achieved a significantly (28%) lower utility cost when compared to the conventional system. However, the overall fixed costs and annual operating costs for the flocculation system were higher than those of the conventional system. Additionally, both processes resulted in negative profit and a sensitivity analysis showed that the feedstocks cost substantially impacted the DDGS, DWGS, and corn oil production costs. Related to environmental aspects, the LCA results showed that the flocculation process achieved the lowest Global Warming Potential (GWP) of the several electricity supply technologies analyzed and presented a significant reduction in CO2 equivalent emissions when compared to a conventional system. The flocculation process resulted in approximately 57% lower greenhouse gas emissions.

Recent advancement and strategy on bio-hydrogen production from photosynthetic microalgae

Recently, ensuring energy security is a key challenge to political and economic strength in the world. Bio-hydrogen production from microalgae is the promising alternative source for potential renewable and self-sustainability energy but still in the initial phase of development. Practically and sustainability of microalgae hydrogen production is still debatable. The genetic engineering and metabolic pathway engineering of hydrogenase and nitrogenase play a key role to enhance hydrogen production. Microalgae have photosynthetic efficiency and synthesize huge carbohydrate biomass, used as 4th generation feedstock to generate bio-hydrogen. Recent genetically modified strains of microalgae are the attractive source for enhancing bio-hydrogen production in the future. The potential of hydrogen production from microRNAs are gaining great interest of researcher. The main objective of this review is attentive discussed recent approaches on new molecular genetics engineering and metabolic pathway developments, modern photo-bioreactors efficiency, economic assessment, limitations and knowledge gap of bio-hydrogen production from microalgae.

Techno-economic analysis of chemically catalysed lignocellulose biorefineries at a typical sugar mill: Sorbitol or glucaric acid and electricity co-production

Global concerns about depletion of fossil reserves has driven countries towards bio-economies utilising mostly first generation feedstocks. The economic viability of energy self-sufficient biorefineries processing sugarcane lignocelluloses into sorbitol or glucaric acid and electricity was investigated. Aspen Plus® simulations represented glucose conversion processes via SO₂-steam explosion or dilute acid pre-treatment, followed by enzymatic hydrolysis. The most economically viable sorbitol scenario using dilute acid pretreatment with a capital investment cost per litre of US$ 3.96/L was marginally profitable having a selling price 5% below the US$ 655/t market price. To secure private investment, the sorbitol selling price should reach US$ 1283/t.

Mexican biomasses valorization through pyrolysis process: Environmental and costs analysis

Biomasses valorization by pyrolysis is a good option for reducing environmental problems. In this study, the environmental performance of three Mexican biomass valorizations (castor husk, coffee pulp and Pinus sawdust) by the pyrolysis was compared. The environmental impacts of all equipment involved in pyrolysis were evaluated. In addition, the financial viability of pyrolysis technology of coffee pulp was studied. The biomass with the lowest impact for all the selected categories was the Pinus sawdust, followed by castor husk and coffee pulp. The GWP category had values greater than 700 kg CO₂eq for all the biomass studied. GWP category is caused by the emissions, mainly due to the high amounts of CH₄ and CO₂ released for all the studied biomasses. Furthermore, the equipment with the greatest impact are the separator, the pyrolyzer and the cyclone. Finally, it was observed that even the least favorable biomass with the environment is viable from a financial point of view.

Process integration for ethanol production from corn and corn stover as mixed substrates

This work investigated all possible process integration strategies for ethanol production from corn and dilute acid pretreated corn stover (CS) as mixed substrates. Three corn to pretreated CS ratios (20%:10%, 10%:20% and 5%:25%) were examined. When the ratio of corn to pretreated CS was 20%:10%, the process integration strategy that mixed corn with CS hydrolysate for liquefaction followed by SSF resulted in the highest ethanol titer of 99.3 g/L. Mixing liquefied corn with pretreated CS for hydrolysis/saccharification followed by fermentation was the best strategy for the other two ratios. The strategy of mixing liquefied corn with pretreated CS for 6 h hydrolysis followed by fermentation showed the highest productivity for all the tested ratios.

Process design and economic analysis of a biorefinery co-producing itaconic acid and electricity from sugarcane bagasse and trash lignocelluloses

Itaconic acid has economic potential as a commodity biochemical for the sugar industry, but its production is limited due to high production costs. Using cheaper and alternative lignocellulosic feedstocks together with achieving higher product titres have been identified as potential strategies for viable IA production. Consequently the use of sugarcane bagasse and trash for the production of itaconic acid (IA) and electricity have been investigated for an integrated biorefinery, where the production facility is annexed to an existing sugar mill and new combined heat and power (CHP) plant. Three IA biorefinery scenarios were designed and simulated in Aspen Plus®. Subsequent economic analyses indicated that cheaper feedstocks reduced the IA production cost from 1565.5 US$/t for glucose to 616.5 US$/t, but coal supplementation was required to sufficiently lower the production cost to 604.3 US$/t for a competitive IA selling price of 1740 US$/t, compared to the market price of 1800 US$/t.

Ethanol production potential from AFEX™ and steam-exploded sugarcane residues for sugarcane biorefineries

BACKGROUND

Expanding biofuel markets are challenged by the need to meet future biofuel demands and mitigate greenhouse gas emissions, while using domestically available feedstock sustainably. In the context of the sugar industry, exploiting under-utilized cane leaf matter (CLM) in addition to surplus sugarcane bagasse as supplementary feedstock for second-generation ethanol production has the potential to improve bioenergy yields per unit land. In this study, the ethanol yields and processing bottlenecks of ammonia fibre expansion (AFEX™) and steam explosion (StEx) as adopted technologies for pretreating sugarcane bagasse and CLM were experimentally measured and compared for the first time.

RESULTS

Ethanol yields between 249 and 256 kg Mg-1 raw dry biomass (RDM) were obtained with AFEX™-pretreated sugarcane bagasse and CLM after high solids loading enzymatic hydrolysis and fermentation. In contrast, StEx-pretreated sugarcane bagasse and CLM resulted in substantially lower ethanol yields that ranged between 162 and 203 kg Mg-1 RDM. The ethanol yields from StEx-treated sugarcane residues were limited by the aggregated effect of sugar degradation during pretreatment, enzyme inhibition during enzymatic hydrolysis and microbial inhibition of S. cerevisiae 424A (LNH-ST) during fermentation. However, relatively high enzyme dosages (> 20 mg g-1 glucan) were required irrespective of pretreatment method to reach 75% carbohydrate conversion, even when optimal combinations of Cellic® CTec3, Cellic® HTec3 and Pectinex Ultra-SP were used. Ethanol yields per hectare sugarcane cultivation area were estimated at 4496 and 3416 L ha-1 for biorefineries using AFEX™- or StEx-treated sugarcane residues, respectively.

CONCLUSIONS

AFEX™ proved to be a more effective pretreatment method for sugarcane residues relative to StEx due to the higher fermentable sugar recovery and enzymatic hydrolysate fermentability after high solids loading enzymatic hydrolysis and fermentation by S. cerevisiae 424A (LNH-ST). The identification of auxiliary enzyme activities, adequate process integration and the use of robust xylose-fermenting ethanologens were identified as opportunities to further improve ethanol yields from AFEX™- and StEx-treated sugarcane residues.

Genomic prediction applied to high-biomass sorghum for bioenergy production

The increasing cost of energy and finite oil and gas reserves have created a need to develop alternative fuels from renewable sources. Due to its abiotic stress tolerance and annual cultivation, high-biomass sorghum (Sorghum bicolor L. Moench) shows potential as a bioenergy crop. Genomic selection is a useful tool for accelerating genetic gains and could restructure plant breeding programs by enabling early selection and reducing breeding cycle duration. This work aimed at predicting breeding values via genomic selection models for 200 sorghum genotypes comprising landrace accessions and breeding lines from biomass and saccharine groups. These genotypes were divided into two sub-panels, according to breeding purpose. We evaluated the following phenotypic biomass traits: days to flowering, plant height, fresh and dry matter yield, and fiber, cellulose, hemicellulose, and lignin proportions. Genotyping by sequencing yielded more than 258,000 single-nucleotide polymorphism markers, which revealed population structure between subpanels. We then fitted and compared genomic selection models BayesA, BayesB, BayesCπ, BayesLasso, Bayes Ridge Regression and random regression best linear unbiased predictor. The resulting predictive abilities varied little between the different models, but substantially between traits. Different scenarios of prediction showed the potential of using genomic selection results between sub-panels and years, although the genotype by environment interaction negatively affected accuracies. Functional enrichment analyses performed with the marker-predicted effects suggested several interesting associations, with potential for revealing biological processes relevant to the studied quantitative traits. This work shows that genomic selection can be successfully applied in biomass sorghum breeding programs.

How does technology pathway choice influence economic viability and environmental impacts of lignocellulosic biorefineries?

BACKGROUND

The need for liquid fuels in the transportation sector is increasing, and it is essential to develop industrially sustainable processes that simultaneously address the tri-fold sustainability metrics of technological feasibility, economic viability, and environmental impacts. Biorefineries based on lignocellulosic feedstocks could yield high-value products such as ethyl acetate, dodecane, ethylene, and hexane. This work focuses on assessing biochemical and biomass to electricity platforms for conversion of Banagrass and Energycane into valuable fuels and chemicals using the tri-fold sustainability metrics.

RESULTS

The production cost of various products produced from Banagrass was $1.19/kg ethanol, $1.00/kg ethyl acetate, $3.01/kg dodecane (jet fuel equivalent), $2.34/kg ethylene and $0.32/kW-h electricity. The production cost of different products using Energycane as a feedstock was $1.31/kg ethanol, $1.11/kg ethyl acetate, $3.35/kg dodecane, and $2.62/kg ethylene. The sensitivity analysis revealed that the price of the main product, feedstock cost and cost of ethanol affected the profitability the overall process. Banagrass yielded 11% higher ethanol compared to Energycane, which could be attributed to the differences in the composition of these lignocellulosic biomass sources. Acidification potential was highest when ethylene was produced at the rate of 2.56 × 10-2 and 1.71 × 10-2 kg SO2 eq. for Banagrass and Energycane, respectively. Ethanol production from Banagrass and Energycane resulted in a global warming potential of - 12.3 and - 40.0 g CO2 eq./kg ethanol.

CONCLUSIONS

Utilizing hexoses and pentoses from Banagrass to produce ethyl acetate was the most economical scenario with a payback period of 11.2 years and an ROI of 8.93%, respectively. Electricity production was the most unprofitable scenario with an ROI of - 29.6% using Banagrass/Energycane as a feedstock that could be attributed to high feedstock moisture content. Producing ethylene or dodecane from either of the feedstocks was not economical. The moisture content and composition of biomasses affected overall economics of the various pathways studied. Producing ethanol and ethyl acetate from Energycane had a global warming potential of - 3.01 kg CO2 eq./kg ethyl acetate.

Effect of solids loading on ethanol production: Experimental, economic and environmental analysis

This study explores the effect of high-solids loading for a fed batch enzymatic hydrolysis and fermentation. The solids loading considered was 19%, 30% and 45% using wheat straw and corn stover as a feedstock. Based on the experimental results, techno-economic analysis and life cycle assessments were performed. The experimental results showed that 205±25.8g/L glucose could be obtained from corn stover at 45% solids loading after 96h which when fermented yielded 115.9±6.37g/L ethanol after 60h of fermentation. Techno-economic analysis showed that corn stover at 45% loading yielded the highest ROI at 8% with a payback period less than 12years. Similarly, the global warming potential was lowest for corn stover at 45% loading at -37.8gCO₂ eq./MJ ethanol produced.

Integrated techno-economic and environmental analysis of butadiene production from biomass

In this study, lignocellulose biorefineries annexed to a typical sugar mill were investigated to produce either ethanol (EtOH) or 1,3-butadiene (BD), utilizing bagasse and trash as feedstock. Aspen simulation of the scenarios were developed and evaluated in terms of economic and environmental performance. The minimum selling prices (MSPs) for bio-based BD and EtOH production were 2.9-3.3 and 1.26-1.38-fold higher than market prices, respectively. Based on the sensitivity analysis results, capital investment, Internal Rate of Return and extension of annual operating time had the greatest impact on the MSP. Monte Carlo simulation demonstrated that EtOH and BD productions could be profitable if the average of ten-year historical price increases by 1.05 and 1.9-fold, respectively. The fossil-based route was found inferior to bio-based pathway across all investigated environmental impact categories, due to burdens associated with oil extraction.

Multi-product biorefineries from lignocelluloses: a pathway to revitalisation of the sugar industry?

BACKGROUND

Driven by a range of sustainability challenges, e.g. climate change, resource depletion and expanding populations, a circular bioeconomy is emerging and expected to evolve progressively in the coming decades. South Africa along with other BRICS countries (Brazil, Russia, India and China) represents the emerging bioeconomy and contributes significantly to global sugar market. In our research, South Africa is used as a case study to demonstrate the sustainable design for the future biorefineries annexed to existing sugar industry. Detailed techno-economic evaluation and Life Cycle Assessment (LCA) were applied to model alternative routes for converting sugarcane residues (bagasse and trash) to selected biofuel and/or biochemicals (ethanol, ethanol and lactic acid, ethanol and furfural, butanol, methanol and Fischer-Tropsch synthesis, with co-production of surplus electricity) in an energy self-sufficient biorefinery system.

RESULTS

Economic assessment indicated that methanol synthesis with an internal rate of return (IRR) of 16.7% and ethanol-lactic acid co-production (20.5%) met the minimum investment criteria of 15%, while the latter had the lowest sensitivity to market price amongst all the scenarios. LCA results demonstrated that sugarcane cultivation was the most significant contributor to environmental impacts in all of the scenarios, other than the furfural production scenario in which a key step, a biphasic process with tetrahydrofuran solvent, had the most significant contribution.

CONCLUSION

Overall, the thermochemical routes presented environmental advantages over biochemical pathways on most of the impact categories, except for acidification and eutrophication. Of the investigated scenarios, furfural production delivered the inferior environmental performance, while methanol production performed best due to its low reagent consumption. The combined techno-economic and environmental assessments identified the performance-limiting steps in the 2G biorefinery design for sugarcane industry and highlighted the technology development opportunities under circular bioeconomy context.