Safflower-based biorefinery producing a broad spectrum of biofuels and biochemicals: A life cycle assessment perspective.

Global environmental awareness has encouraged further research towards biofuel production and consumption. Despite the favorable properties of biofuels, the sustainability of their conventional production pathways from agricultural feedstocks has been questioned. Therefore, the use of non-food feedstocks as a promising approach to ensure sustainable biofuel production is encouraged. However, the use of synthetic solvents/chemicals and energy carriers during biofuel production and the consequent adverse environmental effects are still challenging. On the other hand, biofuel production is also associated with generating large volumes of waste and wastewater. Accordingly, the circular bioeconomy as an innovative approach to ensure complete valorization of feedstocks and generated waste streams under the biorefinery scheme is proposed. In line with that, the current study aims to assess the environmental sustainability of bioethanol production in a safflower-based biorefinery using the life cycle assessment framework. Based on the obtained results, safflower production and its processing into 1 MJ bioethanol under the safflower-based biorefinery led to damage of 2.23E-07 disability-adjusted life years (DALY), 2.35E-02 potentially disappeared fraction (PDF)*m2*yr, 4.76E-01 kg CO2 eq., and 3.82 MJ primary on the human health, ecosystem quality, climate change, and resources, respectively. Moreover, it was revealed that despite adverse environmental effects associated with safflower production and processing, the substitution of conventional products, i.e., products that are the typical products in the market without having environmental criteria, with their bio-counterparts, i.e., products produced in the biorefinery based on environmental criteria could overshadow the unfavorable effects and substantially enhance the overall sustainability of the biorefinery system. The developed safflower-based biorefinery led to seven- and two-time reduction in damage to the ecosystem quality and resources damage categories, respectively. The reductions in damage to human health and climate change were also found to be 52% and 24%, respectively. The weighted environmental impacts of the safflower-based biorefinery decreased by 64% due to the production of bioproducts, mainly biodiesel and biogas, replacing their fossil-based counterparts, i.e., diesel and natural gas, respectively. Finally, although the main focus of the developed safflower-based biorefinery was biofuel production, waste valorization and mainly animal feed played a significant role in improving the associated environmental impacts.

Biobutanol production from municipal solid waste: Technical and economic analysis.

Novel processes for the production of acetone-butanol-ethanol (ABE) from municipal solid waste (MSW) were developed and simulated using Aspen Plus®. In scenario 1, a conventional distillation system was used, while a gas stripping system was coupled with a fermenter in scenario 2. In scenario 3, pervaporation (PV) and gas stripping systems right after the fermentation reactor were applied. Gas stripping increased the total ABE produced while the addition of the PV module decreased the number of distillation columns from 6 to 2 as well as created 6.4% increments in the amount of butanol in comparison with scenario 1. Economical evaluation resulted in having payout periods of 15.9, 4.4, and 2.9 years for scenarios 1 to 3, respectively. These results show that using MSW as an inexpensive sugar-rich feedstock together with gas stripping PV system is a promising solution to overcome the major obstacles in the way of the ABE production.

Improvement of ethanol production from birch and spruce pretreated with 1-H-3-methylmorpholinium chloride

Background: Pretreatment is the critically important step for the production of ethanol from lignocelluloses. In this study, hardwood birch (Betula pendula) and softwood spruce (Norway spruce) woods were pretreated with a newly synthesized morpholinium ionic liquid, 1-H-3-methylmorpholinium chloride ([HMMorph][Cl]), followed by enzymatic hydrolysis and fermentation to ethanol. Results: [HMMorph][Cl] was synthesized using inexpensive raw materials, i.e., hydrochloric acid and N-methyl morpholine, following a simple process. The influence of pretreatment time (2, 3, 5, and 8 h) and temperature (120 and 140°C) in terms of hydrolysis efficiency was investigated. Glucose yields from enzymatic hydrolysis were improved from 13.7% to 45.7% and 12.9% to 51.8% after pretreatment of birch and spruce woods, respectively, under optimum pretreatment conditions (i.e., at 140°C for 3 h) as compared to those from pristine woods. Moreover, the yields of ethanol production from birch and spruce were increased to 34.8% and 44.2%, respectively, while the yields were negligible for untreated woods. Conclusions: This study demonstrated the ability of [HMMorph][Cl] as an inexpensive agent to pretreat both softwood and hardwood.

Dilute alkali pretreatment of softwood pine: A biorefinery approach.

Dilute alkali pretreatment was performed on softwood pine to maximize ethanol and biogas production via a biorefinery approach. Alkali pretreatments were performed with 0-2% w/v NaOH at 100-180°C for 1-5h. The liquid fraction of the pretreated substrates was subjected to anaerobic digestion. The solid fraction of the pretreatment was used for separate enzymatic hydrolysis and fermentation. High ethanol yields of 76.9‒78.0% were achieved by pretreatment with 2% (w/v) NaOH at 180°C. The highest biogas yield of 244mL/g volatile solid (at 25°C, 1bar) was achieved by the pretreatment with 1% (w/v) NaOH at 180°C. The highest gasoline equivalent (sum of ethanol and methane) of 197L per ton of pinewood and the lowest ethanol manufacturing cost of 0.75€/L was obtained after pretreatment with 1% NaOH at 180°C for 5h. The manufacturing cost of ethanol from untreated wood was 4.12€/L.

Economic impact of NMMO pretreatment on ethanol and biogas production from pinewood.

Processes for ethanol and biogas (scenario 1) and biomethane (scenario 2) production from pinewood improved by N-methylmorpholine-N-oxide (NMMO) pretreatment were developed and simulated by Aspen plus. These processes were compared with two processes using steam explosion instead of NMMO pretreatment ethanol (scenario 3) and biomethane (scenario 4) production, and the economies of all processes were evaluated by Aspen Process Economic Analyzer. Gasoline equivalent prices of the products including 25% value added tax (VAT) and selling and distribution expenses for scenarios 1 to 4 were, respectively, 1.40, 1.20, 1.24, and 1.04 €/l, which are lower than gasoline price. The profitability indexes for scenarios 1 to 4 were 1.14, 0.93, 1.16, and 0.96, respectively. Despite the lower manufacturing costs of biomethane, the profitability indexes of these processes were lower than those of the bioethanol processes, because of higher capital requirements. The results showed that taxing rule is an effective parameter on the economy of the biofuels. The gasoline equivalent prices of the biofuels were 15-37% lower than gasoline; however, 37% of the gasoline price contributes to energy and carbon dioxide tax which are not included in the prices of biofuels based on the Swedish taxation rules.

Enhanced ethanol and biogas production from pinewood by NMMO pretreatment and detailed biomass analysis.

N-Methyl morpholine-N-oxide (NMMO) is an environmentally friendly and commercially applied cellulose solvent that is suggested for pretreatment of lignocelluloses to improve biofuel productions. However, the underlying mechanisms of the improvements have been poorly understood yet. In an attempt to investigate the mechanisms, pinewood powder and chips were pretreated with 85% (w/w) NMMO at 120°C for 1-15 h. The pretreatment improved ethanol production yield from 7.2% (g/g) for the untreated wood powder to 68.1-86.1% (g/g) and from 1.7% (g/g) for the untreated wood chips to 12.6-51.2% (g/g) of theoretical yield. Similarly, the biogas yields of untreated wood chips and powder were improved from 21 and 66 (mL/g volatile solids) by 3.5-6.8- and 2.6-3.4-folds, respectively. SEM micrographs indicated major increase in the wood porosity by the pretreatment, which would confirm increase in the water swelling capacity as well as enzyme adsorption. The analysis of X-ray diffraction showed considerable reduction in the cellulose crystallinity by the pretreatment, while FTIR spectroscopy results indicated reduction of lignin on the wood surface by the pretreatment.

Techno-economical study of biogas production improved by steam explosion pretreatment.

Economic feasibility of steam explosion pretreatment for improvement of biogas production from wheat straw and paper tube residuals was investigated. The process was simulated by Aspen plus ®, and the economical feasibility of five different plant capacities was studied by Aspen Process Economic Analyzer. Total project investment of a plant using paper tube residuals or wheat straw was 63.9 or 61.8 million Euros, respectively. The manufacturing cost of raw biogas for these two feedstocks was calculated to 0.36 or 0.48 €/m(3) of methane, respectively. Applying steam explosion pretreatment resulted in 13% higher total capital investment while significantly improved the economy of the biogas plant and decreased the manufacturing cost of methane by 36%. The sensitivity analysis showed that 5% improvement in the methane yield and 20% decrease in the raw material price resulted in 5.5% and 8% decrease in the manufacturing cost of methane, respectively.

Techno-economical study of ethanol and biogas from spruce wood by NMMO-pretreatment and rapid fermentation and digestion.

Given that N-methylmorpholine-N-oxide (NMMO) is a promising alternative for the pretreatment of lignocelluloses, a novel process for ethanol and biogas production from wood was developed. The solvent, NMMO, is concentrated by multistage evaporation, and the wood is pretreated with the concentrated NMMO. Thereafter, ethanol is produced by the non-isothermal simultaneous saccharification and fermentation (NSSF) method, which is a rapid and efficient process. The wastewater is treated by upflow anaerobic sludge blanket (UASB) digester for rapid production of biogas. The process was simulated by Aspen plus®. Using mechanical vapor recompression for evaporators in the pretreatment and multi-pressure distillation columns, the energy requirements for the process were minimized. The economical feasibility of the developed biorefinery for five different plant capacities was studied by Aspen Icarus Process Evaluator. The base case was designed to utilize 200,000 tons of spruce wood per year and required M€ 58.3 as the total capital investment, while the production cost of ethanol is calculated to be €/l 0.44.

Palm date fibers: analysis and enzymatic hydrolysis.

Waste palm dates were subjected to analysis for composition and enzymatic hydrolysis of their flesh fibers. The fruit contained 32% glucose and 30% fructose, while the water-insoluble fibers of its flesh consisted of 49.9% lignin and 20.9% polysaccharides. Water-insoluble fibers were settled to 55% of its initial volume in 12 h. The presence of skin and flesh colloidal fibers results in high viscosity and clogging problems during industrial processes. The settling velocity of the fibers was improved by enzymatic hydrolysis. Hydrolysis resulted in 84.3% conversion of the cellulosic part of the fibers as well as reducing the settling time to 10 minutes and the final settled volume to 4% of the initial volume. It implies easier separation of the fibers and facilitates fermentation processes in the corresponding industries. Two kinds of high- and low-lignin fibers were identified from the water-insoluble fibers. The high-lignin fibers (75% lignin) settled easily, while the low-lignin fibers (41.4% lignin) formed a slurry suspension which settled very slowly. The hydrophilicity of these low-lignin fibers is the major challenge of the industrial processes.

Pretreatment of spruce and oak by N-methylmorpholine-N-oxide (NMMO) for efficient conversion of their cellulose to ethanol.

Pretreatment of softwood spruce and hardwood oak with an industrial cellulose solvent, N-methylmorpholine-N-oxide (NMMO), was investigated prior to enzymatic hydrolysis and fermentation to ethanol. The pretreatments were carried out at 90, 110 and 130 degrees C for 1-3 h with 85% NMMO solution, followed by non-isothermal simultaneous saccharification and fermentation (NSSF). This NSSF included hydrolysis with cellulase and beta-glucosidase for 24 h at 45 degrees C, followed by continuous saccharification and fermentation with Saccharomyces cerevisiae at 37 degrees C for 3 days. The NSSF of untreated oak and spruce resulted in 18.6% and 6.8% ethanol compared to the maximum theoretical yield. However, the pretreatment of oak and spruce at 130 degrees C resulted in almost total conversion of cellulose to ethanol and improved ethanol yield up to 85.4% and 89%, respectively. These numbers are comparable with ethanol from pure glucose with the same strain, which yielded between 84% and 90% of the theoretical ethanol yield.