Periodic Reporting for period 1 - COCPIT (sCalable solutions Optimisation and decision tool Creation for low impact SAF Production chain from a lIpid-rich microalgae sTrain)
Berichtszeitraum: 2023-10-01 bis 2025-03-31
COCPIT´s ambition is to enhance the SAF (Sustainable Aviation Fuel) production chain by bringing ground-breaking innovations at each thread of it. It aims also to provide investors with a human centered decision tool in a "test before invest" spirit with a high confidence level to de-risk investments.
A lipid rich microalgae strain is cultivated in an intensified reactor coupled to semi-transparent photovoltaic panels transforming harmful light spectrum into electrical power. The transformation of algal biomass into SAF is studied using two alternative pathways: HEFA (Hydrotreated Esters and Fatty Acids) and HTL (Hydro-Thermal Liquefaction).
The project focuses on the circularity, productivity, sustainability and economic viability of the chain. For HEFA pathway, efficient, low impact and regenerable ionic liquids are used to extract lipids and to catalyse hydrotreatment. For HTL pathway, a continuous reactor, tailored to SAF production from the chosen strain is designed and constructed to reduce clogging issues and to size with higher precision the heat exchangers. Furthermore, the mechanistic models that are developed and used in the design increase the scalability of the HTL. Biocrude upgrading is led to give a high flexibility between SAF and shipping fuel production. The system is designed in a circular way to reduce by-products, feed system with endogenous hydrogen, recirculate nutrients and reduce its water intensiveness.
The whole integrated system is simulated with Unism software and all technical, economical, environmental and life cycle indicators are calculated under the COCPIT decision tool and typical scenarios are compiled. The decision tool is delivered within a marketplace that puts at investor’s service a range of required technological solutions, equipment and skills. It helps them also to choose the best technology that fits their project specificities. The ambition of this tool is to continue growing up after the end of the project to include all certified and promising SAF production pathways.
A lipid rich microalgae strain is cultivated in an intensified reactor coupled to semi-transparent photovoltaic panels transforming harmful light spectrum into electrical power. The transformation of algal biomass into SAF is studied using two alternative pathways: HEFA (Hydrotreated Esters and Fatty Acids) and HTL (Hydro-Thermal Liquefaction).
The project focuses on the circularity, productivity, sustainability and economic viability of the chain. For HEFA pathway, efficient, low impact and regenerable ionic liquids are used to extract lipids and to catalyse hydrotreatment. For HTL pathway, a continuous reactor, tailored to SAF production from the chosen strain is designed and constructed to reduce clogging issues and to size with higher precision the heat exchangers. Furthermore, the mechanistic models that are developed and used in the design increase the scalability of the HTL. Biocrude upgrading is led to give a high flexibility between SAF and shipping fuel production. The system is designed in a circular way to reduce by-products, feed system with endogenous hydrogen, recirculate nutrients and reduce its water intensiveness.
The whole integrated system is simulated with Unism software and all technical, economical, environmental and life cycle indicators are calculated under the COCPIT decision tool and typical scenarios are compiled. The decision tool is delivered within a marketplace that puts at investor’s service a range of required technological solutions, equipment and skills. It helps them also to choose the best technology that fits their project specificities. The ambition of this tool is to continue growing up after the end of the project to include all certified and promising SAF production pathways.
During the first 18 months of COCPIT's launching, a set of experimental plants were designed, the main components were purchased and some of them were constructed and commissioned.
For Instance, the HTL and Hydrotreatment continuous plants were realised at IMT and AAU respectively while LEITAT has screened the first set of Semi-Transparent PV panels to test their IR absorbance, visible light transmittance and electrical efficiency.
At NU the modules preselected by LEITAT were coupled to labscale photobioreactors under controlled conditions. The results have shown a smaller decrease in biomass productivity (-16%) as compared to the reduction in visible light transmittance (-30%).
NU has also produced biomass on different photobioreactors available on its Algosolis platform to feed WP2 (URV) and WP3 (IMT and AAU) with microalgal feedstock. For that end they have used 7 different PBRs going from 40 to 3500 L and production surfaces up to 35 m².
At this stage, 69.8 kg of regular microalgae and 54.34 kg of starved microalgae (20% DM) were produced. AAU and IMT have used starved and regular microalgae and starved, deproteinated microalgae to screen the effects of temperature, residence time and nitrogen content on the HTL process.
The optimal point was set and all the fractions of the HTL process were characterised and the balance of C,H,N,S and O was performed. Biocrude quality was also assessed. Then a continuous HTL reactor available at AAU was used to process starved and regular microalgae and to prepare biocrude and AP reserves to launch the biocrude upgrading and AP treatment
URV has also screened 7 ionic liquids (IL) (5 tailored in the lab and 2 commercial) for the lipid extraction and have also used 2 tailored and 2 commercial ILs for the deproteination. The synthetized IL has shown a very good lipid extraction capacity (90% lipids recovery rate). While the research on deproteination is still underway.
URV has also designed a process for the continuous extraction of lipids using ILs that will be realized on TRL5.
In parallel to that IMT has led a campaign on the dark fermentation (DF) of different microalgae fractions, representing the residues of lipid extraction and the extracted proteins, respectively. Hydrogen production has reached could cover between 54% and 76% of HEFA pathway needs in H2. On the other hand, the DF of supernatant containing the extracted protein (HTL pathway) could cover 30% of upgrading hydrogen needs targeted by COCPIT.
On the other hand, the prospective scenarios have been defined and a map-combining approach has been adopted for data collection to feed them. The process simulation activity was also launched with the definition of process flow chart diagram of each pathway and the mass and energy balances are being built. The first set of equations that will feed the decision tool was also established. The initial user interface of the decision toll was also realized, it allows the insertion of investor’s inputs and it shows the targeted indicators that will be generated.
A questionnaire was circulated among the top management of HELLENIQ and its results were compiled in a market trend analysis that sets recommendations for the SAF market uptake.
For Instance, the HTL and Hydrotreatment continuous plants were realised at IMT and AAU respectively while LEITAT has screened the first set of Semi-Transparent PV panels to test their IR absorbance, visible light transmittance and electrical efficiency.
At NU the modules preselected by LEITAT were coupled to labscale photobioreactors under controlled conditions. The results have shown a smaller decrease in biomass productivity (-16%) as compared to the reduction in visible light transmittance (-30%).
NU has also produced biomass on different photobioreactors available on its Algosolis platform to feed WP2 (URV) and WP3 (IMT and AAU) with microalgal feedstock. For that end they have used 7 different PBRs going from 40 to 3500 L and production surfaces up to 35 m².
At this stage, 69.8 kg of regular microalgae and 54.34 kg of starved microalgae (20% DM) were produced. AAU and IMT have used starved and regular microalgae and starved, deproteinated microalgae to screen the effects of temperature, residence time and nitrogen content on the HTL process.
The optimal point was set and all the fractions of the HTL process were characterised and the balance of C,H,N,S and O was performed. Biocrude quality was also assessed. Then a continuous HTL reactor available at AAU was used to process starved and regular microalgae and to prepare biocrude and AP reserves to launch the biocrude upgrading and AP treatment
URV has also screened 7 ionic liquids (IL) (5 tailored in the lab and 2 commercial) for the lipid extraction and have also used 2 tailored and 2 commercial ILs for the deproteination. The synthetized IL has shown a very good lipid extraction capacity (90% lipids recovery rate). While the research on deproteination is still underway.
URV has also designed a process for the continuous extraction of lipids using ILs that will be realized on TRL5.
In parallel to that IMT has led a campaign on the dark fermentation (DF) of different microalgae fractions, representing the residues of lipid extraction and the extracted proteins, respectively. Hydrogen production has reached could cover between 54% and 76% of HEFA pathway needs in H2. On the other hand, the DF of supernatant containing the extracted protein (HTL pathway) could cover 30% of upgrading hydrogen needs targeted by COCPIT.
On the other hand, the prospective scenarios have been defined and a map-combining approach has been adopted for data collection to feed them. The process simulation activity was also launched with the definition of process flow chart diagram of each pathway and the mass and energy balances are being built. The first set of equations that will feed the decision tool was also established. The initial user interface of the decision toll was also realized, it allows the insertion of investor’s inputs and it shows the targeted indicators that will be generated.
A questionnaire was circulated among the top management of HELLENIQ and its results were compiled in a market trend analysis that sets recommendations for the SAF market uptake.
At M18 the work performed is a preparation for the actions that are meant to go beyond the state of the art.