Periodic Reporting for period 1 - FuelGae (Sustainable On-site and Innovative Technologies for Advanced Transport BioFuels from MιcroalGae)
Reporting period: 2023-10-01 to 2025-01-31
The FUELGAE project aims to develop a novel model for advanced liquid fuels (ALF) production from different CO2 emissions streams of two industrial sectors (biorefinery and energy intensive industries) through a microalgae pilot plant integrated into their infrastructure. The performance of the selected microalgae strains will be improved by adapting them to each industrial case study.
The ALF production will be addressed by developing different technologies: i) selective production of microalgae to obtain polysaccharides or lipids, ii) alternative microalgal biomass treatments, iii) innovative catalytic upgrading systems from biocrude, iv) online microalgae sensor. Additionally to the previously innovative technologies, FUELGAE concept uses advanced modelling tools integrated into Process Analytical Techniques (PAT) to develop a global Digital Twin (DT).
Furthermore, the carbon economy of the FUELGAE approach will be significantly improved through hydrothermal liquefaction (HTL) and, biogas processes. The biochar produced will be tested in agricultural applications, thus creating synergies with energy and biocrude generation. All technologies will be upscaled to TRL5 in the two case study sites; the microalgae pilot plant will be transported and validated in the two industrial sites in Romania (steel plant) and Spain (2G-bioethanol).
FUELGAE technologies will be further evaluated through life cycle and cost assessment (LCA/LCC) to confirm their lower environmental impact, use of resources, and GHG emissions, and a first approach of economical sustainability. DT will be coupled with LCA/LCC to provide a global and dynamic assessment of the FUELGAE concept.
Overall, FUELGAE contributes to advancing the European scientific basis and global technological leadership in the area of renewable fuels, increasing their technology competitiveness and role in transforming the energy system on a fossil-free basis by 2050, in particular in the sectors like aviation and shipping, while supporting the EU goals for energy independence.
The ALF production will be addressed by developing different technologies: i) selective production of microalgae to obtain polysaccharides or lipids, ii) alternative microalgal biomass treatments, iii) innovative catalytic upgrading systems from biocrude, iv) online microalgae sensor. Additionally to the previously innovative technologies, FUELGAE concept uses advanced modelling tools integrated into Process Analytical Techniques (PAT) to develop a global Digital Twin (DT).
Furthermore, the carbon economy of the FUELGAE approach will be significantly improved through hydrothermal liquefaction (HTL) and, biogas processes. The biochar produced will be tested in agricultural applications, thus creating synergies with energy and biocrude generation. All technologies will be upscaled to TRL5 in the two case study sites; the microalgae pilot plant will be transported and validated in the two industrial sites in Romania (steel plant) and Spain (2G-bioethanol).
FUELGAE technologies will be further evaluated through life cycle and cost assessment (LCA/LCC) to confirm their lower environmental impact, use of resources, and GHG emissions, and a first approach of economical sustainability. DT will be coupled with LCA/LCC to provide a global and dynamic assessment of the FUELGAE concept.
Overall, FUELGAE contributes to advancing the European scientific basis and global technological leadership in the area of renewable fuels, increasing their technology competitiveness and role in transforming the energy system on a fossil-free basis by 2050, in particular in the sectors like aviation and shipping, while supporting the EU goals for energy independence.
Progress and Deliverables
The project is progressing as planned, with key developments in KPI analysis, microalgae cultivation requirements, and the biorefinery model.
WP1: Successfully managed consortium meetings and delivered key project and data management documents, completed on schedule without deviations.
WP4: Completed on time, meeting all objectives. KPIs were confirmed, additional ones developed, and requirements for microalgae selection, cultivation, and the photobioreactor defined. The biorefinery model has been further developed.
Microalgae Selection and Cultivation
WP5: Two microalgal species were selected among a shortlist of industrially relevant strains: Stichococcus sp. (polysaccharides producer for Case Study I, CSI) and Chlorella vulgaris (lipids producer for Case Study II, CSII), ensuring high productivity and resilience to industrial off-gases. CO2 tolerance of the selected species was improved up to 30%, and lab-scale photobioreactor (PBR) cultivation conditions were optimized via Design of Experiments (DoE) for scalability, biomass production, and biochemical yields. High-cell density biomass (>4 g/L) has been achieved, enabling future pilot-scale validation.
Method Development and Application
Progress in identifying suitable chemical compounds and applying advanced methods to microalgae, with ongoing biomass analysis.
WP6: Effective lipid and polysaccharide extraction achieved, optimizing process conditions for better recovery. Scalability validation under industrial conditions is ongoing.
Catalyst Design and Reaction Optimization
WP8: Catalysts were designed, characterized, and optimized using model compounds. No delays are expected in meeting project objectives.
Sensor Design and Modeling
WP10: Optical and spectroscopic sensors were developed and tested for real-time microalgae monitoring (flow microscopes, Raman, FTIR spectroscopy), with calibration models in progress. CFD-RSM modeling and process integration into the digital twin are advancing in collaboration with technology partners.
LCA Analysis
WP13: The preliminary LCA model for Advanced Liquid Biofuel production has been created, with impacts calculated. Optimization using plant-wide model results will define baseline cases of the non-optimized concept. Notably, during the PBR stage, more CO2 is captured than emitted, with expected GHG reductions of up to 40% after process optimization.
Dissemination and Exploitation
WP15: Communication and dissemination efforts have maximized project visibility through key events, publications, and stakeholder engagement. Exploitation strategies are being developed with partners to facilitate commercialization pathways.
The project is progressing as planned, with key developments in KPI analysis, microalgae cultivation requirements, and the biorefinery model.
WP1: Successfully managed consortium meetings and delivered key project and data management documents, completed on schedule without deviations.
WP4: Completed on time, meeting all objectives. KPIs were confirmed, additional ones developed, and requirements for microalgae selection, cultivation, and the photobioreactor defined. The biorefinery model has been further developed.
Microalgae Selection and Cultivation
WP5: Two microalgal species were selected among a shortlist of industrially relevant strains: Stichococcus sp. (polysaccharides producer for Case Study I, CSI) and Chlorella vulgaris (lipids producer for Case Study II, CSII), ensuring high productivity and resilience to industrial off-gases. CO2 tolerance of the selected species was improved up to 30%, and lab-scale photobioreactor (PBR) cultivation conditions were optimized via Design of Experiments (DoE) for scalability, biomass production, and biochemical yields. High-cell density biomass (>4 g/L) has been achieved, enabling future pilot-scale validation.
Method Development and Application
Progress in identifying suitable chemical compounds and applying advanced methods to microalgae, with ongoing biomass analysis.
WP6: Effective lipid and polysaccharide extraction achieved, optimizing process conditions for better recovery. Scalability validation under industrial conditions is ongoing.
Catalyst Design and Reaction Optimization
WP8: Catalysts were designed, characterized, and optimized using model compounds. No delays are expected in meeting project objectives.
Sensor Design and Modeling
WP10: Optical and spectroscopic sensors were developed and tested for real-time microalgae monitoring (flow microscopes, Raman, FTIR spectroscopy), with calibration models in progress. CFD-RSM modeling and process integration into the digital twin are advancing in collaboration with technology partners.
LCA Analysis
WP13: The preliminary LCA model for Advanced Liquid Biofuel production has been created, with impacts calculated. Optimization using plant-wide model results will define baseline cases of the non-optimized concept. Notably, during the PBR stage, more CO2 is captured than emitted, with expected GHG reductions of up to 40% after process optimization.
Dissemination and Exploitation
WP15: Communication and dissemination efforts have maximized project visibility through key events, publications, and stakeholder engagement. Exploitation strategies are being developed with partners to facilitate commercialization pathways.