Collaborative Actions to Bring Novel Biofuels Thermochemical Routes into Industrial Scale

Project Information

BioTheRoS

Grant agreement ID: 101122212

DOI

10.3030/101122212

EC signature date 22 August 2023

Start date 1 October 2023

End date 30 September 2026

Funded under

• Climate, Energy and Mobility

Total cost

€ 2 998 625,00

EU contribution

€ 2 998 625,00

Coordinated by

ETHNIKO KENTRO EREVNAS KAI TECHNOLOGIKIS ANAPTYXIS
Greece

Periodic Reporting for period 1 - BioTheRoS (Collaborative Actions to Bring Novel Biofuels Thermochemical Routes into Industrial Scale)

Reporting period: 2023-10-01 to 2025-03-31

Summary of the context and overall objectives of the project

The BioTheRoS project aims to develop cost-effective and sustainable value chains for biofuels production by advancing two key thermochemical conversion technologies, i.e. pyrolysis and the upgrading of its intermediate products, and gasification and Fischer-Tropsch (FT) synthesis, to TRL5. Although these technologies are technically distinct, they are jointly investigated through a multidisciplinary approach, encompassing: (i) feedstock selection, (ii) pilot-scale testing, (iii) scale-up modeling, (iv) integration with renewable hydrogen and Carbon Capture Utilization, and (v) comprehensive life cycle assessments addressing environmental sustainability, socio-economic impact, and economic viability. To support decision-making, BioTheRoS will employ AI-driven predictive models using GIS data and aligned with EU biofuel policies. These tools are designed to forecast biomass demand, mitigate risks, enhance cost-efficiency, and inform the development of innovative business models. The project will also assess the competitiveness of pyrolysis and gasification fuels relative to other renewable alternatives, such as electrification and biofuels, in hard-to-decarbonize sectors, including heavy-duty transport, aviation, and shipping. At the same time, it will develop scale-up strategies based on advanced modeling techniques and pilot-scale demonstrations. Furthermore, BioTheRoS will identify and quantify concrete measures to improve the environmental, social, and economic sustainability of thermochemical biomass conversion processes. This includes evaluating the impact of technology improvements and integration strategies on overall system performance and sustainability indicators. Finally, BioTheRoS will foster international collaboration and stakeholder engagement to enhance global knowledge and accelerate the development of sustainable advanced biofuel value chains. This will be achieved via shared research, aligned EU and global initiatives, and a dedicated knowledge-exchange network.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The project successfully demonstrated the complete pyrolysis biomass-to-fuel chain using forestry residues and barley straw, producing 22.3 and 23.5 liters of FPBO, respectively. AI-driven models identified the most promising biomass feedstocks and optimal plant locations, supported by a user-adjustable tool now undergoing final validation. Although yields were lower than the corresponding ones from clean wood, the use of low-cost residual biomass offers significant economic benefits for large-scale deployment. The produced FPBO was upgraded via continuous hydrotreatment using the ‘Picula™’ catalyst to generate hydrotreated pyrolysis oil (HPO), suitable for jet and diesel fuels, with 5 liters of barley straw-derived HPO produced to date. In parallel, the gasification pathway was validated through two campaigns using softwood and forestry residues in a 1 MW gasifier, achieving effective multi-stage removal of tars, ammonia, and other contaminants, thus enhancing biogenic waste utilization. The cleaned syngas was converted into Fischer-Tropsch (FT) syncrude, fractionated into naphtha, middle distillates, and wax, with partial tail gas recycling. Sufficient FT wax was produced for hydrocracking tests at CERTH, demonstrating 50–60% conversion of C20 hydrocarbons and substantial yields of C7–C14 and C15–C19 fractions. To support industrial adoption, scale-up guidelines were developed focusing on replicating pyrolysis upgrading and optimizing gasification performance and syngas quality. Additionally, an integrated Life Cycle Sustainability Assessment (LCSA) framework combining environmental, economic, and social analyses with a hybrid DEA-TOPSIS method is under development to identify sustainable pyrolysis and gasification pathways, alongside a web-based decision-support platform. Targeted sustainability measures and market analyses ensure commercial viability, with AI-selected optimal biomass feedstocks guiding improvements across the value chain.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

Over 20 biogenic feedstocks were investigated, with barley straw and forestry residues selected for pyrolysis and gasification trials. Pre-treatment, costs, and logistics were analysed and integrated into AI-based models to identify optimal plant locations. This data-driven approach advances the state of the art by combining techno-economic and spatial analysis in a scalable framework. Based on these results, a biomass-to-fuel value chain was demonstrated at TRL 5 via pyrolysis, producing upgraded fuel fractions suitable for blending. Gasification was also validated, providing key insights into gas cleaning. A comprehensive Life Cycle Sustainability Assessment (LCSA) framework combined with a novel hybrid Multi-Criteria Decision Making (MCDM) method (DEA-TOPSIS) is also being developed to evaluate and identify the most sustainable biofuel production pathways. This integrated approach not only captures trade-offs across sustainability dimensions but also provides stakeholders with clear, holistic guidance and offers scalability and flexibility to accommodate diverse feedstocks and technologies for real-world applicability. Furthermore, progress goes beyond the state of the art by identifying how policies, biofuel availability, prices, demand, and RFNBO supply interact to shape the sustainable biofuels market. These insights are essential for enabling more effective scaling of thermochemical production technologies. Further uptake requires demonstration at TRL 6–7, investment mobilization, active stakeholder engagement for market acceptance, and alignment with European sustainability and regulatory standards.

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