Periodic Reporting for period 1 - SUSTEPS (SUSTAINABLE, SECURE AND COMPETITIVE ENERGY THROUGH SCALING UP ADVANCED BIOFUEL GENERATION)
Période du rapport: 2023-09-01 au 2025-02-28
SUSTEPS Project responds to Europe’s goals of achieving climate neutrality by 2050 and cutting greenhouse gas emissions by 55% by 2030. With transportation, especially aviation, being difficult to decarbonize, sustainable algae-based biofuels emerge as a promising solution.
Algae grow rapidly, need neither arable land nor fresh water, and absorb significant CO2. Once harvested, they can be converted into drop-in fuels that integrate seamlessly with existing engines. However, algae-based biofuels face technical, economic, and systemic challenges across their value chain. SUSTEPS aims to deliver cost-effective, scalable solutions to accelerate commercialization and adoption.
SUSTEPS develops a novel bio-refinery concept that utilizes CO2 from high-emission facilities and nutrients from wastewater, lowering costs and reducing environmental impact. It integrates green hydrogen and the recovery of value-added chemicals to enhance process viability and fosters international cooperation to build global knowledge for the scaling-up and sustainability assessment of algae-based biofuel value chains.
SUSTEPS couples biological ingenuity with advanced thermochemical processing in four integrated stages:
Circular feedstock strategy: Algae are cultivated using CO2 captured from cement and steel plants and nutrients recovered from industrial and municipal wastewater. This not only delivers a productive use for waste gases but also lowers the cost of algal growth by displacing synthetic fertilizers.
Hydrothermal liquefaction (HTL): The wet algal slurry is directly converted into a crude-like bio-oil via HTL with the need of energy-intensive drying.
On-site upgrading: The bio-oil undergoes hydrotreatment to refine it into fuel fractions utilizing hydrogen, a portion of which is generated in-house by reforming the light HTL gases, while the remainder is provided as green hydrogen produced via renewable power.
Total valorisation: Membrane and chromatographic separations recover at least three valuable chemicals from the HTL wastewater. The cleaned water is then recycled to the algal ponds, minimizing freshwater demand.
SUSTEPS is expected to advance microalgae cultivation, CO2 fixation, HTL and upgrading technologies, aqueous recycling, and green hydrogen integration. Leveraging industrial waste streams, it aims for carbon-neutral or carbon-negative fuel production. Compliance with EU sustainability standards is ensured through lifecycle and safety assessments.
Through techno-economic analyses and stakeholder engagement, SUSTEPS offers a blueprint for economically viable scaling, strengthens policy frameworks, and supports the development of future algae-based fuel standards. With partners across Europe, America, and Africa, it promotes international knowledge exchange.
Beyond technological innovation, SUSTEPS aims to transform the biofuel sector by demonstrating a TRL 4–5 integrated pilot refinery. By producing negative-emission drop-in fuels, the project is expected to stimulate green investments, create jobs, support EU Green Deal objectives, and enable localized sustainable fuel production globally.
During the first 18 months of the SUSTEPS project (M1–M18), progress has been achieved across all specific objectives, setting a strong foundation for the integrated development of an algae-based biofuel value chain. Key advancements were realized in fostering international collaboration, performing an integrated process design, preliminary experimental trials, and sustainability assessments.
Algae grow rapidly, need neither arable land nor fresh water, and absorb significant CO2. Once harvested, they can be converted into drop-in fuels that integrate seamlessly with existing engines. However, algae-based biofuels face technical, economic, and systemic challenges across their value chain. SUSTEPS aims to deliver cost-effective, scalable solutions to accelerate commercialization and adoption.
SUSTEPS develops a novel bio-refinery concept that utilizes CO2 from high-emission facilities and nutrients from wastewater, lowering costs and reducing environmental impact. It integrates green hydrogen and the recovery of value-added chemicals to enhance process viability and fosters international cooperation to build global knowledge for the scaling-up and sustainability assessment of algae-based biofuel value chains.
SUSTEPS couples biological ingenuity with advanced thermochemical processing in four integrated stages:
Circular feedstock strategy: Algae are cultivated using CO2 captured from cement and steel plants and nutrients recovered from industrial and municipal wastewater. This not only delivers a productive use for waste gases but also lowers the cost of algal growth by displacing synthetic fertilizers.
Hydrothermal liquefaction (HTL): The wet algal slurry is directly converted into a crude-like bio-oil via HTL with the need of energy-intensive drying.
On-site upgrading: The bio-oil undergoes hydrotreatment to refine it into fuel fractions utilizing hydrogen, a portion of which is generated in-house by reforming the light HTL gases, while the remainder is provided as green hydrogen produced via renewable power.
Total valorisation: Membrane and chromatographic separations recover at least three valuable chemicals from the HTL wastewater. The cleaned water is then recycled to the algal ponds, minimizing freshwater demand.
SUSTEPS is expected to advance microalgae cultivation, CO2 fixation, HTL and upgrading technologies, aqueous recycling, and green hydrogen integration. Leveraging industrial waste streams, it aims for carbon-neutral or carbon-negative fuel production. Compliance with EU sustainability standards is ensured through lifecycle and safety assessments.
Through techno-economic analyses and stakeholder engagement, SUSTEPS offers a blueprint for economically viable scaling, strengthens policy frameworks, and supports the development of future algae-based fuel standards. With partners across Europe, America, and Africa, it promotes international knowledge exchange.
Beyond technological innovation, SUSTEPS aims to transform the biofuel sector by demonstrating a TRL 4–5 integrated pilot refinery. By producing negative-emission drop-in fuels, the project is expected to stimulate green investments, create jobs, support EU Green Deal objectives, and enable localized sustainable fuel production globally.
During the first 18 months of the SUSTEPS project (M1–M18), progress has been achieved across all specific objectives, setting a strong foundation for the integrated development of an algae-based biofuel value chain. Key advancements were realized in fostering international collaboration, performing an integrated process design, preliminary experimental trials, and sustainability assessments.
During the first 18 months of the SUSTEPS project (M1–M18), progress has been achieved across all specific objectives, setting a strong foundation for the integrated development of an algae-based biofuel value chain. Key advancements were realized in fostering international collaboration, performing an integrated process design, preliminary experimental trials, and sustainability assessments.
In order to follow the progress more conveniently, a summary of the specific objectives (SO) of SUSTEPS, as outlined in the DoA document, and the progress attained is summarized in Table 1.
To foster international collaboration (SO1), five International Working Groups (IWGs) were established, involving more than 20 experts from 12 countries. These groups, focused on various technical and cross-cutting themes, held regular meetings and defined key performance indicators (KPIs) to guide collaboration and ensure structured expert feedback integration.
In line with the objective of designing a holistic algae-based biofuel production system (SO2), an integrated process model was developed. This model covers the full pathway from algae cultivation to fuel upgrading. It has enabled preliminary environmental, economic, and social sustainability assessments (LCA, TEA, S-LCA), with progress marked by the timely submission of key deliverables and milestones.
The project advanced microalgae cultivation (SO3) through high-throughput screening of different microalgae species subjected to flue-gas CO2 concentrations and pre-treated wastewater. BOUN has generated three different candidate species capable of growing at 3% CO2 with domestic pre-treated wastewater (no additional nutrients were added).
For the development of high-yield biocrude production (SO4), a new hydrothermal liquefaction (HTL) system was set up by PSI. Initial testing with various microalgae strains and preliminary process simulations were completed. These activities align with the project's goal of achieving a biocrude yield of over 50% while reducing nitrogen content.
Efforts to upgrade algae-derived biofuels cost-effectively (SO5) focused on catalyst development, impurity removal, and refining simulations. TUBITAK installed a 4-reactor upgrading system for fast parameter screening towards process optimization and conducted early-stage hydroprocessing experiments. FZJ began modelling of reforming to produce bio- hydrogen reforming processes. Despite challenges in biocrude feedstock availability, early outcomes indicate progress toward meeting SAF production targets.
In addressing side-stream valorization (SO6), SDU initiated membrane-based separation planning and analysed aqueous phase samples. These efforts aim to enhance circularity, reduce freshwater consumption, and recover valuable by-products, supporting overall process sustainability.
The goal of demonstrating a carbon-efficient and economically viable production process at TRL 4 (SO7) is supported by the integration of technical work packages and inter-WP data exchange. Early experimental and simulation results indicate strong alignment towards optimizing carbon efficiency and preparing for full-chain validation.
Finally, for stakeholder engagement and dissemination (SO8), the project website and communication channels were launched. Several dissemination deliverables were submitted, and partnerships with other EU projects were initiated. Plans for newsletters, workshops, and broader stakeholder outreach are in place to maximize the impact and visibility of SUSTEPS results.
Overall, the consortium has demonstrated coordinated progress towards achieving its specific objectives, maintaining strategic alignment and ensuring that the groundwork for the next project phase is established.
In order to follow the progress more conveniently, a summary of the specific objectives (SO) of SUSTEPS, as outlined in the DoA document, and the progress attained is summarized in Table 1.
To foster international collaboration (SO1), five International Working Groups (IWGs) were established, involving more than 20 experts from 12 countries. These groups, focused on various technical and cross-cutting themes, held regular meetings and defined key performance indicators (KPIs) to guide collaboration and ensure structured expert feedback integration.
In line with the objective of designing a holistic algae-based biofuel production system (SO2), an integrated process model was developed. This model covers the full pathway from algae cultivation to fuel upgrading. It has enabled preliminary environmental, economic, and social sustainability assessments (LCA, TEA, S-LCA), with progress marked by the timely submission of key deliverables and milestones.
The project advanced microalgae cultivation (SO3) through high-throughput screening of different microalgae species subjected to flue-gas CO2 concentrations and pre-treated wastewater. BOUN has generated three different candidate species capable of growing at 3% CO2 with domestic pre-treated wastewater (no additional nutrients were added).
For the development of high-yield biocrude production (SO4), a new hydrothermal liquefaction (HTL) system was set up by PSI. Initial testing with various microalgae strains and preliminary process simulations were completed. These activities align with the project's goal of achieving a biocrude yield of over 50% while reducing nitrogen content.
Efforts to upgrade algae-derived biofuels cost-effectively (SO5) focused on catalyst development, impurity removal, and refining simulations. TUBITAK installed a 4-reactor upgrading system for fast parameter screening towards process optimization and conducted early-stage hydroprocessing experiments. FZJ began modelling of reforming to produce bio- hydrogen reforming processes. Despite challenges in biocrude feedstock availability, early outcomes indicate progress toward meeting SAF production targets.
In addressing side-stream valorization (SO6), SDU initiated membrane-based separation planning and analysed aqueous phase samples. These efforts aim to enhance circularity, reduce freshwater consumption, and recover valuable by-products, supporting overall process sustainability.
The goal of demonstrating a carbon-efficient and economically viable production process at TRL 4 (SO7) is supported by the integration of technical work packages and inter-WP data exchange. Early experimental and simulation results indicate strong alignment towards optimizing carbon efficiency and preparing for full-chain validation.
Finally, for stakeholder engagement and dissemination (SO8), the project website and communication channels were launched. Several dissemination deliverables were submitted, and partnerships with other EU projects were initiated. Plans for newsletters, workshops, and broader stakeholder outreach are in place to maximize the impact and visibility of SUSTEPS results.
Overall, the consortium has demonstrated coordinated progress towards achieving its specific objectives, maintaining strategic alignment and ensuring that the groundwork for the next project phase is established.