The FLEXBY project aims to advance biofuel production technologies from TRL 3 to TRL 5 through a structured methodology, including feedstock assessment, lab-scale validation, process optimisation, sustainability analysis, and prototype upscaling. By leveraging innovative techniques, the project enhances biofuel yield, minimizes environmental impact, and improves process efficiency.
During the first half and a year of the proeject, FLEXBY has made significant progress towards advancing biofuel production technologies from TRL 3 to TRL 5. The activities carried out so far have laid a solid foundation for the subsequent phases of the project. Feedstock assessment has been completed, with three main sources identified and characterised: industrial oily sludge from the dairy industry, industrial sludge from Agar-Agar extraction, and microalgae cultivated in wastewater. Partners have optimised cultivation and harvesting protocols for microalgae to ensure sustainable biomass supply, while chemical and physical characterisation has confirmed their suitability for pyrolysis processes.
On the experimental side, lab-scale validation activities have been launched. Although the microwave pyrolysis unit is still being assembled at FRIMA, initial pyrolysis experiments using a standard electric furnace were successfully initiated ahead of schedule. These tests have demonstrated the feasibility of converting biomass into bio-liquid, pyro-gas, and bio-char, with the latter undergoing preliminary evaluation as a fertiliser, activated carbon, and catalyst support.
From a process optimisation perspective, the consortium has initiated the first steps for the development of the Multidisciplinary Design Optimisation (MDO) framework, creating and homogenisating different datsetset from lab-scale experiments. This will ensure that scaling up to TRL 5 is based on robust design parameters and sustainability constraints.
In parallel, progress has been made on the sustainability assessment. The Data Management Plan was delivered, and open access practices were established, including the use of Zenodo for public deliverables and scientific outputs. Life Cycle Assessment (LCA) and techno-economic analysis frameworks have also been defined to monitor energy use, emissions, and cost efficiency.
Overall, FLEXBY’s achievements during this first phase demonstrate that the project is on track, with feedstock secured, lab-scale experiments initiated, optimisation tools under development, and sustainability monitoring in place. These advances provide a strong basis for the upcoming transition towards pilot-scale testing and TRL 5 validation.
