Periodic Reporting for period 1 - FLEXBY (Flexible and advanced Biofuel technology through an innovative microwave pYrolysis & hydrogen-free hydrodeoxygenation process)
Okres sprawozdawczy: 2024-05-01 do 2025-10-31
The transition to clean and sustainable energy is one of Europe’s greatest challenges. Biofuels represent a promising solution, but traditional production methods often rely on food-based crops, compete with food security, and require fossil hydrogen, which increases greenhouse gas emissions. There is a clear need for advanced biofuels that are sustainable, cost-effective, and compatible with existing transport infrastructures, especially in hard-to-decarbonise sectors such as aviation, maritime, and heavy road transport.
The FLEXBY project addresses these challenges by developing an innovative technology for producing advanced biofuels from residues and waste streams. The project uses microwave-assisted pyrolysis combined with catalytic upgrading to transform industrial oily sludge and wastewater-cultivated microalgae into sustainable liquid and gaseous biofuels. This approach avoids competition with food resources, reduces the use of fossil-based hydrogen, and promotes circular economy principles by valorising waste streams.
FLEXBY is progressing from TRL 3 to TRL 5, integrating Artificial Intelligence (AI) and Multidisciplinary Design Optimisation (MDO) to improve process efficiency and ensure safe and sustainable scale-up. By 2050, FLEXBY has the potential to produce 90,000 tonnes of biofuels annually, reducing CO2 emissions by up to 120 million tonnes per year, and capturing around 1% of the global biofuel market. Beyond climate benefits, the project also supports the European Green Deal objectives, strengthens energy security, and is expected to contribute significantly to job creation in the clean energy sector.
The FLEXBY project addresses these challenges by developing an innovative technology for producing advanced biofuels from residues and waste streams. The project uses microwave-assisted pyrolysis combined with catalytic upgrading to transform industrial oily sludge and wastewater-cultivated microalgae into sustainable liquid and gaseous biofuels. This approach avoids competition with food resources, reduces the use of fossil-based hydrogen, and promotes circular economy principles by valorising waste streams.
FLEXBY is progressing from TRL 3 to TRL 5, integrating Artificial Intelligence (AI) and Multidisciplinary Design Optimisation (MDO) to improve process efficiency and ensure safe and sustainable scale-up. By 2050, FLEXBY has the potential to produce 90,000 tonnes of biofuels annually, reducing CO2 emissions by up to 120 million tonnes per year, and capturing around 1% of the global biofuel market. Beyond climate benefits, the project also supports the European Green Deal objectives, strengthens energy security, and is expected to contribute significantly to job creation in the clean energy sector.
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.
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.
FLEXBY introduces a new generation of biofuel technologies that go beyond current solutions in several ways:
1)Feedstock innovation: valorisation of industrial sludge and wastewater-grown microalgae, avoiding food-based crops.
2)Process innovation: integration of microwave-assisted pyrolysis with catalytic upgrading, eliminating the use of fossil hydrogen.
3)Digital innovation: use of AI and MDO to optimise design, minimise costs, and reduce environmental impact.
4)Circular economy: reuse of by-products such as biochar for soil enrichment, activated carbon, and catalyst support.
To reach large-scale deployment, further steps are required: pilot-scale demonstrations (TRL 6–7), continued research in catalytic pyrolysis, and alignment with EU regulatory frameworks. Financial incentives such as carbon credits and supportive policies will also play a crucial role in enabling market entry.
By combining technological innovation, sustainability, and digital optimisation, FLEXBY represents a scalable and cost-efficient pathway to next-generation biofuels. It contributes directly to Europe’s climate neutrality targets, supports the decarbonisation of transport, and strengthens the resilience of the European energy system.
1)Feedstock innovation: valorisation of industrial sludge and wastewater-grown microalgae, avoiding food-based crops.
2)Process innovation: integration of microwave-assisted pyrolysis with catalytic upgrading, eliminating the use of fossil hydrogen.
3)Digital innovation: use of AI and MDO to optimise design, minimise costs, and reduce environmental impact.
4)Circular economy: reuse of by-products such as biochar for soil enrichment, activated carbon, and catalyst support.
To reach large-scale deployment, further steps are required: pilot-scale demonstrations (TRL 6–7), continued research in catalytic pyrolysis, and alignment with EU regulatory frameworks. Financial incentives such as carbon credits and supportive policies will also play a crucial role in enabling market entry.
By combining technological innovation, sustainability, and digital optimisation, FLEXBY represents a scalable and cost-efficient pathway to next-generation biofuels. It contributes directly to Europe’s climate neutrality targets, supports the decarbonisation of transport, and strengthens the resilience of the European energy system.