Periodic Reporting for period 1 - NIAGARA (Next advanced bIofuels from AlGae biomAss and oRganic biogenic wAstes for electricity generation through fuel cells application)
Periodo di rendicontazione: 2024-05-01 al 2025-10-31
Without decisive action, energy-related greenhouse gas (GHG) emissions will more than double by 2050 and increased oil demand will heighten concerns over the security of supplies. The criticality of dependence on fossil fuel and oil is mainly in transport (94% of energy use in transport representing 64.5% of the oil consumption in 2014, i.e. 2 425 Mtoe). If the world is to achieve net-zero emissions by 2050, fossil fuel usage in transport will have to drop from 90% to less than 10% while biofuels will have to increase to 15%, and electricity to more than 80%.
NIAGARA aims to develop and demonstrate at TRL4 a reliable process to produce sustainable advanced biofuels from biogenic wastes and microalgae (Figure 1). The NIAGARA process will produce a renewable and biogenic advanced gaseous fuel (called biosyngas) usable in fuel cells among other application technologies (Fischer-Tropsch liquid fuel, ammonia, methanol).
NIAGARA is bringing together (1) the culture of carbohydrate-rich microalgae on effluents, (2) the conversion of vraious feedstocks through hydrothermal carbonization (HTC), (3) the aqueous phase reforming (APR) and gasification of the HTC products, (4) the final refining of the syngas to the Solid Oxide Fuel Cell (SOFC) standards, (5) the generation of electricity through SOFC, (6) the valorization of every waste streams and (7) the integration of artificial intelligence tools for the optimization of process parameters.
The mixture of both available biogenic wastes and microalgae feedstocks into a biofuel will maximize efficient circularity in the conversion processes, optimize the recovery of energy, secondary products, and in-process recyclable inputs for increased economic and environmental sustainability. Simulation and modelling of the value chain will be carried out to determine the best process routes that optimize gains in terms of production cost, GHG and energy consumption.
NIAGARA aims to develop and demonstrate at TRL4 a reliable process to produce sustainable advanced biofuels from biogenic wastes and microalgae (Figure 1). The NIAGARA process will produce a renewable and biogenic advanced gaseous fuel (called biosyngas) usable in fuel cells among other application technologies (Fischer-Tropsch liquid fuel, ammonia, methanol).
NIAGARA is bringing together (1) the culture of carbohydrate-rich microalgae on effluents, (2) the conversion of vraious feedstocks through hydrothermal carbonization (HTC), (3) the aqueous phase reforming (APR) and gasification of the HTC products, (4) the final refining of the syngas to the Solid Oxide Fuel Cell (SOFC) standards, (5) the generation of electricity through SOFC, (6) the valorization of every waste streams and (7) the integration of artificial intelligence tools for the optimization of process parameters.
The mixture of both available biogenic wastes and microalgae feedstocks into a biofuel will maximize efficient circularity in the conversion processes, optimize the recovery of energy, secondary products, and in-process recyclable inputs for increased economic and environmental sustainability. Simulation and modelling of the value chain will be carried out to determine the best process routes that optimize gains in terms of production cost, GHG and energy consumption.
A review of scientific studies, databases, and regional reports was used to estimate available feedstocks for HTC and microalgae cultivation. These feedstocks include sewage sludge, digestate, agricultural residues, livestock manure, food and agro-industrial waste, and byproducts from sectors such as dairy, slaughterhouses, pulp and paper, and breweries. The analysis shows that Europe generates enough waste and biomass to support several HTC biorefineries with capacities of 30,000 tDM per year, highlighting strong potential for regional development.
Various microalgae strains were also tested for their ability to grow on different effluents—both incoming streams (like wastewater and digestate) and recycled flows (such as the HTC aqueous phase and APR effluent)—while producing biomass suitable for HTC, especially rich in carbohydrates. Some strains achieved high carbohydrate yields when grown in NIAGARA recirculating streams, which is a crucial first step toward validating the NIAGARA concept.
At the core of the NIAGARA project is the development of thermochemical processes that convert these feedstocks into valuable gaseous biofuels. Over 60 HTC experiments have been conducted at the lab scale using different wastes and various microalgae biomass, supported by the creation of an AI-based process model. Ongoing lab- and pilot-scale tests will further refine this model.
The HTC aqueous effluent has been characterized, pretreated, and processed through APR to produce hydrogen (about 15 mmol H2/gC) and methane. This marks the first time APR has been applied to such a complex, nitrogen-rich wastewater. Strategies to reduce catalyst deactivation are already in place, and further work—such as phosphate removal—is planned.
The main HTC product, hydrochar, has also been analyzed. Hydrochars derived from waste need to be blended with those from biomass to enable effective gasification in a fixed-bed reactor. To support pilot-scale testing, 700 kg of hydrochar-like material were produced by torrefying 1.5 tonnes of rapeseed cake pellets. These torrefied pellets show similar characteristics to hydrochars, except for the oxygen content, and meet the criteria required for upcoming gasification trials.
The biosyngas produced in the NIAGARA project combines the gaseous products from the gasification of HTC hydrochar and the APR process. This renewable fuel is then used to power a SOFC, generating both electricity and heat. A carbon-safe gas composition was defined to ensure stable SOFC operation at temperatures above 600 °C, providing a reliable basis for efficient, carbon-free energy production. NIAGARA also established quantitative links between operating conditions, performance, and degradation, creating a predictive tool for optimizing SOFC operation with varying biosyngas compositions. The team also developed a novel diagnostic method—Total Harmonic Distortion Analysis (THDA)— and successful electroplating methods to increase the lifespan of the fuel cells. Finally, the development of regenerable hot-gas sorbents marks a major advance in sulfur control above 500 °C, enabling the direct and efficient use of the NIAGARA biosyngas in SOFC systems.
Enhancing the circularity of the NIAGARA process is a key objective. The CO2 generated during thermochemical processes will be captured using a newly developed solvent with high absorption capacity, fast reaction rates, and strong thermal stability. Its performance surpasses that of the conventional solvent monoethanolamine (MEA), which will be tested in a pilot-scale unit already commissioned on MEA.
NIAGARA aims to minimize liquid effluents by recycling them into microalgae cultivation, with the goal of discharging only clean water—mainly from the algae harvesting stage. In addition, the solid residue from gasification, known as biochar, has shown strong potential as a plant growth medium. When properly conditioned and washed, it performs as well as or better than conventional substrates.
The industrial scale-up of the NIAGARA process is being explored through modeling and simulation of best-case scenarios. Preliminary models have provided initial mass and energy balances, which will be refined as more detailed data become available. A preliminary life cycle assessment (LCA) offered an early environmental evaluation of the NIAGARA system. Three feedstock scenarios were analyzed using a parameterized LCA approach to account for variability in feedstock composition and process conditions. A model plant will also be developed to perform a techno-economic assessment over the system’s lifetime.
Finally, the NIAGARA project is guided by the principles of Responsible Research and Innovation (RRI), ensuring that all outcomes are not only scientifically robust but also socially responsible, transparent, and environmentally sustainable.
Various microalgae strains were also tested for their ability to grow on different effluents—both incoming streams (like wastewater and digestate) and recycled flows (such as the HTC aqueous phase and APR effluent)—while producing biomass suitable for HTC, especially rich in carbohydrates. Some strains achieved high carbohydrate yields when grown in NIAGARA recirculating streams, which is a crucial first step toward validating the NIAGARA concept.
At the core of the NIAGARA project is the development of thermochemical processes that convert these feedstocks into valuable gaseous biofuels. Over 60 HTC experiments have been conducted at the lab scale using different wastes and various microalgae biomass, supported by the creation of an AI-based process model. Ongoing lab- and pilot-scale tests will further refine this model.
The HTC aqueous effluent has been characterized, pretreated, and processed through APR to produce hydrogen (about 15 mmol H2/gC) and methane. This marks the first time APR has been applied to such a complex, nitrogen-rich wastewater. Strategies to reduce catalyst deactivation are already in place, and further work—such as phosphate removal—is planned.
The main HTC product, hydrochar, has also been analyzed. Hydrochars derived from waste need to be blended with those from biomass to enable effective gasification in a fixed-bed reactor. To support pilot-scale testing, 700 kg of hydrochar-like material were produced by torrefying 1.5 tonnes of rapeseed cake pellets. These torrefied pellets show similar characteristics to hydrochars, except for the oxygen content, and meet the criteria required for upcoming gasification trials.
The biosyngas produced in the NIAGARA project combines the gaseous products from the gasification of HTC hydrochar and the APR process. This renewable fuel is then used to power a SOFC, generating both electricity and heat. A carbon-safe gas composition was defined to ensure stable SOFC operation at temperatures above 600 °C, providing a reliable basis for efficient, carbon-free energy production. NIAGARA also established quantitative links between operating conditions, performance, and degradation, creating a predictive tool for optimizing SOFC operation with varying biosyngas compositions. The team also developed a novel diagnostic method—Total Harmonic Distortion Analysis (THDA)— and successful electroplating methods to increase the lifespan of the fuel cells. Finally, the development of regenerable hot-gas sorbents marks a major advance in sulfur control above 500 °C, enabling the direct and efficient use of the NIAGARA biosyngas in SOFC systems.
Enhancing the circularity of the NIAGARA process is a key objective. The CO2 generated during thermochemical processes will be captured using a newly developed solvent with high absorption capacity, fast reaction rates, and strong thermal stability. Its performance surpasses that of the conventional solvent monoethanolamine (MEA), which will be tested in a pilot-scale unit already commissioned on MEA.
NIAGARA aims to minimize liquid effluents by recycling them into microalgae cultivation, with the goal of discharging only clean water—mainly from the algae harvesting stage. In addition, the solid residue from gasification, known as biochar, has shown strong potential as a plant growth medium. When properly conditioned and washed, it performs as well as or better than conventional substrates.
The industrial scale-up of the NIAGARA process is being explored through modeling and simulation of best-case scenarios. Preliminary models have provided initial mass and energy balances, which will be refined as more detailed data become available. A preliminary life cycle assessment (LCA) offered an early environmental evaluation of the NIAGARA system. Three feedstock scenarios were analyzed using a parameterized LCA approach to account for variability in feedstock composition and process conditions. A model plant will also be developed to perform a techno-economic assessment over the system’s lifetime.
Finally, the NIAGARA project is guided by the principles of Responsible Research and Innovation (RRI), ensuring that all outcomes are not only scientifically robust but also socially responsible, transparent, and environmentally sustainable.
To ensure further uptake and success of the NIAGARA model, research and demonstration activities will be needed to validate the process performances at pilot and industrial scale. In addition, the establishment of favorable regulatory frameworks and standardization guidelines for this type of gaseous biofuel will be essential to enable their entry into the market.