Powering tomorrow: Integrating biorefineries, carbon capture, and renewable fuels

The world is facing an energy crisis due to increasing energy demands and the depletion of fossil fuels, prompting a shift towards renewable, carbon-neutral resources like biomass. Climate change, fuelled by the relentless burning of fossil fuels, has become one of the most pressing global challenges of our time. Rising temperatures, extreme weather events, and widespread environmental degradation are direct consequences of the heavy reliance on fossil fuels, which currently account for approximately 80% of global energy demand and remain the leading source of greenhouse gas emissions. Despite rapid advancements in renewable energy technologies, large reserves of coal, oil, and natural gas remain untapped, posing a significant obstacle to achieving a low-carbon future.

Advancing integrated biorefineries for low-carbon solutions

Addressing these crises requires an urgent transition to sustainable and renewable energy sources such as biofuels, hydrogen, and solar and wind power, coupled with innovative carbon capture and storage (CCS) technologies. These alternatives not only reduce emissions but also enhance energy security and promote economic resilience. However, transitioning away from fossil fuels demands bold policies, substantial investments, and disruptive shifts in energy production and consumption patterns.

The European Union has established regulatory frameworks to promote the adoption of renewable energy, particularly in the transport sector. The Renewable Energy Directive (RED) sets binding targets for the share of renewable energy in the EU's energy mix, aiming for at least 42.5% by 2030. On the other hand, the Distribution Obligation Law is a regulatory framework designed to increase the use of biofuels in transportation by mandating that fuel distributors incorporate a specified percentage of biofuels into their total annual fuel sales.

Additionally, member states have implemented distribution obligation systems, requiring fuel suppliers to incorporate a specified percentage of biofuels into their annual fuel sales.

Biorefineries, particularly integrated or hybrid biorefineries, play a vital role in combating climate change by offering sustainable, low-carbon alternatives to fossil fuels. They convert renewable biomass sources, such as agricultural residues, waste, and algae, into biofuels, biochemicals, and biomaterials, supporting a circular economy.

Integrated biorefineries utilise advanced processing technologies, including thermochemical, chemical, and biochemical conversion methods, such as gasification, pyrolysis, and transesterification, to produce biofuels like bioethanol and biobutanol. By leveraging existing infrastructure and renewable resources, integrated biorefineries reduce reliance on fossil fuels, support energy security, and contribute to global climate goals, positioning them as essential in the transition to a sustainable, low-carbon future.

Driving decarbonisation: Engineering excellence in fuel production

Recent advancements in technology have transformed the production of methanol and Sustainable Aviation Fuel (SAF), leveraging innovative processes like gasification, electrolysis, and carbon capture.

Gasification converts biomass or waste into syngas, a mix of carbon monoxide and hydrogen, which is then synthesised into methanol or longer liquid hydrocarbons via catalytic processes. The syngas can be combined with electrolysis, powered by renewable energy, that splits water into hydrogen and oxygen, enabling better carbon yield. It can also be used for utilising captured biogenic CO₂. As an additional synergy, the side product oxygen can be used in the gasifier. Carbon capture and storage (CCS) is integral to these processes, providing CO₂ for production while reducing emissions.

SAF production has progressed through several pathways, including Hydro processed Esters and Fatty Acids (HEFA), the most commercially developed route, which uses fats, oils, and greases to produce jet fuel. Another alternative is the Alcohol-to-Jet (MTJ) processes, which enable the direct conversion of methanol or higher alcohols into jet fuel components.

Biorefineries, hybrid refineries, and integrated refineries further optimise production by utilising diverse feedstocks like biomass, waste, and captured emissions or combining them with existing downstream processes. These advancements are crucial for developing sustainable fuels, minimising carbon footprints, and supporting global decarbonisation goals, including achieving net-zero emissions by 2050.

Challenges in biorefineries and biofuels

The biorefinery and biofuel sectors face multifaceted challenges globally and within the EU, encompassing regulatory complexities, market dynamics, and project execution hurdles. Regulatory obstacles include inconsistent policy frameworks and complex compliance requirements, which create uncertainty for investors and hinder project development.

Market challenges are characterised by high production costs, making bio-based products less competitive against fossil-based alternatives, and market volatility, which can deter investment. Project execution is further complicated by technical difficulties, due to engineering challenges and the need for project optimisation. Additionally, securing a consistent and sustainable supply of feedstocks remains a critical concern, with competition for resources and logistical issues posing significant barriers.

Addressing these challenges necessitates collaborative efforts among policymakers, industry stakeholders, and researchers to develop supportive policies, invest in technological advancements, and establish efficient supply chains for sustainable biorefinery and biofuel production.

AFRY: Shaping a low-carbon future through innovation

AFRY is at the forefront of engineering consultancy, offering cutting-edge solutions to drive the shift to sustainable, low-carbon energy. With expertise in advanced biorefinery technologies, gasification, electrolysis, and carbon capture, we specialise in biorefineries. Our services are designed to help clients reduce carbon emissions, enhance energy security, and meet sustainability goals.

We provide a comprehensive range of services, including initial consultations to assess your specific needs, customised planning and design, and seamless implementation of innovative technologies. Our expert project management ensures that all projects are completed on time, within budget, and to the highest standards. Additionally, we offer ongoing technical support, training, and optimisation to ensure systems operate efficiently and continue to deliver value.

By partnering with AFRY, clients gain access to scalable, economically viable solutions that reduce reliance on fossil fuels and position them as leaders in the global effort to combat climate change. Our commitment to excellence ensures that every project supports long-term sustainability and resilience in a rapidly evolving energy landscape.