BioSTEAM, the Biorefinery Simulation and Techno-Economic Analysis Modules, is an open-source steady-state process simulator in Python that enables biorefinery design, simulation, and techno-economic analysis (TEA) under uncertainty through its fast and flexible framework. By incorporating uncertainty as a key feature, BioSTEAM aims to evaluate the landscape of design decisions and scenarios for conceptual and emerging technologies. The applicability of BioSTEAM is demonstrated here in the context of (i) the co-production of biodiesel and ethanol from lipid-cane and (ii) the production of second-generation ethanol from corn stover. Economic metrics evaluated in BioSTEAM closely match benchmark designs modeled in proprietary software (SuperPro Designer, Aspen Plus). Through the automation of unit operation sizing and characterization of utility requirements, process waste streams, and make-up water usage, BioSTEAM also generates data needed for environmental sustainability analyses (e.g., via life cycle assessment). Ultimately, BioSTEAM enables rapid and robust process design, mass and energy balances, and TEA to compare established and early-stage technologies and prioritize research, development, and deployment.

Lignocellulosic biomass is a promising feedstock for sustainable biofuels and bioproducts. Among emerging bioproducts, lactic acid has attracted significant interest because of its growing application in many industries (e.g., packaging, medical, and pharmaceutical). In this study, BioSTEAMan open-source platformwas leveraged for the design, simulation, and evaluation (via techno-economic analysis, TEA, and life cycle assessment, LCA) of lignocellulosic lactic acid biorefineries. With a minimum product selling price (MPSP) between $1.38 and 1.91 kg −1 (5th−95th percentiles, baseline at $1.57 kg −1 ), the biorefinery was capable of producing market-competitive lactic acid (market price between $1.7 and 2.1 kg −1 ), and its performance could be further enhanced (e.g., MPSP down to $1.09 kg −1 , global warming potential of 2.79 kg CO 2 -eq•kg −1 , and fossil energy consumption of 31.7 MJ•kg −1 ) with advancements in key technological parameters (fermentation yield and separation process conversions) and optimization in process operation. Sensitivity analyses focused on the fermentation unit (across titer, yield, and productivity; neutral vs low-pH fermentation) and feedstock characteristics (carbohydrate content and price) were also included to quantify their impact on the sustainability of the biorefinery. Overall, this research highlights the ability of agile TEA/LCA to screen promising biorefinery designs, prioritize research needs, and establish a road map for the continued development of bioproducts and biofuels.

Lignocellulosic biomass is a promising renewable feedstock for the sustainable manufacturing of biofuels and bioproducts. Among emerging bioproducts, 3-hydroxypropionic acid (3-HP) is of particular interest as a platform chemical to produce commercially significant chemicals such as acrylic acid. In this study, BioSTEAMan open-source platformwas leveraged to design, simulate, and evaluate (via techno-economic analysis, TEA, and life cycle assessment, LCA) biorefineries producing acrylic acid via fermentation of sugars (glucose and xylose) to 3-HP. The biorefinery could produce acrylic acid with a minimum product selling price (MPSP) of $1.72−2.08•kg −1 (5th−95th percentiles; baseline at $1.83•kg −1 ). Advancements in key technological parameters (fermentation yield, titer, and saccharification solids loading) could greatly enhance the biorefinery's performance (MPSP of $1.29−1.52•kg −1 with ∼88% probability of market-competitiveness, a global warming potential of 3.00 [2.53−3.38] kg CO 2 -eq•kg −1 , and a fossil energy consumption of 39.9 [31.6−45.1] MJ•kg −1 ). A quantitative sustainable design framework was used to explore alternative fermentation regimes (neutral/ low-pH fermentation across titer, yield, and productivity combinations) and alternative feedstocks (first/second-generation feedstocks across price and sugar/carbohydrate content). Overall, this research highlights the ability of agile TEA−LCA to screen promising biorefinery designs, navigate sustainability trade-offs, prioritize research needs, and establish a roadmap for the continued development of bioproducts and biofuels.

The production of biodiesel from conventional oilseed crops (e.g., soybean) is limited by the low productivity of oil per hectare. Oilcane (derived from sugarcane) holds the potential to improve vegetable oil production in agriculture to help meet projected demand for oil-based biofuels. However, the financial viability of oilcane-derived biofuels remains uncertain, with key questions centered on the technical feasibility of vegetative oil recovery and the economic/environmental implications of designing integrated biorefineries to process multiple oil-rich feedstocks. To address these questions, two biorefinery configurations producing biodiesel and ethanol were evaluated: (i) direct cogeneration of heat and power from bagasse (lower oil recovery) and (ii) an integrated, single-step co-fermentation of both extruded juice and bagasse hydrolysate (higher oil recovery). Sensitivity and uncertainty analyses demonstrated the sustainability gains of improved oil recovery, higher feedstock oil content, and the integration of oil-sorghum processing when oilcane is not in season. For the direct cogeneration and co-fermentation configurations, Monte Carlo simulations resulted in maximum feedstock purchase prices of 34.7 [22.4, 48.4] (median; 5th and 95th percentiles in brackets) and 40.0 [19.3, 63.7] USD•MT −1 and life cycle global warming potentials of 0.313 [0.285, 0.345] and 0.320 [0.294, 0.351] kg CO 2 -eq•L −1 of ethanol (under economic allocation), respectively.

No abstract