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03.03.2025 15:30

High value, zero waste - ATB researchers conceptualise novel biorefinery

Jessica Lietze Presse- und Öffentlichkeitsarbeit
Leibniz-Institut für Agrartechnik und Bioökonomie e.V. (ATB)

What does it mean if our economy works without fossil raw materials such as oil and gas? The logical answer is that we will have to create value almost exclusively with biological, renewable resources. This so-called bioeconomy presents us with major challenges, both locally and globally. Researchers from Leibniz Institute for Agricultural Engineering and Bioeconomy in Potsdam recently published a concept paper in the scientific Biofuel Research Journal, which combines common bioeconomy models into a comprehensive concept. They describe what a circular and sustainable bioeconomy within planetary boundaries could look like. Smart integrated biorefineries are a key component of this vision.

Biomass, i.e. grown, biological raw materials, are a great treasure. We eat it, feed it, burn it or utilise it. What remains is usually composted, landfilled or incinerated. Yet there is still potential in every unused residue. One way to utilise this potential is through intelligent, integrated biorefineries. Unlike conventional biorefineries, in which chemical companies, for example, extract one special biochemical from one special biological starting material, they combine several conversion processes.

The potential of intelligent biorefineries is immense

Dr Nader Marzban is a researcher at Leibniz Institute for Agricultural Engineering and Bioeconomy (ATB) and lead author of the conceptual paper "Smart Integrated Biorefineries in Bioeconomy: A Concept Toward Zero-Waste, Emission Reduction, and Self-Sufficient Energy Production". He describes it like this: "There are many conversion technologies that generate valuable materials from biomass. These include among others microbial fermentation, such as anaerobic digestion, and pyrolysis. Anaerobic digestion, for example, produces biogas, whereby the remaining digestate still contains valuable organic compounds. Instead of using it as a fertiliser, as is traditionally the case, we can convert this digestate into artificial humic substances through hydrothermal humification. When introduced into the soil, it stabilises bacterial diversity and improves soil health. Another promising approach is the combination of anaerobic fermentation with pyrolysis, i.e. carbonisation. Here, biochar acts as a catalyst and increases the efficiency of biogas production. At the same time, the biochar is enriched with nutrients. It can thus keep nutrients available in the soil for a long time and – depending on the process conditions – store carbon for more than a century.

Another example is fermentation. If biochar is added, fermentation inhibitors are broken down, which significantly increases the ethanol and lactic acid yield. In addition, the bioheat and electricity generated during pyrolysis can be used for fermentation, which reduces dependence on external energy sources. CO₂ emissions from pyrolysis can be captured and used for the cultivation of algae, which in turn serve as an alternative source of protein."

The potential of intelligent biorefineries is immense, but so is the number of possible optimisations. Industrial processes such as anaerobic digestion, fermentation, pyrolysis, carbonisation and humification each have adjustable parameters and can be combined in a variety of ways. Instead of relying on a single type of biomass, the researchers work with 90 different raw materials that vary regionally and seasonally. By defining key objectives and adjustable parameters for each process, millions of potential scenarios are created.

Dr Marzban points out: “Investigating all these scenarios experimentally would be extremely costly and time-consuming. Yet time is a luxury that we cannot afford. Our economy is still heavily dependent on fossil raw materials. We are already seeing the negative effects. That's why we rely on AI-driven simulations to identify the most efficient approaches. As process scientists, we proceed step by step and initially optimise subsystems, which we then gradually link together to combine them into a larger whole.”

A sustainable bioeconomy with zero waste and within planetary boundaries

Global industry expertise and extensive research results – including from ATB – provide a rich data basis for the further development of existing biomass conversion processes. Key technologies are sensors that measure directly in the processes and help to gain a better understanding of product-process interactions as well as artificial intelligence, digital twins and advanced modelling techniques. By leveraging data, processing capacities and algorithms, smart integrated biorefineries can be developed that are adaptable and scalable and can process thousands, if not millions, of scenarios.

Prof Barbara Sturm, Scientific Director at ATB and corresponding author of the paper explains: “The smart integrated biorefineries can be developed using networks and dialogues between different modelled systems and then be validated in reality. This validation process allows for the identification of gaps and the uncovering of hidden opportunities, which can be addressed either by repurposing existing technologies and systems or by introducing innovative solutions such as artificial humic substances. In this systemic approach, each biorefinery component actively seeks connections with others, forming larger, integrated networks. This system would constantly simulating the next steps to find out the best way to achieve defined goals. That will enhance sustainability and circularity within bioeconomic models, creating jobs and support the policy maker. Our vision is to achieve a more resilient, efficient and future-proof bio-based economy through this systemic integration.”

The integrated approach could enable us to create a truly sustainable bioeconomy with zero waste and remaining within our planetary boundaries. It increases profitability and competitiveness, which is urgently needed given the lower cost of fossil products. Nevertheless, government support and policy interventions are crucial to facilitate and accelerate the transition to green technologies. In the long term, smart integrated biorefineries will undoubtedly be more profitable than systems focussed on a single process. They will also reduce the need to import raw materials and thus increase the resilience of our economic systems.

Time for implementation

With the concept paper, the ATB team together with partners from the University of Potsdam and the Technical University of Berlin has taken the first step. Now it's time for proving and implementation. This March, ATB will begin construction of a biorefinery for research purposes in Groß Kreutz, Brandenburg, Germany. This will complement the existing pilot plants and facilities at the Potsdam site and the Fieldlab for Digital Agriculture in Potsdam-Marquardt. As part of the Leibniz Innovation Farm for Sustainable Bioeconomy (InnoHof®), a facility is being created that will not only bring together research and practice in a co-creative way, but will also demonstrate the feasibility of such concepts.

Furthermore, ATB is in the process of applying for an extension of the institute in order to integrate such systemic approaches even more consistently into its research. In a joint appointment with the University of Osnabrück, ATB is currently filling a professorship for systems science in bioeconomy. Prof. Sturm emphasises: “We have to think systemic, technical, social and economic innovations together. Only if we understand a system as a whole we will be able to optimise subsystems in such a way that they effectively serve sustainability. With our concept, we will further intensify interdisciplinary bioeconomy research with political decision-makers, industry leaders and the food and nutrition sector with the aim of increasing the resilience of our economic system, making our economy more sustainable and supporting the technological sovereignty of Germany and Europe.”

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Wissenschaftliche Ansprechpartner:

Dr. Nader Marzban
Scientist for Thermochemical Conversion, ATB
Telefon: +49 331 5699-339
E-Mail: nmarzban@atb-potsdam.de

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Originalpublikation:

Marzban N., Psarianos M., Herrmann C., Schulz-Nielsen L., Olszewska-Widdrat A., Arefi A., Pecenka R., Grundmann P., Schlüter O.K., Hoffmann T., Rotter V.S., Nikoloski Z., Sturm B. Smart integrated biorefineries in bioeconomy: A concept toward zero-waste, emission reduction, and self-sufficient energy production. Biofuel Research Journal 45 (2025) 2319-2349. DOI: 10.18331/BRJ2025.12.1.4
https://doi.org/10.18331/BRJ2025.12.1.4

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Weitere Informationen:

https://www.atb-potsdam.de/en/news-and-press/pressemitteilungen/pressemitteilung... Humic Substances for Agriculture
https://www.atb-potsdam.de/en/our-topics/bioeconomy Bioeconomy at ATB
https://www.atb-potsdam.de/en/our-topics/biobased-chemicals Biobased Chemicals
https://www.atb-potsdam.de/en/our-topics/biochar Biochar as all-rounder

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Overview of the smart integrated biorefinery concept
ATB
Marzban et al., 2025, Biofuel Research Journal, DOI: 10.18331/BRJ2025.12.1.4 - https://doi.org/10.18331/BRJ2025.12.1.4

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Working on a bioreactor
Manuel Gutjahr
ATB

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Merkmale dieser Pressemitteilung:
Journalisten, Studierende, Wirtschaftsvertreter, Wissenschaftler
Biologie, Energie, Tier / Land / Forst, Umwelt / Ökologie, Wirtschaft
überregional
Forschungsergebnisse, Wissenschaftliche Publikationen
Englisch

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