Biorefinery and Industry 4.0: Empowering Sustainability

The concept of renewable carbon and its relevance in the context of sustainable economy and mitigation of environmental impacts caused by fossil fuel usage is essential. Carbon is a versatile chemical element, present in various molecules and widely utilized in the industry for fuel production, chemicals, polymer materials, energy, and others. However, the use of fossil carbon is limited and has adverse environmental impacts, such as the emission of carbon dioxide (CO₂) responsible for global warming. In pursuit of alternatives, the concept of renewable carbon gains prominence, referring to resources that can be regenerated through the carbon cycle, such as CO₂ and methane from natural or anthropogenic sources. Renewable carbon sources include microalgae biomass, lignocellulosic residues, the pulp and paper industry, as well as fruit and vegetable processing waste. The production of biofuels and high-value products from these sources forms the foundation of sustainable bioeconomy, which seeks to employ advanced technologies for efficient and circular utilization of natural resources. Sustainable bioeconomy is crucial to address the challenges posed by the growing global population and to ensure environmental preservation. Combining agricultural and forest biomass is a promising strategy to meet the demand for raw materials and expand clean energy and bioproducts production. However, the implementation of biorefineries and other renewable carbon technologies still faces challenges, such as the lack of detailed technical–economic assessments and adequate life cycle analyses.

Precision biomass collection is the process of harvesting and collecting biomass feedstock for various purposes, such as bioenergy, biochemicals, and biomaterials production. It involves using advanced systems or methods to measure and estimate the biomass quantity and quality in a given area. Biomass collection involves compiling, packaging, and transporting biomass to a nearby biorefinery gate. The amount of biomass resource that can be collected at a given time depends on various factors. It includes collection operations, collection equipment efficiency, management practices, and environmental conditions. Biorefinery is a sustainable approach to maximize the utilization of biomass resources and minimize waste generation. The biorefinery concept aligns with the principles of circular economy and zero waste strategy, focusing on efficiently using renewable resources and reducing negative environmental impacts. Biorefineries can extract and convert different biomass components into valuable products by employing various technologies and processes, thereby minimizing waste generation at the biorefinery gate.

The biorefinery is a system that uses biomass feedstock to manufacture biobased products. Based on the feedstock utilized, the biorefineries can be categorized as first generation (edible biomass), second generation (lignocellulosic biomass) and third generation (biomass of algae), which produce both high-value low volume (HVLV) and low-value high volume (LVHV) products of commercial importance. The present chapter deals with elaboration on the technological steps for bioconversion of feedstocks to biofuels and biochemicals. Furthermore, the recent advancements in valorization of all the substrates (first, second and third generations) to biofuels and biochemicals have been discussed. In order to develop sustainable biorefineries, the challenges faced by the biorefineries along with their potential solutions have also been reported.

Implementing lignocellulosic biorefineries to obtain energy and chemical products is a great challenge given the complexity of the raw material and the immaturity of the technology, compared to oil refineries. On the other hand, the development of computer tools has allowed the improvement of industrial processes through automation and optimization of different procedures. This chapter addresses how technological advances, and the implementation and use of computational resources will drive biorefineries in the so-called new industrial revolution or Industry 4.0. Specifically, the optimization of processes using the design of experiments allows for reducing the number of experiments in the search for the best operating conditions in each of the production stages. Thus, time and resources are saved, which is economically favorable. In addition, modeling, and simulation lead to the understanding of complex processes and predict kinetic and thermodynamic models. In the same way, the life cycle analysis allows decisions to be made after evaluating the different criteria, according to the fundamental pillars: environmental, social, and economic. Through simulation, theoretical concepts can be linked to real situations, saving resources and time, and the footprint of the product can be established from the beginning to the end of its life cycle. However, all these tools have been used primarily on a laboratory scale. Conducting these studies on a larger scale is crucial to guarantee the competitiveness of biorefineries from technological, economic, and social points of view. In addition, logistics must be perfected throughout the supply and production chain, which can be favored with the digitization and automation of processes. At the same time, these tools can contribute to implementing the circular economy, and the development of sustainable processes. Besides, the integration of processes is presented as an interesting option that can even reduce the dependence on resources of fossil origin. Finally, academia and industry must be strongly united in the search for viable solutions that can be applied to improve processes and not remain only in publications.

Due to the depletion of fossil fuel sources and the issues posed by climate change, there is an increasing demand for renewable and sustainable fuel alternatives. Biofuels are a viable replacement for fossil fuels since they are made from renewable biomass. Degradation and valorization of renewable biomass start in the biorefinery with the main goal of producing biofuels and biochemicals in a more sustainable way. Lignocellulosic biomass (LB) presents one of the most abundant feedstocks for low-carbon fuel production. Enzymes belonging to cellulase, xylanase, pectinase, laccase, amylase, and lipase are utilized for biomass degradation and for the biofuels production. The emphasis of this chapter will be on the smart degrading enzymes designed to produce the two low-carbon biofuels, bioethanol and biodiesel, which are mostly used in the industrial sector. The technological development of commercial enzymes involved in biofuel and chemical production is also discussed.

Currently, non-renewable fossil fuels provide the majority of the world’s energy. Biofuel such as bioethanol is an important alternative and substitute energy source which can be used to cater for the energy requirement in the world. This chapter focuses on producing bioethanol from lignocellulosic biomass due to its abundance in nature. Up-to-date information on recent developments and research on bioethanol is completed to investigate the issues in present literature studies regarding bioethanol production. The methods of the bioethanol conversion process are explored to improve the performance and maximize the yields. Different ranges of parameters are studied to determine the optimum value of each parameter in producing a higher yield of bioethanol. However, further research on the bioethanol technology conversion process is vital to ensure the bioprocess used in producing bioethanol becomes commercially and economically feasible.

A bioeconomy is considered a better way of reducing environmental impacts, particularly greenhouse gases (GHGs) emissions caused by using the fossil fuels. The replacement of these fuels by using biobased products and bioenergy would be beneficial to the environment, as well as to the local economy. Biorefinery is an ideal concept, where a variety of products are produced from organic feedstock, including chemicals, fuels, polymers, etc. Among the various biorefineries, the anaerobic biorefinery concept is becoming popular, which follows anaerobic digestion (AD) as the ultimate step to dispose of any biodegradable waste. Different entities involved in the anaerobic biorefineries are evaluated in this chapter, with emphasis on feedstocks, energy usage, and sustainable applications of by-products and products generated. The factors affecting upstream and downstream processes are discussed. This chapter also presents the present and upcoming applications and market sizes of AD-based products and their by-products, including biofuels, biochemicals, biofertilisers, etc. By incorporating AD technology into biorefineries, sustainable development goals can be achieved more rapidly in areas such as water quality, sanitation, and energy efficiency. The final section discusses future directives that show how anaerobic biorefineries could contribute to the sustainable development of the bioeconomy in future.

The combination of Industry 4.0 and synthetic biology is examined in this book chapter in a well-planned way for establishing a carbon–neutral economy. In light of growing environmental concerns, it is as critical to shift to sustainable practices inclusive of social and economic dimensions. This chapter offers a thorough analysis of the ways in which Industry 4.0's fundamental elements—cyber-physical systems, the Internet of Things, artificial intelligence, and data analytics—can be combined and applied in the field of synthetic biology in order to facilitate the creation of novel and sustainable solutions. The chapter explains the present obstacles of creating an economy that is carbon neutral, and then goes on to discuss how important synthetic biology is in creating biobased alternatives. It explores the revolutionary possibilities of Industry 4.0, explaining how digitalization and intelligent technologies might improve the accuracy, efficacy, and scalability of synthetic biological procedures. The practical outcomes of this convergence are demonstrated through case studies and applications that highlight real-world experiences where Industry 4.0 ingredients have catalyzed advancements in carbon–neutral initiatives. Examining the complex issues raised, the chapter examines the moral and legal implications of merging Industry 4.0 and synthetic biology. It highlights how crucial it is to lead these technical breakthroughs toward socially and ecologically sensitive consequences through ethical governance and sustainable innovation.

Cellulose nanoparticles (CNs) have emerged as one of the most promising eco-friendly materials due to their sustainable potential and outstanding physical and mechanical properties. These properties include exceptional optical attributes, an anisotropic shape, and high mechanical strength. A significant factor that adds to their appeal is that they are derived from cellulose, a resource that is abundant, non-toxic, biodegradable, and biocompatible resource. Lignin, which once was considered an undesirable by-product of the pulping process, has been the subject of extensive research to enhance its value. Although it is primarily used to produce renewable energy in industries, the growing potential of lignin from both process and economic perspectives is noteworthy, especially as the global demand for bio-based products increases. However, the methods employed to valorize this macromolecule present challenges, leaving lignin a somewhat underexploited renewable resource. An innovative approach for lignin has been its conversion into lignin nanoparticles (LNPs). Both LNPs and CNs are emerging as valuable materials in a range of applications in materials engineering, from packaging to biomedical fields. The development of new nanocomposites, derived from CNs and LNPs, merges the benefits of these nanomaterials with their plant-based origins. When integrated with other polymeric matrices, they offer unique properties such as hydrophobicity, UV protection, and antimicrobial activity. This chapter explores the latest advancements in CNs and LNPs production and their potential uses, drawing from contemporary literature.

This chapter explores the importance of early-stage assessments in establishing and operating biorefineries, particularly in the context of the United Nations’ Sustainable Development Goals (SDGs) and the Circular Economy. Assessments are becoming more critical as they predict risks, identify promising technologies, and evaluate environmental impacts. They are crucial for decision-making, resource allocation, risk mitigation, and attracting investments by showing economic and environmental feasibility. The chapter overviews early-stage assessments, including their main elements and potential applications. The increasing use of early-stage evaluations by researchers and professionals demonstrates their establishment as decision-making tools, making it essential to understand and promote their application in biorefineries.

The growing concern for the environment has forced industries to explore sustainable and eco-friendly approaches to generate resources, one of them being biorefineries, which turn biomass into value-added products. Biorefineries emerge as a potential solution, offering green and circular economies by way of substituting the usage of fossil fuels and by production of other value added products from the residues from agricultural, food and other industries. Just like any industry, they look to update to recent technologies, such as Industry 4.0, representing the fourth industrial revolution. Industry 4.0 consists of Cyber-Physical systems that enhance operations through automation, detection of risks and failures, data analysis, etc., using tools such as Big Data Analysis, The Internet of Things, and Artificial Intelligence. Despite the promising outlook, several challenges are there to overcome. High investments, low global competition, price fluctuation, uncertain Return of Investment, innovative processes, etc., are some of the economic challenges. Social acceptance, land usage, stakeholders, policies, and selecting the indicated research areas and staff training, may be some of the social and organizational challenges. In this chapter, those challenges, as well as the opportunity areas for a swift and effective transition toward sustainable and technologically advanced practices are discussed.

This chapter focuses on the significance of biorefineries in the successful implementation of bioeconomy, highlighting their function as integrated processing units for multiple stages of biomass valorization and high-value product generation. Biorefineries are classified into first-(1G), second-(2G), and third-generation (3G) biorefineries based on the type of biomass used. Although 1G biorefineries remain prevalent, the need for sustainable alternatives to biomass supply to ensure continuous production is emphasized. Key aspects of the sustainability of biomass-based biorefineries, such as continuous biomass production, active involvement of farmers in new business models, and promotion of sustainable agricultural practices, are discussed. The importance of including farmers in decision-making and establishing policies for equitable income distribution along the value chain is also emphasized. The development of diverse biorefineries is crucial for a sustainable bioeconomy.

The patent system provides exclusive rights to inventors as an incentive for innovation and the progress of science. However, intellectual property laws can be complex and vary between different countries and regions, so it’s essential for inventors, universities, research institutes, and businesses to understand the laws applicable in their respective jurisdictions to properly protect their intellectual assets. Advances in biotechnology have raised complex questions regarding what can be patented and what cannot be patented as it involves the ethical, social, and legal implications of patenting inventions related to living organisms, genes, and genetic modifications. This work presents a process model to manage the intellectual property in universities and research institutes. This process model creates capabilities to make the Technology Transfer Offices from universities and research institutes more proactive and dynamic and make this office capable of assessing technologies that are forwarded to the office and define strategies for the protection and commercialize of the technologies. All sectors of the economy, and in particular the biorefineries sector, can benefit from the various technologies created (and protected by intellectual property) within universities, research institutes, and companies to transform their processes, which can generate greater gains productivity or improve the efficiency of company processes, or even product characteristics and, above all, to transform a creation into innovation and generate benefits to society.

The artificial intelligence (AI) has been a platform of immense assistance to develop and simplify discoveries in medical science. However, the environmentalist have been researching this concept to benefit the environment to establish multidimensional discoveries of clean energy. An increase in greenhouse gases (GHGs) is caused by most human developmental activities. Direct or indirect emission of GHGs by person, group, event, or any other activity contributes to the carbon footprint. According to the Environmental Protection Agency, USA, major sources of increasing GHGs are transportation (29%), electricity (28%), industry (22%), commercial and residential (12%), and agriculture (9%). Vigorous effects are required to control the increasing GHGs by developing and implementing policies and utilizing new technologies. In this time of challenges presented by climate change, technological advancements in artificial intelligence (AI) or digital assistance have made a significant impact on people’s lifestyles. AI-based technologies to monitor, predict, and reduce GHGs emissions may help in a cleaner environment. This article aims to describe different AI-based approaches to minimize carbon footprints as well as discuss the role of AI in various industries and its economic and societal outcomes. Specifically, we have attempted to fill the research gaps by investigating existing opportunities in the field of AI toward reducing GHG emissions.