18. Transitioning to Sustainability: Challenges and Innovations in Biorefinery Process Design and Control

The transition from fossil fuel-based production to sustainable biomass utilization is critical for addressing environmental concerns and achieving a circular economy. Biorefineries, utilizing renewable biomass feedstocks, provide an alternative to traditional crude oil refineries, reducing greenhouse gas emissions and wastes. Despite the extensive knowledge and research in conventional oil refineries, biorefineries face unique challenges, particularly in feedstock variability and process complexity. The diverse nature of biomass necessitates accurate thermodynamic data and component properties for effective biorefinery design. Additionally, advanced separation techniques and tailored process control methodologies are essential to manage the inherent variability of bio-derived streams and ensure efficient operations. In this paper, critical aspects of biorefinery development are discussed, starting with a discussion of how the physicochemical properties of biomass influence design and operation. The paper then examines the role of process intensification in significantly improving processes by reducing equipment size, lowering energy consumption, and enhancing sustainability. Additionally, the importance of process control is highlighted as a key factor in optimizing biorefinery operations. Effective process control ensures the consistent performance of unit operations, enables real-time adjustments, and improves overall efficiency and product quality. Through these integrated approaches, biorefinery development can move toward more sustainable, cost-effective, and efficient processes.