Open Access Article
Jingyi
Zhang
*a,
Yunhua
Zhu
b,
Troy R.
Hawkins
*a,
Bruno C.
Klein
c,
Andre M.
Coleman
b,
Udayan
Singh
a,
Ryan
Davis
c,
Longwen
Ou
a,
Yiling
Xu
b,
Saurajyoti
Kar
a,
Matthew
Wiatrowski
c,
Song
Gao
b and
Peter
Valdez
b
aSystems Assessment Center, Energy Systems and Infrastructure Analysis Division, Argonne National Laboratory, Lemont, IL 60439, USA. E-mail: trh@alumni.cmu.edu; jingyi.zhang@anl.gov; Tel: +1-(630)252-6428 Tel: +1 630-252-1381
bPacific Northwest National Laboratory, 902 Battelle Blvd, Richland, WA 99352, USA
cCatalytic Carbon Transformation & Scale-up Center, National Renewable Energy Laboratory, Golden, CO 80401, USA
First published on 24th February 2025
The development of microalgal biorefineries, utilizing high-value coproducts, offers a strategy to lower biofuel production costs, while the use of saline-tolerant microalgal species contributes to reducing freshwater consumption. This study evaluates the life cycle performance of saline microalgae cultivation and conversion at a national scale by analyzing economics, greenhouse gas (GHG) emissions, marginal GHG avoidance cost (MAC), water scarcity footprints, land-use change emissions, and resource availability. The Algal Biomass Assessment Tool (BAT) is applied for site selection, while algae farm and conversion models are used for techno-economic analysis (TEA). The Greenhouse Gases, Regulated Emissions, and Energy use in Technologies (GREET) model is employed for life cycle assessment (LCA) by integrating the outputs from BAT and TEA. Our findings demonstrate that electricity and nutrient consumption are the primary drivers of base case GHG emissions, while biomass yield is the key factor determining both GHG emissions and economic performance. Saline microalgal biorefineries can achieve a MAC limit of $80–200/tonne when high-value bio-coproducts, such as whey protein concentrate, are benchmarked, contingent on supply-demand conditions and other market drivers. However, this reduction may not be compatible with current carbon prices. Further increase in biomass yield, reductions in energy and nutrient usage, and the careful selection of high-value protein coproduct targets with high conventional GHG emissions during the design stage are recommended. Additionally, saline microalgal biorefineries show great potential in addressing water stress, as the electricity requirements for desalinating brackish and saline water are relatively low compared to the overall system electricity demand.
However, the commercial production of biofuels from microalgae faces significant challenges, such as the high capital investment required for algae farms and the substantial energy needed for cultivation and harvesting.5 In the United States, the projected decline in conventional fuel prices further challenges the competitiveness of microalgal and other alternative biofuels.6 Moreover, depending on the cultivation conditions, algal systems can consume more freshwater than incumbent sources of fuel production.7
Recent studies suggest that incorporating coproduct revenues can improve the financial viability of algal fuel systems. Relevant coproducts include bioplastics, animal feed, and naphtha.8–11 Additionally, life cycle assessments (LCAs) of algal biofuel production indicate that electricity generation and succinic acid production as coproducts can significantly reduce greenhouse gas (GHG) emissions.12,13 Previous studies discussed the water demand and stress impacts of microalgal biorefineries, which vary significantly by location.14,15
Building on our previous “2022 Algae Harmonization Update” study that examined the resource availability, economic, and environmental performance of saline microalgal biorefineries producing fuels and protein bioproducts,16 this study aims to: (1) providing a comprehensive life cycle performance evaluation for biorefineries that coproduces fuel and protein products and examining trade-offs between carbon emission reduction and cost by using the marginal GHG avoidance cost (MAC); (2) identifying the interrelationship between water stress and other life cycle performance parameters; (3) examining the impact of land use on environmental outcomes; and (4) introducing chicken meat as another benchmark target for algal bio-coproduct, offering additional benchmarks to high-protein products, since the prior study focused on whey and soy protein concentrate (PC) targets.
000 mg L−1 TDS or less is delivered to cultivation ponds, with an FO membrane unit processing pond blowdown water to regulate salinity. The concentrated brine from the FO membrane unit is disposed of via deep well injection. Two downstream processing cases are analyzed: fuel-only and fuel with protein coproduction. In the fuel-only case, algae slurry undergoes HTL to produce biocrude, which is upgraded to sustainable aviation fuel (SAF), diesel, and naphtha. In the fuel and protein coproduction case, algae are first processed for protein extraction before HTL, with subsequent outputs handled similarly. Potential bioproducts are benchmarked with soybean PC, whey PC, and chicken meat. Digestible protein is selected as the basis for estimating the replacement ratio of algae PC to benchmark the three protein targets. More detailed information can be found in Section 1.4 in the ESI.† Herein, this study examines four cases: fuel-only production, fuel and PC production benchmarking soybean PC, fuel and PC production benchmarking whey PC (60% protein content), and fuel and PC production benchmarking chicken meat. Key parameters and assumptions are summarized in Table S1.†
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| Fig. 1 System boundary flow diagram (dashed box: the protein extraction and purification process applies only to cases involving fuel and protein coproduction). | ||
MSPs are calculated using a discounted cash flow rate of return method by integrating the MBSP outputs from the algae farm model with the production costs and market SPs from the algae conversion model. The capital cost estimation for the algae HTL conversion system is based on previous TEA studies,26,27 with equipment costs sourced from Aspen Process Economic Analyzer28 and prior in-house estimates. Variable operating costs are estimated based on raw material consumption results from the conversion model, and unit prices from industrial sources and previous work.
The well-to-wheel GHG emissions are calculated using the Greenhouse gases, Regulated Emissions, and Energy use in Technologies (GREET) 2022 model.29 GHG emissions are quantified using IPCC's Sixth Assessment Report 100 year characterization factors (fossil CH4: 29.8; N2O: 273). Emissions from the combustion of the produced fuel are not included in the life cycle, as these emissions would have otherwise entered the atmosphere. The life cycle inventories (LCIs) are generated from process modeling based on the outputs from BAT and TEA models and integrated into the GREET model. Detailed LCI of the system can be found in Table S6.†
The protein coproduct is benchmarked against soy and whey PC as direct replacements without further processing. In contrast, benchmarking against chicken meat requires additional energy and materials to process the protein coproduct into a chicken meat alternative. The processing cost is assumed to be the same as the material cost, as reported.30 For the LCA, only the major components involved in processing protein coproduct for chicken meat alternatives (CMAs) are included due to data limitations. The upstream LCIs are available in Section 2.3.2 in the ESI.† It is noticeable that the cost and LCA results for processing PC to CMAs are subject to uncertainties due to data limitations.
The GHG emissions from conventional fuel production are derived from the weighted-average GHG emissions of gasoline, jet fuel, and diesel (∼87 g MJ−1). Conventional soybean PC production involves soybean processing with coproducts like soybean hulls, oil, and molasses, with GHG emissions calculated through economic allocation based on literature.31 Whey PC, obtained from liquid whey—a coproduct of cheese production32—has its GHG emissions estimated through economic allocation between cheese and liquid whey in this study.33–35 It is important to note that the GHG emissions attributed to liquid whey, being a cheese production coproduct, warrant careful consideration since substituting whey PC with algae PC will not eliminate cheese production. Nonetheless, with rising protein demand, microalgal PC could potentially fulfill incremental demands when liquid whey falls short. GHG emissions generated from chicken meat production are sourced from the GREET model.36 It is important to note that ILUC and DLUC are not included in the final GHG emission results. However, incorporating ILUC and DLUC can impact environmental outcomes and introduce variability. A separate discussion on land use change (LUC) is available in Section DLUC and ILUC calculation.
![]() | (1) |
The quality-based WSF is calculated by multiplying water consumption by the correction factor R, which represents the hardness level required to desalinate brackish and saline water to freshwater. R is defined as the ratio of the specific energy needed for desalination to the maximum energy required at the highest salinity (40
000 mg L−1) studied. The specific energy consumption (SEC) of reverse osmosis (RO) is derived from a mathematical model for a municipal-scale plant and used to represent the energy needed for desalination and to quantify the quality-based WSF.40 RO, the most commonly used desalination method,41 is chosen for calculating the quality-based WSF instead of FO due to the availability of SEC mathematical model. More detailed information regarding R can be found in Section 3 in the ESI.† Freshwater does not require desalination, thus the quality-based WSF of freshwater is zero.
The quantity-based WSF is calculated by multiplying the water consumption by the characterization factor (CF), which represents local water availability. Brackish and saline water are considered always abundant, giving them a CF of zero. For freshwater, the CF is derived from the AWARE-US model developed by Argonne National Laboratory.42
| WSFi,j = WSFSW,i,j + WSFFW,i,j = Ri,j × SWCi,j + CFFW,i × FWCi,j |
| WSFSW,i,j = WSFquality + WSFquantity = Ri,j × SWCi,j + CFSW,i × SWCi,j = Ri,j × SWCi,j (∵CFSW,i = 0) |
| WSFFW,i,j = WSFquality + WSFquantity = Ri,j × SWCi,j + CFFW,i × FWCi,j = CFFW,i × FWCi,j (∵SECi,j = 0) |
![]() | (2) |
000 mg L−1.WSFi,j – water scarcity footprint at site j in county i.WSFSW,i,j – saline water scarcity footprint at site j in county i.WSFFW,i,j – freshwater scarcity footprint at site j in county i.Ri,j – correction factor at site j in county i.CFi – freshwater characterization factor in county i.SWCi,j – saline water consumption at site j in county i.FWCi,j – freshwater consumption at site j in county i.AMDUS – the national average remaining available water (m3 m−2).AMDi – remaining available water in county i (m3 m−2).SECi,j – specific energy consumption at site j in county i (kW h m−3).SECmax – maximum specific energy consumption at salinity of 40
000 mg L−1 (kW h m−3).TDSi,j – total dissolved solids at site j in county i (mg L−1).
For benchmarking protein coproducts, LUC emissions from conventional soybean PC, whey PC, and chicken meat production are considered. Table S16 in the ESI† summarizes literature on LUC emissions for soybean, milk, and chicken meat production, with soybeans as feedstock for soybean PC and milk for cheese and liquid whey production. The summary table provides an emissions range of LUC in conventional protein product systems.
The MSPs and GHG emissions from fuel and PC coproduction for soybean PC and whey PC are the same, reflecting identical processing steps in these two cases. While conventional whey PC has higher SP ($3.7/kg) and GHG emissions (14 kg CO2-eq. per kg whey PC) with a smaller market size (3.5 MMT/yr), soybean PC features lower SP ($1.3/kg) and GHG emissions (0.47 kg CO2-eq. per kg soybean PC) but a larger market size (13 MMT/yr). Compared to conventional fuel and soybean PC, microalgal fuel and PC coproduction exhibits higher SP and GHG emissions, yet it presents lower values compared to conventional fuel and whey PC in most cases, as demonstrated in Fig. 2(e) and (f). Soybean cultivation consumes significantly less energy than algae cultivation. Specifically, 0.60 kW h of process electricity and 1.8 MJ of process heat are required per kg of algae AFDW, compared to only 0.019 kW h and 0.57 MJ of heat per kg of soybean AFDW production. Comparisons of these energy and nutrient consumption metrics are detailed in Table S17 in the ESI.† Reducing energy consumption is essential to enhance the feasibility of microalgal biorefinery systems and ensure their competitiveness with highly efficient benchmarks, such as those involving soybeans. Conventional whey PC production is energy and material intensive. To produce 1 kg of whey PC (protein content 60%), 80 kg of liquid whey containing 6 wt% dry mass is required, and it commands a higher SP and incurs greater GHG emissions compared to microalgal PC and soybean PC. However, as discussed in section SPs and GHG emissions from conventional products, substituting whey PC with algal PC does not eliminate cheese production; this benchmark is viable only when the supply of liquid whey is insufficient to meet that demand.
The coproduction case for CMAs requires additional energy and materials to convert algal PC into meat substitutes, where 1 kg of CMAs includes 0.3 kg of algal PC, 0.1 kg of soybean PC, and other ingredients for flavoring based on personal communication with an expert in the area.46 Chicken meat, with a SP of $1.6/kg and GHG emissions of 4.7 kg CO2-eq. per kg, falls between soybean PC and whey PC in terms of cost and emissions. However, the CMA case exhibits significantly higher MSPs than the other two fuel and PC coproduction cases due to the additional costs associated with converting microalgae PC to meat alternatives. As depicted in Fig. 2(g), maintaining the MSPs below the cost of conventional fuel and chicken meat appears infeasible at present. Nevertheless, GHG emissions can be kept below those of conventional fuel and chicken meat up to a potential fuel production threshold of roughly 4.2 billion GGE.
For validation purposes, this study's MSPs and GHG emissions are benchmarked against those from other literature.9–11 The comparison shows that MSPs and GHG emissions are all within comparable ranges in similar cases to other studies. However, this study provides a broader range of MSP and GHG emissions by considering saline microalgae cultivation and conversion across the U.S., rather than focusing on specific cases. Detailed comparison can be found in Table S18 in the ESI.†
A biorefinery-level analysis is used to present the primary results of this study, avoiding arbitrary allocation and evaluation based on a specific main product. However, to compare with other studies, MSP per GGE of fuel production by accounting for PC selling price credits and GHG emissions per MJ of fuel and per kg of PC production by using economic allocation approach are detailed in Section 6 of the ESI.† The analysis shows that the MSP of fuel production in the fuel and PC coproduction scenarios is lower than in the fuel-only scenario but remains higher than conventional fuel production. For GHG emissions per MJ of fuel production, using the economic allocation method, all weighted-average GHG emissions are lower than fossil fuels. In addition, GHG emissions are compared based on the production of 1 kg of digestible protein between biorefinery and conventional systems. The whey PC from the biorefinery shows significantly lower weighted-average GHG emissions than conventional whey PC; the chicken meat alternative is slightly higher than conventional chicken minus processing burdens; and the soy PC from the biorefinery exhibits higher emissions than conventional PC. These results align with findings from the biorefinery-level analysis. In addition, the MSP and GHG emission breakdown show that feedstock has the largest contribution to both MSP and GHG emissions, and detailed information can be found in Section 7 in the ESI.†
Electricity consumption is one of the main factors affecting GHG emissions. The GHG intensity of the U.S. electricity grid has declined by 45% between 2011 and 2024, which may further decrease. These factors necessitate a sensitivity analysis around grid emission intensity. By using electricity at half the GHG intensity of the baseline and employing electricity with zero carbon intensity, the scenarios can achieve a substantial reduction in the MAC, as depicted by the purple and green lines in Fig. 3. While the SP is relatively stable with renewable energy according to U.S. EIA's future electricity projections, GHG emissions can be significantly lowered with less carbon-intensive energy sources. The reduction is due to the use of electricity with lower carbon intensity in both microalgae cultivation and biorefinery processes, as well as upstream processes like nutrient fertilizer production utilizing more renewable energy. However, it is notable that in a scenario with a carbon intensity half of the current electricity grid or a electricity grid with zero carbon intensity scenario, some CO2 emission sources may no longer exist or the CO2 concentration from these sources may be much lower, potentially increasing the electricity demand for CO2 capture and transport. The increase in electricity consumption for CO2 capture and transport in a less carbon-intensive electricity scenario has not been incorporated into this study, and further research is needed. The detailed GHG emissions for each case can be found in Section 9 in the ESI.†
Various sources recommend carbon price limits for carbon capture and storage ranging from $80 to $200/tonne CO2 avoidance.47–49 If a nominal target of $200 per tonne is provided, setting it as the threshold for MAC, the findings suggest that only the coproduction of fuel and PC for whey PC, can meet the cost across all sites with different levels of carbon-intensive electricity, influenced by whey PC's high market value and its significant GHG emissions. The cost is not achievable for the other three cases using the current U.S. electricity mix. Although the fuel-only case can achieve lower GHG emissions than conventional fuels, the MAC for the fuel-only case under current U.S. electricity inputs fails to meet the carbon cost primarily due to high MSP values ranging from $6.7 to $13.0 per GGE. No MAC value is illustrated for the coproduction of fuel and PC for soybean PC when using the current U.S. electricity mix, as GHG emissions consistently exceed those from conventional fuel and soybean PC production under current U.S. electricity sourcing assumptions. This renders the coproduction of algal PC to replace soybean PC impractical, especially given the lower energy and nutrient consumption in soybean PC production. Additionally, achieving the carbon cost for fuel and PC production for chicken meat is not feasible under current U.S. electricity inputs, primarily due to the high MSPs arising from the elevated costs associated with processing CMAs.
As shown in Fig. 3 (a), (b), and (d) the MACs for fuel-only as well as fuel and PC coproduction for soybean PC and chicken meat remain unable to achieve $200/tonne cost, even with carbon neutral electricity, despite significant reductions. However, from a development perspective, as arable land becomes increasingly limited for soybean cultivation and chicken farming due to population growth—even if the carbon price threshold remains unchanged—the SP benchmarks for soybean PC and chicken meat will rise, potentially bringing MAC values below the current carbon price threshold. In the short term, however, arable land may not yet be a limiting factor. Current strategies to achieve carbon price threshold should focus on further reducing major cost and environmental hotspots by increasing biomass productivity, recycling or reducing nutrient use, and minimizing energy consumption.
| Biorefinery bio-coproducts | Freshwater usea (m3) | Land use (m2 per year) | SP ($) | GHG emissions (kg CO2-eq.) |
|---|---|---|---|---|
| a Freshwater use values are obtained from GREET model. b CMAs contain 30% of algal biomass by weight, and as a result, 1 kg of protein coproduct can be used to produce 3.3 kg of meat alternatives. | ||||
| Soy PC | 131 | 2980 | 2120 | 1120 |
| Whey PC | 250 | 1850 | 6090 | 24 300 |
| Chicken meat | 259 | 9250 | 5090 | 2270b |
| Saline algae for fuel-only case in this study | 0 | 226 | 1650–3060 | 1140–2630 |
| References | 27 | This study, 50 and 51 | This study and 52–56 | This study and 27 |
Carbon emissions resulting from LUC are also discussed here to illustrate how this factor can influence the final GHG emission results. The carbon emissions from DLUC are relatively minor when compared to the biorefinery-related GHG emissions from the four cases, which can be explained by the site selection criteria in the BAT model. The DLUC emissions are calculated to range from −1.83 to 9.33 g CO2-eq. per MJ, averaging 1 g CO2-eq. per MJ. The probability of original land use in each site and the calculated emissions from DLUC can be found in the SI. Nonetheless, the carbon emissions from ILUC of microalgal biorefineries and the carbon emissions from LUC of conventional soybean PC, whey PC, and chicken meat production exhibit considerable variability, depending on different assumptions. Including ILUC carbon emissions could markedly elevate GHG emissions under certain conditions as discussed in Section 4 in the ESI.† This study considers the GHG emissions from conventional PC and chicken meat production for benchmarking biorefinery-level emissions: 0.05 kg of PC is produced per MJ of fuel, and emissions associated with LUC of conventional PC and chicken meat can be significant, as indicated by the LUC emissions per kg of digestible protein in Table S16 in the ESI.† While LUC carbon emissions could significantly impact overall GHG emission figures, quantifying these variations is beyond this work's scope.
In summary, from a cost perspective, saline microalgal biorefinery for fuel-only production is currently not economically feasible, as its price exceeds that of conventional fuels. Incorporating protein coproducts into the biorefinery process can help address this issue, particularly when benchmarked against high-value products like whey PC. This benchmark requires careful consideration, as whey PC is derived from liquid whey, a cheese byproduct, and is only feasible when demand exceeds supply. Specifically, using microalgal protein coproduct to replace whey PC is only feasible when liquid whey cannot meet the demand for whey PC, necessitating an alternative to fill the supply gap. Furthermore, the protein coproduct benchmark does not improve the overall MSP performance when compared to lower-priced conventional products, such as soy PC. In addition, the study finds that the chicken meat alternative produced from protein coproducts is priced higher than conventional chicken meat. This conclusion, however, is subject to uncertainties due to price variations in chicken meat across different locations and times, as well as the potential for reduced processing costs for vegan meat with advancements in technology and economies of scale. Uncertainty regarding the future market for protein makes it difficult to predict the potential future value of algae-based protein products.
From an environmental impact perspective, three main factors are considered in this study: GHG emissions, GHG emissions from LUC, and freshwater usage. WSF will be discussed separately in the spatially explicit MSPs, GHG emissions, and WSF section since it is location based. Fuel-only production from a microalgal biorefinery can achieve lower GHG emissions compared to conventional fuels. Incorporating a protein coproduct may not further reduce GHG emissions if benchmarked against a more efficient conventional protein product, such as soy PC. Nutrient and energy consumption are the primary contributors to GHG emissions in both algae and soybean cultivation, with soybeans requiring significantly less nutrient and energy input. However, soybeans are typically grown on highly productive farmland and have a significantly lower protein yield per unit area compared with microalgae. These factors mean that replacing soybean with microalgae could reduce LUC effects, including deforestation. Additionally, the biorefinery-level GHG emissions from the coproduction of fuel and protein coproduct are comparable to those of the chicken meat benchmarking case. In this study, the GHG emissions from chicken meat production fall on the lower end of the values reported in the literature,57 suggesting that benchmarking against chicken meat may be more plausible under certain circumstances. Furthermore, the freshwater consumption in saline microalgal biorefinery is much lower than that from other biomass benchmarks.
The MAC results suggest that electricity grid transitions could significantly reduce GHG emissions. However, the reduction alone cannot bring the MAC below the nominal carbon price threshold. The most promising direction for advancing microalgal biorefineries lies in simultaneously increasing biomass yield, reducing nutrient and energy consumption, and developing high-value products with GHG emissions reductions. Further research is needed on meat alternative benchmarks because: (1) microalgal PC can serve as an ingredient for various types of meat alternatives, such as beef, pork, and lamb, which have higher prices and GHG emissions compared to chicken meat; and (2) the market for meat alternatives is relatively new, with significant uncertainties. Additionally, other high-value protein coproduct benchmarks with smaller market sizes, such as pharmaceutical and cosmetic products, deserve further exploration. Their high value and potential GHG emission benefits could position them as feasible benchmarks. Furthermore, their smaller market sizes could complement larger markets, such as meat alternatives, creating a balanced and diversified portfolio of protein coproduct opportunities.
The relationship between MSPs and GHG emissions, and other parameters, is explored using Pearson and Spearman correlations, utilizing data from BAT, TEA, and LCA compiled in an Excel file in the ESI.† When the Pearson or Spearman correlation coefficient exceeds 0.9 or drops below −0.9, with a P value under 0.05%, a significant correlation is indicated. Analysis shows a negative correlation between biomass yield and MSPs, where Spearman correlation coefficients are consistently below −0.9 for all cases. However, no significant correlations are identified between other parameters and MSPs or GHG emissions.
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| Fig. 4 (a) Minimum selling price ($/GGE), (b) greenhouse gas emissions (g CO2-eq. per MJ), and (c) water scarcity footprint (million m3 per year). | ||
Footnote |
| † Electronic supplementary information (ESI) available. See DOI: https://doi.org/10.1039/d4se01423e |
| This journal is © The Royal Society of Chemistry 2025 |