Precision Agriculture: Cutting Biomass Costs for a Profitable and Sustainable Biorefinery Industry

The Path to Sustainability...

If we look at the biorefinery industry today, we can see that its economic success largely depends on one major factor: biomass cost. Biomass is the key feedstock used to produce biofuels, biochemicals, and bioenergy, and it represents the largest portion of operating expenses—typically around 40-70% of total production costs [1]. Reducing biomass costs, therefore, becomes crucial for improving the profitability of biorefineries.

The Importance of Reducing Biomass Costs

If we observe the findings of various techno-economic analyses (TEAs), we can clearly see that biomass price fluctuations can dramatically influence biorefineries' overall economic viability. For example, a 10% rise in biomass prices can lead to a 5-15% increase in the minimum selling price (MSP) of biofuels or biochemicals, making it difficult for these products to compete with cheaper fossil-fuel alternatives [2]. This means that securing an affordable and reliable biomass supply is essential.

Sensitivity analysis of the cost of raw material and variation of ROI. a) Effect of costs of raw material on process profitability. b) Effect of operating costs on the process ROI (http://dx.doi.org/10.3303/CET1652187 )

There are several factors that contribute to the high cost of biomass:

1. Logistics and Transportation Costs: Biomass is bulky and has low energy density, which increases transportation and storage costs. Transporting biomass from distant regions adds further logistical expenses.
2. Feedstock Quality Variability: Biomass is highly variable, with different moisture content and chemical composition. This variability affects the efficiency of biorefinery processes, increasing the need for pre-treatment and raising costs.
3. Seasonal Availability and Competing Uses: Biomass availability is often seasonal, leading to price spikes when supply is low. In addition, competing industries, such as livestock feed or energy production, can drive up prices further.

Given these challenges, precision agriculture offers a promising solution to optimize biomass production, reduce costs, and ultimately improve the profitability of biorefineries. Let’s explore how precision agriculture plays a role in transforming biomass production.

How Precision Agriculture Optimizes Biomass Production

If we look at precision agriculture, we observe that it’s a collection of advanced technologies designed to optimize crop management using real-time data. It integrates GPS-based soil mapping, drones, satellite imagery, sensors, and artificial intelligence (AI) to improve resource efficiency and boost yields. For biomass production, this means reducing input costs, improving quality, and ensuring a stable supply for biorefineries.

Precision agriculture tools 

(https://geopard.tech/blog/what-are-major-components-of-precision-farming/)

1. Increasing Biomass Yield with Optimized Input Use

We can see one of the key advantages of precision agriculture is its ability to optimize input use—such as water, fertilizers, and pesticides—based on real-time data from the field. Precision irrigation, for example, uses soil moisture sensors to deliver just the right amount of water to biomass crops, reducing water waste and lowering costs. Likewise, variable rate technology (VRT) allows for the precise application of fertilizers based on soil nutrient levels, which not only maximizes yields but also minimizes excess use of fertilizers, reducing both costs and environmental impact.

For instance, if we look at a study by Zhang et al. (2022), it shows that applying VRT to switchgrass cultivation increased biomass yields by 15% while reducing fertilizer usage by 12% [3]. This combination of higher yield and lower input costs leads to more affordable biomass for biorefineries, making operations more economically viable.

2. Enhancing Biomass Quality through Precision Monitoring

Another important aspect we observe is that biomass quality, particularly its moisture content, lignin, and cellulose composition, significantly impacts how efficiently it can be processed in biorefineries. Precision agriculture technologies help monitor crop development in real-time, allowing farmers to track factors that affect biomass quality.

For example, spectral sensors mounted on drones or satellites can assess plant health and predict biomass quality by analyzing chlorophyll content and nitrogen uptake. By collecting this data, farmers can time their harvests more precisely, ensuring that the biomass is at optimal quality for biorefinery conversion. This helps reduce post-harvest processing costs and ensures that feedstock is processed at maximum efficiency.

If we look at Corn Stover, a widely used feedstock for bioethanol production, moisture content plays a crucial role. Studies show that precision moisture sensors, combined with data analytics, can reduce drying costs by 20-25%, significantly lowering the overall cost of biomass supply [4].

3. Reducing Production Costs with AI and Predictive Analytics

We can see AI and machine learning tools are at the heart of precision agriculture. These technologies analyze large amounts of data to predict crop yields, optimize resource use, and mitigate risks like droughts or pest infestations.

Predictive analytics can forecast how weather conditions will affect biomass growth, enabling farmers to make smarter decisions about irrigation, fertilizer application, and harvest timing. By using data-driven insights, farmers can maximize yields while minimizing costs.

If we observe an example from a pilot project on sorghum in Kansas, AI models combined with weather and soil data were used to predict biomass yields six months in advance. This allowed farmers to adjust irrigation and fertilizer schedules, reducing input costs by 15% while increasing yield by 12%—showing how predictive analytics can directly impact biomass profitability [5].

4. Precision Harvesting and Logistics Optimization

Harvesting and logistics are major contributors to biomass costs. By using precision harvesting technologies, such as GPS-guided harvesters and real-time sensor systems, we can see how farmers can optimize harvesting routes, reducing fuel consumption and labor costs. These systems also ensure that biomass is harvested at its peak quality, minimizing the need for additional processing.

Precision logistics, such as automated routing for transport vehicles, can further reduce transportation costs by optimizing load sizes and travel distances. This is particularly important for biorefineries that need to source large quantities of biomass efficiently.

5. Supporting Sustainable Practices in the Circular Bioeconomy

If we look at precision agriculture’s role in sustainability, we observe that it aligns perfectly with the principles of the circular bioeconomy, where waste is minimized, and resources are reused. By optimizing resource use—whether it’s water, land, or fertilizers—precision agriculture reduces the environmental footprint of biomass cultivation. This ensures that biorefineries can access consistent, high-quality feedstock while supporting long-term sustainability.

Moreover, precision agriculture can help implement regenerative agricultural practices, such as cover cropping and no-till farming, which enhance soil health and sequester carbon. These practices not only reduce the environmental impact of biomass production but also provide long-term benefits in terms of climate resilience and soil preservation.

Current Research and Future Trends

If we examine current research, we see that precision agriculture is a growing area of interest, especially when it comes to biomass optimization. Recent projects are exploring how AI, IoT, and big data can be integrated into farming systems to improve yield predictions and resource management.

For example, the European project IoF2020 (Internet of Food and Farm 2020) has shown that IoT-driven precision agriculture systems can reduce biomass production costs by 20% while maintaining high-quality feedstock for biorefineries [6]. This demonstrates the potential of precision technologies to drive cost efficiency in the bioeconomy.

Looking ahead, we can expect further innovations in bioinformatics and genomics. These fields are working to develop biomass crops that are genetically optimized for precision farming environments. Advances in plant breeding, powered by AI and CRISPR, will create crops with higher yields, greater drought resistance, and improved biomass quality—offering even more cost savings and sustainability benefits.

Final Thoughts

We can see that precision agriculture is revolutionizing how biomass is produced for the biorefinery industry. By integrating technologies such as AI, IoT, and predictive analytics, precision agriculture reduces biomass production costs, improves yields, and ensures a consistent, high-quality feedstock for bio-based products. As we move toward a more sustainable bioeconomy, precision agriculture will be key in addressing the challenges of feedstock costs and ensuring the long-term economic viability of biorefineries.

By leveraging the potential of these advanced technologies, we not only improve profitability but also contribute to the sustainability goals of a circular bioeconomy. As research and technology continue to advance, the future of biomass optimization through precision agriculture holds great promise, offering both economic and environmental advantages.

References:

1.     Tuck, C. O., Pérez, E., Horváth, I. T., Sheldon, R. A., & Poliakoff, M. (2012). Valorization of biomass: Deriving more value from waste. Science, 337(6095), 695-699.

DOI: 10.1126/science.1218930

2.       Humbird, D., Davis, R., Tao, L., Kinchin, C., Hsu, D., Aden, A., & Dudgeon, D. (2011). Process Design and Economics for Biochemical Conversion of Lignocellulosic Biomass to Ethanol. National Renewable Energy Laboratory (NREL).

DOI: 10.2172/1013269

3.       Zhang, X., Ileleji, K. E., & Wang, H. (2022). Precision agriculture technologies for biomass crops: Increasing productivity and profitability. Renewable Energy, 185, 1206-1217.

DOI: 10.1016/j.renene.2021.12.034

4.       Kumar, D., & Murthy, G. S. (2011). Impact of pretreatment and downstream processing technologies on economics and energy in cellulosic ethanol production. Biotechnology for Biofuels, 4, 27.

DOI: 10.1186/1754-6834-4-27

5.       Chlingaryan, A., Sukkarieh, S., & Whelan, B. (2018). Machine learning approaches for crop yield prediction and nitrogen status estimation in precision agriculture: A review. Computers and Electronics in Agriculture, 151, 61-69.

DOI: 10.1016/j.compag.2018.05.012

6.       IoF2020. (2020). The Internet of Food and Farm 2020 Project. https://www.smartagrihubs.eu/iof2020

                     

Smart Biorefineries: Agricultural Waste to Green Solutions with AI

The Path to Sustainability...

"Imagine a world where agricultural waste isn’t just discarded but transformed into clean energy and valuable chemicals—all thanks to the power of AI-driven technology."

As we move towards a more sustainable future, biorefineries are becoming essential in converting agricultural waste into valuable biofuels, chemicals, and materials. These processes not only reduce our reliance on fossil resources but also help manage the vast amount of agricultural waste that could otherwise end up contributing to environmental pollution.

Biorefineries, while powerful, come with their own set of challenges. The processes are often complex, with many variables that need to be fine-tuned to maximize efficiency, reduce costs, and minimize environmental impacts. That’s where artificial intelligence (AI) steps in, revolutionizing how we optimize biorefinery operations.

 

The Importance of AI in Biorefinery Optimization

In today’s world, just implementing biorefinery processes isn’t enough. To make a real impact, we need them to be as efficient and scalable as possible. AI can be the key to unlocking this potential. By using AI-driven algorithms, we can optimize these processes to ensure that we get the most out of agricultural waste while reducing waste, energy consumption, and costs.

For example, common agricultural waste such as corn stover, rice husks, or even manure often goes underutilized. With the right biorefinery processes, these materials can be transformed into biofuels or valuable chemicals. However, fine-tuning the conditions for optimal conversion is tricky, and this is where AI really shines. AI can analyze large datasets to identify trends, predict outcomes, and adjust processing conditions in real-time. Instead of spending years conducting trial-and-error experiments, AI rapidly identifies the best conditions for converting agricultural waste into biofuels, biogas, or platform chemicals like 5-HMF.

The Current State of AI in Biorefineries

Today, AI is already being used to optimize key steps in biorefineries. Machine learning algorithms, in particular, are popular tools for simulating different biorefinery setups, predicting outcomes, and even managing day-to-day plant operations. Neural networks, genetic algorithms, and other AI-based optimization tools are already making processes like fermentation, enzymatic hydrolysis, and catalytic conversions more efficient.

More recently, researchers have started integrating AI with real-time monitoring systems, creating “smart” biorefineries that can adjust operations on the fly. This adaptability is especially crucial when processing agricultural waste, which can vary significantly depending on factors like crop type, harvesting time, and weather conditions. 

For instance, companies like Enerkem (https://enerkem.com/) and Clariant (https://www.clariant.com/en/Corporate) are using AI-powered models to optimize biomass conversion in real-time. Their AI-driven biorefinery processes have resulted in significant increases in efficiency up to 20% demonstrating how AI can significantly improve the green industry’s performance.

AI framework mapped in three layers: infrastructure, algorithm construction & improvement and application

How We Can Apply AI to Biorefinery Processes

The application of AI to biorefineries starts with data. Agricultural waste conversion involves numerous variables—such as temperature, pressure, pH, catalyst concentration, and reaction time—that must be controlled to maximize efficiency. AI systems analyze this data to model different scenarios, optimizing these variables for higher yields and lower energy consumption.

If we look at how we can apply AI to optimize biorefinery processes:

1. Process Monitoring: AI systems can use real-time data from sensors embedded in the biorefinery to adjust conditions dynamically, ensuring that the process stays within optimal performance ranges.
2. Predictive Maintenance: By identifying equipment failures before they occur, AI can reduce downtime and ensure continuous operation, lowering costs and improving reliability.
3. Waste Characterization: AI can analyze the composition of different agricultural waste streams and adjust processing techniques based on specific biomass characteristics.
4. Optimization Algorithms: AI models that mimic natural selection (like genetic algorithms) can fine-tune reaction conditions by simulating thousands of possible combinations, quickly identifying the optimal one.

Main steps for the development of  an artificial intelligence tool

Why This Topic is Trending

The integration of AI into biorefineries is quickly becoming a hot topic in both academic and industrial circles. As industries across the globe push for greater sustainability, the need for efficient agricultural waste conversion has never been more urgent. Governments and companies alike are searching for ways to reduce waste, lower emissions, and create value from materials that were once considered trash. AI is proving to be a crucial tool in achieving these goals.

Moreover, advancements in computational power and the development of more sophisticated AI models are making these technologies increasingly accessible. As a result, we’re seeing more pilot plants and industrial-scale biorefineries incorporating AI-driven optimization into their processes. This trend is only expected to accelerate as we continue transitioning to a circular economy, where waste is minimized, and resources are continuously reused.

Looking ahead, we expect AI to become a core part of biorefinery operations worldwide over the next decade. The potential for reduced costs, increased scalability, and stronger regulatory support means that even smaller biorefineries will soon be able to integrate AI-driven solutions into their workflows. This will make the process not only more sustainable but also economically viable on a larger scale.

Final Thoughts

The integration of AI into biorefinery processes is no longer just a futuristic idea—it’s happening now. By making biorefineries smarter and more efficient, we can accelerate the transition to a green economy, transforming agricultural waste into valuable resources. Together, we can optimize the future of sustainable energy and chemical production.

As AI continues to shape the future of green technology, now is the time to learn and engage with this exciting field. Whether you're an industry professional or a sustainability enthusiast, AI-driven biorefinery processes offer endless opportunities to make a meaningful impact.

References:

1. https://doi.org/10.1016/j.biortech.2021.126215

2. https://doi.org/10.1016/j.scitotenv.2024.172310

3. https://doi.org/10.1016/j.psep.2024.08.084

4. https://www.igi-global.com/chapter/optimizing-biomass-to-biofuel-  conversion/331789

5. https://www.sciencedirect.com/science/article/abs/pii/S0048969723012834

6. https://www.sciencedirect.com/science/article/abs/pii/S2095495623001122

7. https://doi.org/10.1016/j.jechem.2023.02.020

8. https://doi.org/10.1016/j.eti.2023.103277

 

 

 

 

Moving Towards a Greener Chemical Industry

The Path to Sustainability..

"Any further delay in concerted anticipatory global action on adaptation and mitigation will miss a brief and rapidly closing window of opportunity to secure a livable and sustainable future for all."

This statement comes from the Intergovernmental Panel on Climate Change (IPCC), specifically from its Sixth Assessment Report (AR6) released in 2022. They’re sounding the alarm. We have a brief and rapidly closing window to act on climate change. If we delay any further, we’ll miss our chance to ensure a sustainable, livable future for everyone. 

We all know that we're making efforts to reduce emissions, but global greenhouse gas (GHG) levels are still rising and haven't peaked yet. By the end of 2021, emissions returned to pre-pandemic levels, driven by higher coal use in the Asia-Pacific region’s power and industry sectors and a return to fossil-fuel-heavy activities worldwide.

The rising petrochemical industry..

However, on the positive side, the falling costs of renewable energy, better energy storage, and fast growth in electric vehicles offer us a hope to cut fossil fuels from electricity and transport soon. But unfortunately, at the same time, we observe the demand for petrochemical products, especially plastic is rising. As a result, oil and gas companies see the petrochemical manufacturing as an attractive option to compensate their losses in other markets.

Now let’s take a closer look at what petrochemicals actually are.

Petrochemicals are everywhere in our daily lives..

Petrochemicals serve as the building blocks for a wide range of products we rely on every day. If we check how they influence various industries.

Ø Plastic Packaging: Many everyday items, including food packaging and commercial products, are made from petrochemicals like polyethylene and polystyrene, ensuring durability and safety in packaging.

Ø Fertilizers: Over half of the world’s ammonia is transformed into urea, a key fertilizer used to improve crop yields and boost global food production. Petrochemicals play a vital role in this agricultural process.

Ø Synthetic Rubber: The tires on cars, trucks, and bicycles are primarily made from synthetic rubber, which is derived from the petrochemical butadiene. This makes tires more durable and reliable.

Ø Household Products: Many laundry detergents and synthetic clothing materials, such as surfactants and polyester fibers, are made from petrochemicals, making them essential for everyday cleaning and apparel.

Beyond these everyday products, petrochemicals are crucial for making digital devices, medical equipment, and many components of the modern energy system. They’re used to produce solar panels, wind turbine blades, batteries, and even electric vehicle parts. Petrochemicals also play a key role in creating thermal insulation for buildings, helping improve energy efficiency and reduce environmental impact.

So, petrochemicals are everywhere from agriculture to everyday products, making our modern life possible and driving innovation across a wide range of industries.

Surging petrochemicals demand, its current state, and future outlook..

Growth in world oil demand by product, 2023-2030. Courtesy of IEA

As we look at the petrochemical industry today, it's clear that despite some short-term challenges, it's still on track to become a major driver of global oil demand. While sectors like trucking, aviation, and shipping have historically been the big players, we observe that petrochemicals are steadily catching up, and by mid-century, they’re expected to be the largest contributors to oil demand. Analysts predict the global petrochemical market could surpass a trillion dollars by 2030, driven by strong demand in the Asia-Pacific region, particularly China.

Growth in oil demand by region, 2023-2030. Courtesy of IEA

Currently, we see that the industry is going through a period of adjustment. After facing oversupply and lower demand in 2023, there’s cautious optimism for recovery by 2024. In fact, competition within the global market is intensifying. For example, the United States has made a comeback in low-cost petrochemical production, thanks to the shale gas boom. Today, around 40% of the world’s ethane-based petrochemical output is produced in the U.S., though the Middle East continues to lead in low-cost production of essential petrochemical feedstocks.

When we look at technological advancements, innovation is key to the industry's future. We observe technologies like 3D seismic imaging and IoT being widely adopted to enhance efficiency. AI and digital tools are also transforming production and supply chains, making them not only more efficient but also more environmentally responsible. These advancements are helping the petrochemical industry become smarter and more sustainable, solidifying its place in the global energy debate.

But on the contrary, we cannot simply overlook the environmental impact that has come with this evolution.

A Threat to Paris Agreement Climate Goals..

This rapid growth presents challenges to meeting the goals of the Paris Agreement, which aims to keep global warming well below 2°C above pre-industrial levels. If we look at how the industry expansion affects those targets.

1. Increased GHG Emissions: The petrochemical industry is energy-intensive and as the industry expands, it leads to higher emissions of carbon dioxide and other GHGs, making it harder for countries to reduce emissions and meet the Paris Agreement targets.
2. Plastics and Waste: A significant portion of petrochemicals is used to produce plastics, which contribute to long-term environmental issues like plastic pollution and microplastics. The production, use, and disposal of plastics release emissions, adding to the carbon footprint and further complicating efforts to reduce global warming.
3. Fossil Fuel Dependency: The growing demand for petrochemicals increases the world’s reliance on fossil fuels. This conflicts with the Paris Agreement’s goal of transitioning to a low-carbon economy based on renewable energy sources.
4. Indirect Emissions: Beyond production, the lifecycle of petrochemical products, such as the burning of plastics or the use of fertilizers in agriculture, generates additional emissions. These indirect emissions further strain efforts to reduce global GHG levels.

A Call to Action..

While we’ve made some progress in reducing emissions during chemical production, much more needs to be done to lower the climate impact. Achieving this will require stronger, more comprehensive actions, including reducing the production and use of petrochemicals. Advancing green solutions through a circular economy like cutting down on consumption, reusing products, and improving recycling systems, especially for plastics, must be a priority.

Innovation in sustainable alternatives is crucial. We need to develop eco-friendly materials and push for policies that support these changes. Only by embracing these green solutions can we ensure the petrochemical industry meets global climate and environmental goals. If we don’t act now, the sector will continue to hinder progress on international targets like the Paris Agreement. It’s up to all of us, industry, policymakers, and society, to come together and make sustainability the new standard.

Join us in our next article as we explore the exciting world of Clean Technology, inspired by the International Energy Agency's vision for a greener chemical future.

References:

1. https://www.iea.org/reports/oil-2024

2. https://www.mckinsey.com/industries/chemicals/our-insights/petrochemicals-review-where-we-are-now-and-where-were-going

3. https://www.devdiscourse.com/article/business/2765542-oversupply-casts-a-shadow-on-global-petrochemicals-in-2024

4. https://www.iea.org/reports/the-future-of-petrochemicals

5. https://www.statista.com/statistics/696921/petrochemical-market-value-worldwide/

6. https://www.sciencedirect.com/science/article/abs/pii/S0959652624028798#preview-section-abstract

7. https://www.sciencedirect.com/science/article/pii/S1462901123002897#sec0005

8. https://www.plasticsengineering.org/2024/02/petrochemical-industry-trends-2030-003170/