Mass balance and life cycle assessment of biodiesel from microalgae incorporated with nutrient recycling options and technology uncertainties

This article presents mass balances and a detailed life cycle assessment (LCA) for energy and greenhouse gases (GHGs) of a simulated microalgae biodiesel production system. Key parameters of the system include biomass productivity of 16 and 25 g m−2 day−1 and lipid content of algae of 40% and 25% for low and normal nitrogen conditions respectively. Based on an oil extraction efficiency from wet biomass of 73.6% and methane yields from anaerobically digested lipid‐extracted biomass of 0.31 to 0.34 l per gram of volatile solids, the mass balance shows that recycling growth media and recovering nutrients from residual biomass through anaerobic digestion can reduce the total demand for nitrogen by 66% and phosphorus by 90%. Freshwater requirements can be reduced by 89% by recirculating growth media, and carbon requirements reduced by 40% by recycling CO2 from biogas combustion, for normal nitrogen conditions. A variety of technology options for each step of the production process and allocation methods for coproducts used outside the production system are evaluated using LCA. Extensive sensitivity and scenario analysis is also performed to provide better understanding of uncertainty associated with results. The best performing scenario consists of normal nitrogen cultivation conditions, bioflocculation and dissolved air flotation for harvesting, centrifugation for dewatering, wet extraction with hexane, transesterification for biodiesel production, and anaerobic digestion of biomass residual, which generates biogas used in a combined heat and power unit for energy recovery. This combination of technologies and operating conditions results in life cycle energy requirements and GHG emissions of 1.02 MJ and 71 g CO2‐equivalent per MJ of biodiesel, with cultivation and oil extraction dominating energy use and emissions. Thus, even under optimistic conditions, the near‐term performance of this biofuel pathway does not achieve the significant reductions in life cycle GHG emissions hoped for from second‐generation biofuel feedstocks.