TO-SYN-FUEL Project to Convert Sewage Sludge in Value-Added Products: A Comparative Life Cycle Assessment

Serena Righi (), Filippo Baioli, Andrea Contin and Diego Marazza
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Serena Righi: Department of Physics and Astronomy, University of Bologna, Viale Berti Pichat 6/2, 40127 Bologna, Italy
Filippo Baioli: Interdepartmental Centre for Research in Environmental Sciences, University of Bologna, Via S. Alberto 163, 48123 Ravenna, Italy
Andrea Contin: Department of Physics and Astronomy, University of Bologna, Viale Berti Pichat 6/2, 40127 Bologna, Italy
Diego Marazza: Department of Physics and Astronomy, University of Bologna, Viale Berti Pichat 6/2, 40127 Bologna, Italy

Energies, 2025, vol. 18, issue 19, 1-22

Abstract: Second-, third-, and fourth-generation biofuels represent an important response to the challenges of clean energy supply and climate change. In this context, the Horizon 2020 “TO-SYN-FUEL” project aimed to produce advanced biofuels together with phosphorus from municipal wastewater sludge through a combination of technologies including a Thermo-Catalytic Reforming system, Pressure Swing Adsorption for hydrogen separation, Hydrodeoxygenation, and biochar gasification for phosphorous recovery. This article presents the environmental performance results of the demonstrator installed in Hohenberg (Germany), with a capacity of 500 kg per hour of dried sewage sludge. In addition, four alternative scenarios are assessed, differing in the source of additional thermal energy used for sludge drying: natural gas, biogas, heat pump, and a hybrid solar greenhouse. The environmental performance of these scenarios is then compared with that of conventional fuel. The comparative study of these scenarios demonstrates that the biofuel obtained through wood gasification complies with the Renewable Energy Directive, while natural gas remains the least sustainable option. Heat pumps, biogas, and greenhouse drying emerge as promising alternatives to align biofuel production with EU sustainability targets. Phosphorus recovery from sewage sludge ash proves essential for compliance, offering clear environmental benefits. Although sewage sludge is challenging due to its high water content, it represents a valuable feedstock whose sustainable management can enhance both energy recovery and nutrient recycling.

Keywords: advanced biofuels; green hydrogen; Thermo-Catalytic Reforming; pyrolysis; sewage sludge drying; biochar; char; phosphorus recovery; circular economy (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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