Regular articleModel-based plantwide optimization of large scale lignocellulosic bioethanol plants

•A plantwide economic optimization methodology for large scale bioethanol plants.•Integrated conversion steps: pretreatment, enzymatic hydrolysis and fermentation.•Higher pretreatment temperatures improve liquefaction but might inhibit fermentation.•The cost function is more sensitive to feedstock composition than to model parameters.•Optimal operation ensures a higher and flattened profit curve over a wider operation.

Second generation biorefineries transform lignocellulosic biomass into chemicals with higher added value following a conversion mechanism that consists of: pretreatment, enzymatic hydrolysis, fermentation and purification. The objective of this study is to identify the optimal operational point with respect to maximum economic profit of a large scale biorefinery plant using a systematic model-based plantwide optimization methodology. The following key process parameters are identified as decision variables: pretreatment temperature, enzyme dosage in enzymatic hydrolysis, and yeast loading per batch in fermentation. The plant is treated in an integrated manner taking into account the interactions and trade-offs between the conversion steps. A sensitivity and uncertainty analysis follows at the optimal solution considering both model and feed parameters. It is found that the optimal point is more sensitive to feedstock composition than to model parameters, and that the optimization supervisory layer as part of a plantwide automation system has the following benefits: (1) increases the economical profit, (2) flattens the objective function allowing a wider range of operation without negative impact on profit, and (3) reduces considerably the uncertainty on profit.