Production of phosphate biofertilizers as a booster for the techno-economic and environmental performance of a first-generation sugarcane ethanol and sugar biorefinery

The intensive use of fertilizers and pesticides in agriculture has a significant economic and environmental impact worldwide. Biofertilizers (aka microbial inoculants) could be a potential alternative to decrease costs and the environmental footprint linked to the use of fertilizers while boosting productivity through biological processes. This work aimed to perform a techno-economic-environmental assessment of an industrial biofertilizer production facility integrated with a sugarcane ethanol biorefinery. To this end, systems engineering tools were employed concurrently with techno-economic-environmental analyses to assess the integration of the different processes and their feasibility. Three processes for biofertilizer production are proposed varying in terms of downstream processing and the use of single or double microorganisms. Our findings indicate that the integration of biofertilizer production can enhance the biorefinery's NPV by as much as 137% in the most favorable scenario and by a minimum of 69% in the most unfavorable scenario. Regarding environmental consequences, in general, all scenarios demonstrate an improvement over the base scenario. Global sensitivity analysis showed that the solid-state fermentation and composite formulation steps of the biofertilizer process have the most substantial influence on both economic and environmental outcomes. The uncertainty analysis further unveils that the scenarios without fungus separation exhibited greater resilience in the face of market volatility. The retro-techno-economic study defined the economically viable region. Ultimately, this study demonstrates that the integration of biofertilizers into an ethanol and sugar biorefinery is a more sustainable alternative than the isolated biorefinery regarding the environmental and techno-economic aspects of sustainability. • Three biofertilizer production processes integrated into a sugarcane biorefinery are proposed. • Deterministic techno-economic-environmental analysis of biofertilizer production is performed. • Sensitivity and uncertainty analysis identify key variables and test process robustness.