Imagine a world where we no longer rely on oil and gas for energy and products.

Instead, we use natural, renewable materials to meet our needs while producing zero waste.

Scientists at the Leibniz Institute for Agricultural Engineering and Bioeconomy (ATB) in Germany have developed a new approach to making this a reality.

Their concept, known as smart integrated biorefineries, could transform how we use biological resources and help build a more sustainable economy.

What is a smart integrated biorefinery?

Biomass—natural materials like plants, food scraps, and agricultural waste—is a valuable resource. We use it for food, animal feed, fuel, and other products.

However, much of it still goes to waste, either by being thrown away or burned.

Traditional biorefineries extract only one product from a specific type of biomass, but smart biorefineries do much more.

These new systems combine multiple processes to fully use all available materials, ensuring nothing goes to waste.

This circular bioeconomy approach can help reduce emissions, lower costs, and make industries more efficient.

Innovative ways to turn waste into useful products

Dr. Nader Marzban, lead researcher at ATB, explains that many advanced technologies can help convert biomass into valuable materials. These include:

• Anaerobic digestion – A process where bacteria break down organic waste to produce biogas, which can be used for energy.
• Pyrolysis – A method of heating biomass without oxygen to create biochar (a type of charcoal) that can improve soil health and store carbon for centuries.
• Fermentation – A process that uses microbes to produce useful products like ethanol and lactic acid.

By combining these techniques, biorefineries can achieve remarkable results. For example, when biochar is added during fermentation, it helps break down harmful compounds and boosts the production of valuable substances. Additionally, heat and electricity generated during pyrolysis can power other processes, making the system more self-sufficient. Even the carbon dioxide (CO₂) released from some processes can be captured and used to grow algae, which serve as a source of protein.

Using AI to build the most efficient biorefineries

With so many possible ways to process biomass, researchers must find the best combinations for different conditions. However, testing every possibility in real life would take too long and be too expensive.

Instead, scientists are using artificial intelligence (AI) and digital modeling to simulate and analyze millions of possible biorefinery designs. This helps identify the most efficient and cost-effective ways to convert waste into valuable products while reducing pollution.

A step toward a waste-free future

ATB researchers believe that smart integrated biorefineries can create a truly zero-waste economy. These systems can:

• Make industries more sustainable and competitive.
• Reduce dependence on imported raw materials.
• Lower greenhouse gas emissions.
• Create new jobs in green technology.

To make this vision a reality, ATB is starting construction on a research biorefinery in Groß Kreutz, Germany, this March. This facility will test new biorefinery methods and demonstrate their practical benefits. ATB is also working with universities, policymakers, and industries to develop and expand these innovations.

Professor Barbara Sturm, a scientific director at ATB, emphasizes that collaboration is key. Scientists, businesses, and governments must work together to create a sustainable bioeconomy. The goal is to replace fossil fuels with renewable materials while ensuring economic growth and environmental protection.

With smart biorefineries, the future could be one where nothing goes to waste, everything has value, and our planet is healthier. It’s time to embrace these innovations and build a more sustainable world for future generations.