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Techno-economic analysis of a novel laccase production process utilizing perennial biomass and the aqueous phase of bio-oil

Summary

Researchers developed a new method to produce laccase, a useful enzyme with many industrial applications, by growing oyster mushrooms on prairie plants and waste materials from bio-oil production. Through optimization experiments and economic modeling, they found that this process could produce laccase at prices significantly lower than current commercial enzyme products, making it economically viable at small to moderate production scales. The method has the added benefit of providing farmers with a financial incentive to grow perennial prairie plants instead of traditional crops, supporting ecological and soil health improvements.

Background

Fast pyrolysis of biomass produces bio-oil with an aqueous phase (AP) that is difficult to upgrade through conventional methods but contains organic compounds suitable for microbial bioprocessing. The aqueous phase from bio-oil has been identified as an effective inducer for laccase production in white-rot fungi, particularly Pleurotus ostreatus. Prairie biomass represents a perennial crop with ecological benefits that requires valorization strategies to incentivize farmer adoption.

Objective

This study conducted a techno-economic analysis (TEA) investigating the economic viability of a novel laccase production process that simultaneously valorizes both the aqueous phase of bio-oil and perennial prairie biomass. The research coupled experimental and modeling approaches to optimize solid-state fermentation conditions for minimizing laccase selling price and determine the minimum selling price required for financial viability.

Results

At an 8 Mg/batch base scale, approximately 28 batches can be generated annually with a minimum laccase selling price of $0.05/kU needed to achieve a 5-year return on investment. The fermentation process achieved laccase yields of approximately 1097 U/g or 86,400 U/L under optimized conditions. Sensitivity analysis showed MLSP to be most sensitive to parameters affecting laccase output, particularly the number of batches per year and laccase recovery assumptions, while substrate and AP costs had minimal impact.

Conclusion

The novel laccase production process shows economic promise as an early-stage technology, with estimated selling prices 8-3,100 times lower than laboratory-grade commercial laccase prices. Key recommendations include reducing fermentation time, particularly the induction stage, optimizing downstream processing to improve laccase recovery, and integrating process residues into composting or anaerobic digestion for additional revenue. Further pilot-scale studies and process optimization are necessary to realize the full commercial potential of this system.
  • Published in:Bioresource Technology and Bioprocessing,
  • Study Type:Techno-economic Analysis with Experimental Optimization,
  • Source: 10.1186/s40643-025-00924-2, PMID: 40742523
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