Colombia is experiencing
significant growth in its agricultural
areas, its diverse production chains make the country an excellent
candidate in the development of biorefineries, and as a result, there
is an increasing need to take full advantage of biomass and obtain
high value-added by-products from waste. In this sense, biorefineries
are presented as a great alternative for the use of biomass; however,
the methodologies of biorefinery synthesis lack a parameter that limits
the growth of production lines under incremental exergetic and economic
returns. This research develops a biorefinery synthesis methodology
using an African palm biorefinery as a case study; a novel approach
is developed to facilitate a stop criterion for biorefinery expansion
through a combined consideration of economic incremental returns (IROI)
and exegetical returns of investment (ExROI), avoiding unnecessary
plant expansions or new processes that are not profitable or adequate
in terms of useful energy. The development of this methodology required
simulations in Aspen Plus software and technical-economic and exergetic
evaluation with an incremental approach of four scenarios in Excel.
The base case is palm oil production from African palm clusters. The
second case includes the production of palm kernel oil and palm cake
from residues. The third case implements the production of hydrogen
based on other residues from the base case. The last case study incorporates
the preceding case and the addition of biodiesel and glycerin production
from palm oil. Case 3 exhibits a higher economic performance with
an IROI of 42.98%; in terms of exergy, case 2 exhibits considerable
improvements over the base case, with an ExROI of 158%. A parameter
called the exergo-economic weighted incremental return on investment
(IExWROI) was obtained, evidencing a 75% improvement in case 2 compared
to the base case. The new indicator aims to provide a more comprehensive
approach to biorefinery design by optimization of economic and exergetic
returns, contributing a new alternative for decision-making in regard
to plant design, plant expansion projects, and implementation of subprocesses.