Industrial wastewaters rich in organic carbon have potential
for
value generation, but conventional, low-rate, anaerobic–aerobic
wastewater treatment (WWT) processes often incur significant capital
expenses and energy consumption. In this study, we leveraged experimental
data for biorefinery-derived wastewaters to characterize the implications
of transitioning from a conventional, low-rate process to a high-rate,
multistage anaerobic process. We designed and simulated these WWT
processes across seven first- and second-generation (1G/2G) biorefineries
and evaluated the implications for biorefinery sustainability through
techno-economic analysis (TEA) and life cycle assessment (LCA). Compared
to the conventional design, the new process can substantially reduce
capital costs and electricity usage. These improvements were particularly
evident for 2G biorefineries, translating to 5%–13% lower minimum
product selling prices (MPSPs) and 7%–135% lower 100-year global
warming potentials (GWPs; the 135% reduction is due to the transition
of one biorefinery from net emission [0.87 kg of CO2e·gal–1] to net sequestration [−0.31 kg of CO2e·gal–1]). Biorefineries could further
reduce the MPSP through the renewable identification number (RIN)
credits by upgrading and selling the biogas as renewable natural gas,
but at the expense of increasing GWP. When normalized, the COD management
cost ranged from $–56 to $465 per tonne of COD, indicating
that wastewater could be a net source of revenue for some biorefineries.