Recent Developments, Challenges, and Environmental Benefits of Using Hermetia illucens for Bioenergy Production Within a Circular Economy Approach

This study proposes a novel integrated biorefinery approach that combines Hermetia illucens (Black Soldier Fly) larvae treatment, anaerobic digestion (AD), and hydrothermal carbonization (HTC) to enhance the valorisation of fat-rich food residues. The process was designed to improve biogas yields while mitigating the inhibitory effects of lipid accumulation in AD systems. Results from larval bioconversion showed effective fat removal and a promising potential for protein and biomass valorisation. Downstream integration with AD and HTC enabled thermal self-sufficiency, enhanced energy recovery, and improved digestate dewaterability. Additionally, HTC process water recirculation to the AD unit was evaluated, considering its acidic nature and impact on biomethane production. A thermally integrated process flow was proposed, enabling efficient heat exchange and reduced external energy input. The overall system allows for multi-product recovery—including biogas, hydrochar, and larval biomass—offering a sustainable pathway for circular bioeconomy applications. This study illustrates the feasibility of a synergetic process chain that maximises energy recovery and resource efficiency from food industry waste streams.