Experimental Optimization with the Emphasis on Techno-Economic Analysis of Production and Purification of High Value-Added Bioethanol from Sustainable Corn Stover

Bioethanol-derived biomass is a green sustainable source of energy that is highly recommended as an efficient alternative to the replacement of fossil fuels. However, this type of bioethanol production is always expensive with very low bioethanol concentration. Therefore, this work aims to represent a facile and green approach for bioethanol production with high concentration and purity as well as reasonable cost from corn stover (CS). The goal of this study is to characterize CS and its treated samples with maleic acid (CSM) using various characterization analyses, such as proximate and ultimate analysis, HHV, TGA, FTIR, SEM, and CHNS. The bioethanol production stages: Pretreatment, enzymatic degradation, fermentation, and finally bioethanol separation and purification via the pervaporation process, which have been investigated and optimized are associated with the economic analysis. The optimum operating condition of the pretreatment process was 2% maleic acid, 1:20 solid-to-liquid ratio at 45 psi, 120 degrees C, and 1 h of operation in the autoclave. This process contributes to 53 and 45% lignin and hemicellulose removal, 98% cellulose recovery, and a glucose yield of 741 mg/dL. The yeast isolate succeeded in the production of 1230 mg/dL of bioethanol. This isolated yeast strain was close to Pichia nakasei with a similarity of 98%, and its amplified 18S rRNA gene sequence was deposited in GenBank with the accession number MZ675535. Poly (MMA-co-MA) membrane was synthesized, characterized, and its efficiency for increasing the bioethanol concentration was evaluated using the integrated pervaporation technique. The techno-economic analysis is presented in detail to evaluate the process profitability, which achieves a considerable profit for the whole duration of the project without any losses as it reaches a net profit of USD 1 million in 2023, reaching USD 2.1 million in 2047 for a company with a capacity of 32 thousand tons per year. The sequential strategy offers a promising approach for efficient bioethanol production under mild and environmentally friendly conditions that enable its implication industrially.