Biorefining of corn stover for efficient production of bioethanol, biodiesel, biomethane, and value-added byproducts

Abstract

The present study investigated an integrated biorefinery that employed corn stover as the feedstock for sustainable bioethanol, biodiesel, biogas, chitosan, glycerol, and animal feed production. Corn stover was initially subjected to dilute acid pretreatment (1.8 % v/v H2SO4, 121 °C, and 22 min) followed by enzymatic hydrolysis with a commercial cellulase (37 °C, 72 h) to promote the release of glucose (∼93 wt%) and xylose (∼89 wt%). Mucor indicus fungus was then employed to convert the released sugars into bioethanol, glycerol, and fungal biomass with yields of 0.38 g g−1, 36 mg g−1, and 0.51 g g−1, respectively. The biomass of M. indicus was processed to extract chitosan (6 mg g−1 fungal biomass) and lipids (297 mg g−1 fungal biomass). The lipid was subsequently converted to biodiesel via transesterification in the presence of HCl/ MeOH with the yield of 0.54 g g−1 fungal lipid. The defatted biomass residue was then converted to biogas with 81 % theoretical yield through anaerobic digestion. To ensure process circularity, the nutritional values of pretreated and hydrolyzed corn stover were also investigated with their suitability as livestock. It was determined that 158.1 thousand tons of dry corn stover, which was annually collectible in Iran, could be used for the production of 137.6 kg chitosan, 10.4 ton animal feed, 870.0 kg glycerol, 40.7 million litters ethanol, 2.8 million m3 biodiesel, and 449.2 million m3 biomethane. The utilization of the produced ethanol, biodiesel, and biomethane in transporting sector was shown to have the potential of facilitating 4.3 million tons of equivalent carbon dioxide and a 197.8 million dollars reduction of associated social costs.