Work

The production of muconic acid and butyric acid from sugarcane molasses and lignocelluloses: A techno-economic comparison of biorefinery scenarios

Year: 2025

Type: article

Abstract: Developing biorefineries for biofuels and biochemicals presents technical challenges related to energy demands and technology performance, which influence production costs, profitability, and greenhouse gas (GHG) emissions. The demand for bio-based carboxylic acids, such as cis, cis-muconic acid (ccMA) and butyric acid (BA), is increasing as sustainable alternatives to fossil-based products, with a target market price of approximately $1700/t. This study conducted a techno-economic analysis of eleven biorefinery scenarios integrated with an existing sugarcane mill using Aspen Plus simulations. Mass and energy balances informed equipment sizing, costing, and GHG emissions. A discounted cash flow method was used to assess profitability and determine the minimum selling price (MSP) required to achieve a 20 % internal rate of return (IRR). The most economically attractive scenario involved producing 8.9 t/h of BA from A-molasses (1 G) with green hydrogen as a by-product, achieving an MSP of $1416/t and a 75 % emission reduction (0.99 kg CO₂eq/kg BA). In contrast, ccMA production from A-molasses was economically unviable, with an MSP of $2364/t and a production rate of 6.15 t/h, despite its lower energy demand. Integrating lignocellulosic sugars (2 G) with A-molasses for BA and ccMA production via solubilised lignin yielded an MSP of $1935/t and the lowest emission factor (0.03 kg CO₂eq/kg), corresponding to a 98 % emission reduction. These results highlight that integrating 1 G and 2 G feedstocks can substantially reduce GHG emissions while improving the economic feasibility of bio-based chemical production compared to using 1 G feedstock alone. • Regenerative reagents cut production costs by 20 % in 1 G butyric acid biorefineries, improving economic viability. • Selling green hydrogen, instead of using it for boilers, lower the minimum selling price by 9 % in 1 G configurations. • Lignin utilisation in 1G2G ccMA biorefineries increased production by 13 % and reduced GHG emissions by 99 %, yielding the best outcome. • Co-producing ccMA and BA from 1G2G feedstocks lacked economic advantages over BA-only scenarios due to high operating expenses. • Restricted use of regenerable reagents in ccMA recovery circuits limits economic viability, thus highlighting the need optimise the process.

Source: Industrial Crops and Products

DOI: 10.1016/j.indcrop.2025.121875

Authors: Motshamonyane J. Phasha, Abdul M. Petersen, Johann F. Görgens

Institution: Stellenbosch University

Language: English

Topic: Biofuel production and bioconversion

Subfield: Biomedical Engineering

Field: Engineering

Domain: Physical Sciences

SDGs: Responsible consumption and production, Climate action, Affordable and clean energy, Industry, innovation and infrastructure

Open Access status: gold

Estimated APC paid: $3,720