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<p>This study presents the process design and preliminary techno-economic assessment of a sulfonation-based pretreatment employing a methanesulfonic acid (MSA)–formic acid (FA) co-solvent system for lignocellulosic ethanol production from sugarcane leaves. A batch-resolved, simulation-based framework integrating experimentally validated solvent-recycling data was developed to capture the temporal evolution of mass and energy flows during pretreatment and hydrolysis, providing an alternative approach to conventional steady-state techno-economic analyses by incorporating process dynamics. Optimization using response surface methodology (RSM) and a genetic algorithm (GA) identified conditions yielding 29.40&#xa0;mg&#xa0;g⁻<sup>1</sup> and 30.49&#xa0;mg&#xa0;g⁻<sup>1</sup> reducing sugars with no statistically significant difference, though the optimal parameters differed substantially: 27.5 wt% FA at 81&#xa0;°C for 102&#xa0;min (RSM) versus 20 wt% FA at 89&#xa0;°C for 177&#xa0;min (GA). A 50% solvent recovery strategy, validated across five reuse cycles, maintained hydrolytic efficiency and confirmed the feasibility of partial solvent recycling. The validated data were incorporated into an Aspen Plus® simulation at a scale of 50 tons per batch to evaluate time-dependent mass and energy balances. Solvent recycling reduced chemical costs by approximately 45%, while the RSM-based configuration incurred 19.8% higher pretreatment cost due to greater reagent use and shorter duration. The developed framework provides a systematic basis for dynamic cost–performance evaluation and scalable biorefinery design.</p> Graphical Abstract <p></p>

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Simulation-Based Process Design and Preliminary Techno-Economic Assessment of Sulfonation-Based Pretreatment of Sugarcane Leaves Under Mild Conditions

  • 期刊论文

  • 发表日期：

    2025年12月4日

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  • Chanin Panjapornpon,
  • Apinya Kaoloun,
  • Malinee Sriariyanun,
  • Keerthi Katam,
  • Sunil K. Maity,
  • Atthasit Tawai

摘要

This study presents the process design and preliminary techno-economic assessment of a sulfonation-based pretreatment employing a methanesulfonic acid (MSA)–formic acid (FA) co-solvent system for lignocellulosic ethanol production from sugarcane leaves. A batch-resolved, simulation-based framework integrating experimentally validated solvent-recycling data was developed to capture the temporal evolution of mass and energy flows during pretreatment and hydrolysis, providing an alternative approach to conventional steady-state techno-economic analyses by incorporating process dynamics. Optimization using response surface methodology (RSM) and a genetic algorithm (GA) identified conditions yielding 29.40 mg g⁻1 and 30.49 mg g⁻1 reducing sugars with no statistically significant difference, though the optimal parameters differed substantially: 27.5 wt% FA at 81 °C for 102 min (RSM) versus 20 wt% FA at 89 °C for 177 min (GA). A 50% solvent recovery strategy, validated across five reuse cycles, maintained hydrolytic efficiency and confirmed the feasibility of partial solvent recycling. The validated data were incorporated into an Aspen Plus® simulation at a scale of 50 tons per batch to evaluate time-dependent mass and energy balances. Solvent recycling reduced chemical costs by approximately 45%, while the RSM-based configuration incurred 19.8% higher pretreatment cost due to greater reagent use and shorter duration. The developed framework provides a systematic basis for dynamic cost–performance evaluation and scalable biorefinery design.

Graphical Abstract