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<p>The increasing need for renewable fuels highlights the potential of spent mushroom substrate (SMS) as a sustainable feedstock for biobutanol production. This study evaluated an integrated process that combines pilot-scale experimentation, kinetic modeling, and techno-economic analysis (TEA). SMS from <i>Pleurotus ostreatus</i> containing about 40% cellulose underwent a hybrid pretreatment using dilute sodium hydroxide, microwave, and ultrasonication to enhance enzymatic digestibility. Enzymatic hydrolysis of hybrid-pretreated SMS (derived from 1.2&#xa0;kg pilot-scale biomass) with <i>Trichoderma reesei</i> cellulase achieved 79.85 ± 2.1% sugar conversion efficiency, releasing 42.8 ± 1.4&#xa0;g/L reducing sugars (514.53 ± 1.61&#xa0;mg/g biomass). Subsequent 20&#xa0;L fermentation using <i>Clostridium acetobutylicum</i> MTCC 11274 yielded 9.19 ± 0.01&#xa0;g/L biobutanol (0.37 ± 0.03&#xa0;g/g sugar), validated experimentally before SuperPro Designer scaling, which projected 185,252&#xa0;kg biobutanol per 1,000,000&#xa0;kg SMS batch at 99.99% purity. Techno-economic simulation using SuperPro Designer v13.1 projected a total capital requirement of $952.85&#xa0;million, a production cost of $3.08 per kilogram, a return on investment of 15.78%, and a payback period of 6.34 years. Overall, the findings confirm that SMS-based biobutanol production is technically feasible and economically attractive, offering a scalable pathway for sustainable biofuel generation within circular bioeconomy frameworks.</p>

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Techno-economic assessment of pilot-scale biobutanol production using Pleurotus ostreatus spent substrate

  • 期刊论文

  • 发表日期：

    2026年6月29日

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  • Ashwin Raj Suresh,
  • Srivarshan Shanmuga Sundaram,
  • Arumugam Arumugam,
  • Kirupa Sankar Muthuvelu

摘要

The increasing need for renewable fuels highlights the potential of spent mushroom substrate (SMS) as a sustainable feedstock for biobutanol production. This study evaluated an integrated process that combines pilot-scale experimentation, kinetic modeling, and techno-economic analysis (TEA). SMS from Pleurotus ostreatus containing about 40% cellulose underwent a hybrid pretreatment using dilute sodium hydroxide, microwave, and ultrasonication to enhance enzymatic digestibility. Enzymatic hydrolysis of hybrid-pretreated SMS (derived from 1.2 kg pilot-scale biomass) with Trichoderma reesei cellulase achieved 79.85 ± 2.1% sugar conversion efficiency, releasing 42.8 ± 1.4 g/L reducing sugars (514.53 ± 1.61 mg/g biomass). Subsequent 20 L fermentation using Clostridium acetobutylicum MTCC 11274 yielded 9.19 ± 0.01 g/L biobutanol (0.37 ± 0.03 g/g sugar), validated experimentally before SuperPro Designer scaling, which projected 185,252 kg biobutanol per 1,000,000 kg SMS batch at 99.99% purity. Techno-economic simulation using SuperPro Designer v13.1 projected a total capital requirement of $952.85 million, a production cost of $3.08 per kilogram, a return on investment of 15.78%, and a payback period of 6.34 years. Overall, the findings confirm that SMS-based biobutanol production is technically feasible and economically attractive, offering a scalable pathway for sustainable biofuel generation within circular bioeconomy frameworks.