Towards the Potential of Using Downstream-Separated Solvents as the Pulping Liquor of Upstream Lignocellulose Fractionation for Enhanced Acetone–Butanol–Ethanol Production

Developing efficient, clean, and sustainable lignocellulose pretreatment technologies is essential for second-generation biofuel production. In this study, we attempted to use downstream-separated binary acetone-water, n-butanol-water, and ethanol-water solutions as the initial liquor for upstream organosolv pulping, in order to achieve the efficient and economic closed-circuit clean fractionation of the lignocelluloses for biological acetone–butanol–ethanol (ABE) production. Parameters, including concentration and temperature of the organosolv pulping, were optimized systematically. Results indicated that the 50 wt% ethanol and 30 wt% acetone aqueous solutions and pulping at 200 °C for 1 h exhibited better corn stover fractionation performances with higher fermentable sugar production. The total monosaccharide recovery (including glucose and xylose) was 50.92% and 50.89%, respectively, in subsequent enzymatic saccharification. While pulping corn stover using n-butanol solution as initial liquor showed higher delignification 86.16% (50 wt% of n-butanol and 200 °C for 1 h), the hydrolysate obtained by the organosolv pulps always exhibited good fermentability. A maximized 15.0 g/L of ABE with 0.36 g/g of yield was obtained in Ethanol-200 °C-50% group, corresponding to 112 g of ABE production from 1 kg of raw corn stover. As expected, the lignin specimens fractionated by closed-circuit organosolv pulping exhibited narrow molecule weight distribution, high purity, and high preservation of active groups, which supports further valorization. This novel strategy tightly bridges the upstream and downstream processes of second-generation ABE production, providing a new route for ‘energy-matter intensive’ and environmentally friendly lignocelluloses biorefineries.