Bioethanol-derived biomass is a green sustainable source of energy that is highly recommended as an efficient alternative to the replacement of fossil fuels. However, this type of bioethanol production is always expensive with very low bioethanol concentration. Therefore, this work aims to represent a facile and green approach for bioethanol production with high concentration and purity as well as reasonable cost from corn stover (CS). The goal of this study is to characterize CS and its treated samples with maleic acid (CSM) using various characterization analyses, such as proximate and ultimate analysis, HHV, TGA, FTIR, SEM, and CHNS. The bioethanol production stages: Pretreatment, enzymatic degradation, fermentation, and finally bioethanol separation and purification via the pervaporation process, which have been investigated and optimized are associated with the economic analysis. The optimum operating condition of the pretreatment process was 2% maleic acid, 1:20 solid-to-liquid ratio at 45 psi, 120 °C, and 1 h of operation in the autoclave. This process contributes to 53 and 45% lignin and hemicellulose removal, 98% cellulose recovery, and a glucose yield of 741 mg/dL. The yeast isolate succeeded in the production of 1230 mg/dL of bioethanol. This isolated yeast strain was close to Pichia nakasei with a similarity of 98%, and its amplified 18S rRNA gene sequence was deposited in GenBank with the accession number MZ675535. Poly (MMA-co-MA) membrane was synthesized, characterized, and its efficiency for increasing the bioethanol concentration was evaluated using the integrated pervaporation technique. The techno-economic analysis is presented in detail to evaluate the process profitability, which achieves a considerable profit for the whole duration of the project without any losses as it reaches a net profit of USD 1 million in 2023, reaching USD 2.1 million in 2047 for a company with a capacity of 32 thousand tons per year. The sequential strategy offers a promising approach for efficient bioethanol production under mild and environmentally friendly conditions that enable its implication industrially.

The bioconversion of environmental wastes into energy is gaining much interest in most developing and developed countries. The current study is concerned with the proper exploitation of some industrial wastes. Cellulosic fiber waste was selected as a raw material for producing bioethanol as an alternative energy source. A combination of physical, chemical, and enzymatic hydrolysis treatments was applied to maximize the concentration of glucose that could be fermented with yeast into bioethanol. The results showed that the maximum production of 13.9 mg/mL of glucose was achieved when 5% cellulosic fiber waste was treated with 40% HCl, autoclaved, and followed with enzymatic hydrolysis. Using SEM and FTIR analysis, the instrumental characterization of the waste fiber treatment confirmed the effectiveness of the degradation by turning the long threads of the fibers into small pieces, in addition to the appearance of new functional groups and peak shifting. A potent yeast strain isolated from rotten grapes was identified as Starmerella bacillaris STDF-G4 (accession number OP872748), which was used to ferment the obtained glucose units into bioethanol under optimized conditions. The maximum production of 3.16 mg/mL of bioethanol was recorded when 7% of the yeast strain was anaerobically incubated at 30 °C in a broth culture with the pH adjusted to 5. The optimized conditions were scaled up from flasks to a fermentation bioreactor to maximize the bioethanol concentration. The obtained data showed the ability of the yeast strain to produce 4.13 mg/mL of bioethanol after the first 6 h of incubation and double the amount after 36 h of incubation to reach 8.6 mg/mL, indicating the efficiency of the bioreactor in reducing the time and significantly increasing the product.