Pretreatment is a crucial process in a lignocellulosic biorefinery. Corncob is typically considered as a natural renewable carbon source to produce various bio-based products. This study aimed to evaluate the performance of the hydrothermal-mechanical pretreatment of corncob for biofuels and biochemical production. Corncob was first pretreated by liquid hot water (LHW) at different temperatures (140–180 °C) and duration (30, 60 min) and then subjected to centrifugal milling to produce bio-powders. To evaluate the performance of this combined pretreatment, the energy efficiency and waste generation were investigated. The results indicated that the maximum fermentable sugars (FS) were 0.488 g/g biomass obtained by LHW at 180 °C, 30 min. In order to evaluate the performance of this combined pretreatment, the energy efficiency and waste generation were 28.3 g of FS/kWh and 7.21 kg of waste/kg FS, respectively. These obtained results indicate that the combined hydrothermal-mechanical pretreatment was an effective pretreatment process to provide high energy efficiency and low waste generation to produce biofuels. In addition, the energy efficiency and waste generation will be useful indicators for process scaling-up into the industrial scale. This combined pretreatment could be a promising pretreatment technology for the production of biofuels and biochemicals from lignocellulosic valorization.

One of the major concerns for utilizing ionic liquid on an industrial scale is the cost involved in the production. Despite its proven pretreatment efficiency, expenses involved in its usage hinder its utilization. A better way to tackle this limitation could be overcome by studying the recyclability of ionic liquid. The current study has applied the Box–Behnken design (BBD) to optimize the pretreatment condition of rice straw through the usage of 1-ethyl-3-methylimidazolium acetate (EMIM-Ac) as an ionic liquid. The model predicted the operation condition with 5% solid loading at 128.4 °C for 71.83 min as an optimum pretreatment condition. Under the optimized pretreatment condition, the necessity of the best anti-solvent was evaluated among water, acetone methanol, and their combinations. The study revealed that pure methanol is the suitable choice of anti-solvent, enhancing the highest sugar yield. Recyclability of EMIM-Ac coupled with anti-solvent was conducted up to five recycles following the predicted pretreatment condition. Fermentation studies evaluated the efficacy of recycled EMIM-Ac for ethanol production with 89% more ethanol production than the untreated rice straw even after five recycles. This study demonstrates the potential of recycled ionic liquid in ethanol production, thereby reducing the production cost at the industrial level.

The global reliance on fossil fuels has caused severe environmental challenges, emphasizing the urgent need for sustainable and renewable energy sources. Bioethanol production from lignocellulosic biomass has emerged as a promising alternative due to its abundance, renewability, and carbon-neutral footprint. However, its economic feasibility remains a major obstacle owing to high production costs, particularly those associated with low ethanol titers and the energy-intensive distillation process costs for low titers. High-solid loading processes (≥15% w/w or w/v) have demonstrated potential to overcome these limitations by minimizing water and solvent consumption, enhancing sugar concentrations, increasing ethanol titers, and lowering downstream processing cost. Nevertheless, high-solid loading also introduces operational bottlenecks, such as elevated viscosity, poor mixing, and limited mass and heat transfer, which hinder enzymatic hydrolysis efficiency. This review critically examines emerging pretreatment and enzymatic hydrolysis strategies tailored for high-solid loading conditions. It also explores techniques that improve sugar yields and conversion efficiency while addressing key technical barriers, including enzyme engineering, process integration, and optimization. By evaluating these challenges and potential mitigation strategies, this review provides actionable insights to intensify lignocellulosic ethanol production and advance the development of scalable, cost-effective biorefinery platforms.