Full valorization of sugarcane bagasse: Pilot-validated and industrially profitable integrated biorefinery platform

To overcome the economic bottlenecks of second-generation biorefineries, this study develops a full-component valorization platform for sugarcane bagasse (SCB). Utilizing a mild triethylene glycol (TEG)/water alkaline pretreatment, SCB was efficiently fractionated into active lignin, oligosaccharides, and ethanol. Crucially, the process was validated at a 1,000-tonne pilot scale, achieving 90.2% cellulose retention and 95.3% oligosaccharide recovery. This pilot performance underpinned a commercial simulation for processing one million tonne annually. The subsequent techno-economic analysis (TEA) revealed a total capital investment of CNY 5,233.72 million ($747.67 million) with a 10-year payback period. Significantly, high-value oligosaccharides accounted for 78.2% of total revenue, demonstrating a decisive shift away from ethanol-dependent models. Sensitivity and Monte Carlo analyses further confirmed the project's financial robustness against market fluctuations. This research provides a rigorously validated industrial blueprint, establishing a new techno-economic benchmark for sustainable, high-profit agro-industrial residue valorization.