Process model and economic analysis of itaconic acid production from dimethyl succinate and formaldehyde

A complete process model and economic analysis has been developed for itaconic acid production via catalytic condensation of dimethyl succinate and formaldehyde. The process model is based on experimental yields and selectivities obtained for the condensation reaction and on recovery schemes for itaconic acid developed in our laboratory. For an 18 million kg/yr (40 million lb/yr) itaconic acid production facility with a 10-year lifetime, the model predicts a capital investment of $40 million and an itaconic acid selling price of $2.34/kg ($1.06/lb) to achieve 30% annual return on investment. Feedstock cost is the largest contributor to the price of itaconic acid; succinate conversion and selectivity to the intermediate citraconic acid therefore most strongly influence process economics. Results of these analyses indicate that itaconic acid can be produced catalytically from succinic acid and formaldehyde at lower cost than via the current fungal fermentation route.     

Comparison of plant-based expression platforms for the heterologous production of geraniol

We compared the ability of different plant-based expression platforms to produce geraniol, a key metabolite in the monoterpenoid branch of the terpenoid indole alkaloid biosynthesis pathway. A geraniol synthase gene isolated from Valeriana officinalis (VoGES) was stably expressed in different tobacco systems. Intact plants were grown in vitro and in the greenhouse and were used to generate cell suspension and hairy root cultures. VoGES was also transiently expressed in N. benthamiana. The highest geraniol content was produced by intact transgenic plants grown in vitro (48 μg/g fresh weight, fw), followed by the transient expression system (27 μg/g fw), transgenic plants under hydroponic conditions in the greenhouse and cell suspension cultures (16 μg/g fw), and finally hairy root cultures (9 μg/g fw). Differences in biomass production and the duration of cultivation resulted in a spectrum of geraniol productivities. Cell suspension cultures achieved a geraniol production rate of 1.8 μg/g fresh biomass per day, whereas transient expression produced 5.9 μg/g fresh biomass per day (if cultivation prior to agroinfiltration is ignored) or 0.5 μg/g fresh biomass per day (if cultivation prior to agroinfiltration is included). The superior productivity, strict process control and simple handling procedures available for transgenic cell suspension cultures suggest that cells are the most promising system for further optimization and ultimately for the scaled-up production of geraniol.     

Techno-economic modeling and assessment of cultivated meat: Impact of production bioreactor scale

Increases in global meat demands cannot be sustainably met with current methods of livestock farming, which has a substantial impact on greenhouse gas emissions, land use, water consumption, and farm animal welfare. Cultivated meat is a rapidly advancing technology that produces meat products by proliferating and differentiating animal stem cells in large bioreactors, avoiding conventional live-animal farming. While many companies are working in this area, there is a lack of existing infrastructure and experience at commercial scale, resulting in many technical bottlenecks such as scale-up of cell culture and media availability and costs. In this study, we evaluate theoretical cultivated beef production facilities with the goal of envisioning an industry with multiple facilities to produce in total 100,000,000 kg of cultured beef per year or ~0.14% of the annual global beef production. Using the computer-aided process design software, SuperPro Designer®, facilities are modeled to create a comprehensive analysis to highlight improvements that can lower the cost of such a production system and allow cultivated meat products to be competitive. Three facility scenarios are presented with different sized production reactors; ~42,000 L stirred tank bioreactor (STR) with a base case cost of goods sold (COGS) of $35/kg, ~211,000 L STR with a COGS of $25/kg, and ~262,000 L airlift reactor (ALR) with a COGS of $17/kg. This study outlines how advances in scaled up bioreactors, alternative bioreactor designs, and decreased media costs are necessary for commercialization of cultured meat products.     

Chemical and morphological characterization of sugarcane bagasse submitted to a delignification process for enhanced enzymatic digestibility

Background

While advantages of biofuel have been widely reported, studies also highlight the challenges in large scale production of biofuel. Cost of ethanol and process energy use in cellulosic ethanol plants are dependent on technologies used for conversion of feedstock. Process modeling can aid in identifying techno-economic bottlenecks in a production process. A comprehensive techno-economic analysis was performed for conversion of cellulosic feedstock to ethanol using some of the common pretreatment technologies: dilute acid, dilute alkali, hot water and steam explosion. Detailed process models incorporating feedstock handling, pretreatment, simultaneous saccharification and co-fermentation, ethanol recovery and downstream processing were developed using SuperPro Designer. Tall Fescue (Festuca arundinacea Schreb) was used as a model feedstock.

Results

Projected ethanol yields were 252.62, 255.80, 255.27 and 230.23 L/dry metric ton biomass for conversion process using dilute acid, dilute alkali, hot water and steam explosion pretreatment technologies respectively. Price of feedstock and cellulose enzymes were assumed as $50/metric ton and 0.517/kg broth (10% protein in broth, 600 FPU/g protein) respectively. Capital cost of ethanol plants processing 250,000 metric tons of feedstock/year was $1.92, $1.73, $1.72 and $1.70/L ethanol for process using dilute acid, dilute alkali, hot water and steam explosion pretreatment respectively. Ethanol production cost of $0.83, $0.88, $0.81 and $0.85/L ethanol was estimated for production process using dilute acid, dilute alkali, hot water and steam explosion pretreatment respectively. Water use in the production process using dilute acid, dilute alkali, hot water and steam explosion pretreatment was estimated 5.96, 6.07, 5.84 and 4.36 kg/L ethanol respectively.

Conclusions

Ethanol price and energy use were highly dependent on process conditions used in the ethanol production plant. Potential for significant ethanol cost reductions exist in increasing pentose fermentation efficiency and reducing biomass and enzyme costs. The results demonstrated the importance of addressing the tradeoffs in capital costs, pretreatment and downstream processing technologies.     

Process economics of industrial monoclonal antibody manufacture

Pressures for cost-effective manufacture of antibodies are growing given their high doses and increasing market potential that have resulted in significant increases in total site capacities of up to 200,000 L. This paper focuses on the process economic issues associated with manufacturing antibodies and reviews the cost studies published in the literature; many of the issues highlighted are not only specific to antibodies but also apply to recombinant proteins. Data collated at UCL suggest current benchmark investment costs of $660-$1580/ft2 ($7130-$17,000/m2) and $1765-$4220/L for antibody manufacturing facilities with total site capacities in the range of 20,000-200,000 L; the limitations of the data are highlighted. The complications with deriving benchmark cost of goods per gram (COG/g) values are discussed, stressing the importance of stating the annual production rate and either titre or fermentation capacity with the cost so as to allow comparisons. The uses and limitations of the methods for cost analysis and the available software tools for process economics are presented. Specific examples found in the literature of process economic studies related to antibody manufacture for different expression systems are reviewed. The key economic drivers are identified; factors such as fermentation titre and overall yield are critical determinants of economic success. Future trends in antibody manufacture that are driven by economic pressures are discussed, such as the use of alternative expression systems (e.g. transgenics, E. coli and yeast), disposables, and improvements to downstream technology. The hidden costs and the challenges in each case are highlighted.     

Consolidated ethanol production from Jerusalem artichoke tubers at elevated temperature by <Emphasis Type="Italic">Saccharomyces cerevisiae</Emphasis> engineered with inulinase expression through cell surface display

Ethanol fermentation from Jerusalem artichoke tubers was performed at elevated temperatures by the consolidated bioprocessing strategy using Saccharomyces cerevisiae MK01 expressing inulinase through cell surface display. No significant difference was observed in yeast growth when temperature was controlled at 38 and 40 °C, respectively, but inulinase activity with yeast cells was substantially enhanced at 40 °C. As a result, enzymatic hydrolysis of inulin was facilitated and ethanol production was improved with 89.3 g/L ethanol produced within 72 h from 198.2 g/L total inulin sugars consumed. Similar results were also observed in ethanol production from Jerusalem artichoke tubers with 85.2 g/L ethanol produced within 72 h from 185.7 g/L total sugars consumed. On the other hand, capital investment on cooling facilities and energy consumption for running the facilities would be saved, since regular cooling water instead of chill water could be used to cool down the fermentation system.     

Therapeutic drug monitoring of eculizumab: Rationale for an individualized dosing schedule

The annual cost of eculizumab maintenance therapy in paroxysmal nocturnal hemoglobinuria (PNH) and atypical hemolytic–uremic syndrome (aHUS) exceeds $300,000 per patient. A better understanding of eculizumab pharmacokinetics and subsequent individual dose adjustment could reduce this cost. We measured the trough eculizumab concentration in 9 patients with maintenance therapy (aHUS, n = 7; PNH, n = 2) and determined: 1) the intra- and inter-individual variability; 2) the influence of weight on eculizumab pharmacokinetics; and 3) the rate of elimination of eculizumab following discontinuation. A one-compartment model was developed to describe the pharmacokinetics of eculizumab and predicted complement activity by body weight. Trough eculizumab concentrations were >50 µg/mL in 9/9, >100 µg/mL in 8/9, and >300 µg/mL in 5/9 of patients. Intra-individual variability was low but eculizumab concentrations, closely correlated with patient weight (R² = 0.66, p = 0.034), varied broadly (55 ± 12 to 733 ± 164 µg/mL). Pharmacokinetic modeling showed that the elimination half-life varied greatly, with an increase from 7.8 d in a patient weighing 100 kg to 19.5 d in a 40 kg patient. We predicted that infusions of 1200 mg could be spaced every 4 or 6 weeks in patients weighing <90 and <70 kg, respectively. In this pilot study, the current recommended use of a fixed eculizumab dose for maintenance therapy is associated with excessively high trough concentrations in many patients. Further prospective larger studies are now required to support an individualized schedule adjusted for patient weight and based on the observed trough serum eculizumab concentration.     

Techno-economic analysis of a plant-based platform for manufacturing antimicrobial proteins for food safety

Continuous reports of foodborne illnesses worldwide and the prevalence of antibiotic-resistant bacteria mandate novel interventions to assure the safety of our food. Treatment of a variety of foods with bacteriophage-derived lysins and bacteriocin-class antimicrobial proteins has been shown to protect against high-risk pathogens at multiple intervention points along the food supply chain. The most significant barrier to the adoption of antimicrobial proteins as a food safety intervention by the food industry is the high production cost using current fermentation-based approaches. Recently, plants have been shown to produce antimicrobial proteins with accumulation as high as 3 g/kg fresh weight and with demonstrated activity against major foodborne pathogens. To investigate potential economic advantages and scalability of this novel platform, we evaluated a highly efficient transgenic plant-based production process. A detailed process simulation model was developed to help identify economic “hot spots” for research and development focus including process operating parameters, unit operations, consumables, and/or raw materials that have the most significant impact on production costs. Our analyses indicate that the unit production cost of antimicrobial proteins in plants at commercial scale for three scenarios is $3.00–6.88/g, which can support a competitive selling price to traditional food safety treatments.     

Farm-Scale Production Cost of Switchgrass for Biomass

The economic potential of cellulosic biomass from switchgrass has heretofore been evaluated using estimates of farm costs based on extrapolation from experimental data and budget estimates. The objective of the project reported here was to estimate the cost of production that would be experienced by farmers on commercial production situations. Switchgrass was produced as a biomass crop on commercial-scale fields by ten contracting farmers located from northern North Dakota to southern Nebraska. Results showed a wide range of yields and costs across the five production years and ten sites, with an overall average cost of $65.86 Mg^?1 of biomass dry matter, and annualized yield of 5.0 Mg ha^?1. The low-cost half of the producers were able to produce at an average cost of $51.95 Mg^?1over the 5-year period. When projected to a full 10-year rotation, their cost fell further to $46.26 Mg^?1. We conclude that substantial quantities of biomass feedstock could have been produced in this region at a cost of about $50 Mg^?1 at the farm gate, which translates to about $0.13/l of ethanol. These results provide a more reliable benchmark for current commercial production costs as compared to other estimates, which range from $25 to $100 Mg^?1.     

Techno-economic analysis of biomass to fuel conversion via the MixAlco process

MixAlco is a robust process that converts biomass to fuels and chemicals. A key feature of the MixAlco process is the fermentation, which employs a mixed culture of acid-forming microorganisms to convert biomass components (carbohydrates, proteins, and fats) to carboxylate salts. Subsequently, these intermediate salts are chemically converted to hydrocarbon fuels (gasoline, jet fuel, and diesel). This work focuses on process synthesis, simulation, integration, and cost estimation of the MixAlco process. For the base-case capacity of 40 dry tonne feedstock per hour, the total capital investment is US $5.54/annual gallon of hydrocarbon fuels (US $5.54/annual gallon of hydrocarbon fuels (US 3.79/annual gallon of ethanol equivalent), and the minimum selling price [with 10% return on investment (ROI), internal hydrogen production, and US $60/tonne biomass] is US $60/tonne biomass] is US 2.56/gal hydrocarbon, which is equivalent to US $1.75/gal ethanol. If plant capacity is increased to 400 tph, the minimum selling price of biomass-derived hydrocarbon fuels is US $1.75/gal ethanol. If plant capacity is increased to 400 tph, the minimum selling price of biomass-derived hydrocarbon fuels is US 1.76/gal hydrocarbon (US $1.20/gal ethanol equivalent), which can compete without subsidies with petroleum-derived hydrocarbons when crude oil sells for about US $1.20/gal ethanol equivalent), which can compete without subsidies with petroleum-derived hydrocarbons when crude oil sells for about US 65/bbl. At 40 tph, using the average tipping fee for municipal solid waste (US $45/dry tonne) and current price of external hydrogen (US $45/dry tonne) and current price of external hydrogen (US 1/kg), the minimum selling price is only US $1.24/gal hydrocarbon (US $1.24/gal hydrocarbon (US 0.85/gal ethanol equivalent).     

Step-up/step-down perfusion approach for increased mAb 520C9 production by a hybridoma cell line

The hybridoma cell line, HB-8696, produces a monoclonal antibody, 520C9 (mouse IgG₁) that recognizes the breast cancer oncoprotein, c-erbB2. The effect of perfusion rate (volume of fresh feed/working volume of reactor/day) on cell growth and mAb production was investigated but perfusion at a constant rate and at an arbitrarily increased rate could not maintain exponential cell growth or a higher specific mAb production rate. An optimum step-up/step-down perfusion strategy is therefore proposed for maintaining a steady state production phase at high cell density for ten days. The optimum step-up perfusion could achieve fast cell growth by avoiding any nutrient limited condition and the following optimum step-down perfusion could potentially maintain high live cell density and reduced product dilution as well. The maximum viable cell achieved under optimum perfusion strategy was 2.3 × 10⁷ cells/ml which was 19-fold higher than in optimum batch culture. The mAb yield and volumetric productivity were significantly improved to 52 and 50 mg/l day compared to 25 and 3.8 mg/l day in optimum batch, respectively, and could be maintained for up to ten days.     

Economic assessment of continuous processing for manufacturing of biotherapeutics

Continuous processing offers a promising approach to revolutionize biotherapeutics manufacturing as reflected in recent years. The current study offers a comparative economic assessment of batch and continuous processing for the production of biotherapeutic products. Granulocyte-colony stimulating factor (GCSF), a protein expressed in E. coli, and an IgG1 monoclonal antibody, were chosen as representatives of microbial and mammalian derived products for this assessment. Economic indicators—cost of goods (COGs), net present value (NPV), and payback time have been estimated for the assessment. For the case of GCSF, conversion from batch to integrated continuous manufacturing induced a $COGs/g reduction of 83% and 73% at clinical and commercial scales, respectively. For the case of mAb therapeutic, a 68% and 35% reduction in $COGs/g on translation from batch to continuous process was projected for clinical and commercial scales, respectively. Upstream mAb titer was also found to have a significant impact on the process economics. With increasing mAb titer, the $COG/g decreases in both operating modes. With titer increasing from 2 to 8 g/L, the $COG/g of batch process was reduced by 53%, and that of the continuous process was reduced by 63%. Cost savings in both the cases were attributed to increased productivity, efficient equipment and facility utilization, smaller facility footprint, and reduction in utilization of consumables like resin media and buffers actualized by the continuous processing platform. The current study quantifies the economic benefits associated with continuous processing and highlights its potential in reducing the manufacturing cost of biotherapeutics.     

An economic assessment of algal turf scrubber technology for treatment of dairy manure effluent

Controlling the input of nitrogen (N) and phosphorus (P) from dairies and other livestock operations into the surrounding air- and water-sheds poses both technical and economic challenges to the agricultural community. The purpose of this paper is to assess the economics of algal turf scrubber treatment technology at the farm-scale for a hypothetical 1000-cow dairy. Costs were developed for farms with and without anaerobic pretreatment. The majority of capital costs were due to land preparation, installation of liner material, and engineering fees. The majority of operational costs were due to energy requirements for biomass drying, pumping water, and repayment of capital investment. On farms using anaerobic pretreatment, waste heat from burning of biogas could be used to offset the energy requirements of biomass drying. In addition, biogas combustion exhaust gas could then be recycled back to the algal system to supply dissolved inorganic carbon for optimal algal production and pH control. Under the best case (algal system coupled with anaerobic digestion pretreatment), the yearly operational costs per cow, per kg N, per kg P, and per kg of dried biomass were $454, $6.20, $31.10, and $0.70, respectively. Without anaerobic digestion pretreatment, the yearly operational costs were 36% higher, amounting to $631 per cow, $8.70 per kg N, $43.20 per kg P, and $0.97 per kg of dried biomass. For perspective, a recent survey of 36 Maryland dairy farms found long-term annual profits of about $500 per cow. As no market currently exists for manure grown algal biomass, our cost analysis does not include any value of the biomass generated during manure treatment. In addition, there are a variety of potential uses for the algal biomass from manure treatment that could defray treatment costs. Future opportunities for dairies to participate in nutrient trading approaches to watershed nutrient management may also become important.     

Technoeconomic analysis of five microalgae-to-biofuels processes of varying complexity

The economics surrounding five algae-to-fuels process scenarios were examined. The different processes modeled were as follows: an open pond producing either triacylglycerides (TAG) or free fatty acid methyl ester (FAME), a solar-lit photobioreactor producing either FAME or free fatty acids (FFA), and a light emitting diode irradiated (LED-lighted) photobioreactor producing TAG. These processes were chosen to represent both classical and esoteric approaches presented in the open literature. Viable (or suggested) processing techniques to liberate and purify (and convert) the microalgal triacylglycerides were then modeled to accompany each growth option. The investment and cost per kg of fuel or fuel precursor for each process was determined. The open pond produced TAG at ～$7.50/kg, while the process using the LED-lit photobioreactor produced TAG at ～$33/kg. The scenario containing the solar-lit photobioreactor produced FAME at ～$25/kg, while the open pond produced FAME at ～$4/kg. The scenario containing the solar-lit photobioreactor produced FFA at ～$29/kg. The open pond scenarios appear to be closest to the $1/kg pricepoint at this time, and thus are the most viable economic options. Future technological advancements that reduce the cost of bioreactor vessels, LED lighting, and solvent recovery, may reduce the oil production costs of these scenarios to a more attractive level.     

Economics of Oil Production from Pongamia (<Emphasis Type="Italic">Millettia pinnata</Emphasis>) for Biofuel in Australia

Pongamia (Millettia pinnata) has been widely studied as a potential feedstock for biodiesel fuel, though little is known about its feasibility at a commercial level. Capital budgeting and cash flow analysis was conducted for a potential Pongamia plantation and crushing plant in Queensland, Australia. For annual seed yields ranging from 20 to 80 kg (in shell) per tree, the delivered cost of Pongamia oil was estimated to be between AUD $2.22 and AUD $0.64 per litre. The seed yield range of 20 to 80 kg per tree is roughly equivalent to between 7 and 29 t per hectare at a planting density of 357 trees per hectare. Major components of the delivered cost of (Pongamia) oil are the capital expenses of land acquisition, plantation establishment and the crushing plant construction. The major operational costs include mechanical harvesting; fertiliser; control of weed, pests and diseases; seed crushing; and freight of oil to a refinery. The cost items with the greatest volume sensitivity are the capital expenses, overheads (consisting mostly of salaries and wages of employees) and the expenses associated with harvesting and crushing operations. These costs could be significantly reduced if the seed yield could be increased. Several scenarios were tested to demonstrate the effect of seed yield and oil price on the profitability and cash flow of the Pongamia enterprise. At most plausible oil prices and seed yields, Pongamia oil is not expected to be economically viable.     

Economic aspects of commercial manufacture of biopharmaceuticals

Sustained approvals of new biopharmaceuticals supported by a sparkling pipeline are the drivers for the above-market growth of biopharmaceuticals. Due to usually high therapeutic dose of monoclonal antibodies, they are demanding for high capacity needs. This requires significant capital investment and stimulates innovation for process improvement to decrease cost of goods and to save capital investments. Such process improvements are either ongoing along the learning curve or result from significant process changes through regulatory authorities impact. Both approaches require extensive protein analytical guidance to maintain product quality, safety and equivalency. In addition to second generation processes, second generation products have the feature of optimizing the physiological principle of biopharmaceuticals to the therapeutic need and to decrease the therapeutic dose, which goes along with investment savings and lower cost of goods.     

Addition of citrus pulp and apple pomace in diets for dogs: influence on fermentation kinetics,digestion, faecal characteristics and bacterial populations

Fermentation kinetics, digestibility, faecal characteristics and bacterial populations (aerobes, anaerobes, lactobacilli, lactic acid bacteria, enterococci, coliforms and clostridia) of dog food mixed with citrus pulp and apple pomace were evaluated. The in vitro gas production of a pre-digested dog food mixed with 0, 30, 50 and 70 g/kg dry matter (DM) of citrus pulp or apple pomace was measured, and also an experiment with dogs fed the same dog food with or without the addition of 70 g/kg of either fresh citrus pulp or apple pomace was conducted. Gas production increased linearly (p < 0.001) and quadratically (p < 0.001) as fibre levels augmented. The inclusion of fibre sources in the diets resulted in higher faecal output (p = 0.005) and defecation frequency (p < 0.001), and lower faecal pH (p < 0.001) and digestibility values (p < 0.01). Faecal consistencies and microbial populations did not differ among treatments. The addition of fresh citrus and apple was effective to stimulate the hindgut fermentation, but slightly depressed the digestion.     

Economic assessment of plant cell culture for the production of ajmalicine

Cost estimates have been prepared for commercial-scale production of ajmalicine-rich Catnaranthus roseus biomass using plant cell culture. At the current state of the technology the cost would be approximately $7.30/lb dry biomass ($3215/kg ajmalicine). Naturally-grown C. roseus roots have a 50% lower ajmalicine concentration but would cost only ca. $0.70/lb ($619/kg ajmalicine). The principal reason for the high cost of the plant cell culture route is not the slow specific growth rate (0.35 day(-1)), but rather the slow specific product accumulation rate (0.26 mg/g day). This rate will have to be increased by a factor of 40 to make the process competitive.     

Environmental and economic impacts of solar‐powered integrated greenhouses

Greenhouse vegetable production plays a vital role in providing year‐round fresh vegetables to global markets, achieving higher yields, and using less water than open‐field systems, but at the expense of increased energy demand. This study examines the life cycle environmental and economic impacts of integrating semitransparent organic photovoltaics (OPVs) into greenhouse designs. We employ life cycle assessment to analyze six environmental impacts associated with producing greenhouse‐grown tomatoes in a Solar PoweRed INtegrated Greenhouse (SPRING) compared to conventional greenhouses with and without an adjacent solar photovoltaic array, across three distinct locations. The SPRING design produces significant reductions in environmental impacts, particularly in regions with high solar insolation and electricity‐intensive energy demands. For example, in Arizona, global warming potential values for a conventional, adjacent PV and SPRING greenhouse are found to be 3.71, 2.38, and 2.36 kg CO₂ eq/kg tomato, respectively. Compared to a conventional greenhouse, the SPRING design may increase life cycle environmental burdens in colder regions because the shading effect of OPV increases heating demands. Our analysis shows that SPRING designs must maintain crop yields at levels similar to conventional greenhouses in order to be economically competitive. Assuming consistent crop yields, uncertainty analysis shows average net present cost of production across Arizona to be $3.43, $3.38, and $3.64 per kg of tomato for the conventional, adjacent PV and SPRING system, respectively.     

A novel cleaning process for industrial production of xylose in pilot scale from corncob by using screw-steam-explosive extruder

Steam explosion is the most promising technology to replace conventional acid hydrolysis of lignocellulose for biomass pretreatment. In this paper, a new screw-steam-explosive extruder was designed and explored for xylose production and lignocellulose biorefinery at the pilot scale. We investigated the effect of different chemicals on xylose yield in the screw-steam-explosive extrusion process, and the xylose production process was optimized as followings: After pre-impregnation with sulfuric acid at 80 °C for 3 h, corncob was treated at 1.55 MPa with 9 mg sulfuric acid/g dry corncob (DC) for 5.5 min, followed by countercurrent extraction (3 recycles), decoloration (activated carbon dosage 0.07 g/g sugar, 75 °C for 40 min), and ion exchange (2 batches). Using this process, 3.575 kg of crystal xylose was produced from 22 kg corncob, almost 90 % of hemicellulose was released as monomeric sugar, and only a small amount of by-products was released (formic acid, acetic acid, fural, 5-hydroxymethylfurfural, and phenolic compounds were 0.17, 1.14, 0.53, 0.19, and 1.75 g/100 g DC, respectively). All results indicated that the screw-steam-explosive extrusion provides a more effective way to convert hemicellulose into xylose and could be an alternative method to traditional sulfuric acid hydrolysis process for lignocellulose biorefinery.