Valorization of Maize Lime-Cooking Wastewater Through Lipid and Carotenoid Production by Rhodotorula glutinis Yeast: An Approach Using Pulse Fed-Batch Culture and Techno-Economic Assessment

The increasing generation of agro-industrial residues like nejayote (maize lime-cooking wastewater from the maize nixtamalization process) poses significant environmental challenges in Mexico due to its elevated chemical oxygen demand (COD) and organic load. This study evaluates the physical separation of nejayote via membranes and its use as a low-cost substrate for producing lipids and carotenoids using Rhodotorula glutinis. A batch culture followed by pulse-feeding achieved a COD removal efficiency of 53.6% (0.22 g COD/(L h)) and a biomass concentration of 3.72 ± 0.45 g COD/L within 48 h. The yeast demonstrated a high specific metabolic efficiency, yielding 0.457 g of lipids and 0.0049 g of carotenoids per gram of biomass, with an oleaginous fraction of 46.21% in dry weight. Experimental data calibrated a process model in SuperPro Designer, simulating full-scale processes treating 100, 1000, and 10,000 m³ of nejayote per batch, producing up to 2137.11 MT of lipids and 22.90 MT of carotenoids annually. A techno-economic analysis estimated the investment, operating costs, and financial indicators for all scenarios. Strategies like evaporation and reverse osmosis to concentrate nejayote significantly improved profitability by reducing equipment size. Additionally, a circular economy approach was modeled, recovering process water and nutrient-rich side streams. These findings confirm that integrated physical and biological treatment, coupled with resource recovery, transforms this particularly agro-industrial residue into a technically robust and economically viable biorefinery feedstock, aligning industrial production with sustainable waste management.