Sustainable Production of Chitosan from Mussel Shells with Upcycling of Demineralization Effluent into Calcium Formate

Abstract

This study proposes a sustainable, integrated biorefinery approach to valorize mussel shell waste into high-value products, including chitin, chitosan, and calcium formate. Formic acid was employed as an effective demineralizing agent, enabling not only efficient mineral removal but also the direct conversion of the demineralization effluent into value-added calcium formate. The sequential extraction processes, demineralization, deproteinization, and decolorization, successfully yielded purified chitin (PCH), which was subsequently deacetylated to produce chitosan (CTS) with a degree of deacetylation of 85% and a molecular weight of 75 kDa. The physicochemical properties of all products were characterized using Fourier transform infrared spectroscopy (FTIR), X-ray diffraction (XRD), thermogravimetric analysis (TGA), and scanning electron microscopy (SEM). FTIR and XRD analyses confirmed the successful extraction of chitin and chitosan, demonstrating the feasibility of mussel shells as an alternative biopolymer source. In parallel, calcium formate (CCF) was obtained from the demineralization effluent with a yield of 94.19%, and its formation was verified by FTIR and XRD. Elemental analysis by XRF exhibited 98.3% CaO with minimal non-toxic impurities. The TGA/DTG profiles of CCF exhibited a well-defined two-step thermal decomposition, confirming its anhydrous form. Overall, this environmentally benign process enables the simultaneous production of multiple value-added products while significantly improving resource utilization and reducing waste generation. The proposed integrated biorefinery model offers a promising, economically viable pathway for marine biomass valorization, aligned with the Bio-Circular-Green (BCG) economy concept.