Vogelbusch’s continuous fermentation is highly reliable and achieves high alcohol concentrations and excellent yields continuously over extended periods of time.
The MultiCont© process was introduced to the alcohol industry back in 1970 with resounding success. The process has since been refined, and it is now considered the state-of-the-art technology for alcohol and bioethanol fermentation.
The fermenting mash flows steadily through a series of four to seven fermenters, while the alcohol increases in concentration.
A constant flow of substrate enters the fermentation unit and the same volume of mash leaves the system simultaneously.
As soon as the system is in an equilibrium, level and temperature are automatically controlled and operator supervision is reduced to a minimum.
To promote yeast growth, nutrients and air are added to the first fermenters. Agitators in all fermenters ensure proper mixing to avoid sedimentation of suspended materials and yeast cells.
In the last fermenters saccharification of starch and transformation of fermentable sugars into ethanol is completed. The alcohol mash is then fed to an intermediate tank for distillation.
The largest fermentation cascades consist of fermentation tanks with volumes of up to 5,000 m³.
Compared to simple batch processes, Vogelbusch MultiCont© continuous alcohol fermentation is characterized by
Less fermentation volume is required due to significantly less cleaning frequencies and preparation time. Heat exchangers are designed to match the heat load demands at each stage of fermentation. This results in less total heat exchanger area.
The steady-state character of the process reduces the necessity for automated sequences as well as the demand for single control loops and automated valves.
Compared to batch systems, this results in approximately 20 % less investment costs for the MultiCont© fermentation.
Since the process runs at steady state conditions, less manpower is required for periodic sampling and monitoring, bringing down the operator costs by minimum 50 %.
Yeast is self-sustaining after initial inoculation of the system. Chemicals consumption for CIP is less due to considerably lower fermenter and cooler cleaning frequency, thus also reducing the evaporation load of the overall process. By comparison to batch fermentation, costs for chemicals and yeast are more than 90 % less.
Permanent alcohol protection at even the first fermentation stages minimize contamination risks. Furthermore, continuous processes react very slowly. Consequently, changes in the process can be monitored easily and counteractive measures can be taken early.
Due to low contamination risks and stable process conditions a constant product quality can be achieved. Additionally the byproducts DDGS and CO2 can be obtained at consistent quality as process fluctuations are minimal.
Moreover, the lower consumption of caustic for CIP decreases the sodium content in the DDGS.
While continuous systems are generally cheaper and easier to operate, batch systems are often preferred for highly inhibiting substrates (e. g. low-grade molasses) or in conditions requiring a frequent switch between feedstocks (e. g. molasses vs. grain).
Vogelbusch designs both systems and offers flexible plants for switching between continuous and batch fermentation.
The Promaíz plant produces bioethanol from corn which is used as fuel additive in the local markets. Besides the technology package for the complete plant and detailed planning of piping and…
Almagest opted for Vogelbusch in 2009 to produce top quality extra neutral alcohol with the highest purity and organoleptic demands, to be used in the production of alcoholic beverages. The…
Abengoa Bioenergy reached sustained capacity at their 88 million gallons per year (950,000 liters per day), state-of-the-art fuel ethanol facility located in Madison, Illinois in February 2010.
This is the third…
Abengoa Bioenergy reached sustained capacity at their 88 million gallons per year (950,000 liters per day), state-of-the-art fuel ethanol facility located in Mt. Vernon, Indiana in January 2010 after 18…
Tharaldson Ethanol started up their state-of-the-art fuel ethanol facility located in Casselton, North Dakota in 2009.
The plant utilizes technology licensed by VOGELBUSCH USA Inc., including the Vogelbusch MultiCont© continuous fermentation…
As part of a wet milling complex, this plant is designed to utilize wheat starch and optionally milled grain. It has a daily capacity of 400,000 liters of ethanol and was…
Penford Products Company successfully started up their state-of-the-art fuel ethanol facility in May 2008. The plant utilizes technology licensed by VOGELBUSCH USA Inc. and has a nameplate capacity of 450,000…
The plant was built using know-how provided by VOGELBUSCH USA Inc., including the Vogelbusch MultiCont© continuous fermentation process, and has a nameplate capacity of 908,000 liters per day. The facility…
Abengoa Bioenergy successfully started up their state-of-the-art fuel ethanol facility located in Ravenna, Nebraska in September 2007. The plant utilizes technology licensed by VOGELBUSCH USA Inc., including the Vogelbusch MultiCont©…
The Chief Ethanol Fuels facility is utilizing Vogelbusch-licensed technology. In 2007, a third molecular sieve drying system was designed and installed, raising operating capacity to 832,000 liters per day.
The cooperation…
The plant now operated by Razi (formerly Sugar Cane By-Products Corporation) was designed for a daily capacity of 110,000 liters of high quality pharmaceutical alcohol from cane molasses complying with…
VOGELBUSCH USA Inc. started up the ethanol plant of Cornhusker Energy in spring 2006, with a production capacity of 450,000 liters per day of bioethanol from corn.
The plant employs a…
The 800,000 liters per day plant of CropEnergies, a unit of German Südzucker group, is designed for multiple grain sources together with by-products of beet sugar processing. The plant and…
In March 2004 the molecular sieve unit at the Aventine Renewable Energy plant was brought on stream. With a rated capacity of 1.2 million liters per day (110 mm gallons…
Located in Jilin City in Northeast China, this production line for bioethanol was officially commissioned in November 2003 after an implementation period of 22 months. The plant produces 300,000 tons…
The fine alcohol plant of Harbin Winery, a Chinese producer of potable alcohol from corn, was upgraded by Vogelbusch in several steps. The client required specifically high alcohol quality in…
FEW - International Fuel Ethanol Workshop & Expo
09/23/2024
June 10 - 12, Minneapolis, U.S.
Accurate planning is always the best
02/17/2022
Article on liquefaction and fermentation strategies in bioethanol production publishes in Biofuels International Magazine Jan/Feb 2022
