Bioethanol Plants

About us Contact

we make biotechnology work

Know-how and technology licensing.

Vogelbusch Bioethanol Technology

Bioethanol is dehydrated (highly concentrated) ethanol used as additive to transport fuel. It is a readily available, clean fuel for combustion engines that blends easily with gasoline.

Made from organic matter with advanced, energy saving production technology, bioethanol can considerably reduce traffic related greenhouse gas emissions. Low carbon emissions are a main objective of biofuel promotion policies.

We design facilities that can process ethanol from a wide range of starch or sugar-containing crops. Feedstocks include wheat, corn, milo, barley, rye, potatoes, cassava, sweet potatoes and wet milling by-products, as well as sweet sorghum, sugar cane and sugar beet in the form of molasses, thick juice or syrups. Last but not least products from cellulose conversion processes ("second generation") are utilized.

For key figures for bioethanol plant construction

CHECK OUT OUR » FAQ's

Block diagram

Vogelbusch process for bioethanol production

Yeast is used to ferment sugars into ethanol which is refined and concentrated in further process steps.

Adjusted to feedstock

RAW MATERIAL PREPARATION

STARCH: Grains and tubers are milled before they are used in the process. Starch or by-products from wet milling plants do not require any special treatment and are fed directly to liquefaction.

SUGAR: Molasses and sugar syrups seldom require special treatment; they are diluted and acidified and fed straight to the fermentation unit. For substrates containing large amounts of inhibiting substances (affecting fermentation), pasteurization and/or stripping may be necessary. Occasionally, a sludge removal process may be required.

DESIGN OPTION: Dry milling or wet milling

Each option has its advantages

In the dry milling process the feed contains all the fibers, husks, etc. of the grain. The process is robust and simple, and provides good DDGS as a co-product
In wet milling plants a clear substrate without fibers or sludge is used for ethanol production. The yield is higher but no DDGS is obtained

Transformation into alcohol

BIOREACTION

Starch is treated by liquefaction and saccharification to obtain glucose as a fermentable sugar. The part-saccharified substance is cooled down and fed directly to the fermentation unit. Final conversion of the starch into glucose takes place simultaneously during fermentation. To reuse water and latent heat, the Vogelbusch HotMash© process recycles a decanted stillage stream to liquifaction/saccharification.

At the fermentation stage, yeast is employed to convert monosaccharides into alcohol. The Vogelbusch standard fermentation process in bioethanol production is our advanced MultiCont© continuous fermentation.

Fermentation of the substrate starts in a pre-fermenter under adjusted conditions that promote yeast growth. The fermenting mash flows steadily through a series of main fermenters, while the alcohol increases in concentration. Final alcohol concentrations in the mash of 13 - 15 %vol, (depending on raw material) are regularly achieved. From the last fermenter the alcohol mash is fed to an intermediate tank for distillation.

Conventional batch fermentation systems can be employed for particularly challenging raw materials.

With some non-fibrous substrates such as molasses or starch milk, yeast recycling can be used to improve yield and accelerate fermentation.

The heat generated during fermentation is reused via external heat exchangers, exhaust air from the fermenters is led through a scrubber for recuperation of alcohol and carbon dioxide.

Final product

PRODUCT ISOLATION AND CONCENTRATION

The alcoholic mash is preheated and fed to the distillation column where the crude alcohol is stripped from the mash, leaving behind an alcohol-free liquid, the stillage. The crude alcohol is purified and concentrated to approximately 94%vol, in several process columns in series.

Vogelbusch's proven MultiPressure distillation system saves live steam; in conjunction with advanced thermal integration techniques, the energy consumption of distillation, rectification and dehydration unit is as low as 1,150 kg steam per 1,000 liters of bioethanol.

A dehydration process is used to obtain anhydrous ethanol. Standard Vogelbusch dehydration technology employs a pressure swing adsorption (PSA) process using molecular sieves. The final water content can be reduced below 0.05%wt.

Depending on legal requirements, denaturing of the ethanol may be necessary to make it inedible by the addition of certain substances.

PRODUCT STANDARDS

We have the technology and experience to design processes for a wide range of applications and product specifications. Vogelbusch column systems are optimized to comply with fuel ethanol standards such as ASTM D4806 (U.S.) or EN 15376 (EU), or individual consumer specifications.

Analytic testing is one of the tasks in our laboratory.

Adding value to production

CO-PRODUCT UTILIZATION

As only the sugar respectively starch is needed for the process, the remaining ingredients of the raw material in turn can provide valuable co-products.

Stillage from beet or cane molasses is directly fed to the evaporation section where it is concentrated in a range of 30 - 65 % DS, depending on the purpose of use. The concentrated molasses stillage (vinasses) can be sold as animal food additive or fertilizer, or incinerated to generate process steam. No concentration is required for biogas production.

Grain stillage contains proteins, minerals, fat and fibers which make a valuable animal feed. Insoluble substances in grain stillage are separated in a decanter and mixed with concentrated stillage from the evaporation section before it is sent to the drying section. The dried product is sold as powdered or pelletized distillers’ dried grains with solubles (DDGS). Alternatively, especially for smaller plants, stillage and the solids from decanter can be sold directly. Stillage is also a potential on-site biomass or biogas power source.

Saving energy and water

Our engineering approach is industry-leading performance in terms of primary energy and freshwater consumption

Latent heat from stillage recycling, hot condensates and lutter water reduces not only the energy consumption but also the water demand in the raw material preparation
Pre-concentration of stillage in distillation unit reboilers reduces steam demand in evaporation
Reuse of drying vapors in the evaporation section and return of residue vapors to the dryer - closed loop principle significantly reduces the atmospheric emissions
Using condensates and lutter water as replacement for fresh water in process and utilities minimizes water consumption and liquid discharge

Energy efficiency is a proven, cost-effective way of lowering carbon intensity scores and producing ethanol in an environmentally friendly way.

DESIGN OPTION: Gas dryer or steam dryer

Decisions on dryer technologies are a matter of energy availability and cost. Where cheap steam is available indirect steam heated tube bundle dryers are used. Otherwise gas or light fuel oil fired dryers are employed. Both ring and rotary drum dryers are suitable.

Reducing impacts on production cost

The most important cost factors in bioethanol production are raw materials, energy and initial capital costs.

Our advanced process design concepts for bioethanol plants have a significant impact on these cost drivers and on plant availability. Key issues in this regard are

Continuous fermentation process

Low investment and operating costs
Outstanding yields, concentration and productivity
Reliable and stable operation for extended periods
Easy operation thanks to full automation

Low thermal energy consumption

Recovery and reuse of secondary energy from process streams
Heat integration at each process stage and across the plant as a whole

Water saving and wastewater avoidance

Stillage recirculation
Residue water recirculation and reuse of vapor condensate
Reuse of treated wastewater in utilities (e. g. cooling towers) or for process needs

CUSTOMIZED SOLUTIONS

Continuous development and improvement of our expertise ensures that all our technologies are truly state-of-the-art and not just off-the-shelf designs. Vogelbusch offers flexible design concepts with highly specialized custom solutions that optimize process economics for

Use of multiple feedstocks
Combined or alternative production of bioethanol, industrial and neutral alcohol (product switch distilleries)
Compliance with precise specifications for product quality, steam pressure, etc.
Local maintenance and construction conditions

Highly skilled experts are also available to upgrade or revamp existing plants to increase capacity, improve yield and/or product quality, and save energy and water. We also assist producers seeking to diversify and gaining revenue from by-products from the ethanol-making process.

APPLICATIONS OF BIOETHANOL

Bioethanol can be utilized in combustion engines in different ways

Hydrous ethanol (95 % by volume) contains some water. It can be used directly as a gasoline substitute in cars with modified engines.

Anhydrous (or dehydrated) ethanol is free of water and at least 99 % pure. It can be blended with conventional fuel at rates between 5 % (E5) and 85% (E85). Practically all cars nowadays can utilize E5, most of it even E10; the use of E85 requires socalled FlexFuelVehicles.

ETBE (ethyl-tertiary-butyl-ether) is a gasoline additive that is manufactured from bioethanol.

Average consumption figures for bioethanol production

All figures given here are typical and can vary depending on plant configuration and equipment.

Wheat

Consumption for 1,000 l bioethanol
Wheat	kg	2,420
Starch content	%	62
Steam *	kg	1,400 [3,150]
Power	kWh	115 [260]
Cooling water **	m³	95 [175]
Process water ***	m³	2.7

*) Natural gas as alternative heat source for DDGS drying possible
**) Cooling water dt = 10K
***) Process water partly replaceable by treated condensates

Values in square bracket [ ] include DDGS drying.

Additionally minor amounts of chemicals are necessary; consumption depending on raw material quality.
The amount of enzymes required in starch conversion depends on the producer.

Corn

Consumption for 1,000 l bioethanol
Corn	kg	2,285
Starch content	%	65
Steam *	kg	1,250 [2,750]
Power	kWh	110 [220]
Cooling water **	m³	90 [165]
Process water ***	m³	2

Cassava chips

Consumption for 1,000 l bioethanol
Cassava chips	kg	2,320
Starch content	%	65
Steam	kg	1,350
Power	kWh	115
Cooling water *	m³	90
Process water **	m³	4

*) Cooling water dt = 10K
**) Process water partly replaceable by treated condensates

Additionally minor amounts of chemicals are necessary; consumption depending on raw material quality.
The amount of enzymes required in starch conversion depends on the producer.

Molasses

Consumption for 1,000 l bioethanol
Molasses	kg	3,210
Sugar content *	%	50
Steam	kg	1,700 [3,000]
Power	kWh	70 [100]
Cooling water **	m³	100 [160]
Process water ***	m³	7

*) Fermentable sugar as disaccharides
**) Cooling water dt = 10K
***) Process water partly replaceable by treated condensates

Values in square bracket [ ] include vinasses concentration.

Additionally minor amounts of chemicals are necessary; consumption depending on raw material quality.

Cane juice | Sweet sorghum juice

Consumption for 1,000 l bioethanol
Cane or sweet sorghum juice	kg	8,640
Sugar content *	%	18
Steam	kg	1,200 [2,550]
Power	kWh	60 [90]
Cooling water **	m³	100 [170]
Process water ***	m³	1

Our bioethanol showcase projects

Alcohol Plant in Alejandro Roca
PROMAÍZ - Alejandro Roca, Cordoba, Argentina

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…

Showcase Projects

DRD for bioethanol plant in Zhaodong
COFCO Bioenergy - Zhaodong, PR China

Vogelbusch was employed by COFCO Bioenergy Zhaodong to build an energy efficient distillation, rectification and dehydration system with the aim to replace two existing old and energy intensive units.

The order's…

Showcase Projects

Revamp of bioethanol plant in Vrdy
ETHANOL ENERGY - Vrdy, Czech Republic

Following conceptual design studies for the reduction of the energy demand - and therefore CO2 emissions - Czech bioethanol producer Ethanol Energy assigned Vogelbusch with the basic design of the…

Showcase Projects

Ethanol dehydration in Sarpsborg
BORREGAARD - Sarpsborg, Norway

Borregaard replaced a decades old ethanol dehydration system by a state-of-the-art molecular sieve unit from Vogelbusch. The limited space in the biorefinery recommended a skid construction with minimum footprint. A special…

Showcase Projects

D|D for Cellulosic Ethanol Plant in Hugoton
SYNATA BIO (Abengoa) - Hugoton, Kansas, USA

The commercial-scale, cellulosic ethanol facility in Hugoton utilizes Abengoa’s own enzymatic hydrolysis technology to produce 25 million gallons of ethanol and 21 megawatts of electricity from 300,000 tons of biomass…

Showcase Projects

D|D for Demonstration Plant in Vero Beach
FRANKENS ENERGY (Ineos Bio) - Vero Beach, Florida, USA

VOGELBUSCH USA Inc. supplied the ethanol distillation and dehydration equipment for the 2G (second generation) demonstration plant of Ineos Bio’s , a first-of-its-kind waste-to-bioenergy facility near Vero Beach, Florida.

The project…

Showcase Projects

D|R Pilot Plant in Tennamaram
SIME DARBY | MITSUI ENGINEERING - Tennamaram, Malaysia

Local palm oil producer Sime Darby together with the Japanese company Mitsui Engineering & Shipbuilding Co. Ltd. (MES) installed a pilot plant for second generation (2G) bioethanol in Tennamaram, Malaysia.…

Showcase Projects

Bioethanol Plant in Madison
GREEN PLAINS (Abengoa) - Madison, Illinois, USA

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…

Showcase Projects

Bioethanol Plant in Mount Vernon
GREEN PLAINS (Abengoa) - Mount Vernon, Indiana, USA

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…

Showcase Projects

Bioethanol Plant in Casselton
THARALDSON ETHANOL - Casselton, North Dakota, USA

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…

Showcase Projects

2G Demonstration Plant in Kalundborg
ØRSTED (Inbicon) - Kalundborg, Denmark

Inbicon has developed a proprietary process for the conversion of wheat straw. Complementing this biomass conversion process Inbicon has opted for sound and energy efficient technology from Vogelbusch for part…

Showcase Projects

Bioethanol Plant in Beinheim
ROQUETTE - Beinheim, France

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…

Showcase Projects

Bioethanol Plant in Cedar Rapids
INGREDION (Penford) - Cedar Rapids, Iowa, USA

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…

Showcase Projects

Distillation|Dehydration in Norrköping
LANTMÄNNEN AGROETANOL - Norrköping, Sweden

The bioethanol plant of Lantmännen Agroetanol AB utilises process technology licensed by Vogelbusch for distillation and dehydration. The proprietary MultiPressure system considerably reduces the steam consumption compared to traditional distillation…

Showcase Projects

Bioethanol Plant in USA
Confidential Client, USA

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…

Showcase Projects

Bioethanol Plant in Ravenna
KAAPA ETHANOL (Abengoa) - Ravenna, Nebraska, USA

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©…

Showcase Projects

Bioethanol Plant in Hastings
CHIEF ETHANOL FUELS - Hastings, Nebraska, USA

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…

Showcase Projects

Bioethanol Plant in Lexington
CHIEF ETHANOL FUELS (Cornhusker) - Lexington, Nebraska, USA

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…

Showcase Projects

Bioethanol plant in Zeitz
CROPENERGIES - Zeitz, Germany

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…

Showcase Projects

Bioethanol Plant in Pekin
ALTO INGREDIENTS (Pacific Ethanol) - Pekin, Illinois, USA

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…

Showcase Projects

Bioethanol Plant in Jilin
JILIN FUEL ALCOHOL COMPANY - Jilin Province, PR China

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…

Showcase Projects

FAQ

All information given here is typical and can vary depending on plant configuration. For particular information please send us a message with your project details.

Which minimum capacity is recommended?

The economic minimum capacity of a bioethanol plant is at 300,000 liters per day (= 100,000 tons per year) in Europe; provided that energy cost are favourable it may be 100,000 liters per day in other regions.

How much feedstock is required?

For 1,000 liter alcohol (on average sugar / starch content, all on wet basis) the Vogelbusch bioethanol process requires

Corn 2,350 kg
Wheat 2,630 kg
Sugar Beet 10,000 kg
Sugar Cane 11,000 kg

Can I combine several feedstocks?

Combination of feedstocks is possible, but higher investment costs to cover the different process steps have to be taken into account.

Which location is favourable?

Decisive factors for the plant location are

Short transport routes for raw material and product
Availability of energy (preferable biomass = CO2 reduction)

How much space do I need?

For a 300,000 liters per day facility 5 to 6 hectare are required.

How long does it take to set up the plant?

With permits on hand engineering and construction takes 18 - 24 months.

And the investment for such plant?

Capital expenditure depends on plant capacity and configuration as well as local conditions. Costs for the process plant (excluding building, auxiliaries, infrastructure) for a 300,000 liters per day facility are in the range of 30 to 50 million euros.

In detail this is however depending on the available infrastructure and the raw material used. Grain based plants require higher investment compared to sugar.

Figures are for general reference only since each project has its own particularities that need consideration.

How can I get more information for my bioethanol plant project?

Complete our design questionnaire (check Links & Downloads section below) and send it back to us to get a professional opinion on your project.