Optimization of Continuous Solid-State Distillation Process for Cost-Effective Bioethanol Production

Design and Control Applied to an Extractive Distillation Column with Salt for the Production of Bioethanol

Extractive distillation with salts, unlike other dehydration technologies, is better due to the null toxicity that exists in the distillate, since salt cannot be evaporated. With this distillation technology, it is possible to obtain a high concentration of ethanol, however, there are still problems in the control of the distillation columns in the presence of disturbances. The present work deals with the simulation and control of an extractive distillation column using CaCl2 as a separating agent, for which the Aspen Dynamics® simulator is used. The measurement and control of the ethanol composition are carried out by means of temperature, in addition, four control structures are evaluated and compared. These structures are L, D, LV, and DV, which are the most common in conventional distillation, and their performance is measured by means of deterministic indicators applying changes (disturbances) of composition and the flow rate in the main feed of the column. The most relevant results of this work lead to the fact that by applying a controller, it is possible to maintain the desired purity above the international purity standards (99% ethanol) that govern biofuels.

Feasibility Study on Bioethanol Production by One Phase Transition Separation Based on Advanced Solid-State Fermentation

To fulfill the consumption demand of low-cost fuel ethanol, an advanced process for feedstock fermentation and bioethanol extraction was required. This study proposed a process of combined continuous solid-state distillation and vapor permeation to extract ethanol from fermented sweet sorghum bagasse on the basis of advanced solid-state fermentation technology. Ethanol undergoes only one phase transition separation in the whole process, which drastically reduces energy consumption compared to the repeating phase transitions that occur in conventional bioethanol production. The mass balance and energy consumption of combining processes were simulated overall. A techno-economic evaluation was conducted on the flowsheet. Costs and profit of fuel ethanol produced by one phase transition separation bioethanol-producing technology were comprehensively calculated. The results of the present study show that the proposed process is an energy efficient and cost-effective alternative to conventional bioethanol production.

Silage Fermentation on Sweet Sorghum Whole Plant for Fen-Flavor Baijiu

The technology for producing bioethanol from sweet sorghum stalks by solid-state fermentation has developed rapidly in recent years, and has many similarities with traditional Chinese liquor production. However, the product from sweet sorghum stalks was lacking in volatile flavors, and the level of harmful contents were uncertain, therefore it could not be sold as liquor. In this study, the protein, fat, and tannin in the clusters and leaves of sweet sorghum were utilized to increase the content of flavor compounds in the ethanol product through the anaerobic fermentation of Saccharomyces cerevisiae. Meanwhile, the silage fermentation method was used to extend the preservation time of the raw materials and to further enhance the flavors of Fen-flavor liquor, with ethyl acetate as the characteristic flavor. The effects of different feedstock groups on ethyl acetate, ethyl lactate, methanol, acetaldehyde, acetal, fusel oil, total acid, and total ester were evaluated by analyzing the chemical composition of different parts of sweet sorghum and determined by gas chromatograph. The effect of different fermentation periods on the volatile flavor of sweet sorghum Baijiu was evaluated. The yield of the characteristic volatile flavor was increased by the extension of the fermentation time. Sweet sorghum Baijiu with a high ester content can be used as a flavoring liquor, blended with liquor with a shorter fermentation period to prepare the finished Fen-flavor Baijiu, conforming to the Chinese national standard for sale.

Combined Vapor Permeation and Continuous Solid-State Distillation for Energy-Efficient Bioethanol Production

Extracting ethanol by steam directly from fermented solid-state bagasse is an emerging technology of energy-efficient bioethanol production. With continuous solid-state distillation (CSSD) approach, the vapor with more than 25 wt% ethanol flows out of the column. Conventionally, the vapor was concentrated to azeotrope by rectification column, which contributes most of the energy consumption in ethanol production. As an alternative, a process integrating CSSD and vapor permeation (VP) membrane separation was tested. In light of existing industrial application of NaA zeolite hydrophilic membrane for dehydration, the prospect of replacing rectification operation with hydrophobic membrane for ethanol enriching was mainly analyzed in this paper. The separation performance of a commercial PDMS/PVDF membrane in a wide range of ethanol–water-vapor binary mixture was evaluated in the experiment. The correlation of the separation factor and permeate flux at different transmembrane driving force was measured. The mass and energy flow sheet of proposed VP case and rectification case were estimated respectively with process simulation software based on experimental data. Techno-economic analysis on both cases was performed. The results demonstrated that the additional VP membrane cost was higher than the rectification column, but a lower utilities cost was required for VP. The discount payback period of supplementary cost for VP case was determined as 1.81 years compared with the membrane service lifetime of 3 years, indicating that the hybrid CSSD-VP process was more cost effective and energy efficient.

Saccharomyces bayanus Enhances Volatile Profile of Apple Brandies

Qualitative and quantitative profiles of volatiles in alcoholic beverages depend mainly on the quality of raw materials, yeasts used for fermentation, and processing technique. Saccharomyces bayanus is a yeast species which is not commonly used for the production of alcoholic beverages, but it is able to produce volatiles that add desirable aroma. Since there is little information regarding the application of that microorganism for the production of apple brandies and how it affects volatile profile of finished products, we decided to address that issue. The aim of the study was to determine the impact of S. bayanus on the profile of volatile compounds and sensory properties of apple spirits obtained from three apple cultivars (Topaz, Rubin, and Elise) in comparison to spirits obtained from fermentation carried out spontaneously or with Saccharomyces cerevisiae. Obtained brandies were analysed using gas chromatography-flame ionization detector (GC-FID), solid phase microextraction-gas chromatography-mass spectrometry (SPME-GC-MS) and sensorially. In our study, brandies produced from musts fermented by S. bayanus demonstrated the highest concentration of ethyl esters and increased concentrations of isoamyl acetate, 2-phenylethyl acetate, ethyl palmitate and hexanol. Moreover, our results support the hypothesis that non-Saccharomyces yeasts which are present during spontaneous fermentation and demonstrate higher β-glucosidase activities enhance aroma of alcoholic beverages through releasing aroma compounds from glycosidic forms, e.g., α-phellandrene, (E)-β-fanesene, (Z,E)-α-farnesene, α-farnesene, and farnesol. Considering results obtained in sensory analysis, we proved that S. bayanus is suitable for the production of apple brandies, improving their flavour. Brandies obtained from musts fermented by S. bayanus obtained the highest average range for "overall note" parameter in sensory analysis.