Block diagram<\/p>\n
\n Vogelbusch process for bioethanol production\n <\/h3>\n \n Yeast is used to ferment sugars into ethanol which is refined and concentrated in further process steps.<\/p>\n
![\"\"](\"https:\/\/www.vogelbusch-biocommodities.com\/wp-content\/uploads\/2026\/06\/1-blockdia-bioethanol.gif\"\/)
<\/p>\n\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n \n
\n \n \n Adjusted to feedstock<\/p>\n
\n RAW MATERIAL PREPARATION\n <\/h3>\n \n STARCH:<\/strong> 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.<\/p>\nSUGAR:<\/strong> 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.<\/p>\n\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n \n \n \n \n DESIGN OPTION<\/p>\n
\n DRY MILLING OR WET MILLING\n <\/h3>\n \n Each option has its advantages<\/p>\n
\n- 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<\/li>\n
- 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<\/li>\n<\/ul>\n\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n \n \n \n
![\"\"](\"https:\/\/www.vogelbusch-biocommodities.com\/wp-content\/uploads\/2026\/06\/1-Fermentation.jpg\")
\n \n Transformation into alcohol<\/p>\n
\n BIOREACTION\n <\/h3>\n \n Starch is treated by liquefaction<\/strong> and saccharification<\/strong> 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\u00a9 process recycles a decanted stillage stream to liquifaction\/saccharification.<\/p>\nAt the fermentation<\/strong> stage, yeast is employed to convert monosaccharides into alcohol. The Vogelbusch standard fermentation process in bioethanol production is our advanced <\/a>MultiCont\u00a9<\/a> continuous fermentation. <\/p>\nFermentation 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.<\/p>\n
Conventional batch fermentation systems can be employed for particularly challenging raw materials.<\/p>\n
With some non-fibrous substrates such as molasses or starch milk, yeast recycling<\/strong> can be used to improve yield and accelerate fermentation.<\/p>\nThe 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.<\/p>\n\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n \n
\n \n ![\"\"](\"https:\/\/www.vogelbusch-biocommodities.com\/wp-content\/uploads\/2026\/06\/1-DRD.jpg\")
\n \n Final product<\/p>\n
\n PRODUCT ISOLATION AND CONCENTRATION\n <\/h3>\n \n The alcoholic mash is preheated and fed to the distillation<\/strong> 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. <\/p>\n
Yeast is used to ferment sugars into ethanol which is refined and concentrated in further process steps.<\/p>\n
<\/p>\n\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n \n
Adjusted to feedstock<\/p>\n
\n RAW MATERIAL PREPARATION\n <\/h3>\n \n STARCH:<\/strong> 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.<\/p>\nSUGAR:<\/strong> 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.<\/p>\n\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n \n \n \n \n DESIGN OPTION<\/p>\n
\n DRY MILLING OR WET MILLING\n <\/h3>\n \n Each option has its advantages<\/p>\n
\n- 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<\/li>\n
- 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<\/li>\n<\/ul>\n\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n \n \n \n \n \n
Transformation into alcohol<\/p>\n
\n BIOREACTION\n <\/h3>\n \n Starch is treated by liquefaction<\/strong> and saccharification<\/strong> 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\u00a9 process recycles a decanted stillage stream to liquifaction\/saccharification.<\/p>\nAt the fermentation<\/strong> stage, yeast is employed to convert monosaccharides into alcohol. The Vogelbusch standard fermentation process in bioethanol production is our advanced <\/a>MultiCont\u00a9<\/a> continuous fermentation. <\/p>\nFermentation 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.<\/p>\n
Conventional batch fermentation systems can be employed for particularly challenging raw materials.<\/p>\n
With some non-fibrous substrates such as molasses or starch milk, yeast recycling<\/strong> can be used to improve yield and accelerate fermentation.<\/p>\nThe 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.<\/p>\n\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n \n
\n \n \n \n Final product<\/p>\n
\n PRODUCT ISOLATION AND CONCENTRATION\n <\/h3>\n \n The alcoholic mash is preheated and fed to the distillation<\/strong> 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. <\/p>\n
STARCH:<\/strong> 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.<\/p>\n SUGAR:<\/strong> 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.<\/p>\n\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n \n DESIGN OPTION<\/p>\n Each option has its advantages<\/p>\n Transformation into alcohol<\/p>\n Starch is treated by liquefaction<\/strong> and saccharification<\/strong> 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\u00a9 process recycles a decanted stillage stream to liquifaction\/saccharification.<\/p>\n At the fermentation<\/strong> stage, yeast is employed to convert monosaccharides into alcohol. The Vogelbusch standard fermentation process in bioethanol production is our advanced <\/a>MultiCont\u00a9<\/a> continuous fermentation. <\/p>\n 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 Conventional batch fermentation systems can be employed for particularly challenging raw materials.<\/p>\n With some non-fibrous substrates such as molasses or starch milk, yeast recycling<\/strong> can be used to improve yield and accelerate fermentation.<\/p>\n 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.<\/p>\n\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n \n Final product<\/p>\n The alcoholic mash is preheated and fed to the distillation<\/strong> 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. <\/p>\n\n DRY MILLING OR WET MILLING\n <\/h3>\n
\n
\n \n BIOREACTION\n <\/h3>\n
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.<\/p>\n\n \n PRODUCT ISOLATION AND CONCENTRATION\n <\/h3>\n
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