Thermal Integration

Comprehensive energy management.

Thermally integrated designs

Heat recovery from thermal processes and reuse of secondary energy within and across process units allow a more effective use of primary energy. Besides resource conservation, successful solutions consider the investment costs and the available infrastructure too.

Process optimization of this sort cuts operating costs and improves the greenhouse gas performance of the plant.

VBC Distillation Thermal Integration
Integrated distillation/dehydration/evaporation

Vogelbusch ethanol plants achieve exceptional energy efficiency with proprietary systems such as MultiPressure distillation coupled with direct feed to the molecular sieves for dehydration, and a multi-effect evaporation, driven by waste heat.

The evaporator can run on waste heat from distillation or DDGS dryer, while the condensation from the dehydrated alcohol vapor in a molecular sieve can provide the heat for mash preheating. With thermal integration of rectification and dehydration, using latent heat of feed vapors, there is virtually no steam demand for the dehydration unit (illustration).

Further reduction of energy consumption is obtained by returning still wash, condensates and lutter water to the process so as to reuse heat and water.

Specialized custom solutions

Vogelbusch takes a variety of approaches to thermal integration. Configurations of our proprietary systems are selected in each particular case, according to

  • The properties of the raw materials used,
  • The planned investment costs and
  • Local energy costs
2 thermal integration
Saving energy in ethanol production

Our advanced techniques save energy throughout the process plant.

Read more about

» MultiPressure distillation

» Energy concepts in evaporation

Showcase projects for thermal integration

4 Zhaodong
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 scope included the basic engineering of the unit as well as technical assistance during procurement of critical items such as...

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 process optimization. Production in the reconstructed plant was launched in the fourth quarter in 2018.  

Neutral Alcohol Plant in Verinsko
ALMAGEST - Verinsko, Ihtiman, Bulgaria

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 excellent alcohol quality convinced Almagest to commission Vogelbusch again in 2011 to expand the plant capacity to 80,000 liters per...

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 put into operation in 2008. Vogelbusch provided the know-how and technology package for the process plant and supplied key equipment for...

4 agroetanol
Distillation|Dehydration in Norrköping

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 systems and optimum thermal integration further improves the energy-saving properties of the plant.   The facility, which is Agroetanol’s second production...

4 cropernergies
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 is highly advanced in terms of energy saving and environmental protection. Vogelbusch contributed process design for the raw material processing,...

Bioethanol Plant in Jilin

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 of fuel alcohol annually from maize. The product is used as a 10 % petrol additive.  Process design by Vogelbusch provided...


FEW - International Fuel Ethanol Workshop & Expo

June 12 - 14, 2023 | Omaha, U.S.