Novel Heat-Integrated Hybrid Distillation and Adsorption Process for Coproduction of Cellulosic Ethanol, Heat, and Electricity from Actual Lignocellulosic Fermentation Broth

Cellulosic ethanol (CE) can not only be produced from a nonedible, cheap, and abundant lignocellulose feedstock but also can reduce carbon footprint significantly compared to starch ethanol. Despite great stimulation worldwide, CE production has not yet commercialized because of the complexity of lignocellulose. Therefore, intensive research and development are needed to improve CE technologies. In this study, a cost-efficient and sustainable design was proposed for the coproduction of CE, heat, and electricity from the actual lignocellulosic fermentation broth. First, a conventional coproduction process of CE, heat, and electricity based on hybrid distillation and adsorption (HDA) was simulated and optimized. Subsequently, various heat integrated (HI) techniques such as heat pump (HP), multi-effect distillation (MED), and combined HP-MED were evaluated to improve the CE process. The combined heat and power (CHP) process that utilized the combustible solids of the beer stillage was designed and integrated with the CE process. Structural alternatives were assessed for both economic and environmental impacts. The results show that the proposed HI-HDA process can save 36.9% and 33.6% of total annual costs and carbon footprint, respectively, compared to the conventional CE process. In the proposed HI-HDA coproduction process, the CE recovery process can be self-efficient in energy and the CHP can generate 12.0% more electricity than that in the conventional coproduction process