Industries / Bioethanol
Bioethanol dehydration redefined
Conventional bioethanol dehydration using molecular sieves or azeotropic distillation is often a compromise. We offer a more effective alternative: ith our pervaporation technology, bioethanol can be dehydrated continuously to below 0.1 wt%.
Purity without compromise
In bioethanol production, every penny per litre counts. Yet, many operators accept the limitations of conventional methods: molecular sieves operate discontinuously and require complex regeneration phases, while azeotropic distillation processes often relies on additives to overcome the azeotropic point.
Today’s market demands more: Pharma-grade ethanol and food-grade bioethanol require absolute purity. Residual additives or the formation of by-products such as aldehydes – which can occur in molecular sieves – are unacceptable. This is where DeltaMem provides a clear advantage. Our process requires no third component and generates no by-products, delivering bioethanol of the highest quality for the pharmaceutical and food industries.
Debottlenecking and direct dehydration
DeltaMem technology is not merely an alternative; it is often the decisive problem-solver in existing plants:
- No evaporation required: We can process liquid, water-rich ethanol (even exceeding 10% water content) directly. This saves the energy that would typically be required for the complete evaporation of ethanol (as needed for molecular sieves).
- Debottlenecking: By integrating DeltaMem units, we enhance the capacity of your existing molecular sieves. We specifically process the side streams generated during regeneration, increasing the throughput of the overall plant – a cost-effective alternative to major capital investment in new equipment.
- Continuous flow: Our pervaporation runs in a stable, continuous mode, simplifying process control
- Energy autonomy through electrification: Since our process operates at low temperatures, the integration of heat pumps is possible. This enables a dehydration plant that can be run entirely on electricity, independent of fossil fuels – a major step toward CO₂-neutral production.
Cost advantage: reduced energy consumption
For a bioethanol stream with 8% water content, our pervaporation requires only 0.14 kg of steam per kg of dry ethanol. Compared to thermal processes that must repeatedly evaporate and condense the entire volume, this offers an unbeatable cost advantage per litre of final product.
Case study
In the production of food-grade bioethanol, side streams are generated that are often considered waste. For one of our clients, we supplied a pervaporation skid designed specifically to dehydrate these streams. The result: the side streams can now be utilised as biofuel. Our laboratory tests previously confirmed membrane stability against complex by-products such as fusel oils – turning a disposal challenge into a valuable product stream.
Purity for pharmaceutical applications
While molecular sieves can lead to formation of aldehydes, our process remains inherently clean. This makes DeltaMem the preferred choice for the dehydration of pharma-grade ethanol. No trace of cyclohexane, no thermal degradation products – simply efficient removal of water, delivering high-purity ethanol.
Frequently asked questions
Is DeltaMem able to expand existing molecular sieve plants?
Yes, debottlenecking is one of our core strengths. We integrate our pervaporation units so that they take over the regeneration streams of the molecular sieves, thereby increasing the overall efficiency of the existing facility.
What are the space requirements for a pervaporation plant?
Our systems are designed with a compact with a compact footprint. As they do not require large columns or extensive regeneration vessels, DeltaMem systems can often be retrofitted into space-constrained existing buildings.
Are the membranes stable when exposed fusel oils?
Yes. Through long-term tests and large scale applications in the food-grade ethanol sector, we have demonstrated that our membranes remain stable and maintain their separation performance even when processing complex mixtures containing co-substances like fusel oils.
How does pervaporation differ from conventional molecular sieves?
Unlike molecular sieve processes, pervaporation operates continuously and requires no regeneration cycles. Furthermore, it can directly process liquid, water-rich ethanol with a water content of over 10% without requiring the prior evaporation of the entire stream.