Design and Development of a Novel Vapor Recompression Distillation Unit for Bio Ethanol Manufacturing Process

Bioethanol is an environmentally friendly fuel source that offers significant advantages over fossil fuels, including lower emissions and sustainability. However, conventional distillation methods in bioethanol production are often associated with high energy consumption and inefficiencies. This research introduces a novel vapor recompression distillation unit, designed and fabricated to optimize the bioethanol manufacturing process. Addressing the high energy demands of traditional methods, this study proposes vapor recompression batch distillation as a more energy-efficient and effective solution, enhancing both the sustainability and productivity of bioethanol production. The system consists of two main units: a primary reactor and a calandria reactor, equipped with two programmable control mechanisms. To assess the performance and efficiency of the vapor recompression distillation unit, batch distillation experiments were conducted, measuring variables such as reactor vapor pressure, temperature, vapor flow rate, calandria reactor temperature, and the coefficient of performance (COP). Three distinct ethanol mixtures, derived from Sugar, Jackfruit, and Ice Cream Beans, were prepared as feedstock for the distillation process. Consistent water and yeast amounts were maintained across all mixtures, which were distilled over a period of approximately three hours. Key parameters including pH, electrical conductivity, density, and both kinetic and dynamic viscosity were analyzed for the first effect distillation samples. The study revealed a COP of 1.9851, indicating satisfactory distillation capability. The average conversion efficiency of the system was 25.89% in the first effect, with the Sugar solution achieving the highest ethanol concentration at 22.0%, and the Jackfruit sample the lowest at 18.1%. These results demonstrate the feasibility of using this system for ethanol distillation, significantly reducing both processing time and energy consumption.