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Design, Fabrication and Performance Evaluation of a Low-Cost Batch Bioethanol Distillation System for Small-Scale Renewable Fuel Production
Subject area: Biological & Medical Sciences · Area of research: Biofuel Production Engineering
DOI: https://doi.org/10.64388/IREV10I1-1719587
Abstract
The growing demand for sustainable energy and the increasing cost of fossil fuels have intensified the need for affordable technologies for biofuel production. Although bioethanol is a promising renewable fuel, its large-scale adoption in developing countries is constrained by the limited availability of low-cost distillation systems for producing fuel-grade ethanol. This study presents the design, fabrication, and performance evaluation of a low-cost batch bioethanol distillation system for small-scale renewable fuel production. A 5 L stainless steel distillation unit comprising a reboiler, packed distillation column, shell-and-tube condenser, and temperature control system was designed using AutoCAD and fabricated from locally available materials at a total cost of ₦336,500. The system was evaluated using 4 L of fermented sugarcane bagasse mash containing 8–10% (v/v) ethanol. Performance evaluation showed that the developed unit achieved a 39% distillation efficiency, producing 3.0 ± 0.2 L of distillate per batch with an ethanol purity of 91 ± 0.8% (v/v), which was subsequently upgraded to greater than 99.5% (v/v) using molecular sieves. Fuel characterization confirmed that the distilled bioethanol satisfied the requirements of ASTM D4806 for fuel ethanol. Furthermore, engine performance evaluation of an E10 bioethanol-gasoline blend demonstrated reductions of 18% in carbon monoxide (CO) and 12% in nitrogen oxides (NOₓ) emissions compared with conventional gasoline. The developed distillation system provides an efficient, affordable, and locally manufacturable technology for small-scale bioethanol production, offering a practical pathway for renewable fuel development, agricultural waste utilization, and reduced dependence on fossil fuels in developing countries.
Keywords
Bioethanol, Distillation System, Renewable Energy, Fuel Ethanol, Sugarcane Bagasse, Small-Scale Production, Sustainable Fuel.
References
[1] ASTM International, ASTM D4806-21: Standard Specification for Denatured Fuel Ethanol for Blending with Gasolines for Use as Automotive Spark-Ignition Engine Fuel. West Conshohocken, PA, USA: ASTM International, 2021.
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[3] A. Demirbas, Biofuels: Securing the Planet's Future Energy Needs. London, U.K.: Springer, 2009.
[4] A. A. Kiss and D. J. P. C. Suszwalak, “Enhanced bioethanol dehydration by extractive and azeotropic distillation,” Separation and Purification Technology, vol. 86, pp. 70-78, Jan. 2012.
[5] A. Limayem and S. C. Ricke, “Lignocellulosic biomass for bioethanol production: Current perspectives and future prospects,” Progress in Energy and Combustion Science, vol. 38, no. 4, pp. 449-467, Aug. 2012.
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How to cite this paper
@article{1719587,
author = {Samuel Obadiah Anzaku, Nnorom Achara; Abdulazeez Haruna, Mary Samuel; Aisha Sa’ad, Muhammad Mahmud Jamil; Owolabi Babatope Layi; Shuaibu Ahmed, Wilson Oduwa Uwuigbusun; Monday Imafedia Amodu},
title = {Design, Fabrication and Performance Evaluation of a Low-Cost Batch Bioethanol Distillation System for Small-Scale Renewable Fuel Production},
journal = {Iconic Research And Engineering Journals},
year = {2026},
volume = {10},
number = {1},
pages = {731-735},
issn = {2456-8880},
url = {https://www.irejournals.com/formatedpaper/1719587.pdf},
abstract = {The growing demand for sustainable energy and the increasing cost of fossil fuels have intensified the need for affordable technologies for biofuel production. Although bioethanol is a promising renewable fuel, its large-scale adoption in developing countries is constrained by the limited availability of low-cost distillation systems for producing fuel-grade ethanol. This study presents the design, fabrication, and performance evaluation of a low-cost batch bioethanol distillation system for small-scale renewable fuel production. A 5 L stainless steel distillation unit comprising a reboiler, packed distillation column, shell-and-tube condenser, and temperature control system was designed using AutoCAD and fabricated from locally available materials at a total cost of ₦336,500. The system was evaluated using 4 L of fermented sugarcane bagasse mash containing 8–10% (v/v) ethanol. Performance evaluation showed that the developed unit achieved a 39% distillation efficiency, producing 3.0 ± 0.2 L of distillate per batch with an ethanol purity of 91 ± 0.8% (v/v), which was subsequently upgraded to greater than 99.5% (v/v) using molecular sieves. Fuel characterization confirmed that the distilled bioethanol satisfied the requirements of ASTM D4806 for fuel ethanol. Furthermore, engine performance evaluation of an E10 bioethanol-gasoline blend demonstrated reductions of 18% in carbon monoxide (CO) and 12% in nitrogen oxides (NOₓ) emissions compared with conventional gasoline. The developed distillation system provides an efficient, affordable, and locally manufacturable technology for small-scale bioethanol production, offering a practical pathway for renewable fuel development, agricultural waste utilization, and reduced dependence on fossil fuels in developing countries.},
keywords = {Bioethanol, Distillation System, Renewable Energy, Fuel Ethanol, Sugarcane Bagasse, Small-Scale Production, Sustainable Fuel. },
month = {July},
doi = {https://doi.org/10.64388/IREV10I1-1719587}
}