Adding Carbon Capture to Existing Ethanol Plants - BECCS

Greenhouse Gas emissions will continue to be a challenge for industrial processes for the foreseeable future.

"In 2025. more than 79,228 U.S. jobs were directly associated with the ethanol industry. with an additional 237,292 indirect and induced jobs supported across all sectors of the U.S. economy. The (ethanol) industry created $28.3 billion in household income and contributed $50.4 billion to the nation's GDP. Ethanol biorefineries offer skilled jobs with good wages in rural communities where attractive employment opportunities are often hard to find. Ethanol and feed co-product production provide a valuable market for corn grown in the United States. A typical dry mill ethanol plant adds $2.25 of additional value – over 50 percent – to every bushel of corn processed". Source Renewable Fuels Association

Bio-energy facilities coupled with Carbon Capture and Storage (BECCS) are designed to capture Carbon Dioxide (CO₂) from bio-ethanol production facilities with the intent of permanent storage of the captured CO₂ or further treatment and use of the CO₂ in other industries. Around 90% of current biogenic CO₂ capture (globally) comes from bio-ethanol facilities due to the high concentration of CO₂ in fermentation 'off-gases'.

CO₂ is produced mainly during the fermentation step in ethanol production. The gas is relatively pure compared to other industrial sources, making it easier to capture. The BECCS process involves collecting the CO₂ gas, purifying it, compressing it, optional liquefaction and then either storing it underground or selling it for 're-use'. The key steps in this process include:

• Gas collection: Capturing CO₂ directly from fermentation tanks or exhaust streams.

• Purification: Removing impurities like water vapor and other gases.

• Compression: Increasing pressure for transport or storage.

• Optional Liquefaction: Change the captured CO₂ to a dense supercritical fluid for more efficient storage / retention (underground).

• Utilization or storage: Using CO₂ in industrial applications or injecting it underground.

  
  

Integrating these steps into existing bio-ethanol plants requires careful design to minimize disruption and cost. The efficient Implementation of a BECCS solution is crucial for a number of reasons;

• Preventing Atmospheric Release: The process captures biogenic CO₂ that would otherwise be released during fermentation, thus preventing it from re-entering the atmosphere.

• Mitigating Climate Change: By reducing net emissions, capturing CO₂ contributes to efforts aimed at combating climate change and achieving net-zero emissions targets

• High CO₂ Concentration: Bioethanol facilities have a high concentration of CO₂ in their fermentation off-gases, making it easier and more cost-effective to capture.

• Current Capture Rates: Approximately 90% of the biogenic CO₂ currently captured comes from bioethanol facilities, highlighting their significance in carbon capture efforts.

• Permanent Storage: BECCS involves capturing CO₂ from bioenergy sources and storing it permanently, which can help offset emissions from other sectors.

• Contribution to Carbon Dioxide Removal (CDR): This technology is a key component of CDR strategies, which are essential for stabilizing global temperatures and meeting international climate goals.

To summarize; The on-going capture of CO₂ from bio-ethanol production is (and will continue to be) vital to the continued and sustainable production of bio-ethanol.

Proven Technologies for Carbon Capture in Ethanol Plants

Several approaches can be used to capture CO₂ from ethanol plants. Choosing the right one depends on the existing plant type & size, required CO₂ purity, and the available budget. Various technologies are employed to capture CO₂ from industrial processes and the atmosphere. The main methods include:

Post-Combustion Capture

• Description: CO₂ is removed from the flue gas after fossil fuels are burned.

• Applications: Commonly used in coal-fired power plants and natural gas facilities.

• Advantages: Can be retrofitted to existing plants.

Pre-Combustion Capture

• Description: CO₂ is captured before combustion occurs. The fossil fuel is partially oxidized to produce a gas mixture from which CO₂ can be separated.

• Applications: Widely applied in natural gas processing.

• Advantages: Results in a relatively pure CO₂ stream.

Direct Air Capture (DAC)

• Description: This technology captures CO₂ directly from the ambient air using chemical processes.

• Advantages: Can potentially reduce atmospheric CO₂ levels significantly.

Oxy-Fuel Combustion

• Description: Combustion occurs in a mixture of oxygen and recycled flue gas, resulting in a more concentrated CO₂ stream.

• Advantages: Simplifies the capture process due to higher CO₂ concentration.

Challenges and Considerations

While the benefits are clear, adding carbon capture also involves challenges:

• Regulatory Compliance: Ensuring that the proposed addition to existing plant(s) does not lead to significant upgrades (existing plant) and meets regulatory requirements for the foreseeable future.

• Capital cost: Installing capture equipment requires upfront investment.

• Operational complexity: New systems add complexity to plant operations.

• Space requirements: Equipment needs room for installation, which can be limited.

• Energy demand: Capture and compression consume energy, affecting plant efficiency.

Working with experienced providers like Salof Limited Inc. can help address these challenges. Salof have a significant installed base world-wide, with over 300 years of in house experience and are the market leader in the provision of reliable process systems for BECCS.

Steps to Add Carbon Capture to Your Ethanol Plant

If you are considering adding carbon capture, here are some key steps to follow:

1. Assess your plant’s  CO₂ emissions: Measure the volume and purity of CO₂ produced and decide whether storage or further use is the best outcome.

2. Evaluate capture technologies: Assess available concepts.

3. Select an equipment provider like Salof: Seek more detailed, expert, input regarding the cost, efficiency, fit of specific options.

4. Plan integration: Design how the new capture system will connect to existing equipment & operate in a safe and sustainable manner.

5. Secure financing: Explore funding options, including incentives for emissions reduction and when ready place a PO with your selected equipment provider.

6. Deliver, Implement and commission: Receive the BECCS equipment at the operating site, Install the equipment and verify performance, train operations personnel and hand over to operations.

7. Operate and maintain: Operate, monitor and seek continuous improvement.

   
   

Following these steps ensures a successful facility upgrade with minimal disruption.

Real-World Examples

As of Q2 2026, Salof have delivered more than 160 CO₂ processing plants to our worldwide customer base. An increasing focus within this sector being the addition of BECCS to existing bio-ethanol plants. A recent example of this sector; Midwest ethanol plant selected Salof Limited Inc. to engineer, procure, manufacture & deliver to site a 'turnkey' CO₂ capture and treatment system intended to capture CO₂ from the existing fermentation process and provide liquefied CO₂ at the customer underground injection point for long term storage. The project reduced the bio-ethanol plant emissions by over 90% and generated new revenue from CO₂ sales (in the form of Carbon Credits).

Future Outlook

Currently there are 207 bioethanol plants in the United states producing a combined yearly total of (circa) 18,482 MMg/y bioethanol, with a great majority using corn as the primary feedstock. The demand for low-carbon, green fuels (such as bio-ethanol) will continue to grow. Salof are committed to working with existing / new producers, adding carbon capture to reduce emissions from bioethanol plants, helping position producers to meet the increasing demand, ensure regulatory compliance and remain competitive. On-going advances in capture technology are expected to further improve efficiency and provide additional reductions in capital/operating costs. Combining carbon capture with other innovations, like renewable energy use, can further enhance sustainability. Investing in BECCS today prepares bio-ethanol plants for a cleaner energy future.

"If you want to explore BECCS solutions for your bioethanol plant, consider reaching out to our experts who specialize in CO₂ and industrial gas systems. Taking action now can help secure your plant’s long term future in a low-carbon economy". Bob Luhrs, President.