Thermally self-sufficient heat pump-assisted azeotropic dividing-wall column for biofuels recovery from isopropanol-butanol-ethanol fermentation

•Thermally self-sufficient heat pump-assisted dividing-wall column for biofuel recovery.•Eco-efficient product recovery after isopropanol – butanol – ethanol (IBE) fermentation.•Cost-effective (0.126 $/kgIBE) and energy-efficient (0.673 kWeh/kgIBE) downstream processing.•Heat pumping and heat integration for electrification of industrial biotechnology.•Large-scale downstream process for sustainable industrial biofuels production. Isopropanol-butanol-ethanol (IBE) fermentation is a superior biofuel production technology as compared to acetone-butanol-ethanol (ABE) fermentation due to the better fuel properties of the obtained products. However, low product concentrations, thermodynamic constraints and the presence of microorganisms lead to complex downstream processing that limits the competitiveness of this biofuel production method. Thus, this original research proposes a novel thermally self-sufficient and eco-efficient downstream process for industrial-scale recovery after IBE fermentation (74 ktonne/y capacity), from a highly dilute broth (>97 wt% water). Gas stripping and heat pump-assisted vacuum evaporation were implemented to separate valuable products from most of the broth. Furthermore, an advanced highly integrated heat pump-assisted azeotropic dividing-wall column was designed to recover high-purity (99 wt%) butanol biofuel and isopropanol – ethanol fuel supplement (89 wt%). The proposed purification process recovers over 99 % of biofuel products in a cost-effective (0.130 $/kgIBE) and energy-efficient way (0.673 kWeh/kgIBE) while allowing full recycle of biomass and most of the separated water. Besides improving yield by continuously recovering the inhibitory products, fermentation can be further enhanced by avoiding biomass loss and reducing water requirements. Lastly, the implemented energy-saving techniques ensure complete electrification of the proposed IBE recovery process. Therefore, the original results of this research study significantly contribute to the development of sustainable biofuel production processes. [Display omitted]