A conceptual ethanol production plant, based on conversion of a kraft pulp mill, has been studied. The process uses softwood as raw material, alkaline pre-treatment combined with delignification, and biochemical conversion of sugars to ethanol (i.e. hydrolysis and fermentation). The plant has been analysed by pinch methods in order to find steam-saving possibilities. It is shown in the study that a large amount of steam surplus can be found if energy efficiency measures are implemented. In order to study the possible effect on the profitability of the plant when introducing steam-saving measures, the process has been analysed from a techno-economic point of view. It is shown that implementing energy efficiency measures could have a substantial effect on profitability if the by-product (in this case lignin biofuel or power) is high-valued. It is also shown that lignin as by-product might be more profitable than power, mainly because the demand for CO 2 in lignin extraction might be supplied by CO 2 produced in fermentation of sugars to ethanol. If investments are made to convert a pulp mill to ethanol production, energy efficiency measures should be included in the discussion since they might play an important role in minimising ethanol production cost.
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