Carnegie Mellon University Chemical Engineers have devised a new process that can improve the efficiency of ethanol production, a major component in making biofuels a significant part of the U.S. energy supply.

Carnegie Mellon researchers have used advanced process design methods combined with mathematical optimization techniques to reduce the operating costs of corn-based bio-ethanol plants by more than 60 percent.

The key to the Carnegie Mellon strategy involves redesigning the distillation process by using a multi-column system together with a network for energy recovery that ultimately reduces the consumption of steam, a major energy component in the production of corn-based ethanol.