Review of ethanol distillation process simulation: evolution, challenges, and perspectives

Abstract This article conducts a literature review with the objective to provide a concise literature overview of advanced, and often energy‐saving, distillation methods for bioethanol production, especially highlighting what configurations and process modifications are being studied (e.g., mechanical vapor recompression, pressure swing distillation, advanced column architectures), and the challenges that are currently faced by these configurations, the thermodynamic models used, the congeners and equilibrium implications. The research was made using Scopus and Web of Science databases where only English‐language research articles were considered, with no date range exclusion. Key findings indicate that rigorous heat‐integration strategies can reduce steam consumption by 30–80%, though these methods often come with greater capital necessity and heightened operational complexity. Dynamic simulations underscore that process intensification solutions, while promising in steady‐state scenarios, can become sensitive to fluctuations in feed composition or flow rate, leading to potential bottlenecks in scalability and real‐world reliability. Moreover, the inclusion of second‐generation feedstocks, with typically lower ethanol content and higher variability, magnifies the need for these energy cuts and robust control strategies. Beyond highlighting these advancements, the review underscores lingering challenges related to replicability and full‐scale adoption. Key recommendations include generating more precise interaction parameters for congener‐laden systems, coupling model‐based optimization with real‐world data, and pursuing balanced designs that reconcile energy gains, capital costs, and operational stability. Taken together, these insights point toward a future of increasingly efficient, versatile, and environmentally sound ethanol distillation processes. © 2025 Society of Chemical Industry (SCI).