A new pass-through distillation (PTD) process is introduced for the separation of bioethanol from fermentation broths. This hybrid technology combines distillation with absorption, decoupling evaporation and condensation steps through an absorption-desorption loop. This allows the use of different pressures and heating/cooling utilities, reducing operating temperatures and costs. The PTD process was simulated using Aspen Plus for a 100 ktonne/y bioethanol plant, demonstrating its effectiveness in concurrent alcohol recovery and fermentation (CARAF). Combining PTD with heat pumps resulted in recovery costs of 0.122 /kg EtOH and energy requirements of 1.723 kWth/kg EtOH. Alternatively, combining PTD with multi-effect distillation (MED) resulted in recovery costs of 0.131 /kg EtOH and energy intensity of 1.834 kWth/kg EtOH. The PTD process involves an evaporator, gas/vapor absorber, and regenerator for the absorption fluid. A stripping-absorption module (SAM) was developed to enhance the PTD process. The SAM uses heat pipes to transfer heat from the absorber to the evaporator, enabling efficient heat recovery. The process design and simulation play a vital role in the development of sustainable chemical processes, allowing the application of a process systems engineering approach in biotechnology. The PTD process was evaluated for its ability to remove inhibitory products from the fermentation broth while keeping cells viable for recycling. The process enables the recycle of biomass and most of the water to the fermentation, increasing yield and reducing water requirements. The study also developed a reliable property model for a complex system containing an electrolyte (lithium bromide) and two polar solvents (ethanol and water), which was used to accurately account for interactions in the system. The PTD process was tested at a pilot scale, demonstrating its effectiveness in removing CO2 and ethanol from the fermentation broth. The process was optimized for ethanol recovery and concentration, with the addition of a stripping column to increase ethanol concentration in the vapor phase. The process was also evaluated for its energy requirements, with the use of heat pumps and MED resulting in significant energy savings. The study demonstrated that the PTD process is a viable and effective method for the separation of bioethanol from fermentation broths, with the potential to reduce operating costs and improve the efficiency of the fermentation process. The process has the potential to be applied to other bio-based processes, contributing to the advancement of the biotech industry.A new pass-through distillation (PTD) process is introduced for the separation of bioethanol from fermentation broths. This hybrid technology combines distillation with absorption, decoupling evaporation and condensation steps through an absorption-desorption loop. This allows the use of different pressures and heating/cooling utilities, reducing operating temperatures and costs. The PTD process was simulated using Aspen Plus for a 100 ktonne/y bioethanol plant, demonstrating its effectiveness in concurrent alcohol recovery and fermentation (CARAF). Combining PTD with heat pumps resulted in recovery costs of 0.122 /kg EtOH and energy requirements of 1.723 kWth/kg EtOH. Alternatively, combining PTD with multi-effect distillation (MED) resulted in recovery costs of 0.131 /kg EtOH and energy intensity of 1.834 kWth/kg EtOH. The PTD process involves an evaporator, gas/vapor absorber, and regenerator for the absorption fluid. A stripping-absorption module (SAM) was developed to enhance the PTD process. The SAM uses heat pipes to transfer heat from the absorber to the evaporator, enabling efficient heat recovery. The process design and simulation play a vital role in the development of sustainable chemical processes, allowing the application of a process systems engineering approach in biotechnology. The PTD process was evaluated for its ability to remove inhibitory products from the fermentation broth while keeping cells viable for recycling. The process enables the recycle of biomass and most of the water to the fermentation, increasing yield and reducing water requirements. The study also developed a reliable property model for a complex system containing an electrolyte (lithium bromide) and two polar solvents (ethanol and water), which was used to accurately account for interactions in the system. The PTD process was tested at a pilot scale, demonstrating its effectiveness in removing CO2 and ethanol from the fermentation broth. The process was optimized for ethanol recovery and concentration, with the addition of a stripping column to increase ethanol concentration in the vapor phase. The process was also evaluated for its energy requirements, with the use of heat pumps and MED resulting in significant energy savings. The study demonstrated that the PTD process is a viable and effective method for the separation of bioethanol from fermentation broths, with the potential to reduce operating costs and improve the efficiency of the fermentation process. The process has the potential to be applied to other bio-based processes, contributing to the advancement of the biotech industry.