More than half of the bioethanol plants in operation today use corn or grains as raw materials. The downstream processing of mash after fermn. to produce ethanol and distiller grains is an energy-demanding process, which needs retrofitting for optimization. In addn., the fluctuation in the ethanol and grain prices affects the overall profitability of the plant. For this purpose, a process simulation was performed in Aspen Plus based on an existing industrial plant located in Sweden. The simulations were compared using different scenarios including different concns. of ethanol, using the stillage for biogas prodn. to produce steam instead of distiller grains as a byproduct, and altering the purity of the ethanol produced. Using stillage for biogas prodn., as well as utilizing the steam, reduced the overall energy consumption by 40 % compared to the plant in operation. The fluctuations in grain prices had a high impact on the net present value (NPV), where grain prices greater than 349 USD/ton reached a zero NPV. After 20 years, the plant in operation producing 41,600 tons ethanol/yr can generate a profit of 78 million USD. Compared to the base case, the less purified ethanol resulted in a lower NPV of 30 million USD. [on SciFinder(R)]