balikesİr ethanol plant. outline general information main units of the plant economic analysis of...

BALIKESİR ETHANOL PLANT

OUTLINE

•GENERAL INFORMATION•MAIN UNITS OF THE PLANT•ECONOMIC ANALYSIS OF THE PLANT•DISCUSSION AND CONCLUSION

1-GENERAL INFORMATION

PRODUCT AND CAPACITY PLANT LOCATION RAW MATERIAL SELECTION PLANT LAYOUT

PRODUCT AND CAPACITY

PRODUCT CAPACITY 20,000,000

LT/YEAR ETHANOL 2,200 TONES/YEAR

SLOP 219 TONES/YEAR FUSEL OIL

1-GENERAL INFORMATION

PRODUCT AND CAPACITY PLANT LOCATION RAW MATERIAL SELECTION PLANT LAYOUT

PLANT LOCATION

Located in Balıkesir Organised Industrial Area

Raw material availability

Close to customers Suitable

transportation

1-GENERAL INFORMATION

PRODUCT AND CAPACITY PLANT LOCATION RAW MATERIAL SELECTION PLANT LAYOUT

RAW MATERIAL SELECTION

SUGAR Sugar beets Sugar cane STARCH Grains Potatoes CELLULOSE Wood Grasses

Sugar beet was selected as the raw material.

Molasses is the by-product of the sugar beet.

1-GENERAL INFORMATION

PRODUCT AND CAPACITY PLANT LOCATION RAW MATERIAL SELECTION PLANT LAYOUT

PLANT LAYOUTDehydration unit

Administrative building

Sports Area

Distillation unit

Fermentation unit

Evaporation unit

Control units

Storage tanks

Cooling towers

Steam generetors

Cafeteria

Security

Parking Area

OUTLINE

•GENERAL INFORMATION•MAIN UNITS OF THE PLANT•ECONOMIC ANALYSIS OF THE PLANT•DISCUSSION AND CONCLUSION

2- MAIN UNITS OF THE PLANT

FERMENTATION UNIT DISTILLATION UNIT DEHYDRATION UNIT EVAPORATION UNIT

FERMENTATION UNIT

Glucose 2 Ethanol +2 CO2

Saccharomyces cerevisia is used as the bacteria.

Semi-batch operating unit Fermentation operation-36 hours The loading of the reactants-16 hours The fermentation reactions-24 hours The discharge of the products-12 hours 73,000 kg ethanol is produced in each 36

hours.

FLOW SHEET OF THE FERMENTATION UNIT

4 fermentors with 550 m3 capacity

3 yeast tanks with 0.2, 3 and 40 m3 capacities, respectively

2 molasses storage tanks with 3000 m3 capacity

1 water storage tank with 750 m3 capacity

1 sulfuric acid tank with 50 m3 capacity

1 scrubber with 0.42 m diameter and 5.8 m height

1 separator 1 feed tank with 1000 m3

capacity

T-01 T-02

T-03

T-04

P-1 P-2

P-3

P-4

V-1 V-2

V-3

V-4

V-5

T-05 T-06 T-07

T-08 T-11T-10T-09

F-127

F-126

F-101

F-102

F-103

F-104

V-6 V-7 V-8 V-9

F-105

H-1

F-106

H-2

F-110F-109

V-10 V-11 V-12 V-13

SC-1

F-112

F-114

F-115

F-113

F-117

F-108

S-1

F-107

F-122

T-12

F-123

V-15 V-16 V-17

F-111

F-116

V-19 V-20 V-21V-18

F-118 F-119 F-121F-120

F-124Separator Feed tank

Fermenter 1 Fermenter 2 Fermenter 3 Fermenter 4

Scrubber

Yeast tankYeast tank

Yeast tank

Mollasses tank Mollasses tank

Water tank

Sulfuric acid tank

Mash+yeast from lab.

Fermentation Unit

V-22

P-5

P-6

P-7

F-125

V-14

2- MAIN UNITS OF THE PLANT

FERMENTATION UNIT DISTILLATION UNIT DEHYDRATION UNIT EVAPORATION UNIT

DISTILLATION UNIT

ChemCad 5.2 is used for the design of the distillation unit.

The aim of this unit is to increase the ethanol composition of the mash from 11% to minimum 93%.

In order to achieve this goal two distillation columns are used. Both of the distillation columns are chosen as sieve tray SCDS columns.

FLOW SHEET OF THE DISTILLATION UNIT

H-3

Distillation column

D-1

Distillation column

D-2

RB-1

C-1

RB-2

C-2

D-101

D-102

D-103

P-16

D-104

D-105

D-106

V-23

P-8

P-10

P-9

D-107

D-108

Distillation Unit Feed stream kg/h

Ethanol 2063

Water 16,782

Acetic acid 97

Lactic acid 57

N-butanol 2

N-propanol 10

2-Mth-1-Butanol 5

Alpha-D-Glucose 14

Acetaldehyde 2

Methanol 5

SPECIFICATIONS OF THE COLUMNS

1.COLUMN 2.COLUMN

Inlet stream 11% ethanol 58% ethanol

Outlet stream 58% ethanol 93% ethanol

# of stages 28 35

Feed stage 16 10

Pressure 1 atm 1 atm

Diameter 1.07 m 1.22 m

Height 17.08 m 21.35 m

2- MAIN UNITS OF THE PLANT

FERMENTATION UNIT DISTILLATION UNIT DEHYDRATION UNIT EVAPORATION UNIT

DEHYDRATION UNIT

Dehydration process is used to extract water from alcohol to scale up the alcohol percentage

Molecular sieve adsorption Molecular sieve zeolite 3A was used. Temperature-swing cycle is chosen

for the adsorption system.

FLOW SHEET OF THE DEHYDRATION UNIT

DH-1

CP-1

CP-2

H-5

H-4

HR-1

CR-1

CR-2

HR-2

KD-1

DH-2

D-108

P-6

DH-101

V-24 V-25

DH-101

DH-102

DH-102

DH-102

V-26 V-27

DH-104 DH-104

DH-104

DH-105

V-28 V-29

DH-105

DH-108

DH-109DH-109

DH-110P-26DH-110

V-30

V-31

FL-1

DH-106

F-117

Dehydration Unit

DH-103

There are two column for adsorption and desorption

Increase the ethanol percentage of the feed from 93.4% to 99%.

The amount of the zeolite 3A was 2218.45 kg.

The adsorption time for one column is assumed 3 hours.

Design velocity is assumed 0.5 m/s for the adsorbate

The height of the one adsorption column is 4.887 m

The diameter of the one adsorption column is 0.917 m.

Produced CO2 in fermentation unit is used for the regeneration.

2- MAIN UNITS OF THE PLANT

FERMENTATION UNIT DISTILLATION UNIT DEHYDRATION UNIT EVAPORATION UNIT

EVAPORATION UNIT

In this unit, water in the waste is evaporated and more concentrated slop is obtained.

The feed stream of this unit is the bottom products of the two distillation columns.

Triple effect evaporator is used. Raw steam is used as the heating

medium.

FLOW SHEET OF THE EVAPORATION UNIT

Inlet concentration

0.01

Outlet concentration

0.60

Steam 5726 kg/hr @ 121°C, 205kPa

Average area 119 m2

Steam economy

2.88E-01 E-02E-03

P-11 P-12P-13

P-14CR-3

D-106

S-101

E-101 E-104

P-9

E-107

Evaporation Unit

E-103

E-106 E-109

E-102

E-105

E-108

E-110

OUTLINE

•GENERAL INFORMATION•MAIN UNITS OF THE PLANT•ECONOMIC ANALYSIS OF THE PLANT•DISCUSSION AND CONCLUSION

3-ECONOMIC ANALYSIS OF THE PLANT

INVESTMENT COST

PRODUCTION COST

BREAK-EVEN POINT&NET

PRESENT WORTH

INVESTMENT COST

Purchased Equipment Cost:

Fermentation Unit: $1,120,000Distillation Unit: $380,000Dehydration Unit: $107,000Evaporation Unit: $1,731,000Total PEC: $3,338,000

DIRECT COST $

PEC 3,338,000

Installation 1,335,000

Inst.&control 668,000

Piping 1,335,000

Insulation 40,000

Electr. Inst. 201,000

Building 1,669,000

Yard imp. 334,000

Service fac. 1,001,000

Land 88,000

Total direct cost 10,008,000

INDIRECT COST

$

Engineering& Supervision

1,168,000

Construction 501,000

Contractor’s fee

667,000

Contingency 667,000

Other costs 334,000

Total indirect cost

3,337,000

Fixed Capital Investment: $13,346,000 Working Capital: $2,002,000 Total Capital Investment: $15,348,000

3-ECONOMIC ANALYSIS OF THE PLANT

INVESTMENT COST

PRODUCTION COST

BREAK-EVEN POINT&NET

PRESENT WORTH

PRODUCTION COST

Total product cost: $23,839,000 Fixed cost: $9,139,000 Variable cost: $14,700,000

MANUFACTURING COST

$

Raw material 10,220,000

Operation and supervis. Labor

682,000

Utilities 1,815,000

Maint.&repair 667,000

Supplies&lab 67,000

Local taxes 267,000

Insurance 667,000

Plant overhead 341,000

Depreciation 1,325,000

Total man.cost 16,053,000

GENERAL EXPENSES

$

Administrative 634,000

Distribution&Selling

2,384,000

R&D 1,192,000

General Expenses

3,576,000

Total 7,786,000

3-ECONOMIC ANALYSIS OF THE PLANT

INVESTMENT COST

PRODUCTION COST

BREAK-EVEN POINT&NET

PRESENT WORTH

BREAK-EVEN POINT&NET PRESENT WORTH

V=$0.73/lt ethanol S=$0.715/lt ethanol Break Even Point Capacity (n) = F/(S-V) V>S, Break Even Point Capacity<0 Net Present Worth = -$44,453,000

OUTLINE

•GENERAL INFORMATION•MAIN UNITS OF THE PLANT•ECONOMIC ANALYSIS OF THE PLANT•DISCUSSION AND CONCLUSION

DISCUSSION&CONCLUSION

FERMENTATION UNIT Glucose Conversion of glucose to ethanol:0.92 Byproducts:CO2, acetic acid, lactic acid, methanol,

butanol, propanol, amyl alcohol and acetaldehyde Semi-batch operating unit Yeast separation Duration of the reaction Flow rates of the raw material

THANKS FOR YOUR CONSIDERATION

GROUP E BESTE ERİŞ BİLGE KILIÇ SEDA ÇAKIR TUĞBA ÇEVİK