incbio 1ta (2015 en) 1a1b dgb - proposal
TRANSCRIPT
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CONTINUOUS ULTRASONIC ACID ESTERIFICATION
AND TRANSESTERIFICATION PLANT
DEGUMMING AND BLEACHING
SOLID CATALYST for ACID ESTERIFICATION
1 MT / HOUR – 24 MT / Day
METHANOL DISTILATION
BIODIESEL DISTILATION
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Address: Rua Simão Bolívar 311, 1º Andar – Sala 4, 4470-214 MAIA, PORTUGAL ● Phone: +351 220 171 082 ● Email: [email protected] ● Web: www.incbio.com
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INDEX
1.
About us
2.
System Overview
3. Ultrasonic Reactors
4. Process Description
a. Advantages of using solid catalyst
b. Explosion Proofing – ATEX
c.
Methanol Rectification
5.
Feedstock, Utilities and Reagents
a. Feedstock specification
b.
Utility specification
c. Reagent specification
d.
Product Specification
6. Plant Performance Guarantees
a.
Capacity
7.
Specifications
a.
Technical Certificates and Regulations
b. Plant layout example
c. Scope of Supply
d. Work Not Included
e.
Plant Commissioning, Start-Up and Training
f.
Documentation
g. Factory Acceptance Test (FAT)
h.
Warranty
8. Commercials
a. Price
b. Payment Schedule
c.
Payment Terms
d.
Taxes
e. Schedule
f. Transport and Installation
g. Proposal Validity
Annex I - Hourly Wage Rates, Travel and Accommodation
Annex II – Supervision and Start-Up – Terms and Conditions Expenses
Annex III – Block Flow Diagram (BFD)
Annex IV – Engineering Specifications
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Address: Rua Simão Bolívar 311, 1º Andar – Sala 4, 4470-214 MAIA, PORTUGAL ● Phone: +351 220 171 082 ● Email: [email protected] ● Web: www.incbio.com
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1. About Us
Incbio is a brand owned by Incalculável, which was founded in Portugal in 2006 with the production
of domestic Biodiesel processors and small scale commercial Biodiesel processors. Having since grown
to become the largest Biodiesel equipment provider in the country, since 2008 the company started
working on the construction of large scale Biodiesel equipment, with ultrasonic Biodiesel reactors, a
pioneering equipment which will revolutionize the Biodiesel industry in years to come.
With a continuous investment in R&D, we aim to be pioneers in this sector, developing innovative
systems and methods. The introduction of our ultrasonic Biodiesel reactors is evidence of this
mentality, making us stand out from our competition. Our innovative multi-feedstock Biodiesel
processors, which are able to process feedstock with up to 100% FFA – with yields of up to 100% and
exceeding the international quality standards - further prove this point. Our clients say that incomparison with us, our competition offers analogue solutions in a digital world!
From Design, Engineering, Consultancy and Construction we are able to assist you in as little or as
much as you require. From retrofitting of existing units with state of the art ultrasonic or multi-
feedstock technology to design, manufacture and start-up of complete industrial units, we are ideally
placed to make your Bio-project a reality.
Because we understand very well that profitability is the name of the game, all of our units are
designed to be as efficient as technically possible, helping you maximize your profits. But we alsounderstand that this very profitability starts with the initial capital expenditure on equipment, which
is why we offer what we believe to be the most competitive prices that can currently be found on the
market.
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Address: Rua Simão Bolívar 311, 1º Andar – Sala 4, 4470-214 MAIA, PORTUGAL ● Phone: +351 220 171 082 ● Email: [email protected] ● Web: www.incbio.com
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2. System overview
The Incbio 1TA 1a1b is a fully automated, continuous 1 MT/hour degumming, bleaching, acid
esterification and transesterification plant. It uses technology that is both innovative and widelyproven in the field in a large number of commercially operating plants.
The plant works with ultrasonic reactors, allowing our processors to continuously produce Biodiesel
with optimum conversion rates (>99%) and of consistently high quality.
Methanol recovery module is integrated in the plant as well. As a result of this, we ensure that
methanol usage is kept to a bare minimum.
All components are provided by market leading manufacturers, to ensure the seamless and constant
operation of the plant, and also to ensure that if faults do occur, they can quickly and easily be
addressed.
All wet components are AISI 304 Stainless Steel (except esterification reactor, which is AISI 316L
Stainless Steel), and the plant is fully built in a skid, to reduce to a minimum the time of installation
and commissioning. The methanol distillation and biodiesel distillation column’s structure are built in
Carbon Steel.
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Address: Rua Simão Bolívar 311, 1º Andar – Sala 4, 4470-214 MAIA, PORTUGAL ● Phone: +351 220 171 082 ● Email: [email protected] ● Web: www.incbio.com
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3. Ultrasonic Reactors
When sonicating liquids at high intensities, the sound waves that propagate into the liquid media
result in alternating high-pressure (compression) and low-pressure (rarefaction) cycles, with ratesdepending on the frequency. During the low-pressure cycle, high-intensity ultrasonic waves create
small vacuum bubbles or voids in the liquid. When the bubbles attain a volume at which they can no
longer absorb energy, they collapse violently during a high-pressure cycle.
This phenomenon is called cavitation. During the implosion very high temperatures (approx. 5,000K)
and pressures (approx. 2,000atm) are reached locally. The implosion of the cavitation bubble also
results in liquid jets of up to 280m/s velocity.
Ultrasound has been proven to generate very homogenous emulsions by the high cavitational shear.
As the parameters of ultrasonication are fine-tuned, particle size and distribution is well adjustable
and repeatable.
The ultrasonic reactors are the heart of our systems. Incbio has been conducting extensive R&D inultrasonic Biodiesel reactor technology. After a long time spent in testing with a variety of feedstock’s
we have now got fully functional reactors specifically developed to process Biodiesel on both batch
and continuous plants, applied as a flow-through reactor. These ultrasonic Biodiesel reactors are fully
ATEX compliant and can be retrofitted to any operational Biodiesel plant.
In this configuration the ultrasonic reactor is used to blend methanol with feedstock homogeneously
prior to the esterification
Advantages of our Ultrasonic Biodiesel Reactors
Feedstock flexibility - ultrasounds achieve the same great results with any feedstock, both high and
low FFA feedstock can be used, including blends of different feedstock;
Low power consumption - with a total consumption of approximately 2kWh per ton of Biodiesel
produced, our reactors are unmatched for economy;
No moving parts - ultrasonic reactors have no moving parts, meaning that there is virtually no
maintenance required, apart from regular cleaning operations;
Consistently High Yields and Quality - by creating micro bubbles, that contract and expand increasing
the surface area where the reaction takes place instantaneously, molecular cavitation emulsifies the
feedstock and reagents guaranteeing maximum yields and high quality Biodiesel at all times;
Small plant footprint – due to their energy efficiency, the system has a capacity identical to highly
energy intensive mechanical reactors, which are much larger and require a lot more retention timefor the reaction to occur.
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Address: Rua Simão Bolívar 311, 1º Andar – Sala 4, 4470-214 MAIA, PORTUGAL ● Phone: +351 220 171 082 ● Email: [email protected] ● Web: www.incbio.com
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4. Process Description
The feedstock comes from storage and is blended with water and phosphoric acid, and fed into a CSTR
(continuous stirred reactor), in order to release the gums from the oil. Once the reaction is complete(continuously, as it goes through the CSTR) the feed is sent into a self-cleaning centrifuge to
continuously separate the water and the gums from the oil. After degumming the feedstock is sent to
a second CSTR where it is blended with bleaching earth, in order to remove metals, polymers and
other contaminants, once reacted it goes through a filter press to remove all bleaching earth from the
feedstock. After the previous pre-treatment steps the feedstock is heated to 144°C using steam, mixed
with methanol and sent through the ultrasonic reactor in order to be completely emulsified. The
ultrasonic reactor is installed inline on the piping. The mix is then sent to the guard bed to remove any
remaining contaminants which may affect the performance of the acid esterification catalyst.
After the guard bed the medium is sent directly to the acid esterification reactor (120°C, 8 bar), filled
with a solid catalyst (Lanxess GF101), being esterified continuously as it goes through the resin.
Upon exiting the reactor, the temperature of the medium is adjusted once more to 140°C and fed to
a flash column, so the water and methanol can be removed.
The mixture of TG, methyl esters and residual FFA is then sent directly to the transesterification
equipment. Temperature at this time is approximately 120ºC, and medium is cooled using the cold
feedstock entering the process, thus maximizing energy recovery in the process.
The feedstock is heated to 65°C using steam, mixed with methanol and sodium methylate, and sent
through the ultrasonic reactor (The ultrasonic reactor is installed inline on the piping). During this very
small contact time (approximately 5 seconds), there is an instantaneous conversion of more than 80%.
The mix is then sent to the CSTR (Continuous stirred-tank reactor), for the reaction to be completed,
for 60 minutes. CSTR is kept at the correct temperature with double wall heating, with hot condensate
water.
After the CSTR, the mix is sent through a disk stack centrifuge, to separate the Biodiesel (light phase)
from the Glycerol (heavy phase).
The light phase is then heated to 120°C, and sent through a flash evaporator, to remove methanol and
any water present. The almost finished biodiesel is then sent through a lead-lag system of ion-
exchange resins towers, to remove any traces of glycerol and other contaminants.
Finished biodiesel is then sent to distillation. In distillation, using a WFE evaporator, biodiesel is
vaporised at an extremely high vacuum, and impurities are left behind, producing biodiesel with
excellent quality.
The heavy phase stream is heated to 120°C, and sent through a flash evaporator, to recover methanol.Glycerol is then sent to storage, or to distillation.
The methanol and water mixture is sent to the methanol rectification column to concentrate the
methanol to 99.5% purity, so it can be reused in the reaction. The rectification column is either a tray
column or a packed column, depending on project specifications.
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a.
Advantages of using solid catalyst
Although acid esterification has been widely used in the industry, it has never been exempt from
problems.The major problem is using sulphuric acid, or even other stronger, exotic acids, in contact with the
process equipment. To prevent metal degradation and process equipment short life, it requires the
use of unusual metallurgy (like AL-6XN or Hastelloy C2000), that increases the CAPEX to a point where
the project usually becomes unviable.
By using solid catalyst (Lanxess GF 101) we remove the usage of sulphuric acid, thus removing all the
degradation problems.
Also, the water created in the chemical process will not have sulphuric acid present, thus removing
the necessity of processing a major contaminant.
b.
Explosion Proofing – ATEX
Due to its characteristics, the production area must be considered an ATEX Zone, since it uses
methanol in its process. As such all the equipment must be ATEX 3G certified.
c.
Methanol Rectification
A successful commercial Biodiesel production can only be achieved by keeping the operating costs
down. Methanol is by far the most expensive consumable, and especially due to the acid esterification
requirement of high FFA feedstock (which requires high excess usage of methanol) this excess
methanol must be recovered. To this effect a methanol distillation system must be in operation and
is included in this proposal. The rectification column is either a tray column or a packed column,
depending on project specifications.
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Address: Rua Simão Bolívar 311, 1º Andar – Sala 4, 4470-214 MAIA, PORTUGAL ● Phone: +351 220 171 082 ● Email: [email protected] ● Web: www.incbio.com
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5. Feedstock, Utilities and Reagents
a.
Feedstock specification
Parameter Specification
Free Fatty Acid Up to 25%
Iodine Value 51.0 Min
Melting Point (°C) 45 - 50 Max
Moisture and Impurities 1% Max
b.
Utility specification
Utilities and chemicals having these characteristics are supposed to be made available at battery
limits.
Process water
Type softened
Pressure 3 bar g min.
Temperature ambient
Hardness 1°F max
Iron content max 5 ppm as Fe
Cooling water
Pressure 3 bar g min.
Temperature inlet 20°C max
Temperature outlet 25°C max
Hardness Soft water with zero commercial
hardness, no suspended solids and
Chloride content
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Nitrogen
Type 99,5 % purity
Pressure 8 bar g min.
Max Oxygen 0,1%
Electric power
Driving power 440 V - +/-5% - 50/60 Hz - 3 + N
phases
Control and auxiliary circuit 220 V – 50/60 Hz - 1 phase
Lamps 24 V – 50/60 Hz - 1 phase
c.
Reagent specification
Methanol - Technical grade, 0.15 % max. water content.
Sodium Methylate - Technical grade, 30 % sodium by weight.
d.
Product Specification
If the feedstock used in the plant is as per the specification above, biodiesel will be according to Annex
IV – Mass and Energy Balance.
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Address: Rua Simão Bolívar 311, 1º Andar – Sala 4, 4470-214 MAIA, PORTUGAL ● Phone: +351 220 171 082 ● Email: [email protected] ● Web: www.incbio.com
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6. Plant Performance Guarantees
INCBIO will guarantee that as long as the plant is operated as per the instructions and the raw
materials are kept within parameters to be agreed between INCBIO and the client, the plant capacitywill be as agreed and the transesterification shall have an efficiency of at least 98,5%.
The fulfilment of the guaranteed performance shall be demonstrated during equipment testing,
subject to the following conditions:
- If the installation of the plant is not carried out by INCBIO, the installation shall have been carried
out as per INCBIO’s instructions;
- The quantity and quality of feedstock, reagent, catalyst, utilities and consumables shall be as agreed
between INCBIO and the client. Client shall also make available operational staff in order to operate
the plant during performance tests;
- The test procedures shall be agreed between INCBIO and the client in accordance with standard
industry practice;
- If any part of the Equipment fails to meet the Guaranteed Performances, INCBIO shall at its own cost
make changes and adjustments to the Equipment, as appropriate.
Should the plant not perform as agreed even after the remediation is carried out, after the agreed
schedule for remediation INCBIO shall pay the buyer liquidated damages as per the Sale Agreement.
Under no circumstances shall INCBIO be liable for any direct, indirect, incidental or consequential
damages, including but not limited to loss of profit, use, production, raw materials or end products,
or for any other claim connected to the purchase, delivery, installation or use of the plant. INCBIO’s
limit of aggregate liability for any loss, damage or compensation, including liquidated damages shall
never exceed twenty percent (20%) of the contract price.
All data is to be understood at nominal capacity and within the tolerances of measuring and testing
equipment and procedures. All performance data is to be understood with a tolerance of +\- 2.5% for
the consumption figures and +\- 1% for capacities and yield.
a.
Capacity
1.000 kg/h (24 TPD) of processed product.
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7. Specifications
a.
Technical Certificates and Regulations
The plant will be fully tested by Incbio and will be CE marked to demonstrate the manufacturer’s
compliance with European directives. Furthermore the plant will be fully ATEX Explosive Atmospheres
Regulations (Directive 94/9/EC – ATEX) compliant, whilst all electrical components will be ATEX
certified. All technical rules regarding pressure tanks, piping, plant assembly and installation will be
complied with by Incbio.
b.
Plant layout example
In this example of a plant layout, the following major structures can be observed:
A Tank Farm, with loading and unloading capabilities (for trucks only, or for trucks and/or
trains and/or boats).
Utilities room
Process room, with INCBIO processing equipment, and optional feedstock and biodiesel
processing tanks
Control room, with INCBIO computers, with SCADA to control processing equipment
Laboratory, with optional testing equipment
Offices
Essencial utilities (not included, that can be quoted, upon request) are:
hot oil – Using diesel, biodiesel or gas boiler
Cooling water – From storage tank or Chiller (depending on location)
Compressed air – From compressor
Nitrogen – From Nitrogen generator
Electricity
Fire supression system
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c.
Scope of Supply
Incbio’s scope of supply of the present proposal is the following:
Know-how, basic and detailed engineering
Equipment and machinery complete with motors as described previously.
Field instrumentation.
Power control panel MCC.
Process and utilities piping and valves.
Electric and instrument cables
Computer control system, including hardware, basic and application software, interface to the
plant and operator interface.
Interconnecting pipes between the various Incbio’s process plants
All Lubricants and fillings, including initial filling (except for resins)
d.
Work Not Included The following supplies and services will be excluded from Incbio’s supply:
Erection including all mechanical and electrical connections
Steel structures
Thermal insulation and tracing materials
Interconnecting pipes between the various process plants and between the process plants
and utilities
Civil works of any kind, such as soil investigation, excavations, foundations and anchor bolts,
buildings, channels, drains, masonry, grounding, steel structures, pipe supports, gangways
including design, etc.
All permitting activities Storage facilities for raw materials and finished products as well as for fuel oil, etc.
Final painting of buildings
Electric power supply, power transformer and distribution stations, electrical equipment such
as cables and cable trays required outside the process equipment
Lighting installation required inside and outside the process building
Lightning equipment and fire-fighting equipment, as well as any safety equipment required
by local authorities and/or laws
Production and distribution of utilities outside the battery limits of the plant(s) except for
those expressly quoted
Storage and handling of various products, chemicals and auxiliary materials outside battery
limits, unless otherwise specified Spare parts
Any safety device of any kind required by local authorities, and/or insurance companies
stricter than regulations
e.
Plant Commissioning, Start-Up and Training
In this proposal on-site support of the commissioning and start-up activities are not included. This
training can be done with client’s staff at our facilities in Portugal. Start-up at the client’s facilities can
be arranged, quotation upon request. If only supervision of the installation and start-up activities is
required INCBIO shall provide Engineers to this effect, charges shall be as per the hourly wage tableoutlined in Annex I and in accordance with the terms and conditions set out in Annex II.
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f.
Documentation
All engineering documents will be in the English language, using metric system.
Incbio will provide an Installation, Operation and Maintenance Manual for the system (1 electroniccopy). The IOM Manual will include the following:
Operating Instructions.
Equipment Documentation
o Specification sheets
o Drawings
o Spare parts lists
o Manufacturer IOM manuals
o Test reports (i.e. hydro test reports, data sheets)
Instrumentation Documentation
o Specification sheets
o
Spare parts lists
Manufacturer IOM manuals
P&ID drawings
Module layout drawings
Instrument loop drawings
Junction box drawings
Electrical drawings
Utility table
A complete physical set of documents can be provided on request.
g.
Factory Acceptance Test (FAT)
A factory acceptance test (FAT) will be performed at Incbio prior to shipping of the system. The client
is welcome to witness any of the FAT tests. The FAT will consist of the following:
Hydro test of each tank and exchanger as per the specifications;
Inspection of the modules, all equipment and instrumentation to confirm they conform to the
P&ID and equipment and instrument specification sheets;
Inspection of the modules to confirm they conform to the P&ID’s and layout drawings.
h.
Warranty
All of Incbio’s equipment comes with a 12 month manufacturer’s warranty against defects in design,
workmanship and materials, counting from the date of commissioning, or 18 months counting from
the date of shipment, whichever is soonest. Details on this warranty shall be covered on a separate
document to be included in the Sale Agreement.
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Address: Rua Simão Bolívar 311, 1º Andar – Sala 4, 4470-214 MAIA, PORTUGAL ● Phone: +351 220 171 082 ● Email: [email protected] ● Web: www.incbio.com
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8. Commercials
a.
Price
Our budget price for providing all the services as described on this proposal for a 24TPD system
(1MT/hour), with input feedstock with up to 25% FFA, 1% H2O, comprising of:
Degumming and Bleaching
Acid Esterification and Transesterification
Methanol recovery from all streams
Methanol distillation
Biodiesel distillation
1.205.000 EUROS (One Million, Two Hundred and Five Thousand Euros), Ex-works Incoterms 2010.
b.
Payment Schedule
With the order: 20% T/T as down payment. Upon submission of layout drawings and P&ID for approval: 40% T/T
Upon completion of the commissioning and FAT, before shipping: 40% T/T.
c.
Payment Terms
The first payment is due with the order, all other payments are due Net 7 days after the achievement
of the given milestone. If the Client does not fulfil the terms of payment set out above, INCBIO may
suspend performance of its services until such time as the Client has complied. This shall not affect any
other remedies available to INCBIO, included but not limited to legal action.
d.
Taxes
The price excludes any and all taxes and/or duties, up to the moment the title to all Equipment supplied
by Seller shall pass to Buyer. Any taxes and/or duties due in the Buyers country are not Sellers
responsibility.
e.
Schedule
The complete system will be ready for delivery 38 weeks from receipt of down payment and all
approvals. The schedule requires drawing approval in less than 1 week, each day that an approval
drawing is late will add to the overall schedule.
f.
Transport and Installation
Shipping and installation is not included in this proposal. It can be carried out according to our hourly
wage rate, or by quotation upon request.
g.
Proposal Validity
This proposal is valid for 60 days.
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Annex I - Hourly Wage Rates, Travel and Accommodation Expenses
Hourly wage rate (Values in EUROS - VAT not included):
Category Price/hour
A1. Department directors; Project Director; Specialist Engineer; 77,50
A2. Project Leader; Head of Discipline; Senior Engineer; Senior Architect; 60,00
B1. Architects; Engineers; Superior Technicians; 52,50
B2. Architects; Engineers; Industrial Technicians; Contract Managers; Technical
Translators;43,00
C1. Junior Engineer; Junior Architect; Senior Designer; Planning Technician; Cost
control Technician; Procurement Technician; Inspectors;35,00
C2. Junior Engineer; Junior Architect; Designers; Measurers; Planning Technicians;
Cost control Technician;28,00
D. Trainee Engineer; Trainee Architect; Designers class 1; 26,70
E. Designers class 2; Bilingual project Secretaries; 24,00
F. Designers class 3; Project secretaries; Auxiliary Staff; Document Controllers;
Dactylographer; 19,00
Note:
Regular Working Period:
Designers; Project Designers; Measurers: 37,5 hours/week (7,5h/day)
All Others: 40 hours/week (8h/day)
Coefficient Overtime:
Monday to Friday: 1st Hour: 1,25: Next hours to midnight: 1,34; After midnight per hour: 1,45
Saturday: 1,45
Friday and Holidays: 1,85
Travel and Accommodation Expenses:
The travel expenses in public transportations – train or plane – shall be proven by appropriate
justification. In case of use of own vehicle the correspondent value shall be 0,40 Euros / Km.
Accommodation costs shall be covered by the Client. Sustenance wages per day are as follows:
Category Portugal Abroad
A;B 32,50 75,00
C;D;E;F 25,50 65,00
All values comply with Portuguese legislation, fixed at 50% of maximum values.
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Annex II – Supervision and Start-Up – Terms and Conditions
Should the Client request INCBIO’s assistance to supervise or carry out the erection and/or start-up ofthe plant, INCBIO shall make available, upon a mutually agreed schedule, staff to carry out these
services. The following terms and conditions shall apply:
a) The Client shall have all the materials and equipment on site before INCBIO’s staff is sent over
and commences work;
b) INCBIO’s staff shall only carry out work in accordance with the agreed work schedule, any
extra work shall be agreed in writing by INCBIO and our staff shall be informed that the work
has been approved by us;
c)
Test runs shall be completed when our engineers deem it ready to be tested, even if
accessories and non-essential or ancillary equipment is not yet completed;
d)
Client shall ensure that work is carried out without interruption, any time that our staff is on
site and are unable to proceed with the work will still be charged as normal. Client shall also
ensure all necessary raw materials are readily available;
e) When starting up the plant the client’s operators shall be available to accompany the activities
as required;
f)
All expenses related to commissioning, start-up and performance tests of the plant shall be
covered by the client;
g) After completion of the performance tests, the client shall issue an acceptance certificate to
be handed over to the lead engineer on site, provided that the plant has met the contractual
parameters. Failure to issue the acceptance certificate will lead to INCBIO refusing to honour
any warranties or guarantees on the plant;
h)
Upon request INCBIO can make available staff to operate, maintain or study retrofitting or
capacity increases of the plant.