ABE488 

Bioprocessing Biomass for FuelSemester Design Project

SuperPro Designer® by Intelligen, Inc. Version 7.0

University of Illinois at Urbana-ChampaignCollege of Agricultural, Consumer and Environmental Sciences

Department of Agricultural & Biological Engineering Professor Dr. Vijay Singh

Student team: Felix Bredoire & Mathias Barreto12/06/2011

Design performed

50 million dry grind ethanol / yearConventional Dry Grind

Main assumptions

• SSF• 98% of enzyme conversion• Recycling streams :– Water from distillation and evaporation– 50% of the thin stillage

• Removal of oil from centrifugation and further separation: germ oil and fiber oil

SuperPro Flowsheet

INPUTS• Corn:

– 2962960 lb/day– $0.238/kg

• Enzymes (AA & GA):– 592.6 lb/day– $2.25/kg

• Yeast:– 772.22 lb/day– $1.86/kg

• Water:– 2959968 lb/day– $0.0013/kg

OUTPUTS• Ethanol:

– 967363 lb/day– $0.845/kg

• DDGS:– 1085482 lb/day– $0.215/kg

• Germ oil:– 48801 lb/day– $0.35/kg

• Fiber oil:– 26724 lb/day– $4/kg

Equipment priceSilo/Bin

3% Stirred Reactor 6%

Fermentor 33%

Stripper Column1%

Rectifier Column 0%

Side stripper Column0% Decanter Centrifuge

1%Heat Exchanger

1%

Evaporator 13%

Drum Dryer 38%

Grinder 4%

Total plant cost

1. Equipment Purchase Cost; 7,541,000

2. Installation ; 3,016,000

4. Instrumentation ; 754,0005. Insulation ; 226,0006. Electrical; 754,0007. Buildings; 754,0008. Yard Improvement ; 754,000

9. Auxiliary Facilities ; 754,000

10. Engineering; 3,639,000

11. Construction; 5,094,000

Operating cost

65%3%3%0%

28%

Operating cost

Raw MaterialsFacilityLaborLab/QC/QAUtilities

50%

27%

2%

17%

4%

Detail of utilities

ElectricitySteamCooling WaterChilled WaterSteam (High P)

98% of raw materials = corn

Contribution of each product to the revenue

Ethanol 200 69%

DDGS21%

germ oil1% fiber oil

9%

New enzyme

• Operating cost = 3.1% less• Payback time:3.02 years vs. 4.35 years• Manufacturing cost of ethanol= $0.87/L vs. $0.91/L

Scale up evaluation

25 million 50 million 75 million 100 million 50 million - no enzyme0.82

0.84

0.86

0.88

0.9

0.92

0.94

0.96

0.98

0.954690000000001

0.907350.89946

0.891569999999999

0.867900000000001

annual ethanol production

$/L

Conclusions & Recommendations

• Ethanol selling price < manufacturing cost Importance of coproducts (DDGS, oil)

• Dependency on the market value of corn (63% of operating cost = corn)

• The bigger the plant, the less the manufacturing cost• Actual plant designed: economically viable• BUT, design can be improved by:– Better enzyme efficiency– Use of corn which does not require enzymes addition