Diapositiva 1
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Transcript Diapositiva 1
Optimization Techniques in Engineering and
Construction of a Bioethanol Plant
ABENER
Engineering and Construction for Sustainability
ABENER
ABENER North America
St. Louis, MO
Chris Hutson – Business Development Director
Engineering network – Spain, USA, Holland, Algeria,
Morocco, Mexico, Brazil
Focus – Biofuels, Solar Energy, Power Generation
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Bioethanol - Processes
Raw Material Preparation
Sugar Generation
Fermentation
Distillation
Fermentation C6
Distillation
Natural sugars
Receiving
Crushing
Cereals
Corn
Wheat
Barley
Grain cleaning
Milling
Cooking
Saccharification
Liquefaction
Fermentation C6
Distillation
Biomass
Receiving
Crushing
1st acid Hydrolysis
Separation L/S
Fermentation C5
Distillation
2nd acid Hydrolysis
Fermentation C6
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Project Name
Bioethanol Experiences – Spanish Market
Ecocarburantes Españoles
Bioetanol Galicia
Location
Spain (Cartagena)
Spain (A Coruña)
Client
Ecocarburantes Españoles, S.A.
Bioetanol Galicia, S.A.
Bioethanol Production
26.4 MMGY
33.3 MMGY
Co-product
130,000 TPY DDGS
136,000 TPY DDGS
Eletricity (Cogen)
Consumption
300,000 TPY
352,000 TPY
Raw Materials
Wheat, Barley
Wheat, Barley
Operation
1999
2002
Process
Continuous
Batch
Participation
Full EPC
Full EPC
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Project Name
Bioethanol Experiences – Spanish Market
Biocarburantes Castilla y León
Biocarburantes Castilla y León
Location
Spain (Salamanca)
Spain (Salamanca)
Client
Biocarburantes Castilla y León, S.A.
Biocarburantes Castilla y León, S.A.
Bioethanol Production
46.2 MMGY from cereals
6.6 MMGY from wine alcohol
1.3 MMGY from biomass
130,000 TPY DDGS
Electricity (Cogeneration 45 MW)
Co-product
Consumption
226,800 TPY
5,400 TPY
Raw Materials
Wheat, Barley, Corn,
Wine alcohol
Biomass (from cereals)
Operation
2006
2006
Process
Batch
n/a
Participation
Full EPC
EPC ( cooperation with Ab.Bioenergy)
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ABENER
Project Name
Bioethanol Experiences - USA Market
Bioethanol Illinois
Bioethanol Indiana
Location
USA (Madison, Illinois)
USA (West Franklin, Indiana)
Client
Abengoa Bioenergy of Illinois, L.L.C.
Abengoa Bioenergy of Indiana, L.L.C.
Bioethanol Production
88 MMGY
88 MMGY
Co-product
DDGS
DDGS
Consumption
905,000 TPY corn
905,000 TPY corn
Raw Materials
Corn
Corn
Operation
2010
2010
Process
Continuous
Continuous
Participation
Full EPC
Full EPC
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ABENER
Project Name
Bioethanol Experiences - European Market
Bioethanol France
Bioethanol Rotterdam
Location
France (Lacq)
Netherlands (Rotterdam)
Client
Abengoa Bioenergy France, S.A.
Abengoa Bioenergy Netherlands, S.A.
Bioethanol Production
41.7 MMGY from cereals
10.6 MMGY from wine alcohol
126.7 MMGY
Co-product
150,000 TPY DDGS
347,000 TPY DDGS
CO2, Electricity
Consumption
515,000 TPY cereals
10.6 MMGY wine alcohol
1,180,000 TPY of cereals
Raw Materials
Wheat, Barley, Wine Alcohol
Wheat, Barley, Corn
Operation
2007
2010
Process
Batch
Batch
Participation
Full EPC
Full EPC
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Optimization Techniques – Engineering/Design
Biofuels Process
Process design
Logistics
Civil / Structural
Process provider
Air/Water Permits
Capacity/Design factors/Redundancy
Feedstocks
Batch/continuous
Coproducts
Receiving/Loadout (truck, rail, barge)
Minimize handling/movement
Future expansions
Plant layout
Plant elevation, slope, drainage
Foundation design
Seismic considerations
Platforms/access
Codes/standards
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Optimization Techniques – Engineering/Design
Biofuels Process
Mechanical / Piping
Instrument & Control
Process requirements
Design factors
Equipment redundancy
Operation and maintenance considerations
Codes & Design Standards
Hazardous area classifications
Fire protection
Approved Equipment Suppliers
3D CAD design/model
Moduralized pipe racks and equipment
Process requirements
Selected instrument vendors
Hazardous area classifications
Distributed control system (DCS)
Computer graphics and control features
Automation
Interlocks, Alarms, Safe operation
Reporting
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Optimization Techniques – Engineering/Design
Biofuels Process
Electrical
Utilities
Utility supply/substation
Design factors
Equipment redundancy
Operation and maintenance considerations
Codes & Design Standards
Approved Equipment Suppliers
Hazardous area classifications
Packaged electrical buildings
Process water makeup
Natural gas
Waste water discharge requirements
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Optimization Techniques – Construction
Biofuels Process
Roads, rail, barge
Plant roads constructed for required traffic
Civil Works
(200 trucks/day – 25 trucks/hour)
Local codes and governing bodies
Foundations fermenters, silos,…
51,000 cyd of concrete (Rotterdam Plant)
Critical on site assembly activities
Construction
Works
Modularization
Peak number of worker on site (400-600)
Mechanical
Different hazardous areas (different risks)
Welding: > 80,000 inches
Pipe Rack: 4,500 ft. (approx. 135,000 ft. of pipe)
Silos: up to 9,500 cyd/silo
100 tanks (up to 2.1 MMG)
Cogeneration (up to 45 MW)
Electrical – I&C
170 km. cables
4,500 instruments
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Conclusions I
General Objectives
Maximize Bioethanol/Co-products Production
Minimize Period for Commercial Operation
Best cost-effective solution (bankable project)
EPC - Driving Parameters
Technology supplier
Energy efficiency optimization (Design and Construction)
Minimization of self-consumption (Design and Construction)
Reduction of construction and assembly risks (Project Manag.)
Delivery time of critical equipment (Project Management)
Optimize plant efficiency during Start-Up (Expertise)
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Conclusions II
EPC Contractor
Expertise in diversifying portfolio of projects:
Batch
Continuous
Second Generation
Strong and specialized design and engineering capabilities
Process engineering
Own capabilities
Cooperation/Alliances (technology supplier, manufacturers,…)
Involvement in relevant R&D activity
Multidisciplinary references (Bioethanol, Power, WTP, WWP, I&C,…)
The successful EPC Contractor must help the developer and owner
to achieve their Business Model
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Thanks for your attention!
ABENER
ABENER
Campus Palmas Altas
41012 - Sevilla (Spain)
Tel. +(34) 954 937 000
[email protected]
www.abener.com
14522 South Outer Forty Road
Chesterfield, MO 63017
Tel. 314 275 1100
Fax 314 275 2408
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