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