Process engineering
Critical Aspects in Engineering and Construction of a Bioethanol Plant
A B EN ER Engineering and Construction for Sustainability
A B EN ER A B EN ER International Engineering & Construction Co. Sevilla, Spain Jose Javier – Commercial Director
A B EN ER North America St. Louis, MO Chris Hutson – Business Development Director Cap Kovarik – Business Development Manager
Engineering network – Spain, USA, Holland, Algeria, Morocco, Mexico, Brazil Focus – Biofuels, Solar Energy, Power Generation
2
A B EN ER
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
3
A B EN ER A B EN ER Europe – five(5) biofuels projects Wheat, barley, corn, biomass
A B EN ER North America USA – four(4) biofuels projects Corn, biomass
4
A B EN ER
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
5
A B EN ER
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)
6
A B EN ER
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 7
A B EN ER
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
8
A B EN ER
Critical Aspects – 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
9
A B EN ER
Critical Aspects – 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 10
A B EN ER
Critical Aspects – 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
11
A B EN ER
Critical Aspects – 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
12
A B EN ER
Conclusions I
General Objectives ü Maximize Bioethanol/Co-products Production ü Minimize Period for Commercial Operation ü Best cost-effective solution (bankable project)
EPC - Driving Parameters ü Technology supplier ü Energy efficiency optimization (Design and Construction) ü Minimization of self-consumption (Design and Construction) ü Reduction of construction and assembly risks (Project Manag.) ü Delivery time of critical equipment (Project Management) ü Optimize plant efficiency during Start-Up (Expertise)
13
A B EN ER
Conclusions II
EPC Contractor 9 Expertise in diversifying portfolio of projects: 9 Batch 9 Continuous 9 Second Generation
9 Strong and specialized design and engineering capabilities 9 Process engineering 9 Own capabilities
9 Cooperation/Alliances (technology supplier, manufacturers,…) 9 Involvement in relevant R&D activity 9 Multidisciplinary references (Bioethanol, Power, WTP, WWP, I&C,…)
The successful EPC Contractor must help the developer and owner to achieve their Business Model 14
A B EN ER
Thanks for your attention! A B EN ER
A B EN ER
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 5800 Fax 314 275 5801 15
A B EN ER Engineering and Construction for Sustainability
A B EN ER A B EN ER International Engineering & Construction Co. Sevilla, Spain Jose Javier – Commercial Director
A B EN ER North America St. Louis, MO Chris Hutson – Business Development Director Cap Kovarik – Business Development Manager
Engineering network – Spain, USA, Holland, Algeria, Morocco, Mexico, Brazil Focus – Biofuels, Solar Energy, Power Generation
2
A B EN ER
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
3
A B EN ER A B EN ER Europe – five(5) biofuels projects Wheat, barley, corn, biomass
A B EN ER North America USA – four(4) biofuels projects Corn, biomass
4
A B EN ER
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
5
A B EN ER
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)
6
A B EN ER
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 7
A B EN ER
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
8
A B EN ER
Critical Aspects – 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
9
A B EN ER
Critical Aspects – 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 10
A B EN ER
Critical Aspects – 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
11
A B EN ER
Critical Aspects – 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
12
A B EN ER
Conclusions I
General Objectives ü Maximize Bioethanol/Co-products Production ü Minimize Period for Commercial Operation ü Best cost-effective solution (bankable project)
EPC - Driving Parameters ü Technology supplier ü Energy efficiency optimization (Design and Construction) ü Minimization of self-consumption (Design and Construction) ü Reduction of construction and assembly risks (Project Manag.) ü Delivery time of critical equipment (Project Management) ü Optimize plant efficiency during Start-Up (Expertise)
13
A B EN ER
Conclusions II
EPC Contractor 9 Expertise in diversifying portfolio of projects: 9 Batch 9 Continuous 9 Second Generation
9 Strong and specialized design and engineering capabilities 9 Process engineering 9 Own capabilities
9 Cooperation/Alliances (technology supplier, manufacturers,…) 9 Involvement in relevant R&D activity 9 Multidisciplinary references (Bioethanol, Power, WTP, WWP, I&C,…)
The successful EPC Contractor must help the developer and owner to achieve their Business Model 14
A B EN ER
Thanks for your attention! A B EN ER
A B EN ER
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 5800 Fax 314 275 5801 15
