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ABENEREngineering and Construction for Sustainability
Optimization Techniques in Engineering and Construction of a Bioethanol Plant
2
ABENER
ABENER North AmericaSt. Louis, MOChris Hutson – Business Development Director
Engineering network – Spain, USA, Holland, Algeria, Morocco, Mexico, Brazil
Focus – Biofuels, Solar Energy, Power Generation
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ABENER Bioethanol - Processes
Receiving Crushing Fermentation C6 Distillation
Natural sugars
CerealsCornWheatBarley
Grain cleaning Milling Cooking Liquefaction Saccharification Fermentation C6 Distillation
Biomass
Receiving Crushing 1st acid Hydrolysis Separation L/S Fermentation C5
2nd acid HydrolysisFermentation C6
Distillation
RawMaterial Preparation SugarGeneration Fermentation Distillation
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ABENER
Project Name 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
Bioethanol Experiences – Spanish Market
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ABENER Bioethanol Experiences – Spanish Market
Project Name 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
Co-product 130,000 TPY DDGSElectricity (Cogeneration 45 MW)
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 Bioethanol Experiences - USA Market
Project Name 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 Bioethanol Experiences - European Market
Project Name 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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ABENER Optimization Techniques – Engineering/Design
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
Process design
Logistics
Biofuels Process
Civil / Structural
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ABENER Optimization Techniques – Engineering/Design
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
Mechanical / Piping
Biofuels Process
Instrument & Control
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ABENER Optimization Techniques – Engineering/Design
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
Electrical
Biofuels Process
Utilities
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ABENER Optimization Techniques – Construction
Roads, rail, barge
Plant roads constructed for required traffic
(200 trucks/day – 25 trucks/hour)
Local codes and governing bodies
Foundations fermenters, silos,…
51,000 cyd of concrete (Rotterdam Plant)
Civil Works
Biofuels Process
Construction Works
Critical on site assembly activities
Modularization
Peak number of worker on site (400-600)
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)
Mechanical
Cogeneration (up to 45 MW)
170 km. cables
4,500 instruments
Electrical – I&C
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ABENER Conclusions I
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)
General Objectives
Maximize Bioethanol/Co-products Production Minimize Period for Commercial Operation Best cost-effective solution (bankable project)
EPC - Driving Parameters
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ABENER
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
Conclusions II
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ABENER
Thanks for your attention!
ABENERCampus Palmas Altas41012 - Sevilla (Spain)Tel. +(34) 954 937 [email protected]
ABENER14522 South Outer Forty Road Chesterfield, MO 63017Tel. 314 275 1100Fax 314 275 2408
