Engineering Biorefineries Into Reality
Cdpres 43/GAE/GI.prn/O’Brien & Gere/0307/TPM Biorefinery in NY_0307.ppt
360º Engineering & Project Delivery Solutions
Cdpres 43/GAE/GI.prn/O’Brien & Gere/0307/TPM Biorefinery in NY_0307.ppt
O’Brien & Gere - A National Profile
¾ National rankings
ƒ Top 500 design firms
ƒ Top 100 construction management
firms
ƒ Top 250 design-builders
¾ Winner of national ACEC awards
¾ ISO Certified Quality Management
System
¾ LEED Accreditation
Cdpres 43/GAE/GI.prn/O’Brien & Gere/0307/TPM Biorefinery in NY_0307.ppt
Solutions & Services
Capital & Facilities
Solutions
Environmental
Solutions
Total Water
Solutions
Energy
Air Quality
Conveyance
Research & Development
Facilities
Brownfield Redevelopment
Dams & Reservoirs
EHS & Due Diligence
Reuse & Conservation
SureCloseTM
Decommissioning &
Facility Closure
Site Engineering
Clean Manufacturing
Facilities
Industrial Manufacturing
Facilities
Integrated Process
Systems & Technology
Utilities & Infrastructure
Cdpres 43/GAE/GI.prn/O’Brien & Gere/0307/TPM Biorefinery in NY_0307.ppt
Eco-Sciences
Investigation & Remediation
Vaprōtect® Vapor Intrusion
Wastewater
Water
Wet Weather
Energy Markets
Traditional Power Generation
y Infrastructure
y APC / Duct Injection
y Related Environmental
Control / Compliance
y Central Utility Plants – Industry
y Combined Heat & Power
y Water Supply / Treatment
Alternative / Renewable Energy
y Biofuels / Biomass
Ethanol (corn & cellulosic-based)
Biodiesel
Biogas
Biomass to Energy
y
y
y
y
y
DG/CHP
Wind – Small wind turbines
Energy Storage
Fuel Cells
Solar / Photovoltaic
Sustainability
y Carbon/GHG Management
y Energy Audits / Management
Cdpres 43/GAE/GI.prn/O’Brien & Gere/0307/TPM Biorefinery in NY_0307.ppt
y Carbon Sequestration
y Energy Efficiency
360o Engineering & Project Delivery
Cdpres 43/GAE/GI.prn/O’Brien & Gere/0307/TPM Biorefinery in NY_0307.ppt
Please Visit Us At: www.obg.com
Cdpres 43/GAE/GI.prn/O’Brien & Gere/0307/TPM Biorefinery in NY_0307.ppt
Cdpres 43/GAE/GI.prn/O’Brien & Gere/0307/TPM Biorefinery in NY_0307.ppt
U.S. Ethanol Biorefinery Locations
Cdpres 43/GAE/GI.prn/O’Brien & Gere/0307/TPM Biorefinery in NY_0307.ppt
Biorefinery Life Cycle
RESEARCH &
DEVELOPMENT
REGULATORS
CONSUMERS
EPA, DEC, Etc.
CELLULOSIC
ETHANOL
FINANCING
$$$
EPC DESIGN BUILD
TEAMS
Subcontractors, Venders,
Suppliers
FEEDSTOCK
Willows, Hardwoods,
Switchgrass, Citrus Peels
Cdpres 43/GAE/GI.prn/O’Brien & Gere/0307/TPM Biorefinery in NY_0307.ppt
POLICY
Project Execution Process
Cdpres 43/GAE/GI.prn/O’Brien & Gere/0307/TPM Biorefinery in NY_0307.ppt
Project Execution Plan
¾ Planning is key to success
ƒ Basis of design / process confirmation
ƒ Design deliverables
ƒ Permit strategy
ƒ Procurement / pre-construction plan
ƒ Cost estimate schedule
ƒ Process safety / health & safety plan
ƒ Stage gate process
¾ Detail design / construction
¾ Change management
¾ Start-up / commissioning / optimization
Cdpres 43/GAE/GI.prn/O’Brien & Gere/0307/TPM Biorefinery in NY_0307.ppt
Biorefinery in New York Implementation Approach
Stage Gate Process
PRESENT
MARCH 2008
DEVELOPMENT
STUDY / CONCEPT
DESIGN
MAY 2008
BOD
JULY 2009
DESIGN / CONSTRUCTION
2012
OPERATIONS /
OPTIMIZATION
LAB TESTING
GO
NOGO
GO
NOGO
BOD
PROCURE
PROCESS
EQUIPMENT
PROCUREMENT
CONSTRUCTION
PERMITTING
GO
NOGO
CONSTRUCTION
START UP
OPERATIONS
OPERATIONS /
OPTIMIZATION
OPTIMIZATION
COMMERCIAL SCALE
Cdpres 43/GAE/GI.prn/O’Brien & Gere/0307/TPM Biorefinery in NY_0307.ppt
DETAILED DESIGN
GO
NOGO
Study/Concept Development
¾ Transition between R&D and design
¾ Integrated research/engineering team
¾ Management of team to focus on:
ƒ Bench-scale testing / pilot testing
ƒ Process performance
ƒ System scale-up
ƒ Constructability
ƒ Operability
¾ Basis of Design
¾ Stage Gate Decision Step
Cdpres 43/GAE/GI.prn/O’Brien & Gere/0307/TPM Biorefinery in NY_0307.ppt
Design
¾
¾
¾
Build in flexibility
ƒ Major Unit Processes
ƒ Material Handling
ƒ Utilities/Infrastructure
Permit specific input
Detailed Design Packages
¾
Major equipment
procurement packages
¾
Value engineering/haz-op/
constructability reviews
Stage Gate Decision Step
¾
Cdpres 43/GAE/GI.prn/O’Brien & Gere/0307/TPM Biorefinery in NY_0307.ppt
Procurement & Construction
¾ Construction Sequence Planning
¾ Procurement
– Competitive Bid Process
– Expediting/Material tracking
– Stage Gate Decision Step
¾ Construction Management
–
–
–
–
Schedule & Cost Control
Site/Quality Control
RFI Processing
Progress Reporting
¾ Health & Safety
¾ Start-up/Commissioning
– Integrated Start-up And
Commissioning Team
¾ System Operations
Cdpres 43/GAE/GI.prn/O’Brien & Gere/0307/TPM Biorefinery in NY_0307.ppt
Process Optimization
¾ Goal of Optimization Process
ƒ Demonstration to Commercial Scale Facility
¾ Tie to Design and Operations Plan
ƒ Utility Usage and Trending
ƒ Process Yield Optimization
ƒ Scale-up Factors
ƒ Production Capacity
ƒ Financial and Market Analysis
¾ Stage Gate Decision Step
Cdpres 43/GAE/GI.prn/O’Brien & Gere/0307/TPM Biorefinery in NY_0307.ppt
Execution Challenges
¾ Integration of Known Equipment Technology and New
Technology
ƒ Known Technology - Heat Exchange, Filtration,
Utilities & Infrastructure, Distillation
ƒ Development Technology - Continuous Digestion,
Hydrolysis (Enzyme Vs Acid), Continuous
Economical Fermentation
ƒ Development of Bio-Products
¾ Freezing the “Process Design”
¾ Balance Capital/O&M with Economic Projections
Cdpres 43/GAE/GI.prn/O’Brien & Gere/0307/TPM Biorefinery in NY_0307.ppt
Execution Challenges
¾ Integration of Diverse Groups
ƒ Colleges/Universities
ƒ Government Policy
ƒ Design/Vendors/Contractors
ƒ Natural Resources
¾ Product Distribution Infrastructure
Cdpres 43/GAE/GI.prn/O’Brien & Gere/0307/TPM Biorefinery in NY_0307.ppt