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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ABENER
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
abener@abener.abengoa.com
www.abener.com
14522 South Outer Forty Road
Chesterfield, MO 63017
Tel. 314 275 1100
Fax 314 275 2408
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