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ABENER Engineering and Construction for Sustainability Optimization Techniques in Engineering and Construction of a Bioethanol Plant.

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Presentation on theme: "ABENER Engineering and Construction for Sustainability Optimization Techniques in Engineering and Construction of a Bioethanol Plant."— Presentation transcript:

1 ABENER Engineering and Construction for Sustainability Optimization Techniques in Engineering and Construction of a Bioethanol Plant

2 ABENER 2 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

3 ABENER 3 Bioethanol - Processes

4 ABENER 4 Europe – five(5) biofuels projects Wheat, barley, corn, biomass ABENER North America USA – four(4) biofuels projects Corn, biomass

5 ABENER 5 Project Name Ecocarburantes EspañolesBioetanol 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 Operation 1999 2002 Process Continuous Batch Participation Full EPC Bioethanol Experiences – Spanish Market

6 ABENER 6 Bioethanol Experiences – Spanish Market Project Name Biocarburantes Castilla y León Location Spain (Salamanca) Client 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 DDGS Electricity (Cogeneration 45 MW) Consumption 226,800 TPY 5,400 TPY Raw Materials Wheat, Barley, Corn, Wine alcohol Biomass (from cereals) Operation 2006 Process Batch n/a Participation Full EPC EPC ( cooperation with Ab.Bioenergy)

7 ABENER 7 Bioethanol Experiences - USA Market Project Name Bioethanol IllinoisBioethanol 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 Co-product DDGS Consumption 905,000 TPY corn Raw Materials Corn Operation 2010 Process Continuous Participation Full EPC

8 ABENER 8 Bioethanol Experiences - European Market Project Name Bioethanol FranceBioethanol 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 Participation Full EPC

9 ABENER 9 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

10 ABENER 10 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

11 ABENER 11 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

12 ABENER 12 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

13 ABENER 13 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

14 ABENER 14 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

15 ABENER 15 Thanks for your attention! ABENER Campus Palmas Altas 41012 - Sevilla (Spain) Tel. +(34) 954 937 000 abener@abener.abengoa.com www.abener.com ABENER 14522 South Outer Forty Road Chesterfield, MO 63017 Tel. 314 275 1100 Fax 314 275 2408


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