BALIKESİR ETHANOL PLANT

OUTLINE GENERAL INFORMATION MAIN UNITS OF THE PLANT ECONOMIC ANALYSIS OF THE PLANT DISCUSSION AND CONCLUSION

1-GENERAL INFORMATION PRODUCT AND CAPACITY PLANT LOCATION RAW MATERIAL SELECTION PLANT LAYOUT

PRODUCT AND CAPACITY PRODUCT CAPACITY 20,000,000 LT/YEAR ETHANOL 2,200 TONES/YEAR SLOP 219 TONES/YEAR FUSEL OIL

1-GENERAL INFORMATION PRODUCT AND CAPACITY PLANT LOCATION RAW MATERIAL SELECTION PLANT LAYOUT

PLANT LOCATION Located in Balıkesir Organised Industrial Area Raw material availability Close to customers Suitable transportation

1-GENERAL INFORMATION PRODUCT AND CAPACITY PLANT LOCATION RAW MATERIAL SELECTION PLANT LAYOUT

RAW MATERIAL SELECTION SUGAR Sugar beets Sugar cane STARCH Grains Potatoes CELLULOSE Wood Grasses Sugar beet was selected as the raw material. Molasses is the by-product of the sugar beet.

1-GENERAL INFORMATION PRODUCT AND CAPACITY PLANT LOCATION RAW MATERIAL SELECTION PLANT LAYOUT

Administrative building PLANT LAYOUT Dehydration unit Administrative building Sports Area Distillation unit Fermentation unit Evaporation unit Control units Storage tanks Cooling towers Steam generetors Cafeteria Security Parking Area

OUTLINE GENERAL INFORMATION MAIN UNITS OF THE PLANT ECONOMIC ANALYSIS OF THE PLANT DISCUSSION AND CONCLUSION

2- MAIN UNITS OF THE PLANT FERMENTATION UNIT DISTILLATION UNIT DEHYDRATION UNIT EVAPORATION UNIT

FERMENTATION UNIT Glucose 2 Ethanol +2 CO2 Saccharomyces cerevisia is used as the bacteria. Semi-batch operating unit Fermentation operation-36 hours The loading of the reactants-16 hours The fermentation reactions-24 hours The discharge of the products-12 hours 73,000 kg ethanol is produced in each 36 hours.

FLOW SHEET OF THE FERMENTATION UNIT 4 fermentors with 550 m3 capacity 3 yeast tanks with 0.2, 3 and 40 m3 capacities, respectively 2 molasses storage tanks with 3000 m3 capacity 1 water storage tank with 750 m3 capacity 1 sulfuric acid tank with 50 m3 capacity 1 scrubber with 0.42 m diameter and 5.8 m height 1 separator 1 feed tank with 1000 m3 capacity

2- MAIN UNITS OF THE PLANT FERMENTATION UNIT DISTILLATION UNIT DEHYDRATION UNIT EVAPORATION UNIT

DISTILLATION UNIT ChemCad 5.2 is used for the design of the distillation unit. The aim of this unit is to increase the ethanol composition of the mash from 11% to minimum 93%. In order to achieve this goal two distillation columns are used. Both of the distillation columns are chosen as sieve tray SCDS columns.

FLOW SHEET OF THE DISTILLATION UNIT Feed stream kg/h Ethanol 2063 Water 16,782 Acetic acid 97 Lactic acid 57 N-butanol 2 N-propanol 10 2-Mth-1-Butanol 5 Alpha-D-Glucose 14 Acetaldehyde Methanol

SPECIFICATIONS OF THE COLUMNS Inlet stream 11% ethanol 58% ethanol Outlet stream 93% ethanol # of stages 28 35 Feed stage 16 10 Pressure 1 atm Diameter 1.07 m 1.22 m Height 17.08 m 21.35 m

2- MAIN UNITS OF THE PLANT FERMENTATION UNIT DISTILLATION UNIT DEHYDRATION UNIT EVAPORATION UNIT

DEHYDRATION UNIT Dehydration process is used to extract water from alcohol to scale up the alcohol percentage Molecular sieve adsorption Molecular sieve zeolite 3A was used. Temperature-swing cycle is chosen for the adsorption system.

FLOW SHEET OF THE DEHYDRATION UNIT There are two column for adsorption and desorption Increase the ethanol percentage of the feed from 93.4% to 99%. The amount of the zeolite 3A was 2218.45 kg. The adsorption time for one column is assumed 3 hours. Design velocity is assumed 0.5 m/s for the adsorbate The height of the one adsorption column is 4.887 m The diameter of the one adsorption column is 0.917 m. Produced CO2 in fermentation unit is used for the regeneration.

2- MAIN UNITS OF THE PLANT FERMENTATION UNIT DISTILLATION UNIT DEHYDRATION UNIT EVAPORATION UNIT

EVAPORATION UNIT In this unit, water in the waste is evaporated and more concentrated slop is obtained. The feed stream of this unit is the bottom products of the two distillation columns. Triple effect evaporator is used. Raw steam is used as the heating medium.

FLOW SHEET OF THE EVAPORATION UNIT Inlet concentration 0.01 Outlet concentration 0.60 Steam 5726 kg/hr @ 121°C, 205kPa Average area 119 m2 Steam economy 2.88

OUTLINE GENERAL INFORMATION MAIN UNITS OF THE PLANT ECONOMIC ANALYSIS OF THE PLANT DISCUSSION AND CONCLUSION

3-ECONOMIC ANALYSIS OF THE PLANT INVESTMENT COST PRODUCTION COST BREAK-EVEN POINT&NET PRESENT WORTH

INVESTMENT COST Purchased Equipment Cost: Fermentation Unit: $1,120,000 Distillation Unit: $380,000 Dehydration Unit: $107,000 Evaporation Unit: $1,731,000 Total PEC: $3,338,000

Fixed Capital Investment: $13,346,000 Working Capital: $2,002,000 DIRECT COST $ PEC 3,338,000 Installation 1,335,000 Inst.&control 668,000 Piping Insulation 40,000 Electr. Inst. 201,000 Building 1,669,000 Yard imp. 334,000 Service fac. 1,001,000 Land 88,000 Total direct cost 10,008,000 INDIRECT COST $ Engineering& Supervision 1,168,000 Construction 501,000 Contractor’s fee 667,000 Contingency Other costs 334,000 Total indirect cost 3,337,000 Fixed Capital Investment: $13,346,000 Working Capital: $2,002,000 Total Capital Investment: $15,348,000

3-ECONOMIC ANALYSIS OF THE PLANT INVESTMENT COST PRODUCTION COST BREAK-EVEN POINT&NET PRESENT WORTH

PRODUCTION COST Total product cost: $23,839,000 Fixed cost: $9,139,000 MANUFACTURING COST $ Raw material 10,220,000 Operation and supervis. Labor 682,000 Utilities 1,815,000 Maint.&repair 667,000 Supplies&lab 67,000 Local taxes 267,000 Insurance Plant overhead 341,000 Depreciation 1,325,000 Total man.cost 16,053,000 GENERAL EXPENSES $ Administrative 634,000 Distribution& Selling 2,384,000 R&D 1,192,000 General Expenses 3,576,000 Total 7,786,000 Total product cost: $23,839,000 Fixed cost: $9,139,000 Variable cost: $14,700,000

3-ECONOMIC ANALYSIS OF THE PLANT INVESTMENT COST PRODUCTION COST BREAK-EVEN POINT&NET PRESENT WORTH

BREAK-EVEN POINT& NET PRESENT WORTH V=$0.73/lt ethanol S=$0.715/lt ethanol Break Even Point Capacity (n) = F/(S-V) V>S, Break Even Point Capacity<0 Net Present Worth = -$44,453,000

OUTLINE GENERAL INFORMATION MAIN UNITS OF THE PLANT ECONOMIC ANALYSIS OF THE PLANT DISCUSSION AND CONCLUSION

DISCUSSION&CONCLUSION FERMENTATION UNIT Glucose Conversion of glucose to ethanol:0.92 Byproducts:CO2, acetic acid, lactic acid, methanol, butanol, propanol, amyl alcohol and acetaldehyde Semi-batch operating unit Yeast separation Duration of the reaction Flow rates of the raw material

THANKS FOR YOUR CONSIDERATION GROUP E BESTE ERİŞ BİLGE KILIÇ SEDA ÇAKIR TUĞBA ÇEVİK