1. BALIKESİR ETHANOL PLANT

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

3. 1-GENERAL INFORMATION PRODUCT AND CAPACITY PLANT LOCATION
RAW MATERIAL SELECTION
PLANT LAYOUT

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

5. 1-GENERAL INFORMATION PRODUCT AND CAPACITY PLANT LOCATION
RAW MATERIAL SELECTION
PLANT LAYOUT

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

7. 1-GENERAL INFORMATION PRODUCT AND CAPACITY PLANT LOCATION
RAW MATERIAL SELECTION
PLANT LAYOUT

8. 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.

9. 1-GENERAL INFORMATION PRODUCT AND CAPACITY PLANT LOCATION
RAW MATERIAL SELECTION
PLANT LAYOUT

10. 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

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

12. 2- MAIN UNITS OF THE PLANT
FERMENTATION UNIT
DISTILLATION UNIT
DEHYDRATION UNIT
EVAPORATION UNIT

13. 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.

14. 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

15. 2- MAIN UNITS OF THE PLANT
FERMENTATION UNIT
DISTILLATION UNIT
DEHYDRATION UNIT
EVAPORATION UNIT

16. 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.

17. 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

18. 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

19. 2- MAIN UNITS OF THE PLANT
FERMENTATION UNIT
DISTILLATION UNIT
DEHYDRATION UNIT
EVAPORATION UNIT

20. 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.

21. 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 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 m
The diameter of the one adsorption column is m.
Produced CO2 in fermentation unit is used for the regeneration.

22. 2- MAIN UNITS OF THE PLANT
FERMENTATION UNIT
DISTILLATION UNIT
DEHYDRATION UNIT
EVAPORATION UNIT

23. 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.

24. FLOW SHEET OF THE EVAPORATION UNIT
Inlet concentration
0.01
Outlet concentration
0.60
Steam
°C, 205kPa
Average area
119 m2
Steam economy
2.88

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

26. 3-ECONOMIC ANALYSIS OF THE PLANT
INVESTMENT COST
PRODUCTION COST
BREAK-EVEN POINT&NET PRESENT WORTH

27. 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

28. 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

29. 3-ECONOMIC ANALYSIS OF THE PLANT
INVESTMENT COST
PRODUCTION COST
BREAK-EVEN POINT&NET PRESENT WORTH

30. 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

31. 3-ECONOMIC ANALYSIS OF THE PLANT
INVESTMENT COST
PRODUCTION COST
BREAK-EVEN POINT&NET PRESENT WORTH

32. 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

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

34. 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

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