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BALIKESİR ETHANOL PLANT

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. CAPACITY 20,000,000 LT/YEAR ETHANOL

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BALIKESİR ETHANOL PLANT

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

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

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

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

  8. 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. RAW MATERIAL SELECTION

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

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

  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

  18. SPECIFICATIONS OF THE COLUMNS

  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 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.

  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

  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 • 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 • 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

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