Balikes r ethanol plant
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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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Balikes r ethanol plant

BALIKESİR ETHANOL PLANT


Outline

OUTLINE

GENERAL INFORMATION

MAIN UNITS OF THE PLANT

ECONOMIC ANALYSIS OF THE PLANT

DISCUSSION AND CONCLUSION


1 general information

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

PRODUCT AND CAPACITY


1 general information1

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

PLANT LOCATION


1 general information2

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.

RAW MATERIAL SELECTION


1 general information3

1-GENERAL INFORMATION

  • PRODUCT AND CAPACITY

  • PLANT LOCATION

  • RAW MATERIAL SELECTION

  • PLANT LAYOUT


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

PLANT LAYOUT


Outline1

OUTLINE

GENERAL INFORMATION

MAIN UNITS OF THE PLANT

ECONOMIC ANALYSIS OF THE PLANT

DISCUSSION AND CONCLUSION


2 main units of the plant

2- MAIN UNITS OF THE PLANT

  • FERMENTATION UNIT

  • DISTILLATION UNIT

  • DEHYDRATION UNIT

  • EVAPORATION UNIT


Fermentation 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

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 plant1

2- MAIN UNITS OF THE PLANT

  • FERMENTATION UNIT

  • DISTILLATION UNIT

  • DEHYDRATION UNIT

  • EVAPORATION UNIT


Distillation 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

FLOW SHEET OF THE DISTILLATION UNIT


Specifications of the columns

SPECIFICATIONS OF THE COLUMNS


2 main units of the plant2

2- MAIN UNITS OF THE PLANT

  • FERMENTATION UNIT

  • DISTILLATION UNIT

  • DEHYDRATION UNIT

  • EVAPORATION UNIT


Dehydration 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

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 plant3

2- MAIN UNITS OF THE PLANT

  • FERMENTATION UNIT

  • DISTILLATION UNIT

  • DEHYDRATION UNIT

  • EVAPORATION 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

FLOW SHEET OF THE EVAPORATION UNIT


Outline2

OUTLINE

GENERAL INFORMATION

MAIN UNITS OF THE PLANT

ECONOMIC ANALYSIS OF THE PLANT

DISCUSSION AND CONCLUSION


3 economic analysis of the plant

3-ECONOMIC ANALYSIS OF THE PLANT

  • INVESTMENT COST

  • PRODUCTION COST

  • BREAK-EVEN POINT&NET PRESENT WORTH


Investment cost

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


Balikes r ethanol plant

  • Fixed Capital Investment: $13,346,000

  • Working Capital: $2,002,000

  • Total Capital Investment: $15,348,000


3 economic analysis of the plant1

3-ECONOMIC ANALYSIS OF THE PLANT

  • INVESTMENT COST

  • PRODUCTION COST

  • BREAK-EVEN POINT&NET PRESENT WORTH


Production cost

PRODUCTION COST

  • Total product cost: $23,839,000

  • Fixed cost: $9,139,000

  • Variable cost: $14,700,000


3 economic analysis of the plant2

3-ECONOMIC ANALYSIS OF THE PLANT

  • INVESTMENT COST

  • PRODUCTION COST

  • BREAK-EVEN POINT&NET PRESENT WORTH


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


Outline3

OUTLINE

GENERAL INFORMATION

MAIN UNITS OF THE PLANT

ECONOMIC ANALYSIS OF THE PLANT

DISCUSSION AND CONCLUSION


Discussion 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

THANKS FOR YOUR CONSIDERATION

GROUP E

  • BESTE ERİŞ

  • BİLGE KILIÇ

  • SEDA ÇAKIR

  • TUĞBA ÇEVİK


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