Diapositiva 1

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Optimization Techniques in Engineering and
Construction of a Bioethanol Plant
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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
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Bioethanol - Processes
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ABENER Europe five(5) biofuels projects Wheat,
barley, corn, biomass
ABENER North America USA four(4) biofuels
projects Corn, biomass
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Bioethanol Experiences Spanish Market
Project Name Ecocarburantes Españoles Bioetanol 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 Wheat, Barley
Operation 1999 2002
Process Continuous Batch
Participation Full EPC Full EPC
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Bioethanol Experiences Spanish Market
Project Name Biocarburantes Castilla y León Biocarburantes Castilla y León
Location Spain (Salamanca) Spain (Salamanca)
Client Biocarburantes Castilla y León, S.A. 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) 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 2006
Process Batch n/a
Participation Full EPC EPC ( cooperation with Ab.Bioenergy)
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Bioethanol Experiences - USA Market
Project Name Bioethanol Illinois Bioethanol 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 88 MMGY
Co-product DDGS DDGS
Consumption 905,000 TPY corn 905,000 TPY corn
Raw Materials Corn Corn
Operation 2010 2010
Process Continuous Continuous
Participation Full EPC Full EPC
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Bioethanol Experiences - European Market
Project Name Bioethanol France Bioethanol 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 Batch
Participation Full EPC Full EPC
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Optimization Techniques Engineering/Design
Biofuels Process

• 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
Civil / Structural
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Optimization Techniques Engineering/Design
Biofuels Process

• 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
Instrument Control
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Optimization Techniques Engineering/Design
Biofuels Process

• 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
Utilities
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Optimization Techniques Construction
Biofuels Process

• 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

• Critical on site assembly activities
• Modularization
• Peak number of worker on site (400-600)
• Different hazardous areas (different risks)
• Welding gt 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)

Construction Works
Mechanical

• Cogeneration (up to 45 MW)
• 170 km. cables
• 4,500 instruments

Electrical IC
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Conclusions I
General Objectives

• Maximize Bioethanol/Co-products Production
• Minimize Period for Commercial Operation
• Best cost-effective solution (bankable project)

EPC - Driving Parameters

• 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)

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Conclusions II
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 RD activity
• Multidisciplinary references (Bioethanol,
  Power, WTP, WWP, IC,)
• The successful EPC Contractor must help the
  developer and owner to achieve their Business
  Model

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Thanks for your attention!
ABENER Campus Palmas Altas 41012 - Sevilla
(Spain) Tel. [phone] abener_at_abener.abeng
oa.com www.abener.com
ABENER 14522 South Outer Forty Road
Chesterfield, MO 63017 Tel. [phone] Fax 314
275 2408