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Optimization Techniques in Engineering and Construction of a Bioethanol Plant

Optimization Techniques in Engineering and Construction of a Bioethanol Plant. ABENER North America St. Louis, MO Chris Hutson – Business Development Director. Engineering network – Spain, USA, Holland, Algeria, Morocco, Mexico, Brazil

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Optimization Techniques in Engineering and Construction of a Bioethanol Plant

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  1. Optimization Techniques in Engineering and Construction of a Bioethanol Plant

  2. 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

  3. Bioethanol - Processes

  4. Bioethanol Experiences – Spanish Market

  5. Bioethanol Experiences – Spanish Market

  6. Bioethanol Experiences - USA Market

  7. Bioethanol Experiences - European Market

  8. 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

  9. 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

  10. 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

  11. 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: > 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 – I&C

  12. 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)

  13. 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 R&D activity • Multidisciplinary references (Bioethanol, Power, WTP, WWP, I&C,…) The successful EPC Contractor must help the developer and owner to achieve their Business Model

  14. Thanks for your attention! ABENER Campus Palmas Altas 41012 - Sevilla (Spain) Tel. +(34) 954 937 000 abener@abener.abengoa.com www.abener.com ABENER 14522 South Outer Forty Road Chesterfield, MO 63017 Tel. 314 275 1100 Fax 314 275 2408

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