eng practices for the commercialization of biorefineries r pagel

Baisch Engineering, Inc. | 809 Hyland Avenue | Kaukauna, WI 54130 | 920.766.3521 | www.baisch.com

Engineering Practices for the

Commercialization of a Biomass/Biorefinery

Presented by:

Ron PagelSr. Process Engineer/Project Manager

Baisch Engineering Inc.

International Biomass Conference

May 4-6, 2010 ~ Minneapolis, MNBaisch Booth # 435


• Founded in 1958 in Kaukauna, Wisconsin

• 90 Person Staff, Full Service E&A Firm

• Privately Held, Active Ownership

• Process Driven Company

WHO IS BAISCH?

Provides consulting engineering services to clients throughout North America, Mexico, and worldwide.

Completed over 4500 projects, 3500 since 1990

Provides engineering for $250 million of capital projects per year


PRESENTATION OVERVIEW

Application of Standard Engineering Practices

Working with Technology Partners

Biomass Handling / Logistics

Yield of Various Biomass Species

Questions and Answers


BEGIN WITH THE END IN MIND

“Keep the main thing, the main thing!”


PROJECT TEAM ALIGNMENT

• Owner

• Owner’s Engineer

• Technology Partner

• Environmental Partner

• Contractor

• Financial Partner

• Supply Partner

BEGIN WITH THE END IN MIND


BIOREFINERY PLATFORMS

•Sugar Platform

•Thermochemical Platform

•Biogas Platform

•Carbon-rich Chains Platform

•Plant Products Platform

APPLICATION OF STANDARD

ENGINEERING PRACTICES


WHAT IS THE BIOREFINERY INTENDED TO PRODUCE?

• Ethanol, biodiesel, methanol, bioplastics, clean water, drop in fuels, etc. in XX million gallons per year

• Power

• Co-products




BIOFUELS – CHEMICAL AND BIOLOGICAL PREPARATION

•Micro-organism propagation, storage and use

•Enzyme production and storage

•Micronutrient unloading and storage

•Utility chemicals

•CIP – Sterilization Practices




BIOFUELS FERMENTATION

•Aerobic vs. anaerobic

•Continuous vs. batch, sequencing

•Fermentor feed and control

•Sterilization

•Vessel design

•Inert gas blanketing

•CO2 recovery




BIOFUELS FINISHING

•Distillation, dehydration & evaporation optimization

•Energy recovery

•Vapor recompression

•Energy optimization




BIOFUELS STORAGE AND HANDLING

•Tank farm layout and design

•Rail and truck load-out

•Vapor recovery

•Denaturing / Blending




BIOFUELS UTILITIES

•Steam

•Chilling & cooling

•Compressed air

•Waste recovery for energy use

•Biomass burners / Gasification

•Natural gas supply




FEL1 – FEASIBILITY STUDY – PRELIMINARY ENGINEERING

CLASS 50 ESTIMATE

• “What if ” stage…

• +/- 50% Capital Estimate (CapEx)

• General sketches as to what the plant may look like

• Estimated volume pricing, such as $2.00/Gal EtOH to build






FEL2 – PRELIMINARY ENGINEERING

CLASS 20 ESTIMATE

• +/- 20% Capital Estimate

• Identify preliminary operating expenses (OpEx)

• Preliminary Process Flow Diagrams

• Preliminary General Arrangement drawing

• Preliminary mass balance

• Intended to have budgetary pricing on all major equipment and components




FEL3 – FUNDING GRADE ESTIMATE

CLASS 10 ESTIMATE (ISSUE FOR CONSTRUCTION ENGINEERING PACKAGE)

• Detailed Cost Estimate

• Detailed Process and Instrumentation Drawings

• Computer simulation / model of the process – mass and energy balance

• Detailed General Arrangement, elevation & piping drawings –sufficient to acquire material takeoffs

• Firm pricing on major equipment

• Scope of work document to include basis of estimate


WHAT IS THE AVAILABILITY OF RAW MATERIALS IN

RELATIONSHIP TO THE PROJECT SITE?

• Radius the client site is willing to draw from by truck or rail

• Cost of the raw material

• Handling of the raw material

• Unloading & Storage of the raw material




CONSTRUCTION PARTNERS

Determine the type of construction

1. Pre-engineered buildings vs. traditionally designed structures

2. Steel construction vs. concrete

• Driven by the end product− 3A Food Plant− Agricultural or fuel grade co-products

• Material specifications – carbon steel vs. stainless steel





Engage the Contractor partner as soon as possible

1. Single source

2. Competitively bid





As the project engineer is acting on the owner’s behalf, it is the responsibility of the engineering team to “qualify” the construction partner (General Contractor):

1. Safety culture and record

2. Number of similar facilities completed - schedule and budget records

3. Union or non-union or prevailing wages

4. Complete skill set in-house or subcontract portions of the project execution




ENVIRONMENTAL CONSIDERATIONSListed below are some of the permits that need to be addressed as early as possible.

PERMIT COST ISSUED BY DATE ISSUED

Sidewalk Construction/Driveway Openings County/Township

Driveway Access County/Township

Electrical Permit - Temporary Service County/Township

Building Permit County/Township

Building Permit WI Dept. of Commerce

Plumbing Permit County/Township

Review Petition for Variance WI Dept. of Commerce

Erosion Control/ Permit County/Township

Erosion Control Storm Water Permit County/Township

Erosion Control/Storm Water Permit (NOI) WI Dept. of Commerce

Erosion Control/Storm Water Permit (NOI) WI DNR

Air Permit WI DNR

Petition for Variance - Sprinkler System WI Dept. of Commerce

Fuel Storage Permit WI DNR

WPDES Discharge Permit Application Natural Resource Group, Inc.

Intent Notice of Intent and SWPPP Natural Resource Group, Inc.

Electrical Permit County/Township

Heating Permit County/Township

Scale Installation Permit WI Dept. of Agriculture

Exterior Sight Lighting County/Township

Flammable Liquid Storage - x Tanks County/Township

Total Costs




UTILITY CONSIDERATIONS

• Potable Water / Fire Protection Water volume and quality

• Natural Gas, Liquid Petroleum or Fuel Oil

• Electrical Power & Distribution

• Waste Water Treatment Facility – POTW

• Waste Solids / Co-products




BIOFUELS GENERAL ENGINEERING SUPPORT

•Master planning

•Site design

•Buildings and foundations

•Road and rail

•Process design

•Process piping

•Controls & Instrumentation

•Power distribution

•Field support services

•TCO-ECO and CCO planning




Definition – a technology partner may be a single source equipment supplier for a specific or unique process within the biorefinery or may be the technology holder for the entire process flow of EtOH production.

WORKING WITH TECHNOLOGY PARTNERS


Equipment required when going from an academic setting to the research lab to the pilot plant and finally commercial scale, grows exponentially to achieve the projected biorefinery output.

BIOMASS HANDLING - LOGISTICS

“40 ft glass stirring rod”


• Fractionation of the ligno-cellulosic feedstock (such as wood)

• Further utilization of the fractionates for net production of a wide range of co-products, including energy

• Low capital investment cost

• Benefit the economy




FEEDSTOCK ANALYSIS:


43%

29%

27%1%

Cellulose

Hemicellulose

Lignin

Ash


TYPICAL COMPOSITION OF WOOD


EXAMPLE: BIOREFINERY PROCESSING

1000 BDTPD of a raw material may require 3-4 days of storage,

additional surge capacity in pretreatment through waste

handling.

If the raw material is logs to chipping:

•Average 50% moisture to handle 2000 TPD of raw material

•Bark is 10% (on average) of the mass. Design consideration -

how to handle the bark if it is not part of the downstream

process?



YIELD OF VARIOUS BIOMASS SPECIES

RAW FEED

YIELD IN GALLONS

OF ETHANOL PER

TON OF BIOMASS

AVERAGE

BU/ACRE

POUNDS

OIL/ACRE

GALLONS

BIODIESEL/ACRE

Molasses5 – ton 69.4

Sugar Cane 21-23

Raw Sugar – ton 135.4

Refined Sugar – ton 141.0

Corn6 107.14 140

Biomass8 70.0 - 250.0

Wheat7 ~ 95.0

Switchgrass 20.0

Soybeans9 45 ~500 66

Sorghum 86

RapeSeed/Canola9 32 ~700 92

5 - Molasses is a byproduct of sugarcane and sugarbeet processing6 - Corn has a yield/bushel of 3 gallons/Bu – with a bushel weighing 56 lbs.7 - Wheat has a yield of x gallons/Bu – with a bushel weighing 60 lbs.8 - Stover, bagasse, saw grass, corn cob, woodchip, etc. research for conversion of lingoncellulose9 - 7.6 lbs of oil are required to produce 1 gallon of biodiesel

End product yield greatly differs between Raw Feed processed.

A mass balance and computer simulation can be done to calculate the volumes of raw material, side streams, and end products.


BIOMASS FERMENTATION

Storage Pretreatment Fermentation

CO2 Recovery

Co-Products

Distillation

Dehydration

Evaporation

Raw MaterialStorage

Distribution

YIELD OF VARIOUS BIOMASS SPECIES


PRESENTATION OVERVIEW

Application of Standard Engineering Practices

Working with Technology Partners

Biomass Handling / Logistics

Yield of Various Biomass Species

Questions and Answers


Thank you for your attention

and for the opportunity

to talk with you

International Biomass Conference

May 4-6, 2010 ~ Minneapolis, MNBaisch Booth # 435

eng practices for the commercialization of biorefineries r pagel

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