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Energy Efficient Bioethanol Production

16.4.2008

Dr. Daniel Bethge

Process Engineering / GEA Wiegand GmbH

Process Engineering / GEA Wiegand

Divisions of GEA Group

Process Engineering / GEA Wiegand

Process Engineering Division

Niro A/SNiro Inc.Niro Pharma SystemsAeromatic-Fielder Barr-RosinCollette NVCourtoy NVGEA Liquid Processing ScandinaviaGEA Wiegand GmbHGEA Process Engineering France SAS- Kestner Division- Niro Evaporator Division

Evaporator Department Niro Inc.GEA Messo AGGEA Messo GmbHGEA Jet Pumps GmbHGEA Filtration (Niro Inc.)Tuchenhagen Brewery SystemsTuchenhagen Dairy Systems

Strategic Business UnitEvaporation, Distillation &

Crystallization

Process Engineering / GEA Wiegand

History

Process Engineering / GEA Wiegand

History

Process Engineering / GEA Wiegand

Research and Development

R&D Competence Centre of the Strategic Business UnitGEA Evaporation & Crystallization

Stationary & Mobile Pilot Plants for:

- Fermentation

- Distillation, Rectification

- Dehydration

- Evaporation

- Membrane Filtration

- Crystallization

Laboratory / Analysis

Process Engineering / GEA Wiegand

Apparatus Engineering

certified according to:- DIN ISO 9001- ASME U-Stamp- UDT

certified according to:- DIN ISO 9001- ASME U-Stamp- UDT

Our workshop Beckum:• Tanks• Columns• Heat Exchangers• Storage tanks• Torospherical heads• Flanges• Manholes• Special construction

(New: Third Party Component Manufacturing)

Process Engineering / GEA Wiegand

After Sales Support

• Competent customer service

• Worldwide technical assistance

• Quick and reliable spare part procurement

• Disassembly and reassembly

• Remote support service

Process Engineering / GEA Wiegand

Rectification system for drinking alcohol, 4-column system for the purification of crude alcoholDaily capacity: 120,000 litres of alcohol

Distillation Expertise

Rectification/Distillation Plants

Ethanol(complete turn-key plants)

Drinking alcohol (Vodka)

Glycerine, Isopropanol, Methanol, Solvent recovery

Fermentation(Batch & Continuous)

Molecular sieves

(Dehydration)

Approx. 50 plants have been delivered

Process Engineering / GEA Wiegand

Market Trend

World Ethanol production in Mio To/year

0

20

40

60

80

100

120

2000 2005 2010 2015 2020

Process Engineering / GEA Wiegand

Bioethanol from Grain

ProcessWater

Rectification

Milling +Bran SeparationGrain

Ethanol

DDGS

SaccharificationLiquefactionMashing Fermentation

Enzyme Enzyme CO2

Ethanolstorage Dehydration Distillation

DDGS dryerHigh-

concentrator Decanter

Retentate

Permeate

Condensatpolisher Lutterwater

Pre-evaporator

Process Engineering / GEA Wiegand

Energy Cost

2%9%

39%8%

42%

Percentage of the total energy cost forthe different areas

Milling

Liquefaction/ Fermentation

Distillation, rectification, dehydration

Decantation, evaporation

Drying, pelletizing

capacity: 380.000 l/ dayraw material: cornrecycle stillage : 20%costs of energy: 20€/t steam, 0,07€/KWh electricity, 0,3 €/kg natural gas

Process Engineering / GEA Wiegand

Bioethanol Technology

Process Engineering / GEA Wiegand

Bioethanol Technology

Process Engineering / GEA Wiegand

Bioethanol Technology

Process Engineering / GEA Wiegand

Bioethanol Technology

Process Engineering / GEA Wiegand

Bioethanol Technology

Process Engineering / GEA Wiegand

Advantage

Steam costs ≈ 24 euro / t

Electric energy ≈ 0.08 euro / kWh

Production costs → -2 cent per litre ethanol

380,000 litre per day x 0.02 euro = 7,600 euro per day

7,600 euro per day x 330 days per annum =

Additional earnings: 2,500,000 euro per annum

Process Engineering / GEA Wiegand

Customer Benefits

* based on 100.000 tons p.a. ethanol plant

• Energy saving: 50 %

• CO2 reduction: 15,000 tons p.a. *

• Customer needs less marketable pollution rights

• Additional earnings: 2,500,000 euro p.a. *

Process Engineering / GEA Wiegand

Distillation Towers during Assembly

Process Engineering / GEA Wiegand

MVR

Process Engineering / GEA Wiegand

One-Stop Delivery

decanters

driers

tank farms

ejectors, gas scrubbers

plate heat exchangers

membranes

spirit concentration meters

cooling towers

Process Engineering / GEA Wiegand