Liquid Transportation Fuels from Coal and Biomass Technological Status, Costs, and Environmental Impacts (2009) / Chapter Skim
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Appendix I: Modeling of Capital and Operating Costs and Carbon Emissions of Ethanol Plants with SuperPro Designer®
Appendix I: Modeling of Capital and Operating Costs and Carbon Emissions of Ethanol Plants with SuperPro Designer®
Pages 339-358
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From page 339... ...
This appendix will first discuss the composition of different biomass feedstocks, then the ethanol-plant simulation models that the panel used, and finally an example of an economic analysis gener ated by SuperPro Designer. BIOMASS COMPOSITION Feedstock Description: Poplar and High-Sugar/Glucan Biomass Poplar woodchips were used as biomass feedstock for all initial analyses.
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From page 340... ...
For example, a biorefinery that uses poplar woodchips as a feed stock has to include a burner and a steam electrical generator to burn the lignin residue for electricity generation; in contrast, wheat straw does not have enough lignin to provide any energy for the biorefinery. Therefore, the panel also assessed the process economics and environmental effects of biorefineries using different feedstocks.
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From page 341... ...
The two approaches have the same effect, but the former is more efficient. ETHANOL-BIOREFINERY SIMULATION MODELS Model for Corn-Grain-to-Ethanol Plants The corn-grain-to-ethanol process is well developed and understood and is used by 130–150 ethanol plants in the United States alone; hence, it is a good starting point to evaluate the modeling method with SuperPro Designer.
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From page 342... ...
Cellulosic-Plant Model Process Overview There are a lot of similarities between the cellulosic-ethanol and dry-grind corn ethanol manufacturing processes, and they share at least five main basic unit oper ations (Figure I.3) : size reduction, saccharification, fermentation, distillation, and solids separation (centrifugation)
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From page 343... ...
Included are also the few heat exchangers outside the units that were difficult to model otherwise and that seem to be present in most of the currently explored configurations both in the literature and in discussions with industry. SuperPro Designer probably models some units -- such as the centrifuge, the fermentor and reaction bins, and the drum dryer -- after the actual physical units.
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From page 344... ...
ALTF Appendix I-2
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From page 345... ...
SuperPro Designer® Network Model Description The process is modeled in SuperPro Designer® as a batch process of 19 unit operations (including heat exchangers and flow splitters and mixers) in which some units run in continuous mode (see Figure I.4)
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From page 346... ...
The processing units that have been set as continuous in the network are storage, the shredder, distillation, centrifugation, the drum dryer, the burner, the steam turbine generator, and all mixers, splitters, and heat exchangers. In contrast, reactor-vessel procedures, such as preprocessing and saccharifica tion, could not be resized according to their shorter processing time with respect to fermentation.
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From page 347... ...
1 (Hot Water) Yeast T/Steam Turbine P-3/V-101 S-104 Saccharification Fermentation Turbine Burner P-4/V-102 P-5/V-103 Steam Ash P-9/Burner Water FIGURE I.4 SuperPro Designer® network model for cellulosic-ethanol manufacturing process.
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From page 348... ...
In this design, the fermented mixture distilland is heated as much as possible before entering the distillation sys tem by heat exchange with both the bottoms stream and the residual liquid stream not used as backset and by the evaporated water stream from the drying step. This approach saves as much heat energy as possible for the model.
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From page 349... ...
This unit, nonetheless, was used for separating the real steam generated from the CO2 and water stream resulting from the residual solids burn and was also used to cost the steam turbine. That was achieved after further calculations to find the real available steam for electrical-power output -- and therefore the size of the unit -- were carried out separately in an Excel spreadsheet.
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From page 350... ...
. The actual distillation stage would include a beer column, a rectifier column, a molecular sieve, and a stripper col umn, but the value and the behavior of this set of components were appropriately emulated by the single column modeled in this analysis.
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From page 351... ...
2002. Lignocellulosic Biomass to Ethanol Process Design and Economics Utilizing Co-Current Dilute Acid Prehydrolysis and Enzymatic Hydrolysis for Corn Stover.
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From page 352... ...
EXECUTIVE SUMMARY (2008 prices) Total Capital Investment 207923000.00 $ Capital Investment Charged to This Project 207923000.00 $ Operating Cost 81119000.00 $/yr Production Rate 119454958.36 kg MP/yr Unit Production Cost 0.68 $/kg MP Total Revenues 116032000.00 $/yr Gross Margin 30.09 % Return on Investment 10.91 % Payback Time 9.16 years IRR (After Taxes)
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From page 353... ...
Appendix I 1/0/0 DDR-101 Drum Dryer 160000.00 160000.00 Drum Area = 59.88 m2 1/0/0 DC-101 Decanter Centrifuge 2748000.00 2748000.00 Throughput = 4400.64 L/min 1/0/0 FSP-101 Flow Splitter 0.00 0.00 Size/Capacity = 207810.03 kg/h 1/0/0 SR-101 Shredder 182000.00 182000.00 Size/Capacity = 102938.72 kg/h 1/0/0 SB-101 Solids Bin 771000.00 771000.00 Vessel Volume = 12110.44 m3 1/0/0 C-101 Distillation Column 4782000.00 4782000.00 Column Volume = 182.20 m3 1/0/0 V-104 Seed Fermentor 7200000.00 7200000.00 Vessel Volume = 13056.19 L 1/0/0 Burner Generic Box 9290000.00 9290000.00 Size/Capacity = 1352538.12 kg/h 2/0/0 HX-102 Heat Exchanger 23000.00 46000.00 Heat Exchange Area = 95.36 m2 2/0/0 HX-103 Heat Exchanger 14000.00 28000.00 Heat Exchange Area = 51.18 m2 1/0/0 MX-101 Mixer 0.00 0.00 Size/Capacity = 182244.79 kg/h 1/0/0 HX-105 Heat Exchanger 90000.00 90000.00 Heat Exchange Area = 5488.56 m2 1/0/0 MX-102 Mixer 0.00 0.00 Size/Capacity = 205863.81 kg/h 1/0/0 MX-103 Mixer 0.00 0.00 Size/Capacity = 127857.22 kg/h 1/0/0 Steam Generic Box 13530000.00 13530000.00 Turbine Size/Capacity = 1350432.04 kg/h Unlisted Equipment 0.00 TOTAL 56791000.00 continues
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From page 354... ...
Contingency 23552000.00 CFC = 12+13 31407000.00 3E. Direct Fixed Capital Cost (DFC = TPC+CFC)
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MATERIALS COST - PROCESS SUMMARY Unit Cost Annual Amount Annual Cost Bulk Material ($/kg)
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From page 356... ...
- PROCESS SUMMARY Annual Reference Annual Utility Amount Unit Cost ($) % 56,800,000 kWh 0.00 0.00 6 MW Electricity Available Energy from 475,974,147 kWh 0.00 0.00 54 MW Steam 43 MW Usable Steam Energy 380,779,318 kWh 0.00 0.00 (80%)
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From page 357... ...
- PROCESS SUMMARY Cost Item $ % Raw Materials 42311000.00 52.16 Labor-Dependent 3984000.00 4.91 Facility-Dependent 31616000.00 38.97 Consumables 0.00 0.00 Waste Treatment/Disposal 0.00 0.00 Utilities 3209000.00 3.96 Miscellaneous 0.00 0.00 Advertising/Selling 0.00 0.00 Running Royalties 0.00 0.00 Failed Product Disposal 0.00 0.00 TOTAL 81119000.00 100.00 Annual Operating Cost Breakdown (%) Utilities (4%)
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From page 358... ...
Revenue Stream Flowrates Total Flow of Stream EtOH 119454958.00 kg/yr Total Flow in Steam 10153761372.00 kg/yr Total Production of Recovered Steam 9,999,000,000 kg/yr Total Energy Content of Recovered Steam 2,844,215,150,040 kJ/yr Total Requirements of Steam (High P) 652,362,126 kg/yr Total Energy Content of Steam (High P)
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