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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
