Bioethanol – Fueling Your Success

Bioethanol Production Units – Conception, Engineering and Implementation We Take Responsibility for Our Environment and for Our Customers’ Success Optimized Value Addition Based on Comprehensive Engineering and Technology Know-How Engineering Services Byproduct 1 Milling Liquefaction Saccharification Thin Stillage Stillage Syrup Mash Decantation Evaporation Byproduct 2 Distillation + Dehydration Drying Downstream POWER ALCOHOL Biomass Power Plant Waste Water Treatment Engineering Services 2 Fermentation Mash Flour Utilities Technology Platform GRAIN Technology Platform Bayer Technology Services is the technology compe- tence center for Bayer AG. As experienced partners, we develop the production units that assure efficient implementation of your product development. Years of constant pressure to innovate have paid off with a wealth of unique expertise – in engineering as well as in the field of process technology. The great number of patents we hold on marketable innovations in the area of chemical engineering are proof of our outstanding expertise. Staying in Tune with Nature with Bioethanol Independent studies have shown that fuels produced from bioethanol contribute to the reduction of the CO2 load. Modern process technologies and heat integration have dispelled any doubts about this positive effect. If, in addition to bioethanol-based energy, the producer uses a biomass power plant or a biogas unit, bioethanol production reaches the highest level of CO2 neutrality. We support you in your efforts to combine business success with ecological responsibility. The Right Concept from the Start No two bioethanol projects are alike because each environment is defined by individual parameters. Whether the power plant to supply the energy already exists or whether it is still to be constructed, whether biomass power plants are to be integrated with power generation or with biogas facilities, whether DDGS or other poten- tially recyclable materials result as byproducts – we are ready to consider any option in designing your bio- ethanol unit. We and our specialists will be at your side – from creating the business model to constructing a turn-key facility. In addition to established solutions, we can, above all, offer custom-made plans for success. Bioethanol Opens up a Large Amount of Diversification Potential Independence is not achieved by changing from one dependency to another, but by using freely available resources. Bioethanol is produced from various raw materials world-wide. Each region favors different organic raw materials. In Central and South America it’s sugar cane and molasses, in Asia mainly cassava, and in North America corn. In Europe, the main raw materials are wheat, rye, barley, wheat bran/middlings or sugar beat juice and sugar beat molasses. Bayer Technology Services develops, engineers and imple- ments bioethanol units for all raw materials – always custom-made to meet the client’s requirements. Wheat, the Future European Gold Europe is ideally suited for growing wheat. The climate guarantees excellent yields. And this grain is also readily available in the world-wide market place. Wheat is a reliable basis for bioethanol production and for rapid growth of your success. Production-Integrated Protection of the Environment is a Tradition In the chemical industry, producing a successful brand-name product requires responsible consid- eration of our environment. In this regard, Bayer is among the pioneers. Bayer has for a long time considered the ecological aspects of its production processes. In line with this thinking, Bayer Techno- logy Services has developed new processes for decentralized environmental protection – e.g. waste water recovery units, incinerators and offgas purifi- cation plants. To these we have added innovative concepts for integrating protection of the environ- ment in our production processes. This means that we avoid the generation of solid waste, waste water and offgas in the process chain or that we recycle or eliminate these products. Bayer is also setting benchmarks in the area of CO2 reduction. In-depth studies have been under- taken and, based on the results, Bayer has signifi- cantly reduced CO2 emissions in manufacturing its products – a long time before the public discussion regarding the impact of CO2 emissions in the trans- portation area began. Innovation – the Motor of Economy and Life At Bayer, Innovation has Deep Roots 3 Upstream and Downstream Processes – all from One Source Example 1 Grain Water, Enzymes, Enzymes, Supplies Supplies Lique- Sacchari- faction fication Milling Flour Mash CO2 Sweet Mash Decan- tation Evapo- ration Fermen- tation Distilla- tion Stillage Drying Pelle- tizing Dehydra- tion Wet Cake Animal Feed Example Water, Enzymes, Enzymes, Supplies Supplies Gluten Lique- Sacchari- Separa- faction fication tion Gluten Drying Husking Milling Evapo- ration Drying Pelle- tizing Brans (Byproduct 1) Fusel Oils 2 Grain 4 Ethanol Gluten (Byproduct 2) DDS (Byproduct 3) CO2 Fermen- tation Distilla- tion Dehydra- tion Ethanol Fusel Oils The Entire Spectrum of Processes – Byproducts – the Intelligent Way Quick and Made-to-Measure to Engineer Plants Any investment must first be put to the test. Subject Concepts for modern biorefineries consider byproducts your investment plan to a sound feasibility study at of the production processes and their chances in the Bayer Technology Services and rest assured that it will market place as well. Byproducts have a significant be thoroughly evaluated. We determine all the key influence on the economics of the overall investment in economic data for you. Our results are reliable because a bioethanol process. We break down the raw materials we utilize the combined know-how of many specialists. into their potentially recyclable components, focusing The interdisciplinary exchange of chemical engineering mainly on non-starchy components of the basic materials specialists and engineering experts promotes transpar- and examining them for usability in a variety of animal ency and generates reliable scenarios. In the area of feeds and as food additives. In this way we define whether upstream processes, we work together with Frings the byproducts should be developed as commodities or Austria Co. in Graz, Austria. as specialty products. Of course, you may want to also contribute your own Energy from Biomass Power Plants – key indicators to the study. Or we can consult with you Putting on the Pressure on the basis of the decision criteria you specify. The list of process variations that should be investigated is based on the selection of key indicators: Raw Materials Byproducts Energy Concepts Construction- and Logistics-Related Constraints Local Promotion Programs We Furnish the Following Results: • Process Descriptions including Material and Energy Balances • Consumption • Investment Costs • Operating Costs • Presentation of the Results based on Key Economic Indicators (Rol, ROCE, etc.) Sustainable Processes Based on User Know-How Bayer Technology Services has had close ties to the owners of process units for decades. We begin to make use of this know-how early on, in the planning stage. Whether we are performing a concept study or working on a process design – we keep an eye on the overall process from the start. Especially in the areas of process optimization and tying energy to individual process steps, our know-how comes fully into play. Our process design teams include experts with extensive experience in the areas of project management and production. This is our way of achieving efficiency and assuring flawless opera- tion of your bioethanol unit. This approach during the planning phase transitions seamlessly to the concept of “Owner’s Engineering”. Thereby, sustainable solutions are found and your long-term success is assured. Customer-Specific Solutions • • • • • Bioethanol units with production capacities of several hundred cubic meters per day are particularly well-suited to using energy that is generated in a biomass power plant. This is an economically and ecologically attractive way of producing the power necessary for the manufac- turing process. In combination with a targeted selection of high-value byproducts, thermal utilization of biomass from the process or from locally available raw materials may tip the scales in favor of the investment decision. In addition, it would enable the investor to significantly improve the CO2 balance of an overall process. 5 Market-Driven Concepts – Goal-Oriented Engineering and Cost-Efficient Implementation Creative Concepts – Always Conceived Engineering Services – with an Eye on Economics Partial Services or the Whole Thing A bioethanol unit “off the rack” is usually not economical Bayer Technology Services provides all necessary because each project is characterized by a highly spe- engineering services for you. cific environment and individual requirements. Following are some of the parameters that may influence a project: • • • • • • • Greenfield or Existing Infrastructure Different Raw Materials Different Products and Byproducts Logistics Energy / Utilities Waste and Waste Water Handling Climate Bayer Technology Services has the necessary expertise in all areas and you profit from customer- and market- specific solutions that meet all requirements. The result: Efficient and profitable units. Equipment Design Decades of close association with the owners of process units and daily contact with the world-wide network of Bayer plants have made us experienced owner’s engineers. Consequently, even in the planning stage, we look at details, such as: • • • • • Simple Operability / Good Accessibility Servicing / Maintenance High Availability Personnel Safety Process Safety Large Projects Reliably Mastered on the Basis of Experience Basic Engineering Detail Engineering Construction Management Commissioning 6 Architecture / Construction Engineering Logistics Planning Process Planning Process Control Technology Piping Equipment Design Layout / 3-D Modeling Owner’s Engineering – Trust in Comprehensive Experience Simulation Investment Costs Basic Evaluation / Feasibility Studies Cost Estimates Safety Analyses Permit Planning Basic Engineering Cost Calculations Detail Engineering Procurement / Expediting Construction Management Training / Startup Support / Training Simulator We offer our engineering services either as a complete package or as individual service modules. Engineering services in the following areas are optional: • • • • • • • Process Improvement Profitability • • • • • • • • • • Start-up Our many years of experience in implementing large investment projects at Bayer AG mean safety and reliability for you. We know how to handle large investment volumes and we are used to assuming responsibility. Europe – a Growth Market for Biofuels Wheat The EU guidelines regarding the use of biofuels in the member countries set an ambitious target. By the year 2010, biofuel-based energies are to make up 5.75 % of all fuel consumption. By 2020, this portion is to climb to 20 %. Because the demand for biofuels will also strongly increase in other regions of the world, producers within the EU will have to meet a considerable part of the EU’s biofuel demand. To supply the 5.75 % consumption of spark-ignited (Otto) fuel, 2.9 million tons of bioethanol will be needed in Germany and about 12.4 million tons in the 25 nations of the European Union. The dramatic increase of crude-oil prices is also fanning this develop- ment. The cost of producing fossil fuels has significantly increased and what is now political intention may tomor- row be economic necessity. In any case – biofuels are the growth market of today’s fuel-related economy. Barley Rye Triticale Sorghum Sugar Beets ... Bioethanol Byproducts The Raw Materials Choices for Your Bioethanol Unit Using freely available resources will make you independ- ent of oil and gas in the future. Europe has the best con- ditions to achieve high yields in growing raw materials, especially wheat. The European climate is ideal for growing this grain. And, in addition, this raw material can be bought in the worldwide market place. Of course, other types of grain are also suitable for a custom-made bioethanol production unit. In Germany, aside from wheat, rye can also be economically used. In close cooperation with the farming industry, the chemical industry can take advantage of the regional aspects of agriculture. We develop highly profitable bioethanol units, well-suited for all relevant raw materials. With our versatile expertise you can reap a lot of success. Projected Biofuel Quota in Europe in % 20.00 5.75 2.75 2006 2010 2020 A Future with Potential Energy (Electricity, Steam) 7 International Locations: Americas: Bayer Technology Services Americas 8500 West Bay Road Baytown, TX 77520, USA Phone: +1-281-383-6000 Fax: +1-281-383-5487 E-mail: btsamericas@bayer.com DAC-P-0064-98-10 DIN EN ISO/IEC 17025 Bayer Technology Services GmbH PT ME - Werkstofftechnik Asia: Bayer Technology and Engineering (Shanghai) Co., Ltd. F3 Lot, Muhua Road, Shanghai Chemical Industry Park Shanghai 201507, P.R. China Phone: +86-21-6712-0280 Fax: +86-21-6712-0290 E-mail: btsasia@bayertechnology.com Benelux: Bayer Antwerpen N.V. Bayer Technology Services Haven 507, Scheldelaan 420 2040 Antwerp 4, Belgium Phone: +32-3-540-3236 Fax: +32-3-540-3600 E-mail: btsbenelux@bayant.bayer.be Bayer Technology Services GmbH Verfahrens- und Projekt-Engineering Technischer Service für Betriebsbetreuung Mexico: Bayer de Mexico, S.A. de C.V. Bayer Technology Services Blvd. Miguel de Cerv. Saavedre 259 11520 Mexico, D.F., Mexico Phone: +52-55-57283016 Fax: +52-55-57283019 E-mail: btsmexico@bayertechnology.com Subsidiaries: Ehrfeld Mikrotechnik BTS GmbH Mikroforum Ring 1 55234 Wendelsheim, Germany Phone: +49-67 34-91 93-00 Fax: +49-67 34-91 93-05 E-mail: info@ehrfeld.com ZEPTOSENS Bayer (Schweiz) AG Benkenstr. 254 4108 Witterswil, Switzerland Phone: +41-6 17-26 81-81 Fax: +41-6 17-26 81-70 E-mail: info@zeptosens.com www.ehrfeld.com www.zeptosens.com Cooperation Partners: FRINGS AUSTRIA Gesellschaft m.b.H. Andritzer Reichsstr. 66 8045 Graz, Austria Phone: +43-3 16-69 42 16 Fax: +43-3 16-69 62 22 E-mail: office@frings-austria.com www.frings-austria.com www.bayertechnology.com Bayer Technology Services GmbH 51368 Leverkusen, Germany Phone: +49-2 14-30-8 09 00 Fax: +49-2 14-30-9 66 25 30 E-mail: info@bayertechnology.com