Ethanol from Wood Chips (Gasification and Mixed Alcohols Synthesis)
Ethanol Production Costs Report | Issue S | Q4 2024
| Report Details |
| 100 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 100 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This report presents the economics of Anhydrous Ethanol production from wood chips in the United States. In the process examined, wood feedstock is submitted to direct gasification, producing synthesis gas. Next, the syngas is converted to mixed alcohols. The alcohol mixture is then distilled, yielding ethanol and a mixture of higher molecular weight alcohols.
The report provides a comprehensive study of Ethanol production and related Ethanol production cost, covering three key aspects: a complete description of the Ethanol production process examined; an in-depth analysis of the related Ethanol plant capital cost (Capex); and an evaluation of the respective Ethanol plant operating costs (Opex).
The Ethanol production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Ethanol plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Ethanol plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises four major sections: (1) Feedstock Gasification; (2) Syngas Treatment; (3) Alcohol Synthesis and Purification; and (4) Power Generation.
Feedstock Gasification. Woodchips particles are grounded in a hammer mill for size reduction, then dried by contact with hot flue gas in rotary dryers. The dry feedstock is fed to a Gasifier along with oxygen, steam, and olivine, yielding synthesis gas (syngas), char, and ash. Virtually all olivine and char are removed from the gasifier outlet in two-stage cyclone separators, while the syngas is routed to the Tar reformer.
Syngas Treatment. In the Tar reformer, hydrocarbons are converted to additional CO and H2. Recycled CO2 is also fed to this reactor to be converted to CO. The hot syngas is routed to Quenching, where it is cooled and scrubbed with water, removing impurities. The quenched syngas is sent to the Acid Gases Scrubber, which employs a monoethanolamine solution to remove H2S and CO2. The syngas is routed to a multi-stage compressor, while the acid gases are discarted. CO2 is partially recycled upstream, with its remainder being vented to the atmosphere.
Alcohol Synthesis and Purification. The purified syngas is compressed, mixed with recycled methanol, and fed to the Alcohol Synthesis Reactor, where it is converted to linear alcohols. The reactor outlet is degassed and dried: unreacted syngas is recovered, while water is removed from the product stream by adsorption in molecular sieves. The dried alcohols are then separated in two columns, yielding ethanol and mixed alcohols product streams that are condensed and sent to storage, and a methanol stream that is used to wash water off of the molecular sieves in the degassing and drying area, which is recycled to the Reactor.
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Ethanol production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Ethanol process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Ethanol production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Ethanol plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
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Details: 100 kta United States-based plant | Q4 2024 | 107 pages | Issue N From $799 USD
The cost analyses presented in this report target a 100 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
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