Bio-Isobutanol Production from Corn
Isobutanol Production Costs Report | Issue B | Q4 2024
| Report Details |
| 180 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 180 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 provides the economics of bio-based Isobutanol production from corn in the USA using a typical fermentation process. In this process, distiller's dried grains with solubles (DDGS) are generated as by-product.
The report provides a comprehensive study of Isobutanol production and related Isobutanol production cost, covering three key aspects: a complete description of the Isobutanol production process examined; an in-depth analysis of the related Isobutanol plant capital cost (Capex); and an evaluation of the respective Isobutanol plant operating costs (Opex).
The Isobutanol 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 Isobutanol 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 Isobutanol 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 three major sections: (1) Liquefaction & Saccharification; (2) Fermentation; and (3) Products Separation.
Liquefaction & Saccharification. Initially, the corn is ground in order to increase its surface area, exposing the starch and allowing more efficient hydrolysis to occur. Then, in liquefaction and saccharification steps, the startch content of the corn is broken down into smaller glucose units. Such liquefaction and saccharification involves enzymatic hydrolyses of the startch under controlled temperature and pH, where alpha-amylase and gluco-amylase hydrolyze starch into fermentable sugars.
Fermentation. Next, the glucose solution from saccharification is fed to the fermentation vessel, where Isobutanol is produced from glucose by fermentation. The fermentation is carried out in batch mode and under anaerobic process conditions.
Products Separation. During the fermentation, a stream is continuously removed from the fermenter and passed through a Isobutanol recovery system to reduce the the Isobutanol content in the broth. After removal of the alcohol, the broth is recycled back to the fermenter. Subsequently, the stream separated in the Isobutanol recovery system goes through concentration and distillation steps to produce Isobutanol with 99.5 wt% purity. The recovered unfermented material goes through the centrifugation, evaporation and drying stages to produce Distiller's Dried Grains with Solubles (DDGS) as a by-product.
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Production Process Information
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Production Process Information
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Production Costs Datasheet
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Operating Cost Details
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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 Isobutanol 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 Isobutanol 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 Isobutanol 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 Isobutanol 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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