Commodity Production Costs Report
Ethanol Production from Sorghum
Ethanol Operating Costs & Plant Construction Costs
This report presents an economic analysis of hydrous Ethanol production in the United States using a typical process based on sorghum feedstock. In this process, free sugars are extracted from the sorghum, while cellulose is hydrolyzed. The mixture is then fermented to produce hydrated ethanol.
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.
Key reference(s): ?
The process under analysis comprises three major sections: (1) Juice Processing; (2) Bagasse Processing; and (3) Distillation.
Juice Processing. Sorghum juice is extracted through milling, neutralized with lime, and clarified before undergoing multiple-effect evaporation to adjust sugar concentration. The concentrated juice is then fermented in parallel batch fermenters with yeast to produce Ethanol at a controlled temperature. Gases from fermentation are sent to a scrubber for Ethanol recovery, and recovered yeast by centrifugation returns to the fermenters. Steam generated from the evaporation step is used in other process units.
Bagasse Processing. Part of the sorghum bagasse undergoes pretreatment with high-temperature and dilute sulfuric acid to extract and convert hemicelluloses into their monosaccharides, such as xylose. After pH adjustment with ammonia, most of the resulting hydrolysate is enzymatically hydrolyzed to extract glucose from cellulose. This process starts in a high-solids continuous reactor and finishes in parallel batch fermenters with cellulase enzymes. These are produced on-site by fungi with the unused hydrolysate as a substrate. After hydrolysis, glucose and xylose are fermented with bacteria into Ethanol at a controlled temperature. The unfermented bagasse is sent to a cogeneration unit for steam and electricity generation. Excess gases from fermenters are also directed to a scrubber for Ethanol recovery.
Distillation. The wine from fermentation, containing about 8-10 vol% Ethanol, is concentrated to 93 wt% Ethanol through a concentration column, removing water and solids in the bottom stream. After a separation step, the solids, mainly composed of lignin, are directed to the cogeneration unit, where they are burned. The resulting Ethanol/water mixture is withdrawn as a side stream and then further purified in a rectifying column to obtain Hydrous Ethanol (93 wt%) as the distillate. Vent gases are removed from the system at the top of the concentration column.
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Professional report based on Q3 2024 economic data, ensuring timely evaluations.
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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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