Bioethanol

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 Technology Platform

CO2
GRAIN

Upstream
Flour
BIOETHANOL PROCESS

BIOETHANOL PROCESS
Mash
Byproduct 1

Milling Liquefaction Saccharification Fermentation

Understanding all Dimensions of Bioethanol

Mash

POWER
ALCOHOL

Downstream
Stillage Thin Stillage

Mash Syrup
Decantation
Cake

Evaporation
Byproduct 2
Distillation +
Dehydration Drying
Cooling Water
Process Water
Waste Water

Chemicals
Steam, El. Power

Air, N2

CIP

Utilities

Biomass
Power Plant Waste Water Treatment Utilities

Engineering Services Technology Platform

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At Bayer, Innovation has Deep Roots
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
Innovation – the Motor of Economy and Life
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.
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 Upstream and Downstream Processes –
all from One Source

Example 1

Grain Water, Enzymes, Enzymes, CO2

Supplies Supplies

Milling Lique- Sacchari- Fermen-

faction fication tation
Flour Mash Sweet Mash

Evapo- Decan- Distilla-

ration tation tion
Stillage
Syrup

Drying
Pelle- Dehydra-
tizing Wet Cake tion

Animal Feed Ethanol Fusel Oils

Example 2

Grain Water, Enzymes, Enzymes, CO2

Supplies Supplies
Customer-Specific Solutions

Gluten
Husking Separa- Lique- Sacchari- Fermen-
Milling tion faction fication tation

Gluten Evapo- Distilla-

Drying ration tion

Drying
Pelle-
tizing
Dehydra-
tion

Brans Gluten DDS

(Byproduct 1) (Byproduct 2) (Byproduct 3) Ethanol Fusel Oils

4
The Entire Spectrum of Processes –
Quick and Made-to-Measure
Any investment must first be put to the test. Subject
your investment plan to a sound feasibility study at
Bayer Technology Services and rest assured that it will
be thoroughly evaluated. We determine all the key
economic data for you. Our results are reliable because
we utilize the combined know-how of many specialists.
The interdisciplinary exchange of chemical engineering
specialists and engineering experts promotes transpar-
ency and generates reliable scenarios. In the area of
upstream processes, we work together with Frings
Austria Co. in Graz, Austria.
Of course, you may want to also contribute your own
key indicators to the study. Or we can consult with you
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.)
Byproducts – the Intelligent Way
to Engineer Plants
Concepts for modern biorefineries consider byproducts
of the production processes and their chances in the
market place as well. Byproducts have a significant
influence on the economics of the overall investment in
a bioethanol process. We break down the raw materials
into their potentially recyclable components, focusing
mainly on non-starchy components of the basic materials
and examining them for usability in a variety of animal
feeds and as food additives. In this way we define whether
the byproducts should be developed as commodities or
as specialty products.
Energy from Biomass Power Plants –
Putting on the Pressure
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.
Sustainable Processes
Based on User Know-How
Customer-Specific Solutions
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.
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 • Basic Evaluation / Feasibility Studies
are some of the parameters that may influence a project: • Cost Estimates
• Greenfield or Existing Infrastructure • Safety Analyses
• Different Raw Materials • Permit Planning
• Different Products and Byproducts • Basic Engineering
• Logistics • Cost Calculations
• Energy / Utilities • Detail Engineering
• Waste and Waste Water Handling • Procurement / Expediting
• Climate • Construction Management
• Training / Startup Support / Training Simulator
Bayer Technology Services has the necessary expertise
in all areas and you profit from customer- and market- We offer our engineering services either as a complete
specific solutions that meet all requirements. The result: package or as individual service modules. Engineering
Efficient and profitable units. services in the following areas are optional:
• Architecture / Construction Engineering
• Logistics Planning
• Process Planning
Process Improvement • Process Control Technology
• Piping
• Equipment Design
• Layout / 3-D Modeling

Simulation
Owner’s Engineering –
Trust in Comprehensive Experience
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
Equipment
Profitability engineers. Consequently, even in the planning stage,
Design
we look at details, such as:
• Simple Operability / Good Accessibility
Engineering Services

• Servicing / Maintenance
• High Availability
Investment • Personnel Safety
Costs
• Process Safety

Large Projects Reliably Mastered

on the Basis of Experience
Our many years of experience in implementing large
Basic investment projects at Bayer AG mean safety and
Engineering
reliability for you. We know how to handle large
investment volumes and we are used to assuming
Detail
Engineering responsibility.

Construction
Management

Commissioning

6 Start-up
 Europe – a Growth Market for Biofuels
Wheat
The EU guidelines regarding the use of biofuels in the
Barley member countries set an ambitious target. By the year
Rye 2010, biofuel-based energies are to make up 5.75 % of
all fuel consumption. By 2020, this portion is to climb to
Triticale 20 %. Because the demand for biofuels will also strongly
Sorghum increase in other regions of the world, producers within
the EU will have to meet a considerable part of the EU’s
Sugar Beets
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.

Energy
(Electricity, Steam) Bioethanol Byproducts

The Raw Materials Choices

for Your Bioethanol Unit Projected Biofuel
Using freely available resources will make you independ- Quota in Europe in % 20.00
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 A Future with Potential
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 5.75
materials. With our versatile expertise you can reap
a lot of success.
2.75

2006 2010 2020

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International Locations:
Americas:
Bayer Technology Services Americas
8500 West Bay Road DAC-P-0064-98-10
Baytown, TX 77520, USA
Phone: +1-281-383-6000 DIN EN ISO/IEC 17025
Fax: +1-281-383-5487 Bayer Technology Services GmbH
E-mail: btsamericas@bayer.com 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 Technology Services GmbH

Bayer Antwerpen N.V. Verfahrens- und Projekt-Engineering
Bayer Technology Services Technischer Service für Betriebsbetreuung
Haven 507, Scheldelaan 420
2040 Antwerp 4, Belgium
Phone: +32-3-540-3236
Fax: +32-3-540-3600
E-mail: btsbenelux@bayant.bayer.be

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 ZEPTOSENS

Mikroforum Ring 1 Bayer (Schweiz) AG
55234 Wendelsheim, Germany Benkenstr. 254
Phone: +49-67 34-91 93-00 4108 Witterswil, Switzerland
Fax: +49-67 34-91 93-05 Phone: +41-6 17-26 81-81
E-mail: info@ehrfeld.com 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

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
May 2006

www.bayertechnology.com