Starch Based Biorefinery Presented by Christian Abel / GEA Wiegand GmbH
GEA Group Structure Executive Board GEA Group 5 segments, more than 250 companies Chairman: Jürg Oleas Chief Financial Officer : Dr. Helmut Schmale Executive board Member: Niels Graugaard GEA Group is one of the largest solution providers for Food & Energy Processes. Focus on Process Technology & Components for demanding production processes. GEA Group is one of the World's market and technology leaders in 90 percent of its businesses. In 2008, GEA Group reported income in excess of 5.2 billion EUROS with a workforce of more than 20,000 people. 2
Integrated Bio-Refinery Concept 3
Processes offered by GEA Complete starch process line Wheat Maize Potato & Tapioca Complete Ethanol process line Barley Maize Wheat Corn Integrated Energy & Pollution control systems Combined Drying & Evaporation systems with heat recovery Integrated Feed house Superheated Steam Dryers Sugar Process Engineering & Equipment Industrial Biotec Process Engineering & Equipment 4
Equipment offered by GEA Disc bowl Separators 2&3 phase Decanters 2&3 phase Rotary Vacuum filters Westfalia Separator Homogenisers Rotating & Static screens & washers Filtration systems MF, UF, NF, RO Evaporation systems Falling film Mechanical vapour recompression Forced recirculation Wiegand Distillation columns Molecular Sieve Dehydration Fermentation systems 5
Equipment offered by GEA Ring & Flash Dryers Native & Modified Starch Vital Wheat Gluten Corn Gluten Meal DDGS Rotary Dryers Fibre & Steepwater DDGS Dextrose, Sugar & Polyols Fluid Bed dryers & Coolers Barr Rosin Wheat Germ Maize Germ Dextrose, Sugar & Polyols 6
Block diagram recovery of wheat starch wheat flour dosing mixing homogenizer fibres screening 3-phase-decanter starch/gluten screening fresh water starch refining gluten separation gluten/b-starch nozzle separator starch recovery nozzle separator preconcentration process water dewatering dewatering self-cleaning separator decanter dewatering drying drying drying A-starch gluten waste water B-starch 7
Starch process components 8
Starch processing equipment Westfalia Separator Homogenizer for Slurry Preparation Bend Screen for Gluten Separation Centrifugal Fibre Screening 9
Starch processing equipment Westfalia Separator Hydrocyclon for A-starch washing Three-Phase Separator Classification Washing Clarification Concentration Vacuum Drum Filter 10
Starch industry: effluent Wiegand 1-effect (2 calandrias) falling film evaporator, heated by MVR ( pre-evaporator) 11
Ring dryer for vital wheat gluten Barr Rosin to Atmosphere Air to Atmosphere 042-370-04 043-370-01 042-420-01 042-330-01 043-420-02 042-220-01 042-760-01 042-760-02 043-760-01 Steam 042-520-01 Gluten 041-330-01 042-330-02 042-330- 03 Air Air Air Air Condensate 042-420-02 Filtrate 041-320-02 041-320-03 042-320-01 042-660-01 Air Air Air Air Air Air Gluten to Storage 12
Steam Tube dryers for fibre & steeepwater Barr Rosin 13
Sugar processing starch factory starch milk acidification liquefaction liquefaction reaction conversion saccharification saccharification refining refining refining refining drying evaporation evaporation evaporation glucose special glucose syrups dextrose syrup modified starch crystallization evaporative crystallization crystallization isomerization hydrogenation centrifugation centrifugation spray drying refining refining drying drying conditioning evaporation evaporation drying dextrose monohydrate dextrose anhydride total sugar high fructose syrup sorbitol evaporation blending separation evaporation enriched/concentrated fructose syrup fructose syrup 14
Sugar processing equipment Wiegand 2-effect falling film evaporation plant with Mechanical Vapour Recompression for dextrose Evaporation rate: 14,000 kg/h 4-effect plate heat evaporation plant Product: sorbitol Evaporation rate: 6,600 kg/h 15
Sugar and sweetener Barr Rosin Application Beet Sugar Cane Sugar Coated Sugars Confectionary Sugars Dextrose Monohydrate Anhydrous Dextrose Fructose Maltitol Other Polyols Beet Pulp/Animal Feeds (inc. DDGS) 16
Rotary dryer for sugar with fluidised bed cooler Barr Rosin CYCLONES SCRUBBER WET SUGAR HEATER ROTARY DRYER RE-HEATER EXHAUST FAN CHILLER FLUIDISED BED COOLER PRODUCT 18
Ethanol from starch 19
Complete process line bioethanol Wiegand 20
Ethanol reference samples Wiegand Rectification and dehydration plant Product: drinking alcohol Daily capacitiy: 60,000 l of alcohol Location: Germany Year of construction: 1993 Fuel Ethanol plant from corn Capacity: 380,000 l/d Location: Ukraine During assembly Fuel Ethanol plant from rye/wheat Daily capacity: 660,000 l/ Location: Germany Year of Construction: 2004 21
Stillage decanters Westfalia Separator Dry matter of sludge: 28 35% DS Separation efficiency: 65 % - 80 % 22
Coupling SSD dryer & evaporator Barr Rosin Wiegand 23
Direct fired rotary dryer for DDGS Barr Rosin 24
Chemical building blocks Succinic Acid 1,3 Propanediol Acetic Acid Glucose Lactic Acid Gluconic Acid 25 Citric Acid 1,4 Propanediol
Biorefinery Wiegand Lactic Acid Lysin 26
Membrane Applications in Biorefinery Wiegand Microfiltration for Biomass Retention/Recovery Ultrafiltration / Nanofiltration for product purification Reverse Osmosis for pre-concentration & water treatment 27
Cargill Poland Westfalia Separator Wiegand Barr Rosin Integrated starch & raw ethanol plant Capacity 1750 t/d wheat Raw ethanol capacity 70.000 l/d Location: Poland Year of construction: 2006 28
Integrated feed-house for corn wet mill Vapour to next Effect Exhaust to Atmosphere Rotary Dryer for Fibre & Steepwater Waste Heat Evaporator WHE Dump Stack Ring Dryer for Gluten Fluid Bed Germ Dryer R T O Regenerative Thermal Oxidiser 29
Integrated feed-house 30
Dryer evaporator coupling Ring dryer exhaust heated, 3-effect evaporator 31