DOE/ID/12050-1

Engineering 81Economic Studies for Direct Application of Geothermal Energy

ETHANOL PRODUCTION FOR AUTOMOTIVE FUEL USAGE

Quarterly Report, 2 July - 30 September 1979

BY S.C. May R.A. Stenzel M.C. Weekes J. Yu

Date Issued - 31 October 1979

Work Performed Under Contract NO. DE - AC07 - 791D12050 for the Idaho Operations Office

Bechtel National, Inc. San Francisco, California

DISCLAIMER This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency Thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.

DISCLAIMER Portions of this document may be illegible in electronic image products. Images are produced from the best available original document.

ABSTRACT

1
1

The p r o d u c t i o n of e t h a n o l f r o m p o t a t o e s , s u g a r b e e t , and w h e a t u s i n g g e o t h e r m a l resources a t t h e R a f t R i v e r a r e a of I d a h o i s b e i n g e v a l u a t e d . The s o u t h c e n t r a l s e c t i o n o f Idaho produces approximately 18 m i l l i o n b u s h e l s of wheat, 1 . 3 m i l l i o n t o n s of s u g a r b e e t and 24 m i l l i o n c w t p o t a t o e s annually. Based on t h e s e p r o d u c t i o n f i g u r e s , a 20 m i l l i o n g a l l o n / y r e t h a n o l f a c i l i t y h a s been s e l e c t e d a s t h e l a r g e s t scale p l a n t t h a t can be s u p p o r t e d w i t h t h e c u r r e n t a g r i c u l t u r a l resources. The p l a n t w i l l o p e r a t e on a l l t h r e e f e e d s t o c k s n o m i n a l l y p r o c e s s i n g p o t a t o e s f o r f i v e months, s u g a r b e e t f o r f o u r months and wheat f o r t h r e e months of the year. The p r o c e s s f a c i l i t y w i l l u s e c o n v e n t i o n a l a l c o h o l t e c h n o l ogy u t i l i z i n g g e o t h e r m a l f l u i d a t a maximum o f 280 F a s a n e n e r g y source. The p r o c e s s f l o w d i a g r a m s f o r all t h r e e f e e d s t o c k s are c u r r e n t l y b e i n g p r e p a r e d . There w i l l be basically three feedstock preparation sections, although the l i q u e f a c t i o n and s a c c h a r i f i c a t i o n s t e p s f o r p o t a t o e s and w h e a t w i l l i n v o l v e common e q u i p m e n t . The f e r m e n t a t i o n , d i s t i l l a t i o n a n d b y - p r o d u c t h a n d l i n g s e c t i o n s w i l l b e common to a l l three feedstocks. T h r e e g e o t h e r m a l e n e r g y e x t r a c t i o n s y s t e m s were c o n s i d e r e d t o accommodate t h e e n e r g y r e q u i r e m e n t s of t h e e t h a n o l f a c i l i t y ( f l a s h e d steam, p r e s s u i z e d f l u i d a n d s e c o n d a r y heat transfer). Pressurized geothermal f l u i d with d i r e c t h e a t t r a n s f e r h a s b e e n s e l e c t e d a s t h e u s a g e mode t o m i n i Tentatively, t h e geothermal supply mize scale d e p o s i t i o n . w e l l s w i l l b e l a i d o u t i n s q u a r e g r i d s w i t h 1/4 m i l e s p a c i n g . The number o f wells r e q u i r e d w i l l b e d e t e r m i n e d a f t e r t h e p r o c e s s h e a t load is c a l c u l a t e d .

I
1
I, I

TABLE OF CONTENTS

Figures Tables

......................... .........................

iii

iv

Sect ion
1

Page INTRODUCTION

.................. . .
.

1-1

ETHANOL PRODUCTION TECHNOLOGY. 2.1 2.2 2.3 2.4

2.5

2-1 2-1 2-4 2-6 2-8 2-9

..... .... Feedstock Preparation . . . . . . . . . Saccharification and Fermentation . . . . Anhydrous Ethanol Production . ... By-product Processing . . . . . . . . . .
Feedstock Requirement
. I

PROCESS FLOW DIAGRAM PREPARATION 3.1 3.2 3-3 3.4 3.5

.......

3-1 3-1
3-2

Establishment Process Conditions and Scope.

...... Sugar Beet Processing . . . . . . Potato Processing Description . . Wheat Processing . . . . . . . .

Process Flow Diagrams

.... ..... ... .....

....

3-2 3-19 3-29

GEOTHERMAL RESOURCE 4.1 4.2 Resource Extraction and Requirement Geothermal Fluid Properties

4-1 4-1 4-3

....

TABLE O F CONTENTS
(continued )

Section
5
CONCEPTUAL D E S I G N O F GEOTHERMAL ENERGY GATHERING, T R A N S F E R , AND D I S P O S A L SYSTEM

Page

5.1
5.2

5.3

.... W e l l Field Design . . . . . . . . ... B r i n e G a t h e r i n g System ......... Brine Disposal. . . . . . .. .. ........ . ....... . ..........
........ .......... ..........

5-1 5-1 5-4 5-4

ECONOMIC FACTORS

6.1
6.2

6.3
6.4 6.5

...... G e o t h e r m a l Well C o s t s . C r o o k ' s Property ... G l o v e r ' s Prospect . . . Electric Rates .... C o o l i n g Water . . . . .

6-1 6-1 6-1 6-2 6-2 6-2

REFERENCES

ii

FIGURES
Number Page
W e l l and P i p e l i n e Location R a f t R i v e r Area
,

1-1

.............

1-2

3-1

Block F l o w Diagram S u g a r B e e t P r o c e s s i n g 20 MM G a l / Y r E t h a n o l P l a n t

.......

3-7

3-2

20 MM G a l / Y r Nominal E t h a n o l F a c i l i t y S u g a r Beet P r o c e s s i n g Preliminary P r o c e s s Flow Diagram

..........

3-8

3-3

20 MM G a l / Y r Nominal E t h a n o l F a c i l i t y S u g a r Beet P r o c e s s i n g - P r e l i m i n a r y P r o c e s s Flow Diagram B l o c k Flow Diagram P o t a t o P r o c e s s i n g 20 MM G a l / Y r E t h a n o l P l a n t

..........
........

3-9

3-4

3-24

3-5

20 MM G a l / Y r Nominal E t h a n o l F a c i l i t y Preliminary Potato Processing P r o c e s s Flow Diagram

..........

3-25

3-6

20 MM G a l / Y r

Ethanol F a c i l i t y

P r e l i m i n a r y Product R e c o v e r y P o t a t o Case

...............

3-26

4-1

R e l a t i v e Energy C o s t v s Brine Return Temperature

........

4-2

iii

. .

. _ ...

TABLES

Number

Page

1-1
2-1

S c o p e of Work

.................

1-4

R e c e n t Wheat P r o d u c t i o n i n South C e n t r a l Idaho R e c e n t S u g a r Beet P r o d u c t i o n i n South C e n t r a l Idaho Recent Potato Production i n South C e n t r a l Idaho A v e r a g e C o m p o s i t i o n of S u g a r P r i n c i p a l D e s i g n Bases S u g a r Beets P r i n c i p a l D e s i g n Bases S u g a r Beets Average

.. . . .
.........
......... Beet ( C l e a n ) . . .
'

2-2

2-2

2-2

2-3

2-3 3-3

3-1 3-2

rocessing . . .- .P . ..........

3-5

3-3

3-4 3-5

ation . . .- .F e .r m . e.n t . ....... P o t a t o Composition (Clean). . . . . . .

3-14 3-20

P r i n c i p a l D e s i g n Bases potatoes

. . . .- .P r.o c.e s.s i.n g. . . . . . . . 3 - 2 1

-

3-6

P r i n c i p a l D e s i g n Bases Potato F e r m e n t a t i o n

...........

3-22 5-2

5 -1

G e o t h e r m a l R e s o u r c e D e s i g n Bases

.......

iv

Section 1 INTRODUCTION

The e x i s t e n c e o f e x t e n s i v e g e o t h e r m a l r e s o u r c e s i n t h e U n i t e d S t a t e s r e p r e s e n t s an untapped p o t e n t i a l energy s o u r c e t o supplement a v a i l a b l e f o s s i l f u e l s . High t e m p e r a t u r e g e o t h e r m a l r e s o u r c e s How-

(<350 F ) w i l l most l i k e l y b e u s e d t o g e n e r a t e e l e c t r i c i t y .
e v e r , such high temperature r e s o u r c e s are l i m i t e d . by t h e U.S.

Extensive s t u d i e s

Geological S u r v e y a n d o t h e r s h a v e shown t h a t l o w temperaT h e s e lower t e m p e r a t u r e geoA number o f d i r e c t

t u r e r e s o u r c e s a r e much more a b u n d a n t .

thermal r e s o u r c e s are s u i t a b l e for direct use.

a p p l i c a t i o n s f o r space h e a t i n g a n d a g r i c u l t u r e u s e s a r e c u r r e n t l y i n existence. T h e s e a p p l i c a t i o n s by t h e i r n a t u r e a r e l i m i t e d t o
For t h i s study

energy consumption a t or n e a r t h e geothermal s o u r c e .

t h e u s e of g e o t h e r m a l e n e r g y f o r t h e p r o d u c t i o n o f e t h a n o l a s a f u e l is being evaluated. Ethanol produced w i t h geothermal r e s o u r c e s e n e r g y t o a mobile form t o

w i l l be a b l e t o c o n v e r t t h e non-mobile

supplement our automotive f u e l requirements.

T h i s t e c h n i c a l and economic e v a l u a t i o n o f e t h a n o l p r o d u c t i o n u s i n g geothermal resources is s p e c i f i c a l l y d i r e c t e d to a site adjacent

t o t h e D e p a r t m e n t of E n e r g y R a f t R i v e r T e s t F a c i l i t y .

The l o c a t i o n s

o f t h e p r o p e r t i e s owned by Messrs. G . C r o o k , e t . a 1 a n d F r a n k G l o v e r r e f e r r e d t o i n t h i s s t u d y a r e shown i n F i g u r e 1-1.

1-1

T h i s s t u d y i s d i v i d e d i n t o n i n e major t a s k s t o
0

--

Evaluate t h e a v a i l a b i l i t y of farm p r o d u c t s i n t h e R a f t River region t o produce e t h a n o l . P r o v i d e t h e n e c e s s a r y c o n v e r s i o n process. E s t a b l i s h t h e c o n d i t i o n s a n d a v a i l a b i l i t y of t h e geothermal resource. P r o v i d e an economic a n a l y s i s . D e t e r m i n e i n s t i t u t i o n a l r e q u i r e m e n t s f o r commercial o p e r a t i o n .

0 0

0 0

The n i n e t a s k s ,

i n c l u d i n g a l l of t h e s u b t a s k s , a r e shown i n

T a b l e 1-1.
I

The s t u d y was begun on J u l y 2 , 1 9 7 9 .

T h i s report c o v e r s r e s u l t s

a c c o m p l i s h e d from t h e i n c e p t i o n of t h e p r o j e c t t o t h e l a s t week o f September 1979.

1-3

T a b l e 121 SCOPE O F WORK

Task 1

Define C u r r e n t Ethanol Production Technology

1.1

Feedstock Requirement Feedstock Preparation S a c c h a r i f i c a t i o n and Fermentation Anhydrous E t h a n o l P r o d u c t i o n By-product Processing

1.2 1.3 1.4

1.5

Task 2

P r o c e s s Flow Diagram P r e p a r a t i o n 2.1 2.2 2.3

E s t a b l i s h P r o c e s s C o n d i t i o n s and Scope

Prepare A l t e r n a t i v e P F D ' s f o r S e l e c t e d F e e d s t o c k s
E s t a b l i s h Process Requirements
'

Task 3

D e f i n i t i o n of G e o t h e r m a l R e s o u r c e R e q u i r e m e n t s
3.1

Process C o n d i t i o n s
E s t a b l i s h m e n t of G e o t h e r m a l B r i n e Flow R e q u i r e m e n t s S t u d y of P h y s i c a l a n d C h e m i c a l C o n s t r a i n t s

3.2 3.3

Task 4

C o n c e p t u a l D e s i g n of G e o t h e r m a l E n e r g y G a t h e r i n g T r a n s f e r a n d Disposal S y s t e m s
4.1
W e l l F i e l d Design

4.2 4.3 4.4

4.5

B r i n e G a t h e r i n g System Energy E x t r a c t i o n System B r i n e Disposal Resource Property V a r i a t i o n s

System O p t i m i z a t i o n
1-4

4.6

Table 1-1
( cont inued )

Task 5

Conceptual Design of Alcohol Facility 5.1 5.2 5.3 Definition of Overall Facility Preparation of Process Equipment Specifications Establish Facility and Equipment Lists

Task 6

Economic Analysis of Geothermal-Alcohol Scheme

6.1
6.2
6.3

Capital Cost Estimate Operating Cost Analysis Economic Evaluation and Comparison with Other Energy Sources

Task 7

Implementation Plan for Demonstration Facility

7.1
7.2
7.3

Define Program Goals Information Transfer Technical Demonstration

Task 8

Site Institution Requirement for Demonstration Project

8.1

Feedstock Availability Environmental Effects Resources Leasehold Arrangement Procedural Considerations

8.2 8.3
8.4

Task 9

Final Report

1-5

Section 2 ETHANOL PRODUCTION TECHNOLOGY

2.1

Feedstock Requirement Wheat, s u g a r b e e t s a n d p o t a t o e s were s e l e c t e d a s t h e c a n d i d a t e raw m a t e r i a l s f o r e t h a n o l f e r m e n t a t i o n . Over

t h e p a s t few years (1975-1978), p r o d u c t i o n o f e a c h o f t h e s e crops i n t h e c o u n t i e s a r o u n d t h e R a f t R i v e r Geot h e r m a l P r o j e c t h a s b e e n s u f f i c i e n t t o s u p p o r t a "commer-

c i a l - s c a l e " e t h a n o l p r o d u c t i o n f a c i l i t y ( 2 0 MM g a l / y r o r
larger).
0 0

The f o l l o w i n g shows t h e a v e r a g e a n n u a l p r o d u c t i o n : Wheat ( w i n t e r )

Wheat ( s p r i n g )
10,000,000

bushels

8,000,000 b u s h e l s 1,300,000 t o n s
24,000,000

0
0

Sugar b e e t s Potatoes
2-2,

'

cwt.

T a b l e s 2-1,
by c o u n t i e s .

a n d 2-3

summarize t h e a p p r o x i m a t e p r o d u c t i o n

T h e s e q u a n t i t i e s c a n n o t be c o n s i d e r e d as t h e

resources a v a i l a b l e solely for e t h a n o l production.

One

c a n n o t i n t r o d u c e a new demand e q u i v a l e n t t o t h e e x i s t i n g demand f o r t h e s e a g r i c u l t u r a l p r o d u c t s w i t h o u t s e r i o u s l y u p s e t t i n g t h e local market conditions. In order to obtain

raw materials a t a r e a s o n a b l e

p r i c e , t h e t o t a l demand

must b e k e p t close t o t h e a c h i e v a b l e p r o d u c t i o n i n t h e area. About 40 p e r c e n t o f t h e t o t a l c r o p l a n d i n t h e s e f i v e c o u n t i e s

i s u s e d f o r t h e s e t h r e e crops.

O t h e r c r o p l a n d acreage

2-1

T a b l e 2-1

(Ref. 2 )

R e c e n t Wheat P r o d u c t i o n i n South C e n t r a l Idaho

County acreage planted Cassin Jerome Min i d o k a Twin F a l l s Powers Totals

60,000 15,000

W i n t e r Wheat yield bu/ac.

46 76 70 66 34 44.2

S p r i n g Wheat acreage planted

35,000 16,000 22,000 20,000 40,000 133,000

production MM bu
2.76 1.14 .7 1.32 4.25

yield bu/ac.
71 69 75 76 45

production MM bu
2.48 1.10 1.65 1.52 1.8

10,000
20,000 125,000 230,000

avg

10.17

64.3

avg

8.55

T a b l e 2-2

(Ref. 2)

R e c e n t S u g a r Beet P r o d u c t i o n i n South C e n t r a l Idaho

County Cassin

acreage planted
17,000 5,000 30,000 14,000

yield tons/ac.
18 18 18 20 16.5

production tons
306,000 40,000 540,000 280,000 132,000

Jerome
Minidoka Twin F a l l s Power
Totals

8,000
74,000

18.2

avg

1,348,000

2-2

T a b l e 2-3

(Ref. 2)

Recent P o t a t o Production i n South C e n t r a l Idaho

County Cassia Jerome Minidoka Twin F a l l s Power

Totals

acreage planted
25,000 15,000 35,000 19,000 16,000

yield cwt/ac
245 265 235 300 235 225 avg

production cwt
6,125,000 3,975,000 8,225,000 2,700,000 3,760,000 24,785,000

110,000

c o u l d b e u s e d t o i n c r e a s e p r o d u c t i o n , however i r r i g a t i o n

water i s i n l i m i t e d s u p p l y .

Rather than a t t e m p t t o markedly

i n c r e a s e t h e p r o d u c t i o n of one of t h e s e p o t e n t i a l f e e d s t o c k s , t h e s t r a t e g y should be t o s e e k a f r a c t i o n of each c r o p ' s a n n u a l p r o d u c t i o n f o r f e e d s t o c k a n d t o work w i t h t h e g r o w e r s a s s o c i a t i o n s t o e n s u r e t h a t t h e r e w i l l be a d e q u a t e s u p p l i e s f o r a l l t h e buyers.

T h i s m u l t i - c r o p f e e d s t o c k c o n c e p t h a s been a d o p t e d f o r t h i s study.
A 20 m i l l i o n g a l l o n p e r y e a r e t h a n o l p r o d u c t i o n

c a p a c i t y was s e l e c t e d a s b e i n g t h e l a r g e s t s c a l e t h a n c a n b e s u p p o r t e d by t h e a g r i c u l t u r a l resources o f t h e s o u t h c e n t r a l area.

T h e f a c i l i t y would n o m i n a l l y process p o t a t o e s

f o r f i v e months, s u g a r b e e t s f o r f o u r months and wheat f o r t h r e e months o f t h e y e a r .

2-3

I n e a c h y e a r , c r o p p r o d u c t i o n s and p r i c e s w o u l d d i c t a t e t h e a c t u a l p r o c e s s i n g mix and run d u r a t i o n so t h a t t h e

lowest c o s t ( p e r g a l l o n o f p r o d u c t i o n ) f e e d s t o c k would
b e p u r c h a s e d on t h e o p e n m a r k e t . Sugar b e e t acreage

would b e c o n t r a c t e d f a r i n a d v a n c e t h r o u g h t h e g r o w e r s

a s s o c i a t i o n , s o t h e p r o c e s s r u n on s u g a r b e e t s is essent i a l l y fixed before planting t i m e .

Only a g r i c u l t u r a l r e s o u r c e s i n t h e s o u t h c e n t r a l area of I d a h o were c o n s i d e r e d . There is v e r y l i t t l e p r o d u c t i o n

o f w h e a t , s u g a r b e e t s a n d p o t a t o e s i n t h e Utah c o u n t i e s

j u s t s o u t h o f t h e Idaho-Utah

state line.

Truck shipment

o f t h e s e materials from o t h e r p r o d u c i n g areas i n I d a h o and p e r h a p s Oregon would a d d t o o much t o t h e c o s t o f t h e materia-s

t o be a n economic a l t e r n a t i v e .

2.2

Feedstock Preparation Feedstock p r e p a r a t i o n technology f o r wheat, s u g a r b e e t s and p o t a t o e s was d i s c u s s e d w i t h c o n v e n t i o n a l processors ( m i l l e r s , s u g a r f a c t o r i e s , s t a r c h p l a n t s and d e h y d r a t o r s ) w i t h equipm e n t v e n d o r s a n d w i t h saccharification/fermentation e x p e r t s .

F o r e a c h of t h e t h r e e f e e d t o c k s t h e r e a r e b a s i c a l l y t w o

p r e p a r a t i o n approaches:

1) whole p r o d u c t p r o c e s s i n g a n d ,

2 ) refined product preparation.

The s e c o n d , a n d more

c o s t l y a p p r o a c h , p r o d u c e s c l e a n s u b s t r a t e material which

is t h e o r e t i c a l l y amenable t o c o n t i n u o u s f e r m e n t a t i o n .
2-4

Whole p r o d u c t p r o c e s s i n g is c o n d u c i v e o n l y t o b a t c h f e r m e n -

tation.

For w h e a t a n d p o t a t o e s w h o l e p r o d u c t p r o c e s s i n g

s c h e m e s were c h o s e n .

Both r e q u i r e l i q u e f a c t i o n a n d
For the

saccharification steps p r i o r to fermentation.

b e e t case, a' p a r t i a l l y r e f i n e d p r o d u c t p r e p a r a t i o n scheme w a s selected, s i n c e t h e r e i s l i t t l e e x p e r i e n c e w i t h ferment a t i o n o f t h e whole b e e t ( j u i c e and p u l p ) .

The p r e p a r a t i o n steps f o r wheat w i l l t e n t a t i v e l y c o n s i s t

of c l e a n i n g , then d r y g r i n d i n g with no s e p a r a t i o n followed by s l u r r y i n g w i t h water t o a s t a r c h - d r y s o l i d s ( D S ) c o n t e n t s u i t a b l e f o r fermentation t o produce approximately 1 0 % ethanol. The pH o f t h e s l u r r y i s a d j u s t e d t o 6 . 5 i n

p r e p a r a t i o n f o r g e l a t i n i z a t i o n and e n z y m a t i c l i q u e f a c t i o n .

P o t a t o e s a r e washed w i t h water, d r a i n e d a n d d i s i n t e g r a t e d
without peeling. The g r o u n d p o t a t o e s a r e c e n t r i f u g e d t o a
T h e pH i s a d j u s t e d t o 6 . 5 a s i n

DS c o n t e n t o f 2 1 p e r c e n t .

wheat p r e p a r a t i o n p r i o r t o g e l a t i n i z a t i o n and l i q u e f a c t i o n .

Sugar b e e t s are processed using c o n v e n t i o n a l beet-sugar t e c h n o l o g y . The b e e t s a r e washed w i t h water, d r a i n e d , s l i c e d i n t o t h i n s t r i p s ( c o s s e t t e s ) a n d t h e n t h e j u i c e phase i s e x t r a c t e d from t h e i n s o l u b l e p o r t i o n of t h e b e e t s ( p u l p ) i n

a h o t water d i f f u s i o n p r o c e s s .

The t h i n j u i c e c o n t a i n s a b o u t

1 4 p e r c e n t s u c r o s e and i s p a r t i a l l y c o n c e n t r a t e d b e f o r e f e r mentation to ethanol. These f e e d s t o c k p r e p a r a t i o n s i n v o l v e physical processes.

simple, well-established,

2-5

The refined product approach involves conventional separation processes which produce high quality starch (wheat and potatoes) and low impurity, concentrated juice (beets). The major by-product materials are produced in the preparation steps rather than in the post-fermentation processing.

In order to minimize the cost of the three feedstock preparation sections in the facility, the simpler approach was selected for this study.

2.3

Saccharification and Fermentation Both potato and wheat starches must be converted into fermentable sugars.

Enzymatic schemes were selected for

liquefaction and saccharification based on starch conversion literature and discussions with enzyme producers. The processing conditions selected are well-established and the amylase enzymes required are commercially available. Processing steps for wheat and potato starch are nearly identical so the same equipment can be used for both:
0

Addition of the liquefying enzyme (alpha amylase) to the raw starch slurry. Cooking the slurry to liberate the starch molecules (gelatinization) and to allow enzymatic breakdown of the starch bonds (liquefaction). Cooling the slurry and pH adjustment to 4.5. Conversion of starch to glucose (saccharification) by addition of the saccharifying enzyme (glucoamylase) and holding the solution for about 48 hours.

2-6

The saccharification step can be carried out simultaneously with fermentation with the penalty of a higher glucoamylase dose.
A

clean substrate is desirable.

Both batch fermentation and continuous fermentation schemes were considered in the process of selecting preparation steps for each feed material. Continuous fermentation offers

the advantages of high fermentation rates (low residence time) and l o w yeast makeup requirements. strate. It requires a clean sub-

Continuous fermentation is also more susceptible to The batch

contamination than the conventional batch process.

fermentation approach was chosen along with the whole product processing approach because of its relative simplicity and its proven reliability.

Batch fermentation consists of charging a fermentation tank with the sugar (glucose or sucrose) solution, addition of brewers yeast and nutrients and holding the mash for about

48 hours to allow completion of the sugar conversion to

ethanol. Cooling is required to remove the heat of reaction, C. By-products

maintaining the mash temperature at about 3 0 '

of the reactions include yeast, carbon dioxide, fusel oils (high-molecular weight alcohols) and aldehydes.

After the fermentation period, the tank is emptied, cleaned and sterilized and is ready to receive another charge of sugar solution. Multiple fermentation tanks are employed
2-7

t o a v o i d enormous t a n k s i z e s and t o r e d u c e t h e t o t a l c y c l e

time

f i l l , f e r m e n t , empty a n d c l e a n .

The s u g a r s o l u t i o n s f r o m b e e t and p o t a t o p r o c e s s i n g h a v e

lower t h a n d e s i r e d s u g a r c o n t e n t s f o r optimum f e r m e n t a t i o n
and t h e subsequent d i s t i l l a t i o n .

Prior t o f e r m e n t a t i o n

b o t h w i l l be c o n c e n t r a t e d t o b e e q u i v a l e n t t o t h e s u g a r c o n t e n t of t h e wheat p r o c e s s i n g s o l u t i o n .

2.4

Anhydrous E t h a n o l P r o d u c t i o n The p o s s i b i l i t y o f p r o d u c i n g a 1 9 0 p r o o f e t h a n o l f o r b l e n d i n g w i t h g a s o l i n e w a s a b a n d o n e d e a r l y i n t h i s s t u d y by

m u t u a l a g r e e m e n t w i t h DOE'S T e c h n i c a l R e p r e s e n t a t i v e .

The f o l l o w i n g d i s t i l l a t i o n m e t h o d s f o r p r o d u c i n g a n h y d r o u s
2 0 0 p r o o f e t h a n o l were s u b s e q u e n t l y e x a m i n e d :
0

C o n v e n t i o n a l l o w pressure s t r i p p i n g , r e c t i f i c a t i o n and benzene-water-ethanol a z e o t r o p i c d i s t i l l a t i o n .

Vacuum d i s t i l l a t i o n t o a v o i d t h e w a t e r - e t h a n o l
azeotropic condition. Extractive d i s t i l l a t i o n with gasoline to d i r e c t l y produce a gasoline/alcohol mixture. D i s t i l l a t i o n f o l l o w e d by v a p o r p h a s e d e h y d r a t i o n using adsorption agents.

The l a s t t w o s c h e m e s o f f e r p r o m i s e o f s i g n i f i c a n t e n e r g y s a v i n g s b u t a r e r e l a t i v e l y u n d e v e l o p e d processes.

Vacuum

d i s t i l l a t i o n does not appear t o y i e l d real cost/energy s a v i n g s because of t h e g r e a t e r investment i n d i s t i l l a t i o n

2-8

equipment.

K a t z e n ( R e f . 1) o f f e r s a d u a l - p r e s s u r e d i s t i l However, i t

m o d i f i c a t i o n o f t h e c o n v e n t i o n a l process.

r e q u i r e s a steam t e m p e r a t u r e ( f r o m c o a l - f i r e d b o i l e r s ) t h a t
i s c o n s i d e r a b l y h i g h e r t h a n t h a t a v a i l a b l e f r o m t h e geo-

The more c o n v e n t i o n a l scheme was t h e r e f o r e s e l e c t e d :

0

A b e e r s t i l l p r o d u c i n g a 7 3 mole p e r c e n t e t h a n o l

o v e r h e a d and a s t i l l a g e b o t t o m s p r o d u c t w i t h f u s e l o i l s t a k e n o f f a s a s i d e draw.
0

A benzene-water-ethanol azeotropic d i s t i l l t i o n with a n h y d r o u s e t h a n o l a s bottoms p r o d u c t . Water f r o m t h e benzene s t r i p p e r is e s s e n t i a l l y f r e e of benzene and ethanol.

2.5

By-product By-product

Processing t y p e a n d q u a n t i t i e s were c o n s i d e r a t i o n s i n t h e

s e l e c t i o n of t h e p r e p a r a t i o n schemes f o r each f e e d s t o c k . R e f i n e d p r o d u c t p r e p a r a t i o n p r o d u c e s a number o f d i f f e r e n t front-end by-products. With a m u l t i p l e f e e d s t o c k f a c i l i t y ,

t h e h a n d l i n g , s t o r a g e a n d m a r k e t i n g o f a number o f d i f f e r e n t b y - p r o d u c t m a t e r i a l s may n o t b e a t t r a c t i v e , e v e n i f some high-value

materials such as g l u t e n are produced.

Process

c o m p l e x i t y a n d low u t i l i z a t i o n of p r o c e s s e q u i p m e n t a r e

real drawbacks.

The w h o l e p r o c e s s i n g a p p r o a c h c a r r i e s t h e n o n - f e r m e n t a b l e s ( e x c e p t f o r b e e t p u l p ) t h r o u g h t h e process t o t h e b e e r s t i l l . The w h o l e s t i l l a g e f r o m each f e e d m a t e r i a l c o n t a i n s y e a s t , o t h e r i n s o l u b l e s a n d d i s s o l v e d s o l i d s from w h i c h a s i n g l e -

2-9

t y p e of by-product-animal-feed

would be r e c o v e r e d .

Its

a d v a n t a g e i s a s i n g l e r e c o v e r y s c h e m e t h a t accommodates each feedstock.

P r o d u c t i o n of a w e t b y - p r o d u c t

f o r animal feeding o n s i t e
W h i l e i t would p r o d u c e a

was a n o p t i o n c o n s i d e r e d b r i e f l y .

c o n s i d e r a b l e e n e r g y s a v i n g s by r e d u c i n g d r y i n g r e q u i r e m e n t s , t h e o p t i o n a d d s c o m p l e x i t y by i n t r o d u c i n g a n o t h e r i n d u s t r y i n t o t h e area. The f e e d l o t o p t i o n may n o t b e p r a c t i c a l i n

t h e g e o t h e r m a l resource s i t e area.

The b y - p r o d u c t p r o c e s s i n g scheme s e l e c t e d i n v o l v e s :
0

C e n t r i f u g a l s e p a r a t i o n of whole s t i l l a g e i n t o a s l u d g e and a t h i n l i q u o r c o n t a i n i n g t h e d i s s o l v e d sol i d s . Evaporation of t h e t h i n l i q u o r t o a syrup-like product. Blending t h e s y r u p w i t h t h e s l u d g e and d r y i n g i t w i t h g e o t h e r m a l f l u i d a s t h e h e a t source. G r i n d i n g t h e d r y s o l i d s f o r s t o r a g e and s a l e a s d r y animal feed.

T h r e e s e p a r a t e d r y p r o d u c t s c o u l d be produced or t h e y c o u l d be b l e n d e d f o r s a l e a s a s i n g l e p r o d u c t .

2-10

Section 3 PROCESS FLOW DIAGRAM PREPARATION

3.1

Establishment Process Conditions and Scope The process conditions for the three feedstock have been generally established. Final conditions for wheat proces-

sing are subject to confirmation by a test being conducted at Novo Laboratories. There will be basically three feed-

stock preparation sections, although the liquefaction and saccharification steps for wheat and potatoes will involve common equipment. The fermentation, distillation and by-

product handling sections will be common to all three feedstocks.

A design rate of 2 5 4 0 gpm of ethanol will be

produced from the fermentation step.

Twenty million gallons

per year of 199O proof ethanol will be recovered.

Utility resources assumed to be available for the process e s are:

Electric Power Cool ing water Process water Potable water Hot water (max.temp.)

4.16 kV, 3 @ , 60 Hertz at the plant fence line 60 F source from wells
60
60

F source from wells

F source from wells

280 F geothermal water

3-1

3.2

Process Flow Diagrams

The process f l o w d i a g r a m f o r each f e e d s t o c k a r e i n v a r i o u s s t a g e s of p r e p a r a t i o n .
The following s e c t i o n s provide t h e

s t a t u s of t h e s u g a r b e e t p r o c e s s i n g a n d p o t a t o p r o c e s s i n g

process f l o w d i a g r a m s a t t h e e n d o f t h e r e p o r t p e r i o d .

3.3

S u g a r Beet P r o c e s s i n g S u g a r b e e t s are p r o c e s s e d f o u r c o n t i n u o u s months e a c h y e a r , November t h r o u g h F e b r u a r y , f o l l o w i n g 3 m o n t h s o f w h e a t processing. T h r e e hundred twenty-one thousand t o n s of

b e e t s a r e r e c e i v e d by t h e p l a n t f o r c l e a n i n g a n d p r o c e s s i n g . On-site s t o r a g e capacity is 120,000 t o n s . About 2 1 , 0 0 0 t o n s

o f t r a s h a n d s i l t a r e removed i n c l e a n i n g t h e b e e t s o v e r t h e four-month period. The d a i l y s l i c e c o n t a i n s 442 t o n s o f

s u g a r o f w h i c h 432 t o n s a r e e x t r a c t e d a s a t h i n j u i c e i n t h e d i f f u s i o n process. The t h i n j u i c e ( 1 3 . 8 5 % s u g a r ) i s T h e s e 442 t o n s y i e l d a n e t o f

concentrated t o 19% sugar.

2 1 3 . 1 t o n s of e t h a n o l ( c a 9 1 . 6 % n e t y i e l d ) a t t h e e n d of b a t c h f e r m e n t a t i o n of t h e c o n c e n t r a t e j u i c e .
T h e beer

(10.3% w t e t h a n o l ) is d i s t i l l e d t o a 87% w t e t h a n o l overhead product, t h e n d e h y d r a t e d t o a 99.2% w t e t h a n o l p r o d u c t column.

i n a benzene-water-ethanol

Beet p u l p from t h e
sale.

d i f f u s i o n s t e p i s d e w a t e r e d a n d d r i e d f o r by-product

The w h o l e s t i l l a g e from t h e b e e r s t i l l i s e v a p o r a t e d t o a s y r u p and d r i e d w i t h t h e b e e t pulp. Fusel oils (higher

m o l e c u l a r w e i g h t a l c o h o l s ) a r e a l s o r e c o v e r e d a s a byp r o d u c t w h i c h may b e b l e n d e d w i t h t h e e t h a n o l p r o d u c t . 3-2

D e s i g n Basis T a b l e 3-1 p r e s e n t s t h e assumed c o m p o s i t i o n of t h e s u g a r b e e t s processed i n t h e plant.

T a b l e 3-1 Average Composition o Sugar B e e t (Clean)

S o l u b l e d r y matter
Marc

18.87% 5.00% 76.13%

100.00%

Water

JUICE

Sucrose N-free organics (carbohydrates, acids, saponins) ( b e t a i n e , a m i d e s , amino a c i d s , p u r i n e s , p y r a m i d i n e s , ammonia a n d n i t r a t e s )

16.00%

1.20% 1.17%

N-organics

I n o r g a n i c s ( K , C a , Mg, N a ,
Water

PO4, C1, SO4)

50%
76.13%

Marc I n s o l u b l e pectic material, p r o t e i n s ,

Cellulose, lignin, hemicelluloses

saponins

1.25% 1.25%
2.50%

Bound water

100.00%

3-3

The as-delivered

b e e t s a r e a s s u m e d t o c o n t a i n a t o t a l of

seven p e r c e n t (on a clean b e e t b a s i s ) f o r e i g n matter r o c k s , t r a s h and s i l t .

--

In cleaning t h e b e e t s a l l foreign

m a t t e r i s removed a n d 0 . 1 p e r c e n t o f t h e s o l u b l e d r y matter h a l f sucrose) i s assumed t o b e l o s t i n w a s h i n g ( o r i n s t o r a g e ) .

Beets a r e p r o c e s s e d 2 4 - h r s p e r d a y , s e v e n d a y s p e r week a t a d e s i g n stream f a c t o r o f 90 p e r c e n t

2769.44 t o n s p e r

stream d a y o r 2492.5 t o n s p e r d a y on a c a l e n d a r d a y b a s i s .
T a b l e s 3-2 and 3-3 s u m m a r i z e t h e p r i n c i p a l d e s i g n b a s e s f o r
each p r o c e s s s e c t i o n .

Each s e c t i o n i s d e s c r i b e d b e l o w .

F i g u r e 3-1 i s a n o v e r a l l

b l o c k d i a g r a m o f t h e b e e t p r o c e s s i n g and F i g u r e 3-2

is a

p r o c e s s f l o w d i a g r a m o f t h e s t e p s up t o d i s t i l l a t i o n . F i g u r e 3-3 s h o w s t h e p r o d u c t r e c o v e r y s e c t i o n .

B e e t R e c e i v i n g and S t o r a g e

--

S u g a r beets a r e s h i p p e d t o

t h e e t h a n o l f a c i l i t y by end-dump n e t l o a d a v e r a g e s 25 t o n s .

tractor-trailers.

The

T r u c k s a r e weighed i n ( g r o s s )

and o u t ( t a r e ) t o r e c o r d t h e a s r e c e i v e d t o n n a g e s .
A t t h e s c a l e t r u c k s a r e d i r e c t e d t o one of t w o dump s t a t i o n s ,

one f o r d i r e c t p r o c e s s i n g and t h e o t h e r f o r t r a n s f e r t o storage. Five t r u c k s p e r hour are routed t o t h e d i r e c t

p r o c e s s i n g s t a t i o n w h e r e a h y d r a u l i c dump p l a t f o r m e l e v a t e s
t h e t r u c k s t o d i s c h a r g e t h e b e e t s i n t o t h e w e t hopper.

3-4

T a b l e 3-2 PRINCIPAL DESIGN BASES SUGAR BEETS

PROCESSING

E l e v a t i o n and N o r m a l Atmospheric P r e s s u r e

4800-ft;

12.24 p s i a

Beet R e c e i v i n s t i Storase Receiving periods Carrier Loads per day Direct process R e c l a i m from storage Maximum reclaim r a t e d a y l i g h t h o u r s , 7-days per week 25-ton n e t t r a c t o r - t r a i l e r s ( e n d dump) 214 f o r 6 0 d a y s max r a t e 1235 t p d 1728 t p d 150 tph

Beet Washing

Flume w a t e r Wash water Direct recycle Pond recycle L o s t t o sludge

2000 .gal/ton

400 g a l / t o n 60 percent 19 percent 1 percent

o f ' b e e t s flumed ( d e s i g n ) of b e e t s ( d e s i g n ) (design) (maximum) (minimum)

Beet S1 i c i n g

S l i c e rate
Compressed a i r t o s l i c e r s

924 t p d p e r m a c h i n e 3 0 l b / t o n of b e e t s s l i c e d
4 hours

(cleaning) K n i f e block cycle t i m e

Diffusion A v e r a g e d i f f u s i o n temp. Draft L e n g t h of c o s s e t t e s Diffuser constant Diffusion t i m e Sugar i n pulp Sugar i n sliced b e e t s Diffuser capacity 7OoC + 273' = 343O K 120 lb juice/100 l b cossettes 13 m/lOO-g. cossettes 6.6 x 10 64 min. . 3 5 2 9 % w t ( 1 . 2 3 7 % w t on p u l p ) 15.95% w t 3200 t p d 3-5

T a b l e 3-2

(continued)

PRINCIPAL DESIGN BASES SUGAR BEETS

PROCESSING

Pulp Dewatering
Raw p u l p m o i s t u r e Screened pulp moisture Pressed pulp moisture S u g a r loss i n p u l p P r e s s water r e t u r n

93% w t 85% w t 80% w t 2.237% w t on p u l p 8 0 % o n raw p u l p

U t i l i t y and Energy Requirements

E l e c t r i c power

t o be determined

Process water C o o l i n g water H o t g e o t h e r m a l water G e o t h e r m a l steam

Thin J u i c e Concentration Sucrose e x i t concentration Number of e f f e c t s Heat r e c o v e r y

19.8 p e r c e n t w e i g h t

2 p r e h e a t i n g , water h e a t i n g and d i f f u s e r h e a t i n g

3-6

JOB

13412

I -

&
-!
-

cw

i
-

=i 1

i i

A t t h e o t h e r dump s t a t i o n b e e t s a r e dumped i n t o a d r y

hopper and f e d o n t o a p i n c h - r o l l e r removes weeds a n d l e a v e s .

t r a s h s c r e e n which conveyor

A traveling-stacker

t r a n s f e r s t h e b e e t s t o o n e of t w o p a r a l l e l s t o r a g e p i l e s .
A t r a n s v e r s e s l e w i n g boom i s u s e d t o s t a c k t h e b e e t s up

t o a h e i g h t of t w e n t y f e e t a n d t o a w i d t h o f 115 f e e t .
A t f u l l capacity, each p i l e w i l l contain 60,000 tons.

T r a n s v e r s e a i r d u c t s , spaced a t 25 f t .

intervals, dis-

t r i b u t e v e n t i l a t i o n a i r s u p p l i e d by l o w p r e s s u r e f a n s .

Beets a r e r e c l a i m e d a t up t o 1 5 0 t o n s p e r h o u r by f r o n t e n d l o a d e r s w o r k i n g t h e toe o f a p i l e . They l o a d a move-

a b l e h o p p e r p o s i t i o n e d a b o v e t h e reclaim b e l t c o n v e y o r . The reclaim c o n v e y o r d i s c h a r g e s i n t o t h e w e t dump h o p p e r from which b e e t s e n t e r t h e flume system.

B e e t Washing

--

The b e e t s a r e c l e a n e d t o remove r o c k s ,

t r a s h and s o i l p r i o r t o s l i c i n g .

Beets a r e s l u i c e d i n t o

t h e flume s y s t e m w i t h a m i x t u r e o f f r e s h and r e c y c l e d f l u m e water.

A f e e d e r which i n t h e flume r e g u l a t e s t h e

f l o w o f b e e t s i n t o t h e downstream p o r t i o n o f t h e flume.
A Dyer-type

r o c k c a t c h e r removes r o c k s from t h e l i g h t e r

b e e t s u s i n g a n upward f l o w o f water t o l i f t t h e b e e t s a n d a l l o w t h e r o c k s t o s e t t l e downward i n t h e r o c k c h u t e .

A c h a i n conveyor removes t h e collected r o c k s .

Weeds, trash

l e a v e s a n d b e e t t a i l s a r e removed i n a D a l t o n - t y p e separator.

The t r a s h i s d i s c h a r g e d f r o m a r o t a t i n g drum

3-10

o n t o a b e l t conveyor f o r t r a s h d i s p o s a l .

The b e e t s r e t u r n

t o t h e f l u m e and e n t e r t h e washer which h a s a d e w a t e r i n g

section a t the inlet. F r e s h water i s a d d e d a s t h e b e e t s

p a s s o n t o a c u r v e d s c r e e n a n d a r e washed by s p r a y s a n d by a g i t a t i o n . C l e a n b e e t s a r e d i s c h a r g e d by a d e w a t e r i n g F l u m e water a n d w a s h water

T h e water c a n

screw o n t o a b e l t c o n v e y o r .

p a s s o v e r a t r a s h s c r e e n a n d i n t o a sump.

be r e c y c l e d d i r e c t l y or d i s c h a r g e d t o a g r a v i t y c l a r i f i e r f o r cleanup.
S i l t s e t t l e s o u t i n t h e c l a r i f i e r and is

pumped t o o n e o f t w o s i l t p o n d s .

The c l a r i f i e r o v e r f l o w

( a b o u t 80 p e r c e n t ) i s r e c y c l e d t o t h e head end o f t h e flume. The s i l t p o n d s a l l o w f u r t h e r c l a r i f i c a t i o n t o occur so a d d i t i o n a l water c a n b e r e c y c l e d . Sludge accumulates i n

t h e p o n d s a n d i s d r e d g e d a t t h e e n d of t h e b e e t p r o c e s s i n g season.

Beet S l i c i n g

-- Washed

b e e t s are conveyed t o a b u c k e t

e l e v a t o r w h i c h l i f t s them t o a h o r i z o n t a l t r a n s f e r c o n v e y o r a b o v e t h e 50 t o n c a p a c i t y c l e a n b e e t b i n . The b i n

i s mounted a b o v e t h r e e 1 0 0 0 t o n p e r d a y c a p a c i t y r o t a r y slicers. R o t a t i n g k n i f e b l o c k s c u t t h e b e e t s i n t o t h i n slices (cossettes).

The k n i f e b l o c k s a r e c h a n g e d o u t Compressed a i r The cossettes

a b o u t every four hours f o r sharpening.

is used t o c l e a n t h e b l o c k s d u r i n g o p e r a t i o n .

a r e f e d o n t o a weigh b e l t conveyor ( w e i g h t o m e t e r ) which

a u t o m a t i c a l l y weighs and t o t a l s t h e d a i l y s l i c e .

3-11

Diffusion

--

Hot w a t e r e x t r a c t i o n of t h e j u i c e f r o m t h e

cossettes is c a r r i e d o u t i n a c o n t i n u o u s slope d i f f u s e r .
The 3200 t o n per d a y c a p a c i t y S i l v e r D.d.S.
1

d i f f u s e r is

steam j a c k e t e d t o m a i n t a i n t h e j u i c e a n d p u l p a t t h e
d e s i r e d t e m p e r a t u r e (160 F a v e r a g e ) .

Cossettes e n t e r t h e
Hot w a t e r

lower e n d a n d a r e c o n v e y e d upward by t h e s c r o l l s .

a n d p u l p r e t u r n water e n t e r t h e t o p e n d a n d p a s s downward c o u n t e r c u r r e n t l y c o n t a c t i n g t h e cossettes.

By d i f f u s i o n

t h e j u i c e phase passes from c e l l u l a r material i n t o t h e

liquid.

Exhausted cossettes ( p u l p ) are d i s c h a r g e d from

t h e t o p end o f t h e d i f f u s e r and d r o p o n t o a d e w a t e r i n g s c r e e n . The t h i n j u i c e i s d i s c h a r g d ( o n l e v e l c o n t r o l ) from t h e l o w end of t h e d i f f u s e r i n t o a tank. The t h i n

j u i c e amounts t o a b o u t 120 p e r c e n t b a s e d , i n t h e w e i g h t o f t h e e n t e r i n g cossettes. The s u g a r c o n t e n t i s 1 3 . 6 5 p e r c e n t

a n d r e p r e s e n t s a 97.8 p e r c e n t s u g a r r e c o v e r y .

Pulp Dewatering

--

The raw p u l p i s s c r e e n e d t o remove f r e e

w a t e r and t h e n conveyed t o e i g h t v e r t i c a l s c r e w presses

f o r d e w a t e r i n g t o a b o u t 80 p e r c e n t m o i s t u r e c o n t e n t .

Nearly 33 t o n s per h o u r

of p r e s s e d p u l p a r e g e n e r a t e d .
drying. Screening

T h i s material is conveyed t o by-product

water a n d press water a r e pumped t h r o u g h a h e a t e x c h a n g e r

1 5 8 ' F ) and r e t u r n e d h o t (

t o t h e d i f f u s i o n water i n l e t .

H e a t e d makeup water i s a l s o a d d e d t o t h e r e t u r n water

stream a h e a d of t h e h e a t e x c h a n g e r .

Steam p r e h e a t i n g t h e

water h e l p s t o c o n t r o l b a c t e r i a l g r o w t h i n t h e d i f f u s e r .
3-12

Thin Juice Concentration

--

Multiple-effect evaporation

is used to raise the sugar concentration in the juice for

optimum fermentation and alcohol recovery.

modified

two-effect evaporator system raises the sugar concentration to 19.8 percent weight. Hot geothermal brine (280 F) in the

first effect vaporizes water which is used as steam to the second effect. The evaporator condensates along with vapor The re-

from the second effect preheat the thin juice feed.

maining vapor from the second effect provides all of the diffuser's steam needs. The coincentrated juice is then

cooled to 80F prior to fermentation.

Fermentation

--

Fermentation of the sucrose solution is

carried out batch-wise in ten 170,000 gal fermenters to yield a net 2540 gallons per hour of ethanol. summarizes the fermentation parameters. Table 3-3

The total cycle

time per fermenter is 6 0 hours and eight batches are always in some stage of fermentation at any one time. One fermenter is being filled and one is being emptied and cleaned at any one time.

At the start of a cycle, concentrated juice,

yeast and
H C 1 is

nutrients are pumped into the fermentation tank. added in-line to drop the pH to 4 . 5 from 6.5.

As the

fermentation proceeds, heat released by the reaction increases the mash temperature. Carbon dioxide formed in

the reaction also is released into the vapor space.

3-13

Table 3-3 PRINCIPAL DESIGN BASES

FERMENTATION

SUGAR BEETS

Chemical Reactions and Conversions (Basis 100 lb glucose) Sucrose hydrolysis (100%) C12H22011 + H2-----------) 2C6H1206 95.0 lb + 5.0 lb 100.0 lb

Glucose conversion to ethanol (91.88%) gH126 91.82 lb yeast 2C2H50H

+ 2C02
44.85 lb

46.97 lb

to yeast. (3.636%) C2H1206 3.6363 lb

to other organics (4.545%)

innoculum

yeast

+ 1 452C02 + 1.452 H20

.9091 lb

1.8181 lb .9091 lb

2.5 CgH1206 ------+3CH3CHO 4.5454 1b.

4C02 + CH3(CH2)3CH2 OH 1.777 lb .8897 lb

+ 3H2O
.545 lb

1.3333 lb

Fermentation

-0.2385 lb/100 lb ethanol produced 0.954 lb/100 lb ethanol produced 48 hours 85O F -goo F 3-14

Yeast Makeup Nutrient Requirements Fermentation Time Fermentation Temperature

T a b l e 3-3

(continued)

PRINCIPAL D E S I G N BASES

FERMENTATION

2 2 kcal/g-mole

(430 Btu/lb e t h a n o l )
6 hours
6 hours

F e r m e n t e r F i l l Time F e r m e n t e r Empty
&

C l e a n Time

T o t a l B a t c h Cycle Time Maximum/Design Capacity

60 hours 120 8

Off-gas

Scrubbing

-3 f e e t per s e c o n d
20 ga1/1000 ACFM
2. i n . W.G.
goo F ( a v g )

Vapor s u p e r f i c i a l v e l o c i t y
L/G P r e s s u r e drop
G a s i n l e t temperature G a s e x i t temperature

60 F ( a v g )
60 F ( a v g ) r e p l a c e m e n t o f water i n o f f - g a s

L i q u i d c i r c u l a t i o n temp.
Make u p water

Beer Well
Surge capacity Recirculation rate
8 h r s @ 80% f u l l

1 5 0 0 gpm

3-15

The mash i s c i r c u l a t e d t h r o u g h p l a t e - t y p e t h e b u l k t e m p e r a t u r e r e a c h e s a b o u t 90'

F.

e x c h a n g e r s when C o o l i n g water

(60 F ) r e m o v e s t h e b u l k o f t h e h e a t o f r e a c t i o n a n d l i m i t s

t h e mash temperature r i s e .

Cooling is r e q u i r e d o n l y p a r t

o f t h e f e r m e n t a t i o n t i m e s o one e x c h a n g e r c a n be used t o serve t w o fermenters. Alternately, t h e mash i s c i r c u l a t e d

c o n t i n u o u s l y , most o f t h e t i m e b y p a s s i n g t h e e x c h a n g e r . Evolved v a p o r s , mainly C02, column t o r e c o v e r e t h a n o l . pumped t o t h e b e e r w e l l . t h e atmosphere.

are water-scrubbed

in a tray

Blowdown f r o m t h e s c r u b b e r i s Scrubber off-gas

is vented t o

A t t h e e n d o f t h e 48 h o u r f e r m e n t a t i o n p e r i o d , t h e f e r m e n t e d

mash c o n t a i n i n g 9 . 8 % e t h a n o l i s pumped t o t h e b e e r w e l l . The empty f e r m e n t e r i s c h e m i c a l l y c l e a n e d by i n t e r n a l s p r a y i n g machines, s t e r i l i z e d w i t h an i o d i n e s o l u t i o n and r i n s e d w i t h s t e r i l e water. The s p e n t s o l u t i o n s a r e r o u t e d

t o wastewater t r e a t m e n t , a n d t h i s t a n k i s a g a i n r e a d y f o r
service.

The f e r m e n t e d mash ( b e e r ) c h a r g e d t o t h e b e e r w e l l c o n t a i n s

water, y e a s t , d i s s o l v e d s o l i d s ( o r g a n i c a n d i n o r g a n i c ) ,
f u s e l o i l and a l d e h y d e s i n a d d i t i o n t o t h e e t h a n o l . y i e l d o f e t h a n o l b a s e d on sucrose i s 91.6 p e r c e n t . The n e t
An e i g h t -

h o u r s u r g e c a p a c i t y is p r o v i d e d a n d t h e t a n k c o n t e n t s a r e c i r c u l a t e d continuously t o provide a uniform feed t o t h e d i s t i l l a t i o n section.

3-16

Ethanol D i s t i l l a t i o n

--

Fermented b e e r from t h e b e e r w e l l

is p r e h e a t e d w i t h t h e c o n d e n s i n g v a p o r s from t h e a z e o t r o p i c
column a n d t h e b e e r s t i l l t h r o u g h f e e d / t o p s e x c h a n g e r s t o r e c o v e r t h e c o n d e n s i n g load o f t h e v a p o r from b o t h columns. The b e e r i s f u r t h e r h e a t e d t h r o u g h a f e e d / b o t t o m s e x c h a n g e r t a k i n g a d d i t i o n a l h e a t from t h e b o t t o m o f t h e b e e r s t i l l .
A t r i m h e a t e r using geothermal f l u i d w i l l provide .the f i n a l

h e a t necessary t o provide a bubble-point beer still.

feed i n t o the

The b e e r s t i l l i s o p e r a t e d a t a p r e s s u r e o f 1 0 p s i g a t t h e b o t t o m o f t h e c o l u m n , w h i c h c o r r e s p o n d s t o t h e maximum t e m p e r a t u r e a v a i l a b l e from t h e geothermal f l u i d f o r r e b o i l d u t y i n t h e thermosiphon r e b o i l e r . F u s e l o i l is c o n c e n t r a t e d

i n t h e u p p e r p a r t o f t h e column and i s removed a n d waterwashed i n a s e p a r a t e f u s e l o i l w a s h e r . The a l c o h o l and water

r e c o v e r e d from t h e f u s e l o i l washer is r e t u r n e d t o t h e b e e r

s t i l l feed.

Trace q u a n t i t i e s o f a l d e h y d e p r o d u c e d i n t h e
A f t e r conden-

f e r m e n t e r i s removed a s a n o v e r h e a d stream.

s a t i o n , t h e aldehyde is r e b l e n d e d w i t h t h e e t h a n o l p r o d u c t . E t h a n o l - w a t e r c l o s e t o t h e azeotropic c o m p o s i t i o n i s cond e n s e d a g a i n s t t h e in-coming b e e r f e e d p r i o r t o i t s e n t r y as a bubble-point f e e d t o t h e a z e o t r o p i c d i s t i l l a t i o n column.

Benzene i s u s e d t o f o r m a t e r n a r y azeotrope w i t h t h e e t h a n o l /

water m i x t u r e i n t h e a z e o t r o p i c column.
overhead w i t h t h e benzene.
3-17

The water i s removed

The c o n d e n s e d l i q u i d i s c o l l e c t e d

i n a phase s e p a r a t o r .

The benzene i n t h e upper p h a s e is

r e c y c l e d b a c k t o t h e t o p o f t h e column.

The a q u e o u s p h a s e

c o n t a i n i n g t r a c e q u a n t i t y of hydrocarbon is f e d t o a hydrocarbon s t r i p p e r . The b o t t o m stream o f t h e a z e o t r o p i c column

T h i s stream i s c o o l e d a n d pumped t o s t o r a g e .

i s 99.2% e t h a n o l .

I n t h e hydrocarbon s t r i p p e r e s s e n t i a l l y a l l o f t h e hydroc a r b o n r e m a i n i n g i n t h e f e e d i s removed o v e r h e a d a n d f e d b a c k t o t h e f e e d s t r e a m t o t h e a z e o t r o p i c column.

The bottom

stream i s s e n t t o wastewater t r e a t m e n t .

By-product

Recovery

--

T h e b o t t o m stream f r o m t h e b e e r s t i l l

c o n t a i n i n g t h e y e a s t a n d d i s s o l v e d s o l i d s i s pumped t o t h e whole s t i l l a g e t a n k f o r f u r t h e r p r o c e s s i n g .

The w h o l e s t i l l a g e a t t h i s p o i n t c o m b i n e s w i t h t h e b e e t p u l p and is c e n t r i f u g e d t o p r o d u c e a t h i n s t i l l a g e and a

35% s o l i d s stream f o r d r y i n g t o produce an animal feed

by-product.

T h e t h i n s t i l l a g e i s c o n c e n t r a t e d t o 5 4 % medium s y r u p t h r o u g h

a mechanical vapor recompression f a l l i n g f i l m e v a p o r a t o r

system. The c o n d e n s a t e c o l l e c t e d f r o m t h i s m e c h a n i c a l v a p o r

r e c o m p r e s s i o n s y s t e m i s f e d t o t h e wastewater t r e a t m e n t system.

3-18

T h e medium s y r u p c o m b i n e s w i t h t h e c e n t r i f u g e d s o l i d s a l o n g w i t h some r e c y c l e d d r i e d s o l i d s a n d f e d t o a t u r b u l i z e r t o m i x t h e s e streams t o y i e l d a 4 5 % s o l i d s t r e a m a s a f e e d t o t h e geothermal f l u i d d r y e r s .

The f i n a l p r o d u c t from t h e

d r y e r s is 90% s o l i d a n d 1 0 % m o i s t u r e .

The d r i e d p r o d u c t ,

p a r t o f w h i c h i s r e c y c l e d , i s f e d t h r o u g h a hammer m i l l
f o r s i z e r e d u c t i o n f o l l o w e d b y c o o l i n g p r i o r t o i t s conveyance t o t h e by-product
storage a w a i t i n g shipment.

The material b a l a n c e f o r t h i s s e c t i o n o f t h e p l a n t is n o t

complete a t t h i s t i m e .

3.4

Potato P r o c e s s i n g D e s c r i p t i o n
P o t a t o e s a r e processed f o r f i v e c o n t i n u o u s m o n t h s e a c h y e a r ,

March t h r o u g h J u l y , f o l l o w i n g t h e f o u r m o n t h s of s u g a r b e e t processing. 360,000 t o n s o f potatoes are r e c e i v e d by t h e

p l a n t f o r c l e a n i n g and p r o c e s s i n g d u r i n g t h i s p e r i o d .

On-

s i t e storage capacity is 36,500 t o n s .

i s 2 , 6 3 0 t o n s of p o t a t o e s p e r d a y .

The d e s i g n mash r a t e

The d a i l y mash c o n t a i n s

3 8 9 t o n s o f s t a r c h w h i c h i s c o n v e r t e d t o 432 t o n s of s u g a r .
A t t h e end of batch f e r m e n t a t i o n ,

t h i s s u g a r is converted
The b e e r (11.25% w t .

t o 2 0 3 t o n s per d a y of e t h a n o l . is d i s t i l l e d t o a 87% w t .

ethanol)

overhead product, then dehydrated

t o a 99.2% w t . e t h a n o l p r o d u c t i n a b e n z e n e - w a t e r - e t h a n o l
column.

3-19

The w h o l e s t i l l a g e f r o m t h e b e e r s t i l l i s c e n t r i f u g e d . The c a k e i s d r i e d t o 9 0 % s o l i d s . Approximately 206 t o n s

of t h i s d r i e d animal feed are produced p e r s t r e a m days. F u s e l o i l s ( h i g h e r molecular w e i g h t a l c o h o l s ) a r e a l s o recovered as a by-product.

D e s i g n Bases T a b l e 3 . 4 p r e s e n t s t h e a s s u m e d c o m p o s i t i o n of t h e p o t a t o e s p r o c e s sed i n t h e plant. T a b l e 3-4

AVERAGE POTATO COMPOSITION ( C L E A N ) FJa t e r

77.5% 15.0%

Starch P r o t e i n s and f a t s Fiber

2.1% 5.4%
100.0%

A l l f o r e i g n m a t t e r i s removed a n d 0 . 1 p e r c e n ,

of t h e s l u b l e

d r y matter i s assumed t o b e l o s t i n d e w a t e r i n g .

P o t a t o e s a r e p r o c e s s e d 2 4 - h r s p e r d a y , s e v e n d a y s p e r week a t
a d e s i g n stream f a c t o r of 9 0 p e r c e n t ( 2 6 3 0 t o n s p e r stream d a y ) .

T a b l e s 3 . 5 a n d 3 . 6 s u m m a r i z e t h e p r i n c i p a l d e s i g n b a s e s f o r each process section.

3-20

T a b l e 3-5
P R I N C I P A L D E S I G N BASES

PROCESSING

POTATOES

P o t a t o R e c e i v i n g and S t o r a g e Receiving periods Carrier Loads p e r d a y d a y l i g h t h o u r s , 7 - d a y s p e r week 20-ton n e t t r a c t o r - t r a i l e r s ( e n d dump)

130

Direct p r o c e s s

2607 t p d

P o t a t o Washina

F1 ume w a t e r
Wash water

1920 gal/ton of p o t a t o e s flumed ( d e s i g n )

1 0 0 g a l / t o n of p o t a t o e s ( d e s i g n )
98 p e r c e n t ( d e s i g n )

Direct r e c y c l e
Pond r e c y c l e
Lost t o s l u d g e

P o t a t o Mashing Mashing r a t e 870 t p d p e r m a c h i n e

Mash D e w a t e r i n g Raw mash moisture D e w a t e r e d mash m o i s t u r e C o n c e n t r a t e moisture

78% w t

69% w t
98% w t

3-21

T a b l e 3-6 PRINCIPAL D E S I G N B A S E S

POTATO FERMENTATION

C h e m i c a l Reactions a n d C o n v e r s i o n s ( B a s i s 1 0 0 l b . g l u c o s e )

Glucose conversion

t o e t h a n o l (91.818%)
gH1Z06

yeast

2 C2H50H

2 CO2

91.812 l b

46.97 l b

44.85 l b

t o y e a s t (3.636%)
C6H1206

innoculation

yeast

1.452 C 0 2

1.452 H 2 0

3.636 l b

1.8181 l b

.go91 l b

. g o 9 1 lb.

t o o t h e r o r g a n i c s (4.545%)
2.5 CgH1206 4.545 l b yeast 3CH3CH0 1.3333 l b

4 C02

CH3

(CH2)3 C H 2 0 H .8897 l b

1.777 l b

3-22

Each P r o c e s s s e c t i o n i s d e s c r i b e d b e l o w .

F i g u r e 3-4

is a n

o v e r a l l b l o c k d i a g r a m o f t h e p o t a t o p r o c e s s i n g 'and F i g u r e 3-5 i s a p r o c e s s f l o w d i a g r a m of t h e s t e p s up t o d i s t i l l a t i o n . F i g u r e 3 . 6 shows t h e p r o d u c t s r e c o v e r y .

P o t a t o R e c e i v i n g and S t o r a g e

--

Potatoes are s h i p p e d t o t h e
The n e t

e t h a n o l f a c i l i t y by e n d dump t r a c t o r - t r a i l e r s . l o a d a v e r a g e s 20 t o n s .

T r u c k s a r e weighed i n ( g r o s s ) and
A t the

o u t ( t a r e ) t o record t h e as r e c e i v e d tonnages.

s c a l e , t r u c k s ae d i v e r t e d t o t h e dump s t a t i o n w h e r e p o t a t o e s

a r e dumped i n t o t h e p o t a t o c e l l a r w h i c h p r o v i d e s s t o r a g e
space f o r 1 4 days' p o t a t o requirement (36,500 t o n s ) . P o t a t o e s a r e r e c l a i m e d by f r o n t - e n d l o a d e r s w o r k i n g a t t h e

toe of a p i l e .

The l o a d e r s t r a n s f e r t h e ' p o t a t o e s t o t h e

reclaim b e l t c o n v e y o r w h i c h d i s c h a r g e s i n t o t h e s l a b s t o r a g e area which p r o v i d e s p o t a t o s t o r a g e f o r 8 h o u r s o f p l a n t

operation.

P o t a t o Washing

--

The p o t a t o e s a r e c o n v e y e d v i a a f l u m e t o
F l u m e water is r e c y c l e d .

one of t h r e e p o t a t o washers.

Wash water i s s u p p l i e d t o e a c h w a s h e r a t 7 5 g a l l o n s p e r minute. The wash water f l o w f r o m t h e w a s h e r t o a t w o Suspended s o l i d s s e t t l e o u t

c o m p a r t m e n t s e t t l i n g pond.

i n t h e f i r s t compartment and c l a r i f i e d water f l o w s i n t o t h e second compartment from which i t is r e c y c l e d a s flume

water makeup.

S l u d g e a c c u m u l a t e s i n t h e s e t t l i n g pond

a n d i s d r e d g e d a t t h e e n d of t h e p o t a t o p r o c e s s i n g s e a s o n . 3-23

I
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COOKED POTATO MAS1;

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P o t a t o Mashing a n d D e w a t e r i n g

--

Washed p o t a t o e s a r e con-

veyed t o one o f t h r e e f e e d b i n s and t h e n t o t h r e e d i s i n t e g r a t o r s where t h e potatoes are c r u s h e d , and r e s i d u a l f o r e i g n

matter (tramp i r o n , e t c . ) is s e p a r a t e d from t h e mash a n d

d i s c h a r g e d t o waste.
T h e mash f l o w s from t h e d i s i n t e g r a t o r s

t o s c r e e n s w h e r e c o u r s e p o t a t o p i e c e s a r e removed a n d recycled t o t h e d i s i n t e g r a t o r s . The s c r e e n e d mash f l o w s t o a

c e n t r i f u g e where i t s m o i s t u r e c o n t e n t is reduced t o approximately 69 p e r c e n t . The c e n t r a t e c o n t a i n i n g 0 . 3 p e r c e n t s t a r c h ,

i s d i s c h a r g e d t o t h e wastewater t r e a t m e n t f a c i l i t y .

Starch Liquefaction

--

A t w o p e r c e n t s o l u t i o n o f sodium

h y d r o x i d e is a d d e d i n - l i n e mash f r o m 5.6 t o 6.5.

t o r a i s e t h e pH o f t h e d e w a t e r e d

A l p h a amylase i s n e x t a d d e d t o t h e

mash t o b r e a k down t h e s t a r c h b o n d s a n d 1 0 , 6 7 0 p o u n d s p e r h o u r of 1 0 p s i g d i r e c t steam a r e a d d e d t o r a i s e t h e temperat u r e of t h e mash t o 221 F f o r g e l a t i n i z a t i o n a n d c o o k i n g of t h e s t a r c h . The s t a r c h i s c o o k e d f o r f i v e m i n u t e s i n a

t u b u l a r cooker a t 221 F a n d is t h e n f l a s h cooled t o 2 0 3 O F . The c o o k e d mash n e x t e n t e r s a b a f f l e d h o l d t a n k w h i c h prov i d e s 90 minutes d e t e n t i o n t i m e . A g i t a t o r s are provided

f o r adequate mixing of t h e hold tank c o n t e n t s t o p r e v e n t s e t t l i n g o f s u s p e n d e d matter. The h o l d t a n k e f f l u e n t i s

cooled t o 140 F a n d t r e a t e d w i t h a f i v e p e r c e n t h y d r o c h l o r i c a c i d s o l u t i o n t o lower t h e p H from 6 . 5 t o 4.5.

3-27

Saccharification

--

Glucoamylase is added to the liquified

starch to break down the starch dextrins to produce a high yield of fermentable glucose.

This takes place in ten 170,000

gallon saccharification vessels each with 60 hours retention time. A steam jacket around each saccharification vessel Each vessel is also

maintains the contents at 140 F.

equipped with an agitator to ensure adequate mixing of the reactants.

Fermentation

--

Fermentation of the glucose solution is

carried out batch-wise in ten 170,000 gallon fermenters to yield a net 2 5 4 0 gallons per hour of ethanol. Table 3 - 3

in the beet processing section summarizes the fermentation parameters. The fermentation conditions' are identical to

that described in the beet section.

Alcohol Distillation

--

The distillation scheme for the

potato case is identical to that described for the beet case except for a higher solids concentration bottom stream from the beer still in the potato case. The fibers

from the potato processing were not separated prior to distillation, therefore all of the fibers come in with the beer feed to the still.

3-28

By-product

Recovery

--

The w h o l e s t i l l a g e f o r t h e p o t a t o

case h a s a much lower d i s s o l v e d s o l i d s c o n t e n t t h a n i n t h e

b e e t case. T h e r e f o r e , t h e t h i n s t i l l a g e produced from t h e

c e n t r i f u g e may g o d i r e c t l y t o wastewater t r e a t m e n t w i t h o u t being processed through t h e mechanical vapor recompression system. The e n e r g y c o n s u m p t i o n , t h e r e f o r e , i s e x p e c t e d

t o b e lower t h a n t h a t n e c e s s a r y f o r t h e s u g a r b e e t case.

The c e n t r i f u g e d s o l i d s f r o m t h e w h o l e s t i l l a g e w i l l b e r e c o v e r e d i n a s i m i l a r manner t o t h a t d e s c r i b e d u n d e r t h e s u g a r b e e t case.

3.5

Wheat P r o c e s s i n s Work on t h e w h e a t p r o c e s s i n g o p t i o n h a s b e e n s t a r t e d . Equipment m a n u f a c t u r e r s h a v e b e e n c o n t a c t e d a n d a w h e a t p r o c e s s i n g p l a n t ( f l o u r m i l l ) was v i s i t e d . Wheat m i l l i n g

tests are being conducted t o d e t e r m i n e w h e t h e r removal

of t h e g l u t e n p o r t i o n o f t h e w h e a t i n t h e m i l l i n g s e c t i o n
o f t h e p l a n t w i l l h a v e a f a v o r a b l e e f f e c t on p r o c e s s

economics.

The p r o c e s s f l o w d i a g r a m w i l l b e p r o d u c e d

a f t e r t h e t e s t r e s u l t s become a v a i l a b l e .

3-29

Section 4 GEOTHERMAL RESOURCE

The overall process heat requirements will dictate the geothermal brine requirements. These have not been completed, but a prelimi-

nary estimate of the requirements is between 100 and 200 million BTU/hr. The following discussion covers how the geothermal brine

will be used in the system and the brine flow requirements.

4.1

Resource Extraction and Requirement Three different energy extraction systems were considered:
(1) flashed steam; ( 2 ) pressurized

geothermal fluid with

a direct transfer of heat, and ( 3 ) use of a secondary heat transfer fluid. The pressurized fluid system has been

selected since it minimizes the potential scaling problems in the brine transfer system. Thus, there will be no direct In the

injection of the brine into the process streams.

event steam injection is required, as in potato cooking, a secondary l o o p incorporating a steam generation system will be utilized.

Since the overall

heat balance is not completed, only a

preliminary estimate can be made for the geothermal fluid flow requirements. Figure 4-1 shows the relationship

between geothermal fluid return flow temperature and this number of wells required and the relative energy cost to supply the process heat load.
4-1

1 .o

TOTAL HEAT LOAD = 100 x TBRINE IN = 2800~ WELLS, PUMPING POWER, AND LAND ONLY

lo6 BTU/HR

0.75

v)

I-

8 w
Fr
W

>

INTER EST RATE

0.50

12

0 . 2 5

10

NO. OF
SUPPLY

WELLS

0 150

J
250

175

200
BRINE OUT

225

OF

Figure 4-1

RELATIVE ENERGY COST VS BRINE R E T U R N TEMPERATURE

4.2

Geothermal F l u i d P r o p e r t i e s

P h y s i c a l and chemical p r o p e r t i e s of t h e geothermal f l u i d c o n s t r a i n t t h e method by w h i c h t h e f l u i d may b e u s e d . The e f f e c t s o f t h e s e p r o p e r t i e s r e l a t e t o t h e s c a l i n g

,
I

t e n d e n c y o f t h e f l u i d , a n d p o t e n t i a l c o r r o s i o n by t h e n o n - c o n d e n s i b l e g a s e s and b r i n e s a l i n i t y .

Analysis of the t o t a l dissolved s o l i d s i n the Raft River

KGRA i n d i c a t e s t w o d i f f e r e n t sources o f g e o t h e r m a l water

e x i s t i n d e e p wells.

One o f t h e s e i s o f a l o w s a l i n i t y

( a p p r o x i m a t e l y 1 0 0 0 ppm TDS) and o n e o f a h i g h s a l i n i t y ( a b o u t 6 0 0 0 ppm T D S ) .

These waters are a s s o c i a t e d w i t h

l o c a l g e o g r a p h i c a l c o n d i t i o n s known a s t h e B r i d g e f a u l t and t h e narrows S t r u c t u r e (Ref. 3 ) .

T h e f l u i d t e m p e r a t u r e o f these t w o sources i s a l s o d i f -

ferent.

Bottom h o l e t e m p e r a t u r e s i n d e e p w e l l s v a r y by
F f o r t h e same d e p t h .

a s much a s 5 '

Non-condensible

g a s e s are p r e s e n t i n t h e geothermal b r i n e .

Materials t e s t i n g h a s shown t h e r e a r e t r a c e a m o u n t s o f
hydrogen s u l f i d e i n t h e b r i n e s (Ref. 4 ) . T h e s e a r e of

s u f f i c i e n t q u a n t i t y t o cause c o r r o s i o n p r o b l e m s w i t h copper a l l o y s . The f i n a l m a t e r i a l s s e l e c t i o n w i l l t a k e

the fluid properties into consideration.

4-3

Section 5 CONCEPTUAL D E S I G N OF GEOTHERMAL

ENERGY GATHERING, TRANSFER, AND DISPOSAL SYSTEM

A v i s i t w a s made

t o t h e DOE R a f t R i v e r s i t e on S e p t e m b e r 1 9 a n d

2 0 t o o b t a i n d e s i g n i n f o r m a t i o n on t h e g e o t h e r m a l r e s o u r c e s a n d

c o s t e s t i m a t e s f o r u s e of t h e g e o t h e r m a l r e s o u r c e s a t t h e Crook
and Glover p r o p e r t i e s .
A summary o f t h e g e o t h e r m a l resource

c h a r a c t e r i s t i c s i s shown i n T a b l e 5-1.

5.1

Well F i e l d D e s i g n D i s c u s s i o n s were h e l d w i t h g e o l o g i s t , h y d r o l o g i s t s , a n d e n g i n e e r s o f EG&G c o n c e r n i n g t h e R a f t R i v e r a r e a .

No report

i s a v a i l a b l e which can s u p p l y t h e d e s i g n c o n d i t i o n s f o r
t h e g e o t h e r m a l resources n o r i s t h e r e a n y g e n e r a l a g r e e m e n t on t h e e x t e n t of t h e r e s o u r c e .

T h e r e i s major f a u l t i n g i n t h e R a f t R i v e r a r e a s o t h a t i t

is v e r y d i f f i c u l t t o p r e d i c t t h e r e s u l t s from e x p l o r a t i o n

d r i l l i n g even i f it is n e a r an e x i s t i n g w e l l .

Multi-legged

wells are n o t worth t h e a d d i t i o n a l e x p e n d i t u r e j u s t t o i n crease t h e f l o w b u t c a n be u s e d t o i m p r o v e a bad w e l l .

The flow i n c r e a s e is small f o r multi-legged

wells, t h e cost

i s l a r g e , a n d t h e r e a r e c h a n c e s of p l u g g i n g o n e or t h e
o t h e r l e g s due t o o b s t r u c t i o n s from t a i l i n g s .

5-1

T a b l e 5-1
G e o t h e rmal R e s o u r c e

D e s i g n Bases

W e l l Supply

T e m p e r a t u r e = 280 F ( a t s u r f a c e ) F l o w = 6 0 0 gpm/well w i t h 200 KW pumping power D e p t h = 5000 f e e t

Cost = $ 7 0 0 , 0 0 0 t o $ 9 0 0 , 0 0 0 ( 1 9 7 9 $ ) ( n o t including exploration cost)

L i f e = One new w e l l e v e r y o t h e r y e a r f o r 7 w e l l s d r i l l e d .
Well S p a c i n g

On a 1 / 4 M i l e S q u a r e G r i d
Gases

Non-condensible Redundancy

N o H2S

7 wells d r i l l e d f o r 5 p r o d u c i n g w e l l s ( t h e 2 wells c a n n o t b e u s e d , f o r reinjection).

Scaling

F l a s h i n q of t h e b r i n e s h o u l d n o t b e a l l o w e d . Keep p r e s s u r e a b o v e 1 0 0 p s i g .

Brine D i s D o s a l

Same q u a n t i t y a s o b t a i n e d f r o m t h e s u p p l y w e l l m u s t
be r e i n i e c t e d .

One r e i n j e c t i o n w e l l per 2 s u p p l y w e l l s i n t o 1 5 0 0 t o 2500 a q u i f e r . Maximum r e i n j e c t i o n p r e s s u r e = 250 p s i g

N o p a r t i c l e s g r e a t e r t h a n 200 m i c r o n

5-2

E s t i m a t e s of w e l l o p e r a t i n g c o n d i t i o n s a l s o v a r y .

Although

t h e 5 MW Power P l a n t w a s d e s i g n e d f o r 290 F , more r e c e n t d a t a i n d i c a t e d a n a v e r a g e t e m p e r a t u r e of 270 t o 280 F

(pumped a n d a t t h e w e l l h e a d ) .

A d d i t i o n a l t e m p e r a t u r e loss Flows o f 500 t o 6 0 0 gpm

Well d e p t h s a r e t y p i -

i n t h e p i p e l i n e s can be expected.

p e r w e l l a r e p o s s i b l e w i t h pumping.
c a l l y 5000 f e e t .

A l t h o u g h w e l l s c a n b e s e l f f l o w i n g , pumping i s recommended.
A s t u d y f o r w e l l pumping f o r t h e 5 MW p l a n t c o n c l u d e d t h e r e

i s a n optimum o p e r a t i n g p r e s s u r e .
i n c r e a s e s t h e flow.

I n c r e a s i n g t h e pump h e a d

S u b m e r s i b l e pumps h a v e been c o n s i d e r e d .

T h e i r u s e should be considered as developmental f o r t h i s application. L i n e pumps c a n b e u s e d f o r pump d e p t h s of

800 f e e t and p o s s i b l e t o 1 2 0 0 t o 1 5 0 0 f e e t .

W e l l l i f e i s unknown.

A l t h o u g h some w e l l s h a v e b e e n i n

e x i s t e n c e s i n c e 1975, i n s u f f i c i e n t i n f o r m a t i o n is a v a i l a b l e t o project t h e o p e r a t i n g l i f e .
based upon a maximum l i f e of 5 y e a r s .

Most a n a l y s e s a r e
Longer w e l l flows

are p o s s i b l e b u t a t t h e e x p e n s e s of i n c r e a s e d pump s e t t i n g
d e p t h s and pump h o r s e p o w e r . T h e r e f o r e , a recommendation

of o n e new w e l l e v e r y o t h e r y e a r f o r e v e r y 5 t o 7 p r o d u c t i o n w e l l s was made.

5-3

5.2

Brine G a t h e r i n g System
A s u p p l y w e l l f i e l d l a y o u t u s i n g a square g r i d w i t h a

w e l l s p a c i n g o f 1 / 4 t o 1 / 2 a m i l e i s recommended. similar t o o i l f i e l d s .

T h i s is

A g e n e r a l comment i s t h a t t h e r e i s

i n s u f f i c i e n t s p a c e on t h e Crook a n d G l o v e r p r o p e r t y t o s u p p l y t h e e t h a n o l p r o d u c t i o n f a c i l i t y ( b a s e d upon o u r p r e l i m i n a r y estimate of f i v e wells). Adjacent p r o p e r t i e s

w i l l b e n e e d e d t o s u p p l y t h e h e a t load r e q u i r e m e n t .

5.3

Brine Disposal
F o r b r i n e r e i n j e c t i o n , t h e f l u i d m u s t be i n j e c t e d such

t h a t i t d o e s n o t c o n t a m i n a t e t h e d r i n k i n g water s u p p l y . N o r m a l l y t h i s m i g h t b e i n t o t h e same a q u i f e r t h e b r i n e i s o b t a i n e d f r o m ( a t l e a s t a b o u t t h e same d e p t h ) .

More r e c e n t

t e s t i n g h a s shown a n a q u i f e r a t 1 5 0 0 t o 2500 f e e t w i l l a c c e p t

reinjected flow r e a d i l y (Ref. 5 ) .

on a l o n g term b a s i s i s n ' t known.

Whether t h i s c a n be used
It is estimated a r e i n -

j e c t i o n p r e s s u r e o f 250 t o 3 0 0 p s i i s r e q u i r e d a t t h e e n d

of f i v e y e a r s .

I t i s recommended t h e r e b e o n e s t a n d b y
One r e i n j e c t i o n w e l l

w e l l f o r e v e r y t w o i n j e c t i o n wells.

p e r t w o s u p p l y w e l l s is required f o r t h e s h a l l o w a q u i f e r whereas a one-to-one aquifer

r a t i o is required f o r t h e deeper

.
5 m i c r o n f i l t r a t i o n may b e r e q u i r e d .

The o n l y p r e s e n t p r e t r e a t m e n t f o r r e i n j e c t i o n i s 2 0 0 m i c r o n filtration.

5-4

Section 6
ECONOMIC FACTORS

D u r i n g t h e v i s i t t o R a f t R i v e r , d i s c u s s i o n s were h e l d w i t h DOE p e r s o n n e l i n o r d e r t o o b t a i n w e l l d r i l l i n g costs.

In addition,

d i s c u s s i o n s were h e l d w i t h t h e owner o f t h e t w o p r o p e r t i e s u n d e r consideration

G a r y C r o o k and F r a n k G l o v e r .

6.1

G e o t h e r m a l Well C o s t s
W e l l d r i l l i n g c o s t s were o b t a i n e d from t h e DOE i n a paper

" G e o t h e r m a l W e l l D r i l l i n g E s t i m a t e s B a s e d on P a s t W e l l
Costs".
It is e s t i m a t e d t h a t an annual i n f l a t i o n rate f o r
A 5 0 0 0 f o o t w e l l may c o s t up t o

w e l l s i s a s h i g h a s 25%.
$900,000

(1979$) n o t including e x p l o r a t i o n costs.

A review

o f o t h e r DOE c o n t r a c t s showed e x p l o r a t i o n c o s t s t o r a n g e from $11,000 ( o n e case) t o $100,000

( t w o cases) (Ref. 6 ) .

6.2

Crook's P r o p e r t y
Mr.

Crook p r o v i d e d t h r e e a l t e r n a t i v e s f o r t h e cost o f h i s 1 ) An o u t r i g h t s a l e would c o s t $ 3 5 0 , 0 0 0 ( l a n d

property.

v a l u e o f h i s p r o p e r t y by o t h e r e s t i m a t e s . i s a b o u t $ 1 0 , 0 0 0 ) .
2 ) A l e a s e a r r a n g e m e n t a t $25,00O/year

w i t h him r e t a i n i n g

t h e r i g h t t o u s e o f 1 5 0 gpm o f g e o t h e r m a l water a t l e s s

t h a n 180 F f o r h i s g r e e n h o u s e .
I

3 ) S e l l seven acres n o t

i n c l u d i n g greenhouse b u t including geothermal r i g h t s a t $150,000. F o r t h i s case h e w i l l a l s o r e t a i n t h e r i g h t s

t o t h e u s e o f 1 5 0 gpm f l u i d f l o w .
6-1

Mr.

C r o o k d o e s n o t h a v e water r i g h t s .

H i s land is l o c a t e d

on a f l o o d p l a i n a n d would p r o b a b l y be a p o o r l o c a t i o n f o r an e t h a n o l p l a n t .

6.3

Glover's Prospect F r a n k G l o v e r owns 1 6 0 a c r e s a t t h e R a f t R i v e r s i t e .

H e h a s h i r e d an a p p r a i s e r t o determine t h e v a l u e of h i s

property but has not y e t

obtained the report.

When h e

does, he w i l l send t h e results.

T h e r e a r e n o p r o d u c i n g water w e l l s on h i s p r o p e r t y .

He

h a s p e t i t i o n e d t o d r i l l a small e x p l o r a t o r y w e l l b u t as y e t has not received approval.

6.4

Electric R a t e s

E l e c t r i c i t y is o b t a i n e d from t h e R a f t R i v e r E l c t r i c a l Coop.
A r a t e s c h e d u l e was o b t a i n e d a n d shows t h e power

c o s t f o r i n d u s t r i a l user t o b e l e s s t h a n 0 . 0 2 $/KW-Hr.
The co-op i n d i c a t e d t h e r a t e s w i l l r i s e s u b s t a n t i a l l y i n December.
For i n s t a l l a t i o n cost of commercial s i z e

e l e c t r i c a l l o a d s , s p e c i a l r a t e s may b e o b t a i n e d .

6.5

C o o l i n g Water The R a f t R i v e r i s a c l o s e d resource s o t h a t t h e r e c a n b e n o c o n s u m p t i v e u s e s of water.

T h i s is i n t e r p r e t e d t o

mean b o t h g e o t h e r m a l a n d c o o l i n g water.

P r e s e n t water

users may s e l l t h e i r water r i g h t s t o o t h e r p a r t i e s i n

6-2

the future.

I n a d d i t i o n , water r i g h t s a r e g i v e n o n l y T h u s t h e 1 0 acres

on r e a l i t i v e l y l a r g e a r e a s of l a n d .

of t h e C r o o k ' s p r o p e r t y d o e s n o t h a v e w a t e r r i g h t s . However t h e 1 6 0 a c r e s t h a t h i s 1 0 acres is p a r t o f , h a s water r i g h t s .

6-3

REFERENCES

1.

Grain Motor Fuel Alcohol-Technical and Economic Assessment Study, HCP/J6639-01, Raphael Katzen Associates for U.S. DOE under Contract No. EJ-78-C-01-6639.

2.

1978 Agricultural Statistics, USDA, Economic, Statistics and Cooperative Service, Boise, Idaho, 1978.

3.

C.A. Allen, R.E. Chaney, and R.E. McAtee, Geochemical Modelinq at Raft River, Geothermal Resources Council, Transactions,
Vol. 3, Sept. 1972.

4.

R.L. Miller, Corrosion of Copper-Base Alloys in a Geothermal Brine, AIME International Symposium on Oilfield and Geothermal chemistry, Jan. 1979.

5.

Discussions with R. Chappel of

DOE,

I d a h o Operations Office

and K. Jones of EG&G, Idaho, Sept. 1979.

6.

Discussions with C. Allen, D. Goldman, and S. Spencer of EG&G, Idaho, Sept. 1979.