ASTM E1344-90(1997)e1
(Guide)Standard Guide for Evaluation of Fuel Ethanol Manufacturing Facilities
Standard Guide for Evaluation of Fuel Ethanol Manufacturing Facilities
SCOPE
1.1 This guide shall apply to FEMF as defined in Standard Terminology E1126. The guide is primarily intended for, but not exclusively limited to the evaluation of fermentation ethanol (ethyl alcohol) processes. This guide is primarily intended for, but not exclusively limited to, fermentation ethanol processes for small scale (less than 1000 gal/day capacity) plants.
1.2 This guide applies to both batch process and continuous process FEMF systems. Since a wide variety of equipment configurations can exist, this guide will describe the necessary general requirements common to all FEMF facilities.
1.3 This guide is to be used in conjunction with applicable local, state, and Federal codes for designing, constructing, and operating FEMF facilities.
1.4 This guide is limited to use with plants possessing the following operational characteristics, which are fairly typical of small scale ethanol plants and are as follows:
1.4.1 Capacity: Up to 500000-proof gal/year of 190-proof ethanol,
1.4.2 Normal Feedstocks: No. 2 yellow corn, or other suitable sample grade corn, barley, or grain sorghum (also referred to as milo). There are other starch grains such as wheat, rye, or oats, and starch tubers such as potatoes that can be used as feedstocks. Sugar crops (sugar cane, sugar beets, and molasses, that is a by-product of sugar plants) and cellulose crops (wood chips, straw, etc.) are also potential feedstock sources. However, since much of the interest in proposed ethanol plants in recent years has centered on the use of corn, barley, and milo as feedstocks for ethanol production, it is expected that the majority of plants proposed in the near future will be largely based on these abundant feedstocks. This guide concentrates on the use of corn, milo, and barley as feedstocks,
1.4.3 Normal Process Fuels: Natural gas, propane, fuel oil, wood, or coal,
1.4.4 Products: Ethanol at 190-proof or less. Distillers grains at 60 to 75% moisture by weight and thin stillage, for use as animal grade feed and not human grade food,
1.4.5 Process: The ethanol production process referred to in this guide involves dry milling of grain, batch or continuous cooking, enzyme hydrolysis, batch fermentation, continuous distillation, and pressing or centrifuging for dewatering of stillage (for example, separating suspended solids from the stillage), and
1.4.6 Variations: One variation in the ethanol production process is addressed in this guide. This variation allows for the cooking, hydrolysis, and fermentation processes to be completed either as a batch in the same process vessel or in separate vessels.
1.4.6.1 With limitations, this guide can be used to evaluate facilities with operating characteristics that differ from those just listed. However, variations from those characteristics listed will tend to lessen the reliability of the guide.
1.4.6.2 An example of a fairly minor variation would be the substitution of wheat as a feedstock. Wheat processing characteristics are reasonably similar to those of corn, barley or milo. However, wheat tends to foam considerably more than corn, so vessels need to be sized at least 10% greater than if corn is used, or the use of an antifoam agent would be advisable.
1.4.6.3 An example of a significant variation from the process characteristics utilized in this guide would be the substitution of potatoes as a starch feedstock. Processing requirements for use of potatoes vary significantly from processing requirements of corn, barley, and milo. Therefore, use of this guide is not recommended for evaluation of a potato feedstock ethanol facility.
1.5 Use of Guide as Checklist This guide should be used as a checklist for evaluation of proposed small scale manufactured fuel ethanol facilities. It is intended to be used by investors, bankers, and other parties interested in the commercial development of such fuel alcohol facilities. It is not intended to be used as a guide for the designi...
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Designation: E 1344 – 90 (Reapproved 1997)
Standard Guide for
Evaluation of Fuel Ethanol Manufacturing Facilities
This standard is issued under the fixed designation E 1344; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (e) indicates an editorial change since the last revision or reapproval.
e NOTE—Section 11 was added editorially in April 1997.
INTRODUCTION
The purpose of this guide is to provide guidelines and evaluation criteria to enable a prospective
purchaser, or lender, or both, to effectively review the plans, specifications, and plant operating
concept of a mass produced fuel ethanol manufacturing facility (FEMF) and to determine whether its
design, as proposed, meets the requirements of ASTM design practice standards. ASTM Practice
E 1117isarecognizedstandardfortheevaluationofperformanceanddesignpracticesforfuelalcohol
manufacturing facilities.
1. Scope of corn, barley, and milo as feedstocks for ethanol production,
it is expected that the majority of plants proposed in the near
1.1 This guide shall apply to FEMF as defined in Terminol-
future will be largely based on these abundant feedstocks.This
ogy E 1126. The guide is primarily intended for, but not
guide concentrates on the use of corn, milo, and barley as
exclusively limited to the evaluation of fermentation ethanol
feedstocks,
(ethyl alcohol) processes. This guide is primarily intended for,
1.4.3 Normal Process Fuels: Natural gas, propane, fuel oil,
but not exclusively limited to, fermentation ethanol processes
wood, or coal,
for small scale (less than 1 000 gal/day capacity) plants.
1.4.4 Products: Ethanol at 190-proof or less. Distillers
1.2 This guide applies to both batch process and continuous
grains at 60 to 75 % moisture by weight and thin stillage, for
process FEMF systems. Since a wide variety of equipment
use as animal grade feed and not human grade food,
configurations can exist, this guide will describe the necessary
1.4.5 Process: The ethanol production process referred to in
general requirements common to all FEMF facilities.
this guide involves dry milling of grain, batch or continuous
1.3 This guide is to be used in conjunction with applicable
cooking, enzyme hydrolysis, batch fermentation, continuous
local, state, and Federal codes for designing, constructing, and
distillation, and pressing or centrifuging for dewatering of
operating FEMF facilities.
stillage (for example, separating suspended solids from the
1.4 This guide is limited to use with plants possessing the
stillage), and
following operational characteristics, which are fairly typical
1.4.6 Variations: One variation in the ethanol production
of small scale ethanol plants and are as follows:
process is addressed in this guide.This variation allows for the
1.4.1 Capacity: Up to 500 000-proof gal/year of 190-proof
cooking, hydrolysis, and fermentation processes to be com-
ethanol,
pletedeitherasabatchinthesameprocessvesselorinseparate
1.4.2 Normal Feedstocks: No. 2 yellow corn, or other
vessels.
suitable sample grade corn, barley, or grain sorghum (also
1.4.6.1 With limitations, this guide can be used to evaluate
referred to as milo). There are other starch grains such as
facilities with operating characteristics that differ from those
wheat, rye, or oats, and starch tubers such as potatoes that can
justlisted.However,variationsfromthosecharacteristicslisted
be used as feedstocks. Sugar crops (sugar cane, sugar beets,
will tend to lessen the reliability of the guide.
and molasses, that is a by-product of sugar plants) and
1.4.6.2 An example of a fairly minor variation would be the
cellulose crops (wood chips, straw, etc.) are also potential
substitution of wheat as a feedstock. Wheat processing char-
feedstock sources. However, since much of the interest in
acteristics are reasonably similar to those of corn, barley or
proposed ethanol plants in recent years has centered on the use
milo. However, wheat tends to foam considerably more than
corn, so vessels need to be sized at least 10 % greater than if
ThisguideisunderthejurisdictionofASTMCommitteeE48onBiotechnology
corn is used, or the use of an antifoam agent would be
and is the direct responsibility of Subcommittee E48.05 on Biomass Conversion.
advisable.
Current edition approved March 30, 1990. Published May 1990.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.
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E 1344 – 90 (1997)
1.4.6.3 An example of a significant variation from the No. 10, Standard for Portable Fire Extinguishers
process characteristics utilized in this guide would be the No. 13, Standard for Installation of Sprinkler Systems
substitution of potatoes as a starch feedstock. Processing No. 30, Flammable and Combustible Liquids Code
requirements for use of potatoes vary significantly from No. 70, National Electric Code
processing requirements of corn, barley, and milo. Therefore, No. 77, Recommended Practice on Static Electricity
useofthisguideisnotrecommendedforevaluationofapotato No. 85A, Prevention of Furnace Explosions in Fuel Oil and
feedstock ethanol facility. Natural Gas-Fired Single Burner Boiler-Furnaces
1.5 Use of Guide as Checklist This guide should be used as No. 101, Life Safety Code
a checklist for evaluation of proposed small scale manufac- No. 395, Standard for the Storage of Flammable and Com-
tured fuel ethanol facilities. It is intended to be used by bustible Liquids on Farms and Isolated Construction
investors, bankers, and other parties interested in the commer- Projects
cial development of such fuel alcohol facilities. It is not 2.3 Other Standards:
intended to be used as a guide for the designing of these Article 16, Fire Prevention Code
facilities, but as a guide to assist in the evaluation of designs UL 30, Cans, Metal Safety
already completed by sellers or manufacturers of such facili- UL 58, Tanks, Steel Underground, for Flammable and
Combustible Liquids
ties. This guide may also be utilized by FEMF designers or
sellers who may wish to review their systems’ conformance UL 142, Tanks, Steel Above-Ground, for Flammable and
Combustible Liquids
with the recommendations of the guide. This guide is to be
used in conjunction with applicable local, state, and Federal CFR Title 49, Parts 100 through 199
codes and regulations. ASME Boiler Construction Codes, Sections I, IV, VII, and
1.6 The values stated in inch-pound units are to be regarded VIII
as the standard. The values given in parentheses are for
3. Terminology
information only.
1.7 This standard does not purport to address all of the
3.1 Definitions:
safety concerns, if any, associated with its use. It is the
3.1.1 alcohols—series of liquid products composed of a
responsibility of the user of this standard to establish appro-
hydrocarbon plus a hydroxyl group, such as ethanol
priate safety and health practices and determine the applica-
(C H OH).
2 5
bility of regulatory limitations prior to use. For specific hazard
3.1.1.1 Discussion—Other alcohols include methanol, iso-
statements, see Section 6 on Hazards, and the safety sections
propanol, butanol, amyl alcohol, etc. Typical fermentation
for each procedure in Section 10.
alcohol is ethanol.
1.8 This guide is arranged as follows:
3.1.2 alpha-amylase—enzyme that acts specifically to ac-
Section
celerate the hydrolysis of starch to dextrins.
3.1.3 anhydrous, without water—term used in chemistry to
Referenced Documents 2
denote absence of water. 199+ proof ethanol is considered
Terminology 3
Summary of Guide 4 anhydrous ethanol.
Significance and Use 5
3.1.4 anhydrous ethanol—100 % ethanol, neat ethanol,
Hazards 6
199 + proof ethanol.
Environmental 7
Other Considerations 8 3.1.5 azeotrope—constant boiling mixture, for ethanol-
Additional Facilities 9
water, the azeotrope of 95.6 % ethanol and 4.4 % water (both
Procedure 10
percentages by volume) boils at one atmosphere pressure.
General Process Description 10.1
Process Design Requirements 10.2
3.1.6 azeotropic distillation—the use of an organic solvent
Grain Handling and Dry Milling 10.2.1
to create a new constant boiling point mixture, a method used
Enzyme Hydrolysis 10.2.2
to produce anhydrous ethanol from the ethanol water azeo-
Batch Fermentation 10.2.3
Continuous Distillation 10.2.4
trope.
Dewatering of Stillage 10.2.5
3.1.7 backset—the liquid portion of the thin stillage that is
Appendix
recycled as part of the process liquid in mash preparation.
3.1.8 basic hydrolysis—the chemical addition of water to a
2. Referenced Documents
compound.
2.1 ASTM Standards:
3.1.9 batch fermentation—batch of nutrient mixture and
E 1117 Practice for Design of Fuel-Alcohol Manufacturing
microorganisms mixed in a vessel and allowed to ferment.
Facilities
E 1126 Terminology Relating to Biomass Fuels
2.2 NFPA Standards:
National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Engineering and Safety Service, 1976.
Underwriters Laboratories, Inc. (UL), 333 Pfingsten Rd., Northbrook, IL
60062.
2 6
For referenced ASTM standards, visit the ASTM website, www.astm.org, or Code of Federal Regulations available from the Superintendent of Documents,
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM U.S. Government Printing Office, Washington, DC 20402.
Standards volume information, refer to the standard’s Document Summary page on AmericanSocietyofMechanicalEngineers(ASME),345E47thSt.,NewYork,
the ASTM website. NY 10017.
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E 1344 – 90 (1997)
3.1.10 beer—term used to describe the product of ethanol 3.1.29 gelatinization—treatment of starch grains with heat
fermentation by microorganisms. and water to cause the swelling and expansion of the starting
material.
3.1.10.1 Discussion—Usually means the alcohol solution
remaining after yeast fermentation of sugars. About 10 % 3.1.30 glucoamylase—enzyme that acts specifically to con-
alcohol is normally contained in the beer solution for a small vert dextrins to glucose by hydrolysis.
scale fuel grade ethanol plant.
3.1.31 glucose—the most prominent simple sugar (6-
3.1.11 BTU—one British Thermal Unit is the amount of membered C H O ) produced from starches and cellulose
6 12 6
heat required to raise 1 lb of water 1°F.
material by hydrolysis.
3.1.12 carbohydrates—molecules consisting of carbon, hy-
3.1.32 hydrolysis—the act of cleaving or splitting of com-
drogen and oxygen that include celluloses, starches and sugars. plex molecules by the chemical addition of a water molecule.
3.1.13 centrifuge—machine that separates a mixture of Acid hydrolysis is defined as the chemical addition of water to
solids and liquids by centrifugal force. a compound such as starch in the presence of an acid as a
3.1.14 continuous fermentation—nonstop flow of nutrients catalyst that will form another compound such as glucose.
into a fermenting vessel, with the simultaneous outflow of 3.1.33 mash—the mixture of sugars, nutrients, and water
products, organisms, and by-products. that is capable of being fermented by microorganisms such as
yeast in ethanol fermentation.
3.1.14.1 Discussion—Optimum culture conditions are
maintained to maximize the production of desired products. 3.1.34 packed distillation column—a column or tube con-
3.1.15 conversion effıciency—the ratio of the actual to structed with internals of ceramic, steel, or fiberglass-type
materials to separate one or more volatile liquids by distilla-
theoretical fuel ethanol yield per unit mass of the feedstock.
tion.
3.1.16 denaturant—toxins or noxious materials added to
ethanol to make it unfit for human consumption. 3.1.35 pH—the measurement of the acid concentration of a
solution. Range is 0 to 14 (acid to basic), with pH 7 being
3.1.17 denatured ethanol—ethanol that is mixed with other
chemicals or denaturants to make it unsuitable for human neutral.
consumption. 3.1.36 plate distillation column—column constructed with
perforated plates to separate one or more volatile liquids by
3.1.18 dextrins—high molecular weight sugars, intermedi-
ates obtained in the conversion of starch to fermentable sugar. distillation.
3.1.19 distillate—the overhead product of distillation such 3.1.37 press—mechanical device that removes liquids from
solids by mechanically pressing the solids against a porous
as ethanol liquid from the top of a beer still.
3.1.20 distillation—the act of vaporizing and condensing a surface.
liquid in sequential steps to effect separation from a liquid 3.1.38 proof—measurement term of concentration of etha-
mixture. nol in water solutions.
3.1.20.1 Discussion—Ethanol is purified by distillation 3.1.38.1 Discussion—100-proofethanolis50 %alcohol(by
volume) and 50 % water. 200-proof is pure or 100 % ethanol.
from a solution of water and alcohol.
3.1.21 distillers grains—the insoluble solids that have been 3.1.39 protein—general term used to cover single cell
separated from the stillage bottoms or beer. Moisture content microorganisms, extract of the microorganisms, (bacteria or
may range from 60 to 85 %, depending upon the level of fungi or algae) that is used for food or feed to animals and
dewatering during separation. humans.
3.1.22 enzyme—biological catalyst that is protein in nature. 3.1.40 reflux, in distillation processes—reflux is the liquid
3.1.22.1 Discussion—Enzymes are used in ethanol produc- condensate recycle to the top of a distillation column to aid in
tion to convert starch to glucose sugars (fermentable sugar). purification of the overhead product (ethanol).
3.1.23 ethanol—ethyl alcohol, the chemical compound 3.1.41 saccharification—the breaking of dextrins (starch)
C H OH, a two carbon alcohol. into simple sugars (hydrolysis).
2 5
3.1.24 feedstock—thebaserawmaterialthatisthesourceof 3.1.42 solids—twotypesofsolidsarepresentinmash.First,
carbohydrate, such as starch, for producing sugars that can be insoluble solids are present as solid matter present in the liquid
fermented into alcohol and carbon dioxide.
portion of the mash. Secondly, soluble solids are dissolved in
3.1.25 fermentation—the biochemical reaction process the liquid portion of the mash.
where microorganisms in a nutrient medium convert a feed- 3.1.43 Stillage—the liquid products or waste remaining
stock to a product.
after distillation of a beer. The soluble residue are water,
3.1.26 flash point—the temperature at which a combustible proteins, etc.
liquid ignites. 3.1.44 sugars—molecules of carbohydrate, namely
3.1.27 FEMF—Fuel Ethanol Manufacturing Facility. monosaccharides and disaccharides such as glucose, galactose,
mannase, sucrose or fr
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