ASTM E1344-90(2006)
(Guide)Standard Guide for Evaluation of Fuel Ethanol Manufacturing Facilities (Withdrawn 2009)
Standard Guide for Evaluation of Fuel Ethanol Manufacturing Facilities (Withdrawn 2009)
SCOPE
1.1 This guide shall apply to FEMF as defined in Terminology E 1126. 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 1 000 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 500 000-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.
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.
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.
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 ChecklistThis 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 designing of these facilities, but as a guide to ...
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NOTICE: This standard has either been superseded and replaced by a new version or withdrawn.
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Designation: E 1344 – 90 (Reapproved 2006)
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.
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 future will be largely based on these abundant feedstocks.This
guide concentrates on the use of corn, milo, and barley as
1.1 This guide shall apply to FEMF as defined in Terminol-
feedstocks,
ogy E 1126. The guide is primarily intended for, but not
1.4.3 Normal Process Fuels: Natural gas, propane, fuel oil,
exclusively limited to the evaluation of fermentation ethanol
wood, or coal,
(ethyl alcohol) processes. This guide is primarily intended for,
1.4.4 Products: Ethanol at 190-proof or less. Distillers
but not exclusively limited to, fermentation ethanol processes
grains at 60 to 75 % moisture by weight and thin stillage, for
for small scale (less than 1 000 gal/day capacity) plants.
use as animal grade feed and not human grade food,
1.2 This guide applies to both batch process and continuous
1.4.5 Process: The ethanol production process referred to in
process FEMF systems. Since a wide variety of equipment
this guide involves dry milling of grain, batch or continuous
configurations can exist, this guide will describe the necessary
cooking, enzyme hydrolysis, batch fermentation, continuous
general requirements common to all FEMF facilities.
distillation, and pressing or centrifuging for dewatering of
1.3 This guide is to be used in conjunction with applicable
stillage (for example, separating suspended solids from the
local, state, and Federal codes for designing, constructing, and
stillage), and
operating FEMF facilities.
1.4.6 Variations: One variation in the ethanol production
1.4 This guide is limited to use with plants possessing the
process is addressed in this guide.This variation allows for the
following operational characteristics, which are fairly typical
cooking, hydrolysis, and fermentation processes to be com-
of small scale ethanol plants and are as follows:
pletedeitherasabatchinthesameprocessvesselorinseparate
1.4.1 Capacity: Up to 500 000-proof gal/year of 190-proof
vessels.
ethanol,
1.4.6.1 With limitations, this guide can be used to evaluate
1.4.2 Normal Feedstocks: No. 2 yellow corn, or other
facilities with operating characteristics that differ from those
suitable sample grade corn, barley, or grain sorghum (also
justlisted.However,variationsfromthosecharacteristicslisted
referred to as milo). There are other starch grains such as
will tend to lessen the reliability of the guide.
wheat, rye, or oats, and starch tubers such as potatoes that can
1.4.6.2 An example of a fairly minor variation would be the
be used as feedstocks. Sugar crops (sugar cane, sugar beets,
substitution of wheat as a feedstock. Wheat processing char-
and molasses, that is a by-product of sugar plants) and
acteristics are reasonably similar to those of corn, barley or
cellulose crops (wood chips, straw, etc.) are also potential
milo. However, wheat tends to foam considerably more than
feedstock sources. However, since much of the interest in
corn, so vessels need to be sized at least 10 % greater than if
proposed ethanol plants in recent years has centered on the use
corn is used, or the use of an antifoam agent would be
of corn, barley, and milo as feedstocks for ethanol production,
advisable.
it is expected that the majority of plants proposed in the near
1.4.6.3 An example of a significant variation from the
process characteristics utilized in this guide would be the
ThisguideisunderthejurisdictionofASTMCommitteeE48onBiotechnology
substitution of potatoes as a starch feedstock. Processing
and is the direct responsibility of Subcommittee E48.05 on Biomass Conversion.
requirements for use of potatoes vary significantly from
Current edition approved Feb. 1, 2006. Published March 2006. Originally
e1
approved in 1990. Last previous edition approved in 1997 as E1344–90 (1997) .
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.
E 1344 – 90 (2006)
processing requirements of corn, barley, and milo. Therefore, No. 70 National Electric Code
useofthisguideisnotrecommendedforevaluationofapotato No. 77 Recommended Practice on Static Electricity
feedstock ethanol facility. No. 85A Prevention of Furnace Explosions in Fuel Oil and
1.5 Use of Guide as Checklist This guide should be used as Natural Gas-Fired Single Burner Boiler-Furnaces
a checklist for evaluation of proposed small scale manufac- No. 101 Life Safety Code
tured fuel ethanol facilities. It is intended to be used by No. 395 Standard for the Storage of Flammable and Com-
investors, bankers, and other parties interested in the commer- bustible Liquids on Farms and Isolated Construction
cial development of such fuel alcohol facilities. It is not Projects
intended to be used as a guide for the designing of these 2.3 Other Standards:
facilities, but as a guide to assist in the evaluation of designs Article 16 Fire Prevention Code
already completed by sellers or manufacturers of such facili- UL 30 Cans, Metal Safety
ties. This guide may also be utilized by FEMF designers or UL58 Tanks, Steel Underground, for Flammable and Com-
sellers who may wish to review their systems’ conformance bustible Liquids
with the recommendations of the guide. This guide is to be UL 142 Tanks, Steel Above-Ground, for Flammable and
used in conjunction with applicable local, state, and Federal Combustible Liquids
codes and regulations. CFR Title 49 Parts 100 through 199
1.6 The values stated in inch-pound units are to be regarded ASME Boiler Construction Codes, Sections I, IV, VII, and
as the standard. The values given in parentheses are for VIII
information only.
3. Terminology
1.7 This standard does not purport to address all of the
safety concerns, if any, associated with its use. It is the
3.1 Definitions:
responsibility of the user of this standard to establish appro-
3.1.1 alcohols—series of liquid products composed of a
priate safety and health practices and determine the applica-
hydrocarbon plus a hydroxyl group, such as ethanol
bility of regulatory limitations prior to use. For specific hazard
(C H OH).
2 5
statements, see Section 6 on Hazards, and the safety sections
3.1.1.1 Discussion—Other alcohols include methanol, iso-
for each procedure in Section 10.
propanol, butanol, amyl alcohol, etc. Typical fermentation
1.8 This guide is arranged as follows:
alcohol is ethanol.
Section 3.1.2 alpha-amylase—enzyme that acts specifically to ac-
celerate the hydrolysis of starch to dextrins.
Referenced Documents 2
3.1.3 anhydrous, without water—term used in chemistry to
Terminology 3
Summary of Guide 4 denote absence of water. 199+ proof ethanol is considered
Significance and Use 5
anhydrous ethanol.
Hazards 6
3.1.4 anhydrous ethanol—100 % ethanol, neat ethanol,
Environmental 7
Other Considerations 8 199 + proof ethanol.
Additional Facilities 9
3.1.5 azeotrope—constant boiling mixture, for ethanol-
Procedure 10
water, the azeotrope of 95.6 % ethanol and 4.4 % water (both
General Process Description 10.1
Process Design Requirements 10.2 percentages by volume) boils at one atmosphere pressure.
Grain Handling and Dry Milling 10.2.1
3.1.6 azeotropic distillation—the use of an organic solvent
Enzyme Hydrolysis 10.2.2
to create a new constant boiling point mixture, a method used
Batch Fermentation 10.2.3
Continuous Distillation 10.2.4
to produce anhydrous ethanol from the ethanol water azeo-
Dewatering of Stillage 10.2.5
trope.
Appendix
3.1.7 backset—the liquid portion of the thin stillage that is
2. Referenced Documents recycled as part of the process liquid in mash preparation.
3.1.8 basic hydrolysis—the chemical addition of water to a
2.1 ASTM Standards:
compound.
E 1117 Practice for Design of Fuel-Alcohol Manufacturing
3.1.9 batch fermentation—batch of nutrient mixture and
Facilities
microorganisms mixed in a vessel and allowed to ferment.
E 1126 Terminology Relating to Biomass Fuels
3.1.10 beer—term used to describe the product of ethanol
2.2 NFPA Standards:
fermentation by microorganisms.
No. 10 Standard for Portable Fire Extinguishers
3.1.10.1 Discussion—Usually means the alcohol solution
No. 13 Standard for Installation of Sprinkler Systems
remaining after yeast fermentation of sugars. About 10 %
No. 30 Flammable and Combustible Liquids Code
2 5
For referenced ASTM standards, visit the ASTM website, www.astm.org, or Engineering and Safety Service, 1976.
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM Underwriters Laboratories, Inc. (UL), 333 Pfingsten Rd., Northbrook, IL
Standards volume information, refer to the standard’s Document Summary page on 60062.
the ASTM website. Code of Federal Regulations available from the Superintendent of Documents,
Withdrawn. U.S. Government Printing Office, Washington, DC 20402.
4 8
Available from National Fire Protection Association (NFPA), 1 Batterymarch Available from American Society of Mechanical Engineers (ASME), ASME
Park, Quincy, MA 02269-9101. International Headquarters, Three Park Ave., New York, NY 10016-5990.
E 1344 – 90 (2006)
alcohol is normally contained in the beer solution for a small 3.1.30 glucoamylase—enzyme that acts specifically to con-
scale fuel grade ethanol plant. vert dextrins to glucose by hydrolysis.
3.1.11 BTU—one British Thermal Unit is the amount of 3.1.31 glucose—the most prominent simple sugar (6-
heat required to raise 1 lb of water 1°F. membered C H O ) produced from starches and cellulose
6 12 6
material by hydrolysis.
3.1.12 carbohydrates—molecules consisting of carbon, hy-
drogen and oxygen that include celluloses, starches and sugars.
3.1.32 hydrolysis—the act of cleaving or splitting of com-
plex molecules by the chemical addition of a water molecule.
3.1.13 centrifuge—machine that separates a mixture of
solids and liquids by centrifugal force. Acid hydrolysis is defined as the chemical addition of water to
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
3.1.14.1 Discussion—Optimum culture conditions are
yeast in ethanol fermentation.
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
theoretical fuel ethanol yield per unit mass of the feedstock.
materials to separate one or more volatile liquids by distilla-
3.1.16 denaturant—toxins or noxious materials added to
tion.
ethanol to make it unfit for human consumption.
3.1.35 pH—the measurement of the acid concentration of a
3.1.17 denatured ethanol—ethanol that is mixed with other
solution. Range is 0 to 14 (acid to basic), with pH 7 being
chemicals or denaturants to make it unsuitable for human
neutral.
consumption.
3.1.36 plate distillation column—column constructed with
3.1.18 dextrins—high molecular weight sugars, intermedi-
perforated plates to separate one or more volatile liquids by
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
as ethanol liquid from the top of a beer still.
solids by mechanically pressing the solids against a porous
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
from a solution of water and alcohol. 3.1.38.1 Discussion—100-proofethanolis50 %alcohol(by
volume) and 50 % water. 200-proof is pure or 100 % ethanol.
3.1.21 distillers grains—the insoluble solids that have been
separated from the stillage bottoms or beer. Moisture content 3.1.39 protein—general term used to cover single cell
may range from 60 to 85 %, depending upon the level of microorganisms, extract of the microorganisms, (bacteria or
dewatering during separation. fungi or algae) that is used for food or feed to animals and
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-
tion to convert starch to glucose sugars (fermentable sugar). condensate recycle to the top of a distillation column to aid in
purification of the overhead product (ethanol).
3.1.23 ethanol—ethyl alcohol, the chemical compound
C H OH, a two carbon alcohol. 3.1.41 saccharification—the breaking of dextrins (starch)
2 5
into simple sugars (hydrolysis).
3.1.24 feedstock—thebaserawmaterialthatisthesourceof
carbohydrate, such as starch, for producing sugars that can be 3.1.42 solids—twotypesofsolidsarepresentinmash.First,
fermented into alcohol and carbon dioxide. insoluble solids are present as solid matter present in the liquid
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-
stock to a product. 3.1.43 Stillage—the liquid products or waste remaining
3.1.26 flash point—the temperature at which a combustible after distillation of a beer. The soluble residue are water,
proteins, etc.
liquid ignites.
3.1.27 FEMF—Fuel Ethanol Manufacturing Facility. 3.1.44 sugars—molecules of carbohydrate, namely
monosaccharides and disaccharides such as glucose, galactose,
3.1.28 fuse oils—complex group of higher mol
...
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