Industrial Accessories Company 4800 Lamar Ave Mission, Kansas 66202 ETHANOL MARKET PP007 1
PRODUCTS & SYSTEMS 1. OEM Baghouse Supplier. 2. FGD Technology for SOx & HCL Removal 3. Fly-ash & Material Pneumatic Conveying 4. Bulk Storage tanks 5. Grain Storage/Distribution Facilities 6. Coal and Bio-Mass Fired Steam Generation Plants 7. Process Controls 8. Field Construction 9. Permitting Assistance for Minor/Major Source 2
CUSTOMER SATISFACTION IAC STRENGTHS: PROVEN EXPERIENCE AND FIELD START-UP ENGINEERING SERVICES CIVIL & STRUCTURAL ELECTRICAL & INSTRUMENTATION PROVEN PRODUCTS AND TECHNOLOGIES FILTRATION PNEUMATIC TRANSPORT FANS AND BLOWERS CONTROLS; PLC; WONDERWARE INTERFACE FLEXIBILITY ON-TIME PROJECT EXECUTION IN-HOUSE CONSTRUCTION COMPANY ADELPHI IN-HOUSE SERVICE STAFF FOR 24-HR SERVICE 3
DESIGN OBJECTIVES DEVELOP DESIGN STANDARDS OPTIMIZE SCHEDULES TRAIN AND MAINTAIN KEY PERSONNEL SUCCESSFUL START-UP LOW FIRST COST SOLUTION 4
PROJECT EXECUTION CUSTOMER ESTABLISHES PROJECT REQUIREMENTS: PLANT GENERAL ARRANGEMENTS PLANT PROCESS REQUIREMENTS COMPLIANCE REQUIREMENTS PROJECT SCHEDULE IAC ESTABLISHES: DESIGN ENGINEERING SCHEDULE APC AND ASH HANDLING REQUIREMENTS SCHEDULE FOR IAC SCOPE OF SERVICES PROVIDE FIELD STAFFING FOR REQUIRED WORK MECHANICAL MILLRIGHTS PIPE FITTERS ASME WELDERS CRANE OPERATORS CONSTRUCTION RENTALS 5
RETROFIT CONSIDERATIONS SPACE LIMITATIONS MODIFICATION OF EXISTING STRUCTURES RELOCATION OF UNDERGROUND FACILITIES CHANGES IN OPERATING PROCEDURES BOP ISSUES: DUCTWORK ROUTING AND MODIFICATIONS CUSTOMIZE DESIGNS FOR PLANT REQUIREMENTS ID FAN UPGRADES POWER DISTRIBUTION & CONTROL SYSTEM UPGRADES 6
IAC SCOPE OF SUPPLY EQUIPMENT APC ISLAND INCLUDING BAGHOUSE AND FGD BAGHOUSES FOR FUGITIVE DUST CONTROL ASH HANDLING AND SILO WITH LOAD OUT STATION COAL AND SAND SILO GRAIN HANDLING PLANT STEAM GENERATION PLANT CONSTRUCTION AND SERVICES MILLRIGHTS FOR MECHANICAL INSTALLATION APC ISLAND INSTALLATION BOILER AND HRSG INSTALLATION BOP INSTALLATION 7
GRAIN HANDLING 8
GRAIN LOADOUT STATION 9
ETHANOL EMISSION SOURCES (dry mills) Grain Receiving, Conveying, & Storage Hammermill Fermentation & Distillation Boiler DDGS Dryer & Cooler DDGS Storage & Loading Storage Tanks Ethanol Loadout Haul Roads, Cooling Towers, Equipment Leaks, etc. 10
GRAIN RECEIVING, HANDLING AND HAMMERMILLS Standard AP-42 emission factors Controlled by fabric filters Potential PSD issues if they are co-located with an existing elevator from whom they will get a majority of their corn. 11
FERMENTATION AND DISTILLATION Usually controlled by a scrubber, and sometimes further vented to the thermal oxidizer on the DDGS dryers. CO2 emissions from fermenters may be sold to a third party 12
DDGS DRYER Controlled by thermal oxidizers to stay minor for PSD Variable VOC emission factors 0.013 lb/1000 gal to 0.17 lb/1000 gal Highly variable HAP emissions Acetaldehyde or methanol highest 13
DDGS COOLER & HANDLING Variable VOC emissions on DDGS cooler 0.0265 lb/ton to 0.147 lb/ton Acetaldehyde highest HAP DDGS Loadout controlled by baghouse 14
STORAGE TANK & ETHANOL LOADOUT Tank emissions using EPA s TANK program Loadout - follow AP-42 If non-dedicated tanks or trucks allowed, controlled by flares in all but smallest plants Rail loadout in dedicated tank cars may be controlled by flares, especially if the plant is over 65 mmgal/yr 15
OTHER SOURCES Haul roads Higher capacity plants may require detailed operating conditions NSPS VV sources Cooling towers Wetcake storage Miscellaneous ancillary sources (germ & bran production, fire pumps, turbines or generators, etc.) 16
IOWA- Permitted Boiler Comparison (55 mmgal/yr plants) Coal 220 mmbtu/hr, with 165,000 lb/hr steam HRSG, 2 methanators, 3 dryers, distillation equip. PM also includes coal, limestone & flyash handling PTEs Natural Gas HRSG (125 mmbtu/hr TO), 2 dryers, methanator, distillation equipment Type NOx (tpy) SOx (tpy) CO (tpy) PM (tpy) VOC (tpy) Coal 95.4 99.2 91.5 57.0 18.6 Gas 93.4 NA 81.8 22.1 22.1 17
50MM GPY ETHANOL PLANT COAL FIRED WITH IAC M-PULSE BAGHOUSE Corn, LP Lincolnway Energy Red Trails Heron Lake Energy Goldfield, IA Nevada, IA Richardton, ND Heron Lake, MN IAC SCOPE OF WORK M-Pulse Baghouse & FGD ID Fan & Motor Duct from Boiler to ID Fan Flyash Handling Silo & Truck Loadout I&C s (APV & Flyash) Mechanical Installation 18
M - Pulse Baghouse 6 x 234TB-BHTP-288 19
M - Pulse Baghouse Penthouse Enclosure Top Roof Door: ASME 12in Headers; 3in Pulse Valves 20
M - Pulse Baghouse with ID Fan and Stack Motor: 900 HP; 8-0 Diameter SST w/insulation Stack 21
FLYASH AND COAL SILO 22
DRY FGD WITH SODIUM BICARBONATE INJECTION 23
BUBBLING BED COMBUSTOR 24
BIO-MASS & MASS BURN BOILERS Biomass Boiler Mass-Burn Boilers 25
STOKER FIRED BOILER BIO-MASS / STRAW & TIRE FEED STEAM CAPACITIES: 25 TO 200 TONS/HR STEAM PRESSURES: 20 140 BAR STEAM TEMPERATURE: 300 540 C FEEDWATER TEMPERATURE: 105 250 C 1. Chain Conveyor 2. Seal Gates 3. Dosing Unit 4. Drop 5. Fire Damper 6. Stoker 7. Water Cooled Duct 8. Vibrating Grate 9. Slag Conveyor 10. Combustion Chamber 11. Air Pre-heater 12. ID Fan 13. FD Fan 14. Combustion Air Intake 15. Air Pre-heater 16. Preheated Combustion Air 17. Feed-water 18. Steam Drum 19. Economizer. 20. Super-heater 1 21. Super-heater 2 22. Super-heater 3 23. Water for atemperaters24. High Pressure Steam to Turbine 25. Fabric Filter. 26. Ash Handling 27. Natural Gas 28. Condenser 29. Feed Water Tank 30. District Heating 26
Contact Information Corporate Address: 4800 Lamar Avenue Mission, Kansas 66202 Corp Tel: (913) 384.5511 E-Mail: iaccorp@iac-intl.com Sales Tel: (800) 334.7431 gsmith@iac-intl.com Corp Fax: (913) 384.6577 Knoxville Address: Pramodh Nijhawan 318 Saint Andrews Drive Knoxville, TN. 37922 Tel:(865) 675-7867 E-Mail: pnijhawan@iac-intl.com Fax: (865) 675-7582 27