Showcase Projects

Involved Processes

Distillation / Rectification

Further Info

Conestoga website

View plant at Google maps

Combined production of neutral alcohol and ethanol

Confidential Client, USA

VOGELBUSCH USA Inc. integrated an Annex Distillery into an existing fuel ethanol plant and supplied equipment for a molecular sieve unit to produce either 378,000 liter per day of Grain Neutral Spirits (GNS) or dehydrated GNS out of a stream of the existing fuel ethanol plant that uses fermented mash from corn. It took nine months to complete the facility from the initial engineering design to the start-up. The facility start-up was at the end of January 2021 and the final products met the GNS specification.

Services performed

Involved Processes

Distillation / Rectification

Dehydration

Additional Annex Distillery

CONFIDENTIAL CLIENT

VOGELBUSCH USA Inc. contributed to the existing ethanol plant an additional distillation unit (Annex Distillery) to produce high quality alcohols. It allows the plant to manufacture more than 216,000 liter per day (20 million gallons per year) of Grain Neutral Spirits (GNS) from a stream of 190 proof ethanol from the existing facility. As an additional option, it is possible to dehydrate the GNS when needed. The facility start-up is scheduled for spring 2021.

Services performed

Involved Processes

Distillation / Rectification

Dehydration

Alcohol Plant in Alejandro Roca

PROMAÍZ - Alejandro Roca, Cordoba, Argentina

The Promaíz plant produces bioethanol from corn which is used as fuel additive in the local markets. Besides the technology package for the complete plant and detailed planning of piping and vessels, Vogelbusch has been assigned with the supply of equipment such as fermenter internals, distillation columns, molecular sieve dehydration and scrubber, as well as the programming of the control system.

This plant was implemented in 2013 with a nameplate capacity of 420,000 liters per day, which was increased to 550,000 liters per day in 2018.

In 2019, an Annex Distillery with a production capacity of 100,000 liters per day was integrated into the facility to increase the capacity. This process group consists of a distillation and rectification unit which processes mash from the existing MultiCont© fermentation.

Services performed

Involved Processes

Dry milling

Liquefaction / Saccharification

Fermentation

Distillation / Rectification

Dehydration

Evaporation

Drying

Further Info

Grand Designs (Biofuels International Magazine, November 2013)

DRD for bioethanol plant in Zhaodong

COFCO Bioenergy - Zhaodong, PR China

Vogelbusch was employed by COFCO Bioenergy Zhaodong to build an energy efficient distillation, rectification and dehydration system with the aim to replace two existing old and energy intensive units.

The order's scope included the basic engineering of the unit as well as technical assistance during procurement of critical items such as distillation trays, molecular sieve internals and factory acceptance test of software of process control system. In Q4 2018 the commissioning start-up was supervised and the client’s operators were trained on the job.

Design capacity of the plant is 1,100,000 liters per day producing fuel alcohol as per Chinese standard. A high degree of thermal integration including latest developments in connection with selected molecular sieve materials made the unit setting new benchmarks regarding energy efficiency in China.

Services performed

Involved Processes

Distillation / Rectification

Dehydration

Further Info

COFCO

Revamp of bioethanol plant in Vrdy

ETHANOL ENERGY - Vrdy, Czech Republic

Following conceptual design studies for the reduction of the energy demand - and therefore CO2 emissions - Czech bioethanol producer Ethanol Energy assigned Vogelbusch with the basic design of the process optimization.

Production in the reconstructed plant was launched in the fourth quarter in 2018.

Services performed

Involved Processes

Distillation / Rectification

Further Info

Ethanol Energy a.s.

Ethanol dehydration in Sarpsborg

BORREGAARD - Sarpsborg, Norway

Borregaard replaced a decades old ethanol dehydration system by a state-of-the-art molecular sieve unit from Vogelbusch. The limited space in the biorefinery recommended a skid construction with minimum footprint. A special feature of the installation is an unusually wide capacity span, which was realized in a fully automated process.

The unit has a maximum output of 105,000 liters of dehydrated ethanol per day. Tailored plant automation allows the operator to perform the required capacity changes in a range of 30 % to 100 % with just one key stroke.

Prefabricated in Austria in three structural steel framings, the plant was shipped and ready for start-up in Sarpsborg within a few weeks, with guarantee runs successfully completed in April 2018.

Services performed

Involved Processes

Dehydration

Further Info

Borregaard AS

Effective purification (Biofuels International Magazine, June 2018)

Glucose Plant for Processing Complex in Volgodonsk

DONBIOTECH - Volgodonsk, Rostov Region, Russia

OOO «DonBioTech», a joint venture of Russian Varshavsky group and German industrial group Evonik, sets up a grain processing facility for the production of L-lysine from wheat.

Vogelbusch has been awarded with the detailed design and the supply of the process plant for the conversion of starch milk to glucose solution which is used as fermentation feedstock. Further services include the system integration of the complete grain processing plant, which consists of several production units.

Commissioning is scheduled for 2021.

Services performed

Involved Processes

Hydrolysis

Evaporation

Filtration

Further Info

ООО «DonBioTech»

Yandex Maps

Biotechnological Complex in Kaluga

BIOTECH ROSVA - Kaluga, Russia

The biotechnological complex put up by JSC «Biotech Rosva» uses wheat as a feedstock to produce speciality goods such as starch, gluten and various starch sugars, which are intended as ingredients for the food industry. A by-product is used as animal feed.

Vogelbusch is responsible for the planning and delivery of the process plants for glucose monohydrate, high fructose syrup (HFS) and sorbitol, and for the system integration of dry milling, starch plant and drying of the by-products.

Commissioning of the individual process units started in 2018, and in summer 2019 the entire product range could be manufactured according to the specification.

Services performed

Involved Processes

Liquefaction / Saccharification

Hydrolysis

Isomerization

Evaporation

Ion exchange

Chromatography

Filtration

Crystallization

Drying

Further Info

AO «Biotech Rosva»

Yandex Maps

Glucose plant for processing compex in Ishim

AMINOSIB - Ishim, Tyumen Region, Russia

ZAO Agroholding «Yubileinii» sets up a wheat processing complex - AminoSib - in Ishim in the Tyumen Region. Vogelbusch has been assigned by the general contractor, Talmax Engineering s.r.o., with the supply of a glucose plant to produce a fermentation substrate.

The order includes the process design as well as the supply of key equipment and the complete automation and control system for the unit. The glucose plant was commissioned by Vogelbusch in 2016 and is started up after finalisation of the complete complex in 2017.

Services performed

Involved Processes

Liquefaction / Saccharification

Hydrolysis

Evaporation

Filtration

Further Info

ZAO Agroholding «Yubileinii»

Video

Dehydration Unit for Gibraltar

CEPSA - San Roque, Gibraltar

CEPSA (Compañía Española de Petróleos, S.A.U.) ordered a molecular sieve dehydration unit from Vogelbusch to purify ethanol which subsequently is to be processed to ETBE.

The 12,000 liters per day unit has been prefabricated and skid-mounted in Austria and transferred to Gibraltar by truck to be integrated in the San Roque oil refinery complex in 2016.

Services performed

Involved Processes

Dehydration

Further Info

CEPSA - Compañía Española de Petróleos, S.A.U.

D|D Ethanol recovery system in California

ALLTECH - Ontario, California, USA

VOGELBUSCH USA Inc. supplied a system for recovery of ethanol from brewery waste streams. The facility was designed as a PLC-controlled, two-stage process that consists of a two-column distillation, which produces an ethanol/water vapour that is then dried in the molecular sieve unit.

For easy installation, the system was prefabricated in two modular skids which were assembled and tested prior to shipment. On site, the components were reassembled, and utility and electrical connections were completed. The 10,000 liters per day unit was commissioned in 2016.

Services performed

Involved Processes

Distillation / Rectification

Dehydration

Further Info

Read article in Biofuels International

Yeast plant in Tashkent

CANDY GOLD - Tashkent, Uzbekistan

Following a feasibility study on the production of baker's yeast, the pre-engineering for a yeast plant designed for a daily capacity of 10,000 kg based on molasses was carried out in 2015.

Services performed

Involved Processes

Molasses preparation

Precipitation

Fermentation

Filtration

Drying

Neutral Alcohol Plant in Verinsko

ALMAGEST - Verinsko, Ihtiman, Bulgaria

Almagest opted for Vogelbusch in 2009 to produce top quality extra neutral alcohol with the highest purity and organoleptic demands, to be used in the production of alcoholic beverages. The excellent alcohol quality convinced Almagest to commission Vogelbusch again in 2011 to expand the plant capacity to 80,000 liters per day.

Further services included the thermal integration of an existing dehydration unit (2013) and an upgrade of the product range (2016).

Services performed

Involved Processes

Dry milling

Liquefaction / Saccharification

Fermentation

Distillation / Rectification

Evaporation

Further Info

„Almagest” AD

D|D for Cellulosic Ethanol Plant in Hugoton

SYNATA BIO (Abengoa) - Hugoton, Kansas, USA

The commercial-scale, cellulosic ethanol facility in Hugoton utilizes Abengoa’s own enzymatic hydrolysis technology to produce 25 million gallons of ethanol and 21 megawatts of electricity from 300,000 tons of biomass per year.

Implemented in 2014, VOGELBUSCH USA Inc. provided process design for the distillation and molecular sieve dehydration areas and also supplied critical equipment for the molecular sieve unit. The unit was transferred to Synata Bio in 2017.

Services performed

Involved Processes

Distillation / Rectification

Dehydration

Further Info

Yeast plant in El-Harrach

CEGRO / AYS - El Harrach, Algeria

SGP Cegro on behalf of AYS Algerian Yeast Society in 2014 ordered a feasibility study to investigate the production of 10,000 tons per year of baker's yeast to be made from imported molasses.

Services performed

Involved Processes

Molasses preparation

Precipitation

Fermentation

Filtration

Drying

Evaporation plant in Prokhladnyy

OOO RIAL – Prokhladnyy, Kabardino – Balkaria

Vogelbusch was assigned by VetterTec to design a new evaporation plant for LLC RIAL’s existing DDGS production plant.

LLC RIAL is a wheat processing plant in Russia for the production of potable alcohol with DDGS as a by-product.

The Vogelbusch evaporation plant is used to concentrate the decanted wheat stillage and has a capacity of 58 tons of steam per hour. The successful start-up of the plant was in 2013.

Services performed

Involved Processes

Evaporation

Further Info

Link to Website

Yandex Maps

D|D for Demonstration Plant in Vero Beach

FRANKENS ENERGY (Ineos Bio) - Vero Beach, Florida, USA

VOGELBUSCH USA Inc. supplied the ethanol distillation and dehydration equipment for the 2G (second generation) demonstration plant of Ineos Bio’s , a first-of-its-kind waste-to-bioenergy facility near Vero Beach, Florida.

The project uses a feedstock-flexible biomass conversion technology. It's unique combination of gasification and fermentation technologies turns different types of waste materials, including municipal solid waste, into advanced biofuels and renewable power.

It can manufacture 8 million gallons per year (87,000 liters per day) of cellulosic ethanol under the new Renewable Fuel Standard and provide power for 1,400 homes in the area. The plant was implemented by Ineos Bio in 2012 and is owned by Frankens Energy since 2018.

Services performed

Involved Processes

Distillation / Rectification

Dehydration

Further Info

D|R Pilot Plant in Tennamaram

SIME DARBY | MITSUI ENGINEERING - Tennamaram, Malaysia

Local palm oil producer Sime Darby together with the Japanese company Mitsui Engineering & Shipbuilding Co. Ltd. (MES) installed a pilot plant for second generation (2G) bioethanol in Tennamaram, Malaysia. Based on technology licensed from the Danish company Inbicon the plant produces bioethanol from empty fruit bunches that are left over from palm oil production.

The cellulosic mash is distilled and rectified in a unit supplied by Vogelbusch. This skid mounted facility was preassembled and tested in Austria, shipped to Malaysia in 2 containers and finally installed on site within only a few days in 2011.

Services performed

Involved Processes

Distillation / Rectification

Further Info

Sime Darby

Mitsui Engineering & Shipbuilding Co., Ltd.

Inbicon A/S

Dehydration Unit in Pointe-a-Pierre

ETHYLCHEM - Pointe-a-Pierre, Trinidad, West Indies

Hydrous ethanol imported from Brazil is the feedstock for a molecular sieve dehydration facility set up by EthylChem at the Pointe-a-Pierre refinery in Trinidad. It has a production capacity of 1,082,000 liters per day (100 MMGY) of fuel ethanol with a purity of over 99.9 per cent that is intended for export primarily to the U.S.

The facility was implemented by VOGELBUSCH USA Inc. in 2010.

Services performed

Involved Processes

Dehydration

Further Info

EthylChem Ltd.

Ethanol dehydration in Osaka

COSMO OIL - Sakai-City, Osaka, Japan

Cosmo Oil produces 140,000 liters per day (12 MMGPY) of low moisture ethanol (300 ppm) utilizing process design by VOGELBUSCH USA Inc.. The skid-mounted unit was installed as part of a larger project to retrofit an existing MTBE production facility at their Sakai Refinery for ETBE production.

Services performed

Involved Processes

Dehydration

Further Info

Cosmo Oil Co., Ltd.

Bioethanol Plant in Madison

GREEN PLAINS (Abengoa) - Madison, Illinois, USA

Abengoa Bioenergy reached sustained capacity at their 88 million gallons per year (950,000 liters per day), state-of-the-art fuel ethanol facility located in Madison, Illinois in February 2010.

This is the third Abengoa Bioenergy plant in the U.S. that utilizes technology licensed by VOGELBUSCH USA Inc., including the Vogelbusch MultiCont© continuous fermentation process. The facility uses 32 million bushels (813,000 metric tons) of local corn and produces approximately 250,000 metric tons of distiller’s dried grains with solubles (DDGS) annually.

Since 2016, the plant is owned by Green Plains.

Services performed

Involved Processes

Liquefaction / Saccharification

Fermentation

Distillation / Rectification

Dehydration

Further Info

Green Plains Inc.

Neutral Alcohol Distillation in Lidköping

LANTMÄNNEN REPPE - Lidköping, Sweden

Renowned starch manufacturer Lantmännen Reppe is one of the largest Swedish alcohol distillers too. The MultiPressure distillation unit in Lidköping, commissioned in 2010, can produce some 50,000 liters of high quality alcohol that add to the company's beverage alcohol supply. The alcohol production is based on wheat starch.

The distillation was set up next to a rectification unit which was provided by Vogelbusch back in 1996 to then plant owner Ceramyl.

Services performed

Involved Processes

Distillation / Rectification

Further Info

Lantmännen Reppe AB

Bioethanol Plant in Mount Vernon

GREEN PLAINS (Abengoa) - Mount Vernon, Indiana, USA

Abengoa Bioenergy reached sustained capacity at their 88 million gallons per year (950,000 liters per day), state-of-the-art fuel ethanol facility located in Mt. Vernon, Indiana in January 2010 after 18 month engineering/construction time.

This is the second Abengoa Bioenergy plant in the U.S. that utilizes technology licensed by VOGELBUSCH USA Inc., including the Vogelbusch MultiCont© continuous fermentation process. The facility uses 32 million bushels (813,000 metric tons) of local corn and produces approximately 250,000 metric tons of distiller’s dried grains with solubles (DDGS) annually.

Since 2016, the plant is owned by Green Plains.

Services performed

Involved Processes

Liquefaction / Saccharification

Fermentation

Distillation / Rectification

Dehydration

Further Info

Green Plains Inc.

Yeast plant in Ahvaz

RAZI YEAST & ALCOHOL COMPANY - Ahvaz, Iran

Razi Yeast & Alcohol Company, formerly Sugar Cane By-Products Corporation, assigned Vogelbusch with the process design, engineering and supply of a complete plant for the production of baker's yeast from cane molasses.

Production in the yeast plant started in 2009, since manufacturing 32,000 kg per day of high quality instant active dry yeast (iADY) which is marketed under the brand name Nabmayeh. The plant is located next to a neutral alcohol facility also supplied by Vogelbusch.

Services performed

Involved Processes

Molasses preparation

Precipitation

Fermentation

Filtration

Drying

Further Info

Razi Yeast & Alcohol Co.

Bioethanol Plant in Casselton

THARALDSON ETHANOL - Casselton, North Dakota, USA

Tharaldson Ethanol started up their state-of-the-art fuel ethanol facility located in Casselton, North Dakota in 2009.

The plant utilizes technology licensed by VOGELBUSCH USA Inc., including the Vogelbusch MultiCont© continuous fermentation process, and is currently operating at a capacity of 1,300,000 liters per day, making it one of the largest dry corn milling ethanol facilities in the world.

Services performed

Involved Processes

Liquefaction / Saccharification

Fermentation

Distillation / Rectification

Dehydration

Further Info

Tharaldson Ethanol LLC

2G Demonstration Plant in Kalundborg

ØRSTED (Inbicon) - Kalundborg, Denmark

Inbicon has developed a proprietary process for the conversion of wheat straw. Complementing this biomass conversion process Inbicon has opted for sound and energy efficient technology from Vogelbusch for part of ethanol fermentation as well as the distillation, dehydration and stillage evaporation.

The 17,000 liters per day demonstration plant served as a showcase project for second generation (2G) bioethanol production at the UN climate summit in Copenhagen in December 2009.

Services performed

Involved Processes

Fermentation

Distillation / Rectification

Dehydration

Evaporation

Further Info

Inbicon A/S

Bioethanol Plant in Beinheim

ROQUETTE - Beinheim, France

As part of a wet milling complex, this plant is designed to utilize wheat starch and optionally milled grain. It has a daily capacity of 400,000 liters of ethanol and was put into operation in 2008.

Vogelbusch provided the know-how and technology package for the process plant and supplied key equipment for distillation and dehydration.

Services performed

Involved Processes

Liquefaction / Saccharification

Fermentation

Distillation / Rectification

Dehydration

Further Info

Roquette Freres

Bioethanol Plant in Cedar Rapids

INGREDION (Penford) - Cedar Rapids, Iowa, USA

Penford Products Company successfully started up their state-of-the-art fuel ethanol facility in May 2008. The plant utilizes technology licensed by VOGELBUSCH USA Inc. and has a nameplate capacity of 450,000 liters per day. Corn hydrolysate from the company’s existing wet corn milling operation is used as feedstock.

Tom Malkoski, Penford’s President and CEO says, “The addition of ethanol will allow our Cedar Rapids plant to increase production and improve asset utilization, while providing us with new flexibility to maximize returns from multiple market opportunities.”

The plant is meanwhile owned by Ingredion.

Services performed

Involved Processes

Liquefaction / Saccharification

Fermentation

Distillation / Rectification

Dehydration

Further Info

Ingredion Inc.

Vinegar fermenter in Golegã

MENDES GONÇALVES - Golegã, Portugal

Mendes Gonçalves, a well known Portuguese producer of vinegar and condiments ordered a vinegar fermenter from Vogelbusch. The new fermenter raised production capacity in Golegã, north of Lisbon by 15,000 liters to some 27,000 liters per day. We supplied the fermenter including IP-8-Self-Priming Aeration and process equipment such as pumps, control valves, instrumentation and MCC, and the process control system.

The preparations for the installation work were performed by the client using specifications for equipment, foundations and construction, and pipework layouts provided by Vogelbusch. The new fermenter was integrated with the existing plant and commissioned in June 2008. Since then nominal output has been running at about 20 % above nameplate capacity, and the customer is fully satisfied with the performance of the equipment.

Services performed

Involved Processes

Fermentation

Further Info

Mendes Gonçalves, SA

Distillation|Dehydration in Norrköping

LANTMÄNNEN AGROETANOL - Norrköping, Sweden

The bioethanol plant of Lantmännen Agroetanol AB utilises process technology licensed by Vogelbusch for distillation and dehydration. The proprietary MultiPressure system considerably reduces the steam consumption compared to traditional distillation systems and optimum thermal integration further improves the energy-saving properties of the plant.

The facility, which is Agroetanol’s second production line in Norrköping, processes wheat for the most part as well as rye and barley. With the experience of their first plant Agroetanol had decided to design the raw material preparation and the fermentation based on own know-how, while other process groups were assigned to contractors. The plant has a design capacity of 470,000 liters ethanol per day and started operations in 2008.

Services performed

Involved Processes

Distillation / Rectification

Dehydration

Further Info

Lantmännen Agroetanol AB

Bioethanol Plant in USA

Confidential Client, USA

The plant was built using know-how provided by VOGELBUSCH USA Inc., including the Vogelbusch MultiCont© continuous fermentation process, and has a nameplate capacity of 908,000 liters per day. The facility uses 32 million bushels (813,000 metric tons) of local corn annually and to produce approximately 250,000 metric tons of distiller’s dried grains with solubles (DDGS).

Services performed

Involved Processes

Liquefaction / Saccharification

Fermentation

Distillation / Rectification

Dehydration

Citric Acid Plant in Kermanshah

KIMIA GHARB GOSTAR - Kermanshah, Iran

The plant of Kimia Gharb Gostar Industries Co. has a capacity of 36 tons per day and is the first citric acid plant set up in Iran. It is suitable for processing of raw sugar and sugar beet molasses. The process concept allows for a choice between production of either of the two commercially available forms of citric acid (monohydrate or anhydrate).

Process planning included the raw material preparation, fermentation and product processing stages, as well as the design of auxiliary plants such as the fermentation air system, the ammonia gas and the cooling water supply. Support services were carried out during the construction of the wastewater treatment plant. Almost all equipment and materials for the process plant was supplied by Vogelbusch. The facility was started up in 2007.

Services performed

Involved Processes

Molasses preparation

Precipitation

Raw Material Preparation

Fermentation

Centrifugation

Evaporation

Ion exchange

Filtration

Crystallization

Drying

Further Info

Ethanol Dehydration in North Sitra

GREEN POWER - North Sitra, Kingdom of Bahrain

Some 400,000 liters per day of crude industrial alcohol from a refinery in Saudi Arabia are processed in the Bahrain unit. After entering the plant, the feed is purified in a rectification column where low-boiling substances such as diethylether and acetaldehyde are separated before being dehydrated by molecular sieve technology to achieve a moisture content below 0.1 % water.

The unit, comprising 12 skids, a rectification column with reboiler and the molecular sieve vessels, was erected in Austria, assembled and tested, and finally disassembled and shipped to Bahrain in containers, where it was reassembled and commissioned. A flare system for thermal oxidation of the separated low-boiling substances was also delivered.

Services performed

Involved Processes

Distillation / Rectification

Dehydration

Bioethanol Plant in Ravenna

KAAPA ETHANOL (Abengoa) - Ravenna, Nebraska, USA

Abengoa Bioenergy successfully started up their state-of-the-art fuel ethanol facility located in Ravenna, Nebraska in September 2007. The plant utilizes technology licensed by VOGELBUSCH USA Inc., including the Vogelbusch MultiCont© continuous fermentation process, and has a nameplate capacity of 88 million gallons per year (950,000 liters per day). The facility uses 32 million bushels (813,000 metric tons) of local corn and produces approximately 125,000 metric tons of distiller’s dried grains with solubles (DDGS) and 300,000 metric tons of wet distiller’s grains with solubles (WDGS) annually.

The plant was acquired by Kaapa Ethanol in 2016.

Services performed

Involved Processes

Liquefaction / Saccharification

Fermentation

Distillation / Rectification

Dehydration

Further Info

Kaapa Ethanol Ravenna, LLC.

Bioethanol Plant in Hastings

CHIEF ETHANOL FUELS - Hastings, Nebraska, USA

The Chief Ethanol Fuels facility is utilizing Vogelbusch-licensed technology. In 2007, a third molecular sieve drying system was designed and installed, raising operating capacity to 832,000 liters per day.

The cooperation first started in 1983 when Chief Ethanol Fuels set up af 120,000 liters per day plant. Vogelbusch process design included MultiCont© continuous fermentation, MultiPressure distillation, and azeotropic dehydration using cyclohexane as an entrainer. The dry milling process was designed to use corn (maize) and/or milo (grain sorghum) as feedstock. By-products include DDGS (distillers’ dried grains with solubles) and DWGS (distillers’ wet grains with solubles).

In 1993, Vogelbusch technology was again featured in the expansion of the facility to a capacity of 325,000 liters per day. Azeotropic dehydration was replaced with a PSA (pressure-swing adsorption), molecular sieve alcohol dryer that was fed directly with vapor from the rectifying column. In addition, 190 proof vapor off the top of the rectifying column was routed to the first effect of a two-stage stillage evaporator where it was condensed and returned to the rectifying column as reflux. This heat-saving design resulted in reducing thermal energy consumption by 25 %.

Five years later, plant capacity was more than doubled to 670,000 liters per day. In addition to providing technology, Vogelbusch also designed and supplied components for a second molecular sieve alcohol drying system.

Services performed

Involved Processes

Liquefaction / Saccharification

Fermentation

Distillation / Rectification

Dehydration

Further Info

Chief Ethanol Fuels, Inc.

A Constant in Changing Times (Ethanol Producer Magazine, July 2011)

Neutral Alcohol Plant in Ahwaz

RAZI YEAST & ALCOHOL COMPANY - Ahwaz, Iran

The plant now operated by Razi (formerly Sugar Cane By-Products Corporation) was designed for a daily capacity of 110,000 liters of high quality pharmaceutical alcohol from cane molasses complying with EU standards. A special challenge was designing the plant for the extreme climatic conditions (0°C to 50°C) and the highest earthquake level UBC Zone 3.

The design and stress calculations in compliance with European standards for apparatus, tanks and pipelines were carried out at Vogelbusch and the assembly was performed in Iran under our supervision.

The following plant components were supplied: molasses reception and storage; continuous fermentation with untreated cane molasses including nutrient preparation and fermentation air supply; distillation with methanol separation and mash column under vacuum, (implemented as an energy saving MultiPressure system) alcohol storage and filling systems for trucks, rail tankers and barrels; central CIP system; cooling water unit; and laboratory. For those groups the complete piping material, the instrumentation and control as well as electrical components were supplied. Automation is based on a modern DCS system.

Following a four-year erection period and a short start-up phase in the first quarter of 2007, a test run was carried out, and the guaranteed product quality was achieved.

Services performed

Involved Processes

Molasses preparation

Fermentation

Distillation / Rectification

Further Info

Razi Yeast & Alcohol Co.

Bioethanol Plant in Lexington

CHIEF ETHANOL FUELS (Cornhusker) - Lexington, Nebraska, USA

VOGELBUSCH USA Inc. started up the ethanol plant of Cornhusker Energy in spring 2006, with a production capacity of 450,000 liters per day of bioethanol from corn.

The plant employs a state-of-the-art Vogelbusch continuous fermentation process. An energy integrated distillation, evaporation and dehydration system ensures maximum efficiency.

In 2016, Chief Ethanol Fuels purchased the Cornhusker Energy ethanol plant.

Services performed

Involved Processes

Liquefaction / Saccharification

Fermentation

Distillation / Rectification

Dehydration

Further Info

Chief Ethanol Fuels, Inc.

Alcohol Dehydration Unit in Alfatar

EURO ETHYL - Alfatar, Bulgaria

Euro Ethyl’s molecular sieve system was supplied preassembled by VOGELBUSCH USA Inc. and the performance test was successfully completed in November 2006.

The plant has a rated capacity of 120,000 liters of dehydrated alcohol per day. The integration of the molecular sieve with the existing plant required additional distillation equipment to increase capacity, and VOGELBUSCH USA Inc. assisted Euro Ethyl with the procurement and installation of used equipment from U.S. sources.

Services performed

Involved Processes

Dehydration

Further Info

"Evroetil" AD

Bioethanol plant in Zeitz

CROPENERGIES - Zeitz, Germany

The 800,000 liters per day plant of CropEnergies, a unit of German Südzucker group, is designed for multiple grain sources together with by-products of beet sugar processing. The plant and is highly advanced in terms of energy saving and environmental protection. Vogelbusch contributed process design for the raw material processing, continuous fermentation, distillation, dehydration, stillage evaporation as well as DDGS drying and supplied key equipment (column trays and molecular sieve).

Start-up of the plant was in 2005 with an implementation period of 15 months.

Services performed

Involved Processes

Dry milling

Liquefaction / Saccharification

Fermentation

Distillation / Rectification

Dehydration

Evaporation

Drying

Further Info

CropEnergies AG

Yeast fermenter in Malmö

SPECIAL YEAST - Malmö, Sweden

The utilization of a hydrolysate made from bakery waste was the object of the order by Special Yeast. The process for this novel feedstock was developed and implemented, including supply of the aeration system.

The unit has a capacity of 9,000 kg per day and was started up in 2006.

Services performed

Involved Processes

Fermentation

Further Info

SpecialYeast AB

Bioethanol Plant in Pekin

ALTO INGREDIENTS (Pacific Ethanol) - Pekin, Illinois, USA

In March 2004 the molecular sieve unit at the Aventine Renewable Energy plant was brought on stream. With a rated capacity of 1.2 million liters per day (110 mm gallons per year) anhydrous alcohol, at that time the largest capacity molecular sieve alcohol dehydration unit in the world.

The molecular sieve unit replaced the ageing cyclohexane dehydration unit and resulted in significant energy savings, while maintaining additional evaporative capacity of the integrated Vogelbusch distillation/evaporation/dehydration plant.

Over more than 20 years Vogelbusch is associated with the facility of Aventine Renewable Energy in Pekin. In 1981 the original plant using Vogelbusch technology was the first MultiCont© continuous fermentation system in the U.S. In 1993 the plant was expanded and later, step after step, a distillation, a molecular sieve for high quality potable and industrial alcohol and a vacuum distillation for yeast recovery were added.

In 2015 Aventine Renewable Energy Holding, merged with Pacific Ethanol, Inc. Its two production facilities in Pekin, IL and one in Aurora, NE are now operating as Pacific Ethanol, Inc.

Services performed

Involved Processes

Liquefaction / Saccharification

Fermentation

Distillation / Rectification

Dehydration

Further Info

Pacific Ethanol, Inc.

Alto Ingredients

Bioethanol Plant in Jilin

JILIN FUEL ALCOHOL COMPANY - Jilin Province, PR China

Located in Jilin City in Northeast China, this production line for bioethanol was officially commissioned in November 2003 after an implementation period of 22 months. The plant produces 300,000 tons of fuel alcohol annually from maize. The product is used as a 10 % petrol additive.

Process design by Vogelbusch provided for the raw material processing, MultiCont© continuous fermentation, MultiPressure distillation and the molecular sieve dehydration process stages as well as DDGS processing. The column trays for the distillation plant were supplied by Vogelbusch.

Services performed

Involved Processes

Dry milling

Liquefaction / Saccharification

Fermentation

Distillation / Rectification

Dehydration

Evaporation

Drying

Further Info

Jilin fuel ethanol plant (International Sugar Journal, 2004)

Neutral Alcohol Plant in Harbin

HARBIN WINERY - Harbin District, PR China

The fine alcohol plant of Harbin Winery, a Chinese producer of potable alcohol from corn, was upgraded by Vogelbusch in several steps. The client required specifically high alcohol quality in terms of organoleptic and analytical criteria and in particular with regard to methanol separation. The facility was designed to set standards in product quality and in energy saving.

The reconstruction was carried out between 1999 and 2003 and comprised the installation of a MultiPressure distillation/rectification (capacity 62,000 liters/day), expansion of an existing D/R plant (to 140,000 liters/day), turnkey supply of a skid mounted molsieve dehydration (10,000 liters/day) and the process design for a MultiCont continuous fermentation (140,000 liters/day).

The plant was later moved and reassembled by the client at a new site out of town and is producing neutral and dehydrated alcohol again there since 2009.

Services performed

Involved Processes

Liquefaction / Saccharification

Fermentation

Distillation / Rectification

Dehydration

Yeast fermenter in Hamburg

OHLY (Deutsche Hefewerke) - Hamburg, Deutschland

DHW of Hamburg decided to convert an existing fermenter to the Vogelbusch aeration system. The given situation required the redesign of the drive and included engineering and supply of the complete aerator system.

The reconstructed fermenter has a capacity of 27,000 kg per day of baker’s yeast made from beet molasses. Operation commenced in 2002.

Services performed

Involved Processes

Fermentation

Further Info

Ohly GmbH

Plant for Baby Milk Powder near Cairo

LACTO-MISR - 10th of Ramadan City, Egypt

This plant for baby milk powder and protein drink concentrates was realised by Vogelbusch in 2002 with a process licensed from a German producer of infant formula. The enterprise is the first manufacturer of infant formula in the Middle East. The production capacity is 32 tons per day. The plant location, 19th of Ramadan City, is an industrial zone close to Cairo.

The process was adapted by Vogelbusch to local conditions with regard to raw material and climate, to allow simple handling and constant product quality as well. Individual process technologies sourced from third parties for drying, dry mixing, and packing have been integrated by Vogelbusch and the quality assurance system was developed together with the licensor.

Services performed

Involved Processes

Raw Material Preparation

Drying

Further Info

Lacto-Misr Co.

Extra Neutral Alcohol D|R in Leopoldov

SLOVENSKE LIEHOVARY À LIKÉRKY - Leopoldov, Slovakia

The plant in Leopoldov produces extra neutral alcohol for the company's well established range of beverage brands.

30,000 liters of high quality alcohol are distilled per day from alcoholic mashes from molasses and grain. Vogelbusch designed the distillation and rectification unit and supplied key equipment for the plant, which was commissioned in 2002.

Services performed

Involved Processes

Distillation / Rectification

Further Info

Slovenské liehovary a likérky, a.s.

Vinegar fermenter in Austria

MAUTNER MARKHOF (Gsonek) - Vienna, Austria

Supply of a vinegar fermenter type 1200 including IP-8-Self-Priming Aeration with a daily capacity of 15,000 liters (10 %) for processing pure ethanol and grape and apple wine.

The unit, originally set up for Gsonek in 1998 in Laa an der Thaya (Lower Austria), was later acquired by Mautner Markhof and integrated in their Vienna production facilities.

Services performed

Involved Processes

Fermentation

Filtration

Further Info

Mautner Markhof Feinkost GmbH

Yeast fermenter in Nuremberg

DEUTSCHE HEFEWERKE - Nuremberg, Germany

DHW Nuremberg enhanced their manufacturing capacity by adding a fermenter which had to be placed outside the production building.

Vogelbusch engineered the expansion and supplied the key equipment (EB4 aerator system including drive, mash pumps and heat exchangers). The fermenter is designed for 25,000 kg of baker's yeast per day made from beet molasses. Start-up was in 2001.

Services performed

Involved Processes

Fermentation

Further Info

Deutsche Hefewerke GmbH Nürnberg

Yeast fermenter in Osaka

ORIENTAL YEAST - Osaka, Japan

To raise the production capacity of Oriental Yeast in Osaka, Komatsugawa Chemical Engineering Co. assigned Vogelbusch with the engineering for an additional yeast fermenter and the supply of key equipment (aeration).

The unit is designed for the production of 20,000 kg per day of baker's yeast made from cane molasses. Start-up was in 2001.

Services performed