Title: Effluent Reuse Options Service to Ethanol Plant at Corning, Iowa IWPCA 90th Annual Conference Counci
1Effluent Reuse OptionsService to Ethanol Plant
at Corning, IowaIWPCA90th Annual
ConferenceCouncil Bluffs, Iowa June 4, 2008
- Mark Duben, P.E.
- Vice President Senior Project Manager
- Howard R. Green Company
- 4685 Merle Hay Road, Suite 106
- Des Moines, Iowa 50322
- 800-593-2339
- mduben_at_hrgreen.com
2Ethanol Facts
- Ethanol Production (millions of gallons)
- Year Iowa U.S. Iowa/U.S.
- 1980 25 175 14
- 1985 67 610 11
- 1990 212 900 24
- 1995 424 1,400 30
- 2000 440 1,630 27
- 2003 598 2,800 21
- 2004 859 3,400 25
- 2005 1,100 3,904 28
- 2006 1,500 4,855 31
- from Iowa Renewable Fuels Association
website
3Ethanol Facts
- Iowa Ethanol Plants
- Current Operating Plants 29
- Current Capacity (millions of gallons per
year) 2,214 - Under Construction/Expansion Plants 14
- Under Construction/Expansion Capy.
(MG/yr) 1,415 - Total Capacity After Construction (MG/yr) 3,629
- from Iowa Renewable Fuels Association
website
4POET Biorefining Corning Ethanol
- 100 acre site
- 3 miles SW of Corning, Iowa (Brooks, Iowa)
- Developed by POET Biorefining and
- POET Design Construction
- BNSF Railroad siding access to main line track
- Direct rail delivery to east west coast markets
- 65 million gallons per year initial capacity
- Over 100 million gallons per year if expanded
5Ethanol Production Block Flow Diagram
Fresh Water Recycled Water Sources
CO2
The process of making ethanol starts here
Enzymes
Yeast
Corn
Hammermill
Slurry Tank
Slurry
Fermentation
5 Gasoline
200 Proof Ethanol
Molecular Sieves
Beer
190 Proof Ethanol
Atmosphere
Regenerative Thermal Oxidizer
Dryer Gas
Ring Dryer
DDGS Final Product
Distillation System
Syrup
Whole Stillage
Wet Grain
Evap. Steam
Centrifuge
Evaporator
Distillate
Thin Stillage
6POET Biorefining Corning Ethanol
- Water Supply Needs (Design)
- 500 gpm (0.72 MGD) raw water initial
- 800 gpm (1.15 MGD) raw water ultimate
- 300 gpm (0.43 MGD) disinfected wastewater
effluent for cooling water initial ultimate - 6 gallons water per gallon ethanol
- Water Supply Needs (Contract)
- 0.56 MGD raw water/0.86 max
- 0.30 MGD wastewater effluent
- 5 gallons water per gallon ethanol
- Water Supply Needs (Actual - Sept. 2007)
- 0.47 MGD raw water (typically 60 of need,
process) - 0.17 MGD wastewater effluent (40 of need,
towers) - 4 gallons water per gallon ethanol
7POET Biorefining Corning Ethanol
- Return Flow Needs
- 20 gpm (0.029 MGD) ultrafilter BW, RO, sanitary
initial - 30 gpm (0.043 MGD) ultrafilter BW, RO, sanitary
ultimate - Flows returned to City of Corning sanitary sewer
system and back to wastewater treatment plant - Ethanol Plant cooling tower blowdown waste
flowstream to river
8POET Biorefining Corning Ethanol
Raw Water
Process Water
Reverse Osmosis
Ultrafiltration
Cooling Tower
WW Effluent
9Corning Municipal Utilities
- Adams County in SW Iowa
- City population of about 1,700
- Water, electric, and gas utilities
- Surface water supply and treatment
- 3 different reservoir sources
- Lake Icaria, Lake Binder, City Reservoir
- 2 MGD surface water treatment plant
10City of Corning
- Wastewater collection
- and treatment
- 1.1 MGD treatment with
- EQ basin
- ADW Flow 0.38 MGD
- AWW Flow 0.52 MGD
- MWW Flow 2.02 MGD
- UV disinfection of effluent
- Effluent pumped to ethanol plant and/or
discharged to river
11Project Elements
- Raw water pump station at WTP
- 10 raw water main WTP to WWTP 2 miles
- UV disinfection of effluent at WWTP
- Effluent lift station at WWTP
- Raw water effluent storage lagoon at WWTP
- Raw water effluent pump station at WWTP
- 10 raw 6 effluent mains WWTP to POET 3.5
miles each - 4 return main POET to Industrial Park 2 miles
12(No Transcript)
13(No Transcript)
14(No Transcript)
15(No Transcript)
16(No Transcript)
17(No Transcript)
18Project Elements
- Division 1 Project
- 10,000 of 10 PVC C900 DR 18 WTP to WWTP
- Raw water pump station foundation/grading at WTP
- UV disinfection equipment at WWTP
- Effluent lift station, valve vault meter vault
at WWTP - Raw water effluent storage lagoon at WWTP
- Raw water effluent pump station
foundation/grading at WWTP - Max Smith Construction of Creston, IA
- 1,341,950 final contract amount
- July 2006 to May 2007
19Project Elements
- Division 2 Project
- Prefabricated raw water pump station at WTP
- 2 vertical turbine pumps Each 800 gpm with
VFDs, and capable
of pumping 1,100 gpm with both pumps - Prefabricated raw water effluent pump station
at WWTP - 2 vertical turbine pumps Each 800 gpm with
VFDs, and capable
of pumping 1,100 gpm with both pumps - 2 vertical turbine pumps Each 300 gpm with VFDs
- Delivery of prefabricated pump stations to sites
- Installation of vertical turbine pumps in pump
stations after Division 1 Contractor set
connected stations on his foundations - USEMCO, Inc. of Tomah, WI
- 356,750 final contract amount
- July 2006 to May 2007
20Project Elements
- Division 3 Project
- Instrumentation controls for overall system
- Instrumentation items, including level pressure
transducers, magnetic flow meters, float
switches, temperature sensors, door switches,
VFDs - Control panels for WTP pump station, WWTP lift
station, WWTP pump station, POET meter vault,
POET ethanol plant - Delivery of instrumentation items and panels to
Division 2 Contractor for installation in
prefabricated pump stations - SCADA screen modifications to existing systems at
WTP and WWTP - Automatic Systems Co. of Ames, IA
- 312,490 final contract amount
- July 2006 to August 2007
21Project Elements
- Division 4 Project
- 18,000 of 10 PVC C900 DR 18 WWTP to POET Site
- 18,000 of 6 PVC C900 DR 18 WWTP to POET Site
- 11,000 of 4 PVC C900 DR 18 POET Site to
Industrial Park - Triple meter vault at POET Site
- Installation of mag meters and control panel from
Division 3 Contractor at POET meter vault - Max Smith Construction of Creston, IA
- 865,978 final contract amount
- September 2006 to May 2007
22Project Elements
- Division 5 Project
- Rehabilitation of Lake Binder raw water pump
station - Add a second raw water pump for backup/redundancy
- Add VFDs for both pumps
- Replace piping, fittings, valves, appurtenances
- Replace electrical equipment and wiring
- Postponed not critical to be completed yet
- Estimated at 50,000
23Project Elements
- Total Project
- Division 1 1,341,950
- Division 2 356,750
- Division 3 312,490
- Division 4 865,978
- Division 5 50,000
- Engineering 430,000
- TOTAL 3,357,168
- CMU also designed and constructed 13 miles of 6
steel high pressure natural gas pipeline to serve
the POET ethanol plant - CMU financed all capital improvements, recovering
costs over 10-year period in water and natural
gas rates
24Project Schedule
- Begin design of Division 1, 2, 3 projects March
2006 - POET ethanol plant construction begins April
2006 - Bid Division 1, 2, 3 projects June 2006
- Begin construction Division 1, 2, 3
projects July 2006 - Begin design Division 4 project July 2006
- Bid Division 4 project September 2006
- Begin construction Division 4 project October
2006 - Complete construction Division 1, 2, 3, 4
projects May 2007 - Provide water for initial startup of POET
plant May 2007 - POET plant in full production June 2007
- Begin design of Division 5 project July 2007
- Complete Division 5 project Postponed
25CMU/POET Project Outcomes
- Less water treatment required by Corning
Municipal Utilities supplying raw water - Less wastewater effluent discharged by City of
Corning beneficial reuse of effluent - Reduced costs for both CMU and POET Biorefining
Corning - Friendlier for the environment
- Win/Win for Corning and POET
26Questions????
- Thanks to
- CMU Mike Goldsmith, Bob Cline, Tim Larsen
- City of Corning Carl Goodson
- POET Biorefining - Corning