System Design Specification Rev 0

Terra Grain Fuels
SYSTEM DESIGN SPECIFICATION
Project 61141
Terra Grain Fuels, LLC Wheat to Ethanol Plant SYSTEM DESIGN SPECIFICATION (SDS)
Belle Plaine, Saskatchewan
August 2, 2006
Date 15Nov06
Revision Issue for Design
Rev No. 0
By DP
Reviewed DP
Approved RM
61141 System Design Specification Rev 0.doc
Delta-T Project Services - Confidential Copyright 2003 Delta-T Corporation. All rights reserved.
Page 1 of 43 Rev 0 15NOV2006
Terra Grain Fuels
SYSTEM DESIGN SPECIFICATION Wheat to Ethanol Plant SYSTEM DESIGN SPECIFICATION (SDS) Table of Contents
Project 61141
LIST OF ATTACHMENTS ...................................................................................... 4 1.0 Project Guidelines ....................................................................................... 5 2.0 Scope of SDS ............................................................................................... 6 3.0 Design Basis ................................................................................................ 7 3.1 General .......................................................................................................... 7 3.2 Raw Material .................................................................................................. 7 3.3 Product Flow Rates........................................................................................ 8 3.4 Product Specifications.................................................................................... 9 3.5 Yields ........................................................................................................... 11 4.0 Process Description .................................................................................. 12 4.1 Plant Summary ............................................................................................ 12 4.2 Area 1200 - Wheat Cleaning and Milling...................................................... 13 4.3 Area 2200 - Liquefaction and Cooking ......................................................... 13 4.4 Area 3100 - Yeast Propagation and Fermentation....................................... 14 4.5 Area 4100 - Distillation ................................................................................. 15 4.6 Area 4300 - Dehydration .............................................................................. 15 4.7 Area 4500 - Stillage Evaporators ................................................................. 15 4.8 Area 5100 - Stillage Separation ................................................................... 16 4.9 Area 7600 - CIP System .............................................................................. 16 5.0 Non Process Description (OSBL) ............................................................. 17 5.1 Area 1100 - Grain Receiving and Storage .................................................. 17 5.2 Area 5300 - DDGS Storage and Shipping.................................................... 18 5.3 Area 6100 - Fuel Ethanol Storage and Loading ........................................... 18 5.4 Area 7700 - Chemical Storage..................................................................... 19 6.0 Utilities ........................................................................................................ 20 6.1 Area 7100: Cooling Water........................................................................... 20 6.2 Area 7200: Steam and Steam Condensate................................................. 20 6.3 Area 7300: Water Supply and Distribution .................................................. 20 6.4 Area 7500: Compressed Air........................................................................ 21 6.5 Area 7800: Fire Protection .......................................................................... 21 6.6 Area 8100: Natural Gas .............................................................................. 21 6.7 Electrical Supply and Distribution................................................................. 21 6.8 Waste Water Treatment ............................................................................... 21 6.9 Process Effluent........................................................................................... 21 6.10 Sanitary Sewage.......................................................................................... 22 6.11 Storm Water................................................................................................. 22 6.12 Solid Waste Disposal ................................................................................... 22
Terra Grain Fuels
SYSTEM DESIGN SPECIFICATION 7.0 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13 7.14 7.15 7.16 7.17 7.18 7.19 7.20 7.21 8.0 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8
Project 61141
General Design Guidelines ....................................................................... 23 Plant Staffing................................................................................................ 23 Plant and Buildings ...................................................................................... 23 Spare Equipment and Capacity ................................................................... 24 Platforms, Stairs and Ladders...................................................................... 24 Control Room............................................................................................... 24 Control System Philosophy .......................................................................... 25 Control Valve Design ................................................................................... 25 Site Conditions............................................................................................. 25 Physical/Thermodynamic Properties............................................................ 25 Winterization ................................................................................................ 25 Materials of Construction ............................................................................. 25 Minimum Design Metal Temperature ........................................................... 25 Operating Range.......................................................................................... 26 Relief and Blowdown.................................................................................... 26 Instrumentation ............................................................................................ 26 Engineering Drawings .................................................................................. 26 Equipment Life ............................................................................................. 26 Paving and Parking ...................................................................................... 26 Safety Showers............................................................................................ 27 Utility Stations .............................................................................................. 27 Lighting ........................................................................................................ 27 Environmental and Safety Considerations .............................................. 28 Atmospheric Emissions................................................................................ 28 Water Supply ............................................................................................... 28 Effluent Discharge........................................................................................ 28 Noise............................................................................................................ 28 Containment of Spills ................................................................................... 28 Solid Waste.................................................................................................. 28 Odor ............................................................................................................. 28 Site Drainage ............................................................................................... 28
Terra Grain Fuels
Project 61141
LIST OF ATTACHMENTS
Attachment 1 Attachment 2 Attachment 3 Attachment 4 Attachment 5 Attachment 6 Attachment 7 Attachment 8 Attachment 9 Attachment 10 Attachment 11 Attachment 12 Attachment 13
Site Conditions Fresh Water Analysis Codes and Standards Process Production and Preliminary Utility Consumption Summary Flour Specification Electrical Voltage and Area Classification Equipment Numbering System Line Numbering System Process Unit Identification Number Instrument and Valve Numbering System Drawing Numbering System Units of Measure Storage Tank Design Criteria and Capacities
Terra Grain Fuels
Project 61141
1.0
Project Guidelines To construct an efficient, safe to operate, cost effective wheat dry mill ethanol facility, with a nameplate capacity of 150 million liters per year (39.6 million gallons per year) of un-denatured anhydrous fuel grade ethanol. Delta-T will provide preliminary engineering sufficient to allow for permitting, pre-engineered building specifications, and long lead equipment requisitioning. Delta-T will design the plant and VCM / EllisDon will build the plant. Delta-T will provide process guarantees. Wheat handling, liquefaction, fermentation, stillage processing, DDGS drying, and all associated utilities will be designed to account for a minimum starch content in the blended wheat of 65% wt. dry basis and a maximum moisture content of 14.5% (by weight). The design of the plant and performance guarantees will be based on the supply of Canadian Prairie Spring (CPS) and Hard Red Spring (HRS) wheat. The plant will also process Durum #4 and #5 wheat as well as corn, but the performance of these feedstocks will not be guaranteed. The initial design will allow for feedstock separation of CPS and HRS. Site area will be set aside for the future addition of storage and separation equipment for other feedstocks. The site is a Greenfield parcel of land in Belle Plaine, Saskatchewan. Expansion is not currently contemplated. Design and plant layout will not include pre-investment for expansion or allocate site area for expansion. The plant capacity is based on 350 stream days per year, 24 hours per day operation. Target mechanical completion is November, 2007. Target startup is December, 2007.
Terra Grain Fuels
Project 61141
2.0
Scope of SDS
This document is intended to give guidance with regard to design criteria, philosophies, and preferences. This document does not convey contractual obligations. It is expected that clarifications and deviations from this document will become necessary as the detailed engineering work by Delta-T and others progresses. Accordingly, it is intended that as engineering proceeds, this document be revised as necessary to provide an up-to-date summary for detailed engineering design. The basic process steps for ethanol production will include: Truck and Rail wheat receiving. Wheat storage and cleaning. Wheat milling. Mash cooking and conversion. Fermentation. Carbon dioxide scrubbing. Fuel ethanol distillation and dehydration. Fuel ethanol product storage. Stillage separation. Stillage evaporation. Distillers Grain & Solubles Drying Dried Distillers Grains with Solubles (DDGS) storage. Chemical storage. Clean-in-Place (CIP) system. Gasoline denaturant offloading and storage. Truck and rail denatured ethanol loading facilities. Truck and rail DDGS loading facilities.
The basic utilities that will be included are: Steam generation and condensate return. Raw water treatment. Instrument / plant air. Cooling water. Natural gas. Power distribution. Fire protection
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Project 61141
3.0 3.1
Design Basis General
Equipment will be designed according to industry-accepted standards for a continuous operation (24 hours /day, 7 days /week) industrial application. The equipment will be designed to meet the production requirements based on operating 350 days per year. The plant is expected to operate continuously except for scheduled maintenance shutdowns, or shutdowns caused by external factors (utilities, feedstock, etc.). The plant throughput will be capable of operating effectively at 50% capacity. The plant will produce no process waste products. All incoming cleaned wheat will be converted to ethanol, CO2, and DDGS. 3.2 Raw Material
The design of the ethanol process is based on receiving predominately Canadian Prairie Spring (CPS) and Andrews (soft white wheat) over time. Wheats of lower starch content will be used, but minimized to ensure maximum ethanol production. For the purpose of this design specification, the blended wheat feedstock has the following definition: Design Basis 13 w/w % 65.0 w/w % 12.9 w/w % 2.1 w/w % 1.8 w/w % 3.2 w/w % 15.0 w/w % 779 kg/m Typical 12.0 - 14.5 w/w % 2% 2% 2% 2%
Moisture Starch (dmb) Protein (dmb) Crude Fat (dmb) Ash (dmb) Crude Fiber (dmb) N.F.E. (dmb) Bulk density Angle of repose Note: - Based on a 60 lbs/bushel test weight dmb = Dry Matter Basis N.F.E. = Nitrogen Free Extract
34 36
The process is designed to guarantee products, capacities, and consumption based on the wheat analysis above. It is forecasted that the blends of wheat anticipated will be of lower starch value in Year 1, but improving beyond the design point in Year 3:
Terra Grain Fuels
Project 61141
Approx. Starch Content (% dmb)
Year 1
(% usage)
Year 2
(% usage)
Year 3
(% usage)
Year 4
(% usage)
Year 5
(% usage)
Hard Red Spring Canadian Prairie Spring or Andrews Approx. Blended Starch Content (% dmb) Durum
62.5 67.5
80 20 63.5
60 40 64.5
40 60 65.5
20 80 66.5
0 100 67.5
60.0
Opportunistic (low quality purchase)
The instantaneous grain flow rate of cleaned wheat required to meet the design capacity of the plant is approximately 48,500 kg/hr based on the design basis wheat composition. 3.3 Product Flow Rates 150 million liters per year of un-denatured anhydrous alcohol (UDA) 428,570 liters per day UDA based on 350 stream days per year production. 17,860 liters per hour UDA based on 24 hours per day production.
3.3.1 Fuel Ethanol
3.3.1 Distillers Dried Grains with Solubles (DDGS) The design capacity for the DDGS dryer system is based on matching the ethanol production noted above. With the range of quality of the raw materials specified in Section 3.2, estimated DDGS production will be approximately 163,500 metric tons per year on the basis that all wet cake and syrup is converted into DDGS. 3.3.2 Wet Distillers Grains with Solubles (WDGS) The production of WDGS will reduce the utility consumption of the plant. Given the limited economic value, no significant amount of total available dried solids will remain as WDGS. 3.3.3 Carbon Dioxide (CO2) Carbon dioxide will not be recovered by the client from the ethanol facility. CO2 will be vented to the atmosphere. The estimated CO2 produced will be approximately 109,400 metric tons per year.
61141 System Design Specification Rev 0.doc Delta-T Project Services - Confidential Copyright 2003 Delta-T Corporation. All rights reserved. Page 8 of 43 Rev 0 15NOV2006
Terra Grain Fuels
SYSTEM DESIGN SPECIFICATION 3.4 Product Specifications
Project 61141
3.4.1 Anhydrous Fuel Ethanol Anhydrous fuel ethanol shall mean ethanol that conforms to the following specification: Analysis Spec. Water content Density Acidity (as Acetic Acid) Copper Inorganic Chlorine Methanol Sulfur Sulfate pHe Test Method ASTM E-203 ASTM D-891B ASTM D-1613 ASTM D-1688D ASTM D-512 ASTM D-5501 ASTM D-5453 TBD ASTM D-6423 Limit 1 Max 792 30.0 Max 0.10 Max 10.0 Max 0.5 Max. 30 4 6.5 9.0 Units % mass kg / m3 mg / L mg Cu / L mg Cl / L % volume ppm ppm pH
The anhydrous fuel ethanol produced will conform to the ethanol requirements (Section 8) in the Canadian General Standards Board Specification CAN/CGSB3.511-2005a. The Canadian General Standards Board Specification was deemed equal to or more stringent than the ASTM standards. 3.4.2 Dried Distillers Grains with Solubles (DDGS) The DDGS is produced by drying the mixture of centrifuge cake and evaporator syrup (concentrated solubles) in a DDGS dryer. The DDGS will have the following specifications and physical characteristics: Water Content Color Odor Texture Density Angle of Repose 10.0 w/w % max as tested by the A.O.A.C. Method (1980 edition). Characteristic dark brown color, no burnt appearance. No burnt odor Balling will be less than 15 w/w % on a U.S.A. Standard Testing Sieve #12 mesh screen (10 mesh Tyler equivalent, 1.7 mm opening). 545 kg/m3 @ 10% moisture. (519 kg/m3 @ 5-6% moisture) 30 to 45 from horizontal depending on the water content.
Terra Grain Fuels
SYSTEM DESIGN SPECIFICATION 3.4.3 Wet Distillers Grains with Solubles (WDGS)
Project 61141
WDGS is the product formed from the combination of centrifuge cake and evaporator syrup without the conventional drying step. The WDGS will contain a maximum of 68 w/w % water. In the event of a dryer failure, WDGS will be collected on a wet-cake pad for transportation offsite. A permanent method of reintroducing the wet-cake from the pad to the dryer will not be provided, but space will be provided for future installation of a conveyor. Access will be provided to allow manual addition of WDGS to the wet cake conveyor feeding the dryer. 3.4.4 Condensed Distillers Solubles (CDS) CDS is the product of the stillage evaporation system, also called syrup. The CDS will have a total solids content of 32 w/w %, as determined by the oven dry method. 30 -35 w/w % is the expected range due to viscosity limitations, feedstock variety, and source. 3.4.5. Carbon Dioxide (CO2) The term Carbon Dioxide (CO2) shall mean a gas produced as a co-product of fermentation. CO2 will be treated in a wet scrubber and vented to the atmosphere. The expected composition of this vented stream is as follows, with a temperature of not more than 38C: (Note: figures are on a dry basis in % w/w or ppm w/w as indicated.) Component CO2 O2 N2 Organics Sulfur Compounds % w/w or ppm w/w 95.5% w/w 0.8% w/w 3.2% w/w 0.5% w/w 40 ppm w/w Max/Min Minimum Maximum Maximum Maximum Maximum
Organic impurities shall not exceed the following limits for individual components: Component Ethanol and Methanol Total aldehydes (as acetaldehyde) Total esters (as ethyl-acetate) Total acids (as acetic acid) Methane Total other hydrocarbons ppm w/w Maximum 4,000 1,000 500 200 100 20
Sulfur compounds shall not exceed the following maximum values and shall normally be below the detection limits of standard gas chromatographic analysis of 2 ppm w/w:
Terra Grain Fuels
Project 61141
Note: These estimates are based on the addition of Sulfuric Acid in quantities at or below those noted in Attachment 4. Component SO2 COS H2S Total other organic sulfur compounds in sum 3.5 Yields ppm w/w Maximum 10 ppm w/w 10 ppm w/w 10 ppm w/w 10 ppm w/w
3.5.1 Ethanol (Starch Utilization) The plant will require an average of 1.96 kilograms of starch to produce one kilogram of anhydrous fuel ethanol. 3.5.2 DDGS The plant will be designed to produce 40.3 dry tonnes of DDGS for every 100 dry tonnes of cleaned wheat processed based on the ethanol yield stated above. 3.5.3 WDGS The plant will be designed to produce no WDGS on an ongoing basis. 3.5.4 CO2 The plant will produce on average 0.909 kilograms of carbon dioxide for every kilogram of anhydrous fuel ethanol produced. Carbon dioxide will be scrubbed and vented to the atmosphere.
Terra Grain Fuels
Project 61141
4.0 4.1
Process Description Plant Summary
Wheat is delivered by truck or rail and stored in steel bins (Area 1100 - Grain Receiving and Storage). The wheat is cleaned to remove oversized and foreign material, and then ground to a meal in hammer mills (Area 1200 Wheat Cleaning and Milling). The flour is wetted and mixed with water, and the wheat starch is converted to fermentable sugars by the action of enzymes which are added to the slurry (Area 2200 Liquefaction and Cooking). In the fermentation step (Area 3100 Fermentation), sugars are converted to ethanol and carbon dioxide by the action of the yeast. The carbon dioxide is scrubbed with water to recover trace amounts of ethanol. The carbon dioxide is then vented to the atmosphere. The ethanol is recovered from the fermented beer by distillation (Area 4100 Distillation) and concentrated to approximately 95 % v/v ethanol. This mixture is an azeotrope and cannot be further purified using standard distillation. Ethanol is then dehydrated in a molecular sieve (Area 4300 - Dehydration) and transferred to the storage and shipping area (Area 6100 Ethanol Storage and Shipping). Residue from the bottom of the first two distillation columns (whole stillage) contains valuable nutrients that are recovered and sold as a high protein animal feed ingredient. The whole stillage is centrifuged (Area 5100 Stillage Separation) where suspended solids are removed and dewatered to form a cake. The liquid decantate or thin stillage, which is partly recycled to the front end of the process as backset, is concentrated by evaporation (Area 4500 - Evaporation). The evaporator is heatintegrated with the process and produces syrup with a solids content of 30% to 35%. The centrifuge cake and the syrup are mixed and fed to a high efficiency low NOX gas-fired dryer system. The dryers removes residual moisture to produce DDGS with 90% dry matter. The DDGS is then transferred to a storage area where it can be loaded on either trucks or rail cars. The following descriptions of the individual process steps highlight special features of the process design as proposed. The key areas are as follows: Area 1200 Area 2200 Area 3100 Area 4100 Area 4300 Area 4500 Area 5100 Area 7600 Wheat Cleaning and Milling Liquefaction and Cooking Yeast Propagation and Fermentation Distillation Dehydration Stillage Evaporators Stillage Separation CIP System
Terra Grain Fuels
Project 61141
4.2
Area 1200 - Wheat Cleaning and Milling
4.2.1 Wheat Cleaning Wheat is cleaned on the way from storage to processing to remove metal, stones and other foreign materials. This equipment is sized to clean at the same rate as the milling facility. The cleaning process consists of coarse scalping using a screen, fines removal using aspiration, destoning, and metal removal. Foreign material is routed to a trash bin supplied by Terra Grain Fuels. 4.2.2 Wheat Milling In order to be able to cook the grain, gelatinize the starch completely, and achieve proper separation in the stillage separation area, the grain must be milled to a specific particle size distribution. Particles that are too coarse will not be cooked properly and will lead to plugging of equipment and lines. Very fine particles will not be removed in the decanter and will lead to high syrup viscosity. The milling system will be designed based on the recommended particle size distribution and capacity requirements specified by Delta-T in Attachment 5. Wheat will be conveyed from the storage bins to a wheat surge bin, sized to handle approximately 4 hours of capacity (near 200 metric tons). Three hammer mills will be provided to grind the wheat to flour. Total milling capacity will be 120% of the process requirements for the facility. The mills will each be provided with a discharge conveyor designed with a seal to minimize the loss of aspiration air to downstream equipment. The mills will have a dedicated dust collector according to NFPA recommendations. The flour will then be transferred to the mashing process by a conveyor and bucket elevator. The wheat flour will be fed to a continuous measuring weigh belt system. This weigh belt system will be used to control the rate of flour addition to the wet process, but will not be certified for trade. 4.3 Area 2200 - Liquefaction and Cooking
The flour is mixed with hot process condensate in the slurry mix tank to form mash. The mix tank is maintained at a temperature of approximately 60 C (140 F). Alphaamylase enzyme is added to reduce the viscosity so that the mixture can flow freely. Ammonia is added to control pH and to provide a source of nitrogen for yeast nutrition. The mash is then pumped to a second slurry mix tank, where the temperature is increased above the gelatinization temperature. Vaporized process condensate is added to the slurry to increase the temperature to 85 o C (185 o F). The slurry is continuously mixed to reduce the effects of high viscosity which develop during gelatinization.
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Project 61141
The mash is then pumped to the liquefaction tank, where the starch is hydrolyzed into dextrin by the action of the alpha-amylase enzyme. The liquefaction tank is divided into multiple segments to simulate several continuously stirred reactors in series. The mash is then heated by steam in one of two heat exchangers to complete the conversion of starch and for sterilization of the mash. The mash is held for 15 minutes in a series of four cooking vessels. After cooking, the mash is cooled in a series of heat exchangers and fed to the fermentation tanks. All tanks in this area are provided with spray machines for routine cleaning via the Clean-in-Place (CIP) system. 4.4 Area 3100 - Yeast Propagation and Fermentation
The fermentation process employs a system of six tanks to allow the fermentation process to be operated in a batch mode. The first tank is used for yeast propagation (production) where yeast is grown rapidly with the addition of a small amount of air. This tank is outfitted with circulation pumps and coolers, with one installed spare cooler to facilitate cleaning each exchanger while the plant is still running. The tank is also outfitted with a top-mounted agitator. Fermentation is accomplished in four tanks, all of equal size. The fermentation process generates heat, which is removed by circulating the fermenting mash through external heat exchangers. The fermenters are piped to circulation pumps and coolers for cooling and transferring beer. These exchangers are plate-and-frame type, designed to minimize plugging between regularly scheduled cleanings. From fermentation, the beer is pumped to the beer well, a holding tank that allows beer to be continuously fed to the distillation system. To recover energy, the beer is preheated in a series of heat exchangers using the incoming mash to the fermenters. The carbon dioxide that is produced during fermentation is collected and routed to a scrubber. Residual ethanol is recovered by the scrubber and the resulting carbon dioxide gas is vented to the atmosphere. Generation of carbon dioxide may produce foaming in the fermenters. Each fermenter and the yeast propagation tank will be equipped with a system to apply an antifoaming agent as necessary. The yeast propagation tank, fermenters, and beer well are sloped-bottom, stainless steel tanks, mounted on concrete pads. The fermenters and beer well will be located outside the main process building. The pumps and heat exchangers will be housed inside a pre-engineered building located in the fermentation area. Proper operating conditions and routine cleaning procedures minimize the rate of contamination by bacteria. Each fermenter, their pumps, and heat exchangers are connected to the CIP system for regular cleaning and sterilization. The fermentation
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Project 61141
system is equipped with piping and controls that allow the system to bypass any fermenter for cleaning or maintenance, as required, while maintaining production. 4.5 Area 4100 - Distillation
The ethanol in the beer is separated from the stillage using a three column distillation system. The three columns are the beer column #1, beer column #2 and the rectifier column. After preheating to a temperature of approximately 77 C (170 F), the beer is split and delivered to the top section of each of the beer columns. The beer is then stripped of ethanol in the main body of the columns. The bottoms product of the beer columns, or whole stillage, is routed to storage prior to being separated in the centrifuges (Area 5100). The ethanol vapor from the top of the beer columns is condensed and pumped to the rectifier column where it is concentrated to near the azeotropic point (95.5 % v/v). The concentrated ethanol is then fed to the dehydration system. The rectifier bottoms with minimal ethanol and volatile organics is returned to the front-end of the process. The distillation system has been integrated for maximum energy efficiency. The overheads from the rectifier column are used to provide heat to be the beer columns. The condensed vapor is then returned to the rectifier column as reflux. Product acidity is controlled by removing dissolved gases from the ethanol with a proprietary process. 4.6 Area 4300 - Dehydration
The final removal of water from the ethanol to produce fuel grade ethanol is achieved in a molecular sieve dehydration system. The molecular sieves work on the principle of selective adsorption in the vapor phase. In this case, water is adsorbed on the sieve bed material while ethanol passes through the bed. The adsorbed water is removed during a regeneration step and is routed back to the distillation system. Regeneration is achieved using a "pressure swing" system that requires virtually no external heat. The pressure swing is achieved with a vacuum system. Adsorption takes place under positive pressure while regeneration is accomplished under vacuum. 4.7 Area 4500 - Stillage Evaporators
Thin stillage from the centrifuges is collected in a surge tank prior to the evaporation system. Thin stillage is concentrated to a minimum concentration of 30 35% total solids to form condensed distillers solubles (CDS), commonly known as syrup. The syrup is stored in the syrup tank and then mixed with centrifuge cake prior to the DDGS dryers.
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Project 61141
The first effect of the evaporator is heated with steam from the boiler plant. Vapor from the first effect heats the second effect, the heat from the second effect heats the third effect and the heat from the third effect heats the fourth and last effect. The thin stillage and syrup tanks provide sufficient surge capacity so that the distillation system can continue to operate at the design rate during regular CIP cleaning of the evaporator system. 4.8 Area 5100 - Stillage Separation
The whole stillage from the bottom of the beer column is routed to the whole stillage tank before it is fed to the decanter centrifuges. The centrifuges remove over 70% of the suspended solids, and produce a cake with approximately 32% w/w total dry matter concentration, and a liquid centrate (thin stillage) with about 12% w/w total solids dry matter. The whole stillage tank provides sufficient residence time so that the distillation system can continue to operate at the design rate during regular maintenance of the centrifuge system. 4.9 Area 7600 - CIP System
In order to keep the process microbiologically clean and to remove residues from heat exchange equipment, tanks, and evaporators, a clean-in-place (CIP) system is provided. The cleaning process uses condensate from the process, thereby minimizing fresh water usage. Caustic is used as a cleaning agent for sanitizing and dissolving most of the residues. A caustic tank and a process condensate tank are provided. The process condensate tank collects condensate from the evaporators and the distillation system. The system includes flushing and CIP piping to all heat exchangers and tanks that require cleaning. Each tank is equipped with a permanently installed spray machine. Manual and automated isolation valves at each piece of equipment require the operator to set the valves properly before beginning the CIP procedure. Piping is included to allow flushing equipment with process condensate prior to beginning the caustic cleaning cycle.
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Project 61141
5.0
Non Process Description (OSBL)
The following summarizes the sections for the off-site process areas: 5.1 1100 5200 5300 6100 7700 Grain Receiving and Storage DDGS Drying DDGS Storage and Shipping Fuel Ethanol Storage and Shipping Chemical Storage
Area 1100 - Grain Receiving and Storage
Wheat will be received predominately by truck with rail as an alternative. Both systems will allow the wheat to be stored in two segregated bins. The required feedstock starch content will be achieved by proper blending of the wheat feedstocks. When trucks arrive at the site, the wheat is sampled and tested. If acceptable, the truck is weighed on a truck scale and allowed to unload. The truck will dump into the unloading pit. The wheat is removed from the pit by a conveyor and bucket elevator and spouted to the segregated storage bins by wheat type. Wheat is removed from the storage bins by a sweep auger and conveyed into a scalper that removes large items from the wheat such as straw, sticks, etc. Additional process equipment (to be determined) will be configured to remove metal, stones and other foreign materials. The wheat passing through the scalper is stored in a 200 metric ton wheat bin. The unloading and storage of whole wheat is a manual operation. 5.2 Area 5200 - DDGS Dryer
The centrifuge cake and the syrup from Area 5100 - Stillage Separation are mixed and fed to a high efficiency low NOX gas-fired dryer system consisting of two 60% capacity ring-flash dryers engineered and manufactured by The Barr Rosin Company. The DDGS dryer system is designed to dry 100% of the wet cake and syrup that is produced by the plant at design conditions. The system will produce DDGS with 90% w/w total solids dry matter content. A performance specification will be developed by Delta-T for this vendor-provided system. The dryer system will meet the emission requirements as defined by the approved permitting documents and appropriate environmental regulations. In each dryer, a mixer receives the wet cake as well as a portion of dry recycle to ensure good conditioning of the feed material. The feed would be homogenous and friable after leaving the mixer. The feed is metered into the disintegrator via a variable screw conveyor. Agglomerates are broken up prior to being dispersed by the high speed venturi where
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Project 61141
the feed encounters hot process gas as it travels to the drying column. Material is then centrifugally classified. The semi-dry material is returned to the disintegrator, and the dried product continues with the exhaust gas to a two-stage collection system. Primary collection will separate the coarse fraction that discharges through a screw conveyor and rotary valve. The exhaust gas and fine fraction would continue to highefficiency cyclones to separate the remaining product. The fine product also discharges through a separate screw conveyor and rotary valve. The exhaust from the cyclone is reheated by a direct fired natural gas burner. Hot DDGS from both dryers is cooled in a single fluid bed cooler. The cooler uses ambient air to reduce the temperature of the DDGS prior to storage. Warm air from the fluid bed cooler is recycled back to the dryers as combustion air. 5.3 Area 5300 - DDGS Storage and Shipping
DDGS is delivered from fluid bed cooler to the storage building, sized for 10 days capacity, via a conveyor. From the conveyor, a leg and distribution conveyor move the material to multiple piles. DDGS is stored on a flat slab on grade prior to loading into trucks or rail cars. Loading of the DDGS requires a front-end loader operator to move the material to a full length in floor conveyor then to a leg conveyor. The leg conveys the DDGS through a legal tender bulk scale and then to a rail car or truck. Both truck and rail siding loadouts will be located in the same shelter and under the same bridge to minimize wind losses. 5.4 WDGS Storage and Shipping
A wet cake pad will also be constructed outside the dryer building. This pad, a flat slab at grade, and is sized to accommodate 24 hours of wet cake from the centrifuges should a dryer be down for maintenance. The wet cake is manually recycled to the dryer. 5.5 Area 6100 - Fuel Ethanol Storage and Loading
Fuel ethanol is pumped to one of two day tanks each sized for 24 hours of production at design rate. The production rate of the ethanol from the distillation / dehydration system will be monitored with in-line instruments, while moisture content will be monitored with laboratory equipment from regularly scheduled samples. After the quality of the ethanol is confirmed, it is transferred to one of the two ethanol storage tanks. A blending system will be used to blend gasoline denaturant (at 1.0% v/v for the Canadian markets or up to 4.76% v/v for the US markets) from a denaturant storage tank into the ethanol as it is transferred to the product storage tanks. The product storage tanks will store 15 days of ethanol. The capability to add additional denaturant in-line before the rail car or truck loadout will be provided.
Terra Grain Fuels
Project 61141
If the ethanol does not meet specification, it will be transferred to the rectifying column for reworking or blending with on-spec product. A single off-spec ethanol pump will be provided to return off-spec product to the rectifying system, beer well, or to the fuel ethanol storage tank for blending. A loading system will be provided to allow the drivers to load their own trucks with minimal assistance from plant operators. One loading arm (1900 liters/min) will be provided with the ability to fill one truck every 30 minutes. Trucks will be bottom loaded. This same system will also be used to load railcars. Area 7700 - Chemical Storage Selected high use chemicals will be stored on site in bulk and distributed on site through dedicated piping systems. The sizing basis for all tanks is shown for reference in the chart in Attachment 13.
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Project 61141
6.0 Utilities The following descriptions of the utilities and auxiliaries areas highlight special features of the design as proposed. The key areas are as follows: 6.1 Area 7100 Cooling Water Area 7200 Steam and Steam Condensate Area 7300 Water Supply and Distribution Area 7500 Compressed Air Area 7800 Fire Protection Area 8100 Natural Gas Electrical Supply and Distribution Waste Water Treatment Process Effluent Sanitary Sewage Storm Water Solid Waste Disposal Area 7100: Cooling Water
An induced draft cooling tower will be provided. The final design will be determined through discussions with the supplier. The cooling water circulating capacity and cooling requirements for the process are identified in Attachment 4. The cooling tower design is to be based on an average return water temperature of 36.1 C (97 F) and a supply temperature of 25 C (77 F). The ASHRAE July 1% frequency for maximum wet bulb temperature will be used for the design basis (21 o C). Two 100 % or three 50% cooling water pumps will be provided based on the least cost option. No chiller will be provided. 6.2 Area 7200: Steam and Steam Condensate
Steam will be provided by two (2) package boilers fueled with natural gas. No alternative fuel source (such as propane) will be available at the site. The steam and condensate return requirements and conditions for the process are identified in Attachment 4. 6.3 Area 7300: Water Supply and Distribution
Configuration for this system is yet to be determined. See Attachment 4 for consumption data and Attachment 2 for required water quality. Water supply will be from the Buffalo Pound Reservoir.
Terra Grain Fuels
SYSTEM DESIGN SPECIFICATION 6.4 Area 7500: Compressed Air
Project 61141
Process air requirements for yeast propagation, fermentation and instrument air requirements to be set by Delta-T. Two, 100% air compressors will be provided for non-sterile air requirements and one air compressor for sterile air requirements. 6.5 Area 7800: Fire Protection
Configuration for this system is yet to be determined. An allowance will be factored into the EPC bid until code requirements are finalized. In general, the plant will require sprinklers in the main process building, and foam protection in the DD structure. A fire water pond (size to be determined) is provided in the scope and will be designed to provide adequate surge space for site fire fighting requirements. The fire water pond will receive boiler blow down as well as the concentrate streams from the ultra, nano and RO water treatment systems. 6.6 Area 8100: Natural Gas
Configuration for gas supply to the site will be coordinated by Terra Grain Fuels. See Attachment 4 for consumption data. 6.7 Electrical Supply and Distribution
Terra Grain Fuels will provide a 138kV incoming feeder, substation, 138kV- 4160V transformer, and switchgear and 575V, 220V and 120V transformers to all users. Power distribution will be procured by Terra Grain Fuels. A partial load backup generator is included in the scope. The need for a full backup system will be based on the power grid reliability data. Power factor correction will be employed. 6.8 Waste Water Treatment
Waste water will be generated from the ultra, nano and RO water systems as concentrates. These concentrate streams will be routed to the fire water pond and then to Mosaic. 6.9 Process Effluent
All effluent generated by the process units, over and above what is directly recycled to the process, will be directed to the water collection tank (in scope) or firewater pond as appropriate. Material from the water collection tank will be recycled into the process at an appropriate flow rate.
Terra Grain Fuels
SYSTEM DESIGN SPECIFICATION 6.10 Sanitary Sewage
Project 61141
Sanitary sewer services such as a septic system will entail staff wash rooms in the administration and the main process building designed for approximately 40 people. The septic system will be maintained by Terra Grain Fuels. 6.11 Storm Water The grading plan and permits are the responsibility of Terra Grain Fuels. 6.12 Solid Waste Disposal Configuration for this system will be by Terra Grain Fuels. The trash material from the wheat scalper will produce approximately 12 metric tons per day of solid waste (assumes a trash level in the wheat at 1% by weight). Trash levels in the wheat will vary and can approach levels as high as 8% by weight.
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7.0 General Design Guidelines The plant shall be designed for continuous operation (24 hours /day, 7 days /week) and shall be designed to meet the production requirements based on operating 350 days per year. All equipment must be capable of reaching and maintaining design performance and throughput upon mechanical completion. In addition, careful consideration must be given to operability and safety during normal operations, startup, shut down, and emergency conditions. Design assumes a single major shutdown for seven (7) days and multiple day or part-day shutdowns to achieve 15 days of planned maintenance. Unit design should allow for as much routine maintenance and inspection as possible to be carried out on the run or during scheduled down times. Uniform piping and instrumentation arrangements shall be used around similar items of equipment to facilitate operation and maintenance. Maximum use shall be made of heat exchange between process streams within the units. Additional cooling will be with closed circuit cooling water loops. 7.1 Plant Staffing
The plant will staff sufficient operators to start up and shut down the process, receive wheat, monitor process controls, perform single analysis, troubleshoot process upsets, perform CIP and other cleaning, perform preventative maintenance, and load DDGS. Plant organization will be by Terra Grain Fuels. Delta-T estimates that the facility will employ approximately 37 people. 7.2 Plant and Buildings
A site layout will be developed jointly between Delta-T and Terra Grain Fuels. Delta-T will provide the optimum configuration for reducing capital and operating cost while maintaining operational flexibility. Terra Grain Fuels will adjust site configuration according to specific site restrictions and permitting requirements. The following is a list of buildings and structures located on the plant: Administration Cleaning and milling Main process including the control room (MPB) Maintenance shop Utility Dryers DDGS Storage Evaporators Fermentation Distillation and dehydration (DD) Product storage Cooling tower pump house Fire water pump house
Delta-T Project Services - Confidential Copyright 2003 Delta-T Corporation. All rights reserved. Page 23 of 43 Rev 0 15NOV2006
Terra Grain Fuels
SYSTEM DESIGN SPECIFICATION 7.3 Spare Equipment and Capacity
Project 61141
In general, spare equipment will be limited to critical applications unless the specific stand-by equipment can be justified by one of the following: Employee Safety. Required to achieve annual production capacity. Prevent damage to plant equipment.
For the purpose of this design basis, only the following process equipment is considered to have installed stand-by spare equipment: Yeast propagation heat exchangers Cooling water pumps Air compressors Hammer mills
Purchase of warehouse spares will be Terra Grain Fuels responsibility. The purchase of the spare parts will be coordinated with the vendors at the time of the equipment purchase. 7.4 Platforms, Stairs and Ladders
In order to provide a safe and adequate work area for operating and maintenance technicians, fixed platforms will be provided in the area of any piece of equipment in accordance with OSHA and/or Canadian requirements. These platforms will be provided with proper handrails and kick plates, and will meet all requirements of the appropriate safety regulations. As a general rule, stairs will be provided to all elevated platforms where operating and maintenance requirements dictate regular access. Regular access shall mean a frequency of at least once per week, or where the personnel are required to carry tools, sample bottles, or anything else that would impede their ability to climb a ladder. Otherwise, ladder access in conformance with applicable safety regulations and design guidelines can be used. Access will be provided to elevated platforms by means of a ladder when infrequent or very irregular access is required, or where space requirements make stairs impractical. All cases of ladder access will be examined and approved on an individual basis. 7.5 Control Room
Configuration for this system will be recommended by Delta-T.
Terra Grain Fuels
SYSTEM DESIGN SPECIFICATION 7.6 Control System Philosophy
Project 61141
Delta-T will provide all programming and a written control narrative identifying functional process operation control requirements. Delta-T will supply a field-bus control system installation. Field-bus technology allows for a lower total installed cost of both control system and instrumentation. It also allows for easier plant commissioning, reconfiguration, maintenance, and troubleshooting. The control system supplier will be selected during the design phase. 7.7 Control Valve Design Control valves will be designed for a turndown of up to 50%. Maximum flow rate will be set at 20% above the normal operating process flow rate. 7.8 Site Conditions
Terra Grain Fuels will supply this information. Conditions are shown in Attachment 1. 7.9 Physical/Thermodynamic Properties
Delta-T will identify physical and thermodynamic properties for the on-site process units. Physical data for wheat, DDGS, and syrup will be based on empirical experience from Delta-T and data provided by Terra Grain Fuels. 7.10 Winterization Equipment and piping will be winterized to minimize interruption of operation or failure due to the effects of low ambient temperature during winter operation. Indicated below are methods for winterizing that may be considered: Insulation. Electric tracing. Heated enclosure or housing. Maintaining a minimum flow. Careful planning of piping layout to eliminate dead legs or low points. Draining or flushing where problems exist during shutdown.
Insulation and electric tracing scope will be based on site conditions and Delta-T design. Low ambient temperature will be based on environmental conditions at site. 7.11 Materials of Construction Delta-T will select process and utility materials. 304 SS and carbon steel are the predominant materials of construction. Delta-T will determine the need to label and/or paint pipe based on the contents. 7.12 Minimum Design Metal Temperature Delta-T shall determine equipment minimum design metal temperature at coincident pressure per the requirements of ASME Section VIII Division 1 (Division 2 for Div. 2 vessels and exchangers). The exemption per Division 1, par. UG-20 (f) is not
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Project 61141
allowed. This exemption states that impact testing is not mandatory for pressure vessel materials which satisfy a list of criteria detailed in Division 1. Similar checks should be made for start-up, shut down, operational upset conditions, and any other sources of cooling. Delta-T shall also take into account internal linings, such as refractory, that will prevent normal warm-up procedures. The minimum design metal temperature (MDMT) also affects hydro test temperatures, especially if the hydro test occurs in the field during normal maintenance shutdown. 7.13 Operating Range The on-site facility will be designed for effective operation at rates down to a minimum of 50% and up to a maximum of 120% of the steady state nominal flow rate. Equipment in the off sites and utility sections will be designed to support this operation. Delta-T will specify capacity safety factors for on-site equipment. Capacity safety factors for equipment in the offsites and utilities sections will be specified according to industry design practice. 7.14 Relief and Blowdown Configuration for this system will be by Delta-T and will conform to local codes. 7.15 Instrumentation All instrumentation necessary to operate, monitor, and troubleshoot the process will be specified by Delta-T. All temperature indicators and sensors located in pipelines, tanks, or vessels will be equipped with thermowells to isolate the sensor from the process fluid. All pressure indicators and sensors located in severe services will be equipped with diaphragm seals to isolate the sensor from those process fluids that will affect the instrument. 7.16 Engineering Drawings Drawings will be generated with intelligent based AutoCAD, minimum release 2000 format. Delta-T will use Rebis plant modeling software to generate 3D plant models, piping isometrics, and bills of materials. As-built P&IDs will be provided upon completion of the performance test. 7.17 Equipment Life Equipment will be specified to meet industry standards for ultimate life and reliability given a program of preventive maintenance is used and the equipment is operated within the manufacturers guidelines. 7.18 Paving and Parking Configuration for this system will be by Terra Grain Fuels.
Terra Grain Fuels
SYSTEM DESIGN SPECIFICATION 7.19 Safety Showers
Project 61141
Configuration for this system will be by Delta-T and will conform to local codes. 7.20 Utility Stations Configuration for this system will be by Delta-T and will conform to local codes. 7.21 Lighting Configuration for this system will be Terra Grain Fuels and will conform to local codes.
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Project 61141
8.0 Environmental and Safety Considerations 8.1 Atmospheric Emissions
Atmospheric emissions will be in compliance with the data provided by Delta-T, and included in the environmental Certificate of Approval application. 8.2 Water Supply
Process and potable water will be supplied from the local Municipality, with the water analysis to be provided by Terra Grain Fuels. Terra Grain Fuels will obtain firewater from the on-site firewater pond. 8.3 Effluent Discharge
See Sections 6.9 and 6.10. 8.4 Noise
Equipment will be specified to obtain a minimum noise level when ever possible (82 db). 8.5 Containment of Spills
Configuration for this system will be by Delta-T according to local and national code. In general, tanks within a building will not be diked unless a barrier is required to prevent a spontaneous chemical reaction. Outside ethanol storage tanks will be diked to hold 110% of the largest tank. 8.6 Solid Waste
No system design is required. 8.7 Odor
Odor from the process is contained via a vent scrubber and by maintaining low dryer temperatures. 8.8 Site Drainage
Configuration for this system will be by Terra Grain Fuels.
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Project 61141
ATTACHMENT 1 Site Conditions

Location Site Elevation (above sea level) Extreme Minimum Design Temperature Extreme Maximum Design Temperature 1.0% Summer Wet Bulb Temperature Average Atmospheric pressure Average Annual Wind Direction Average wind speed Maximum hourly wind speed Maximum gust wind speed Average Annual Precipitation Ground Snow Load Extreme daily snowfall Extreme snow depth Seismic Data Za Zv Zonal Velocity Ratio, v Belle Plaine, Saskatchewan 577 m - 45.6 C 41.7 C 21 C 94.7 KPa West 17.7 km / hr 109 km / hr 138 km / hr 365.1 mm 27.2 mm 48 cm 0 0 0
Terra Grain Fuels
SYSTEM DESIGN SPECIFICATION ATTACHMENT 2 Fresh Water Analysis
Project 61141
Incoming Water (to be verified Terra Grain Fuels)
Delta T Process Water Specification
pH Specific Conductance, at 25C, umhos Alkalinity, P as CaCO3, ppm Alkalinity, M as CaCO3, ppm Hardness, Total, as CaCO3, ppm Calcium Hardness, total, as CaCO3, ppm Magnesium Hardness, Total, as CaCO3, ppm Barium, as Ba, ppm Calcium, as Ca, ppm Chromium, Cr, ppm Copper, as CU, ppm Iron, as Fe, ppm Lead, as Pb Lithium, as Li Magnesium, as Mg, ppm Manganese, as Mn, ppm Nickel, as Ni, ppm Potassium, as K, ppm Sodium, as Na, ppm Strontium, as Sr, ppm Zinc, as Zn, ppm Chloride, as Cl, ppm Chlorate, as ClO4, ppm Fluoride, as F, ppm Phosphorus, as P, ppm Sulfate and Sulfite, ppm Sulfur, Total, as SO4, ppm Silica, Total, as SiO2, ppm
7.5 8.6
6.5 8.5
115 - 207 143 - 255
<150 mg/l
28 - 58
<0.01 mg/l <125 mg/l <1 mg/l <1 mg/l <0.01 mg/l <25 mg/l <1 mg/l <10 mg/l <20 mg/l
0 0.02
17 - 27 0 0.02 3.2 4.8 32 - 51
9.8 16.5
<50 mg/l
86 - 134
<20 mg/l <250 mg/l
0.1 3.2
<10 mg/l
Terra Grain Fuels
SYSTEM DESIGN SPECIFICATION ATTACHMENT 3 Design Codes & Standards
Project 61141
Unless specifically noted to the contrary, the design specifications for the process and the Plant shall conform to the Canadian equivalents of the applicable sections and parts of the codes and standards set forth below, including the most recent revisions and supplements at the time of the execution of the Technology, Engineering, and Procurement Services Agreement. In addition, all appropriate components shall carry the necessary CRN registration. Applicable Category Applicable Standards: Building Codes: Cable Marking: Concrete: Corrosion: Electrical/Instrumentation: Design Code/Guideline Federal, Local, OSHA, Air quality, ANSI NRC-CNRC (Canadian National Building Code) ICEA (Insulated Cable Engineers Association) ACI (American Concrete Institute) NACE (National Association of Corrosion Engineers) NEMA (National Electrical Manufacturers Assoc) NEC (National Electrical Code) ISA (Instrument Society of America) CSA (Canadian Standards Association) EEMAC (Electrical & Electronic Manufacturing Association Canada) IEEE (Institute of Electrical and Electronic Engineers) ICEA (Industrial Cable Engineers Association) OESC (Ontario Electrical Safety Code) FCI (Fluid Control Institute) Electrical Components: Flanges: Fire Protection Heat Exchanger: Nuts, Bolts, Fittings & Line Components: Painting: Personnel Safety: Piping, pumps: Structural Steel: Tanks UL (Underwriters Laboratories) ULC (Underwriters Laboratories Canada) ANSI standard NFPA TEMA (Tubular Exchanger Manufacturers Association) ASTM (American Society of Testing Materials) SAE (Society of Automotive Engineers) SSPC (Steel Structure Painting Council) OSHA (Occupational Safety and Health Association) ANSI (American National Standards Institute) AISC (American Institute of Steel Construction) API (American Petroleum Institute)
Terra Grain Fuels

Valves and Fittings: Vessels (Where required):
Project 61141
MSS (Manufacturers Standardization Society) ASME (American Society of Mechanical Engineers) TSSA (Technical Standards and Safety Authority) Saskatchewan Regulation 262/67 - Design, Construction, Installation and Use of Boilers and Pressure Vessels
Welding: Miscellaneous:
AWS (American Welding Society) CWB (Canadian Welding Bureau) ASTM (American Society for Testing and Materials)
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Project 61141
ATTACHMENT 4 Process Production and Utility Consumption Summary Preliminary Material Balance
Inputs Description Wheat Fresh Water Aqua Ammomia Alpha-Amylase / Beta Glucanase Gluco-Amylase Sulfuric Acid (98%) Urea (50%) Yeast kg/hr 48,510 33,872 275 46 52 49 19 4 Outputs Description Fuel Ethanol (Anhydrous UDA) DDGS Total CO2 incl. water vapor DDGS Dryer Stack Vapor and Yield Losses kg/hr 14,070 19,465 13,930 35,362
Preliminary Utilities Required

Plant Total Steam @ 690 kPag Minimum (kg/hr): At Design Conditions At Maximum Conditions Condensate Header (kPag) Total Plant Electricity @120 /220 / 575 VAC (kW hr/litre) Header Operating Pressure Operating Installed Cooling Tower Circulation Water (m3/hr) 55,000 72,800 69 0.34 0.58
At Design Conditions At Maximum Conditions
3,140 3,770
3 Water Demand @ 15 C (m /hr)
93 126
Makeup Water for Cooling Tower, Boiler, and Miscellaneous uses (m3/hr)
59 82
Compressed Air (SCMH), dry @ 860 kPag Min.
At Maximum Conditions
1,120
Natural Gas (GJ/hr)

61141 System Design Specification Rev 0.doc Delta-T Project Services - Confidential Copyright 2003 Delta-T Corporation. All rights reserved.
Boiler at Max Conditions Dryer at Max Conditions
194
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131
ATTACHMENT 5 FLOUR SPECIFICATION
Fraction # 1 2 3 4 5
U.S. Standard Sieve # Retained on # 14 Retained on # 16 Retained on # 18 Passing #20, Retained on #60 Pan
Particle Size Over 1400 micron Over 1200 microns Over 840 micron Between 840 and 250 micron Under 250 micron
Specification 0.0% 0.0% 15% 65% 15% Maximum Maximum Maximum Minimum Maximum
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Project 61141
ATTACHMENT 6 ELECTRICAL VOLTAGE AND AREA CLASSIFICATION
Chart A: Voltage Drivers Above 250 Above 3/4 / below 250 Up to 3/4 HP Lighting Instruments Voltage 4160 575 120 220 120 or 24 v DC Phase 3 3 1 1 1
Chart B: Electrical Area Classifications Process Area Grain Receiving & Storage Milling Starch Conversion Fermentation, incl. CO2 scrubbing Ethanol Distillation, dehydration Evaporation Stillage Handling & Storage DDGS Drying & Decanting Clean-in-Place DDGS Flat Storage Ethanol and Denaturant Storage Ethanol Storage Tank Vents (1 meter only) Chemical Storage Ammonia Storage Ammonia Storage Tank Vent (1 meter only) Ethanol Load-out Systems Utility
To be Reviewed and Confirmed Electrical Classification Class 2 Div. 2 Gr. G Class 2 Div. 2 Gr. G General Purpose General Purpose Class I Div. 2 Gr. D General Purpose General Purpose General Purpose General Purpose Class 2 Div. 2 Gr. G Class 1 Div. 2 Gr. D Class 1, Div 1, Gr. D General Purpose Class 1 Div. 2 Gr. D Class 1, Div 1, Gr. D Class 1 Div. 2 Gr. D General Purpose
The above table represents a general description of the area classifications anticipated in this facility. A detailed analysis of all plant areas shall be conducted by a licensed electrical engineer to insure adherence to all applicable codes and standards.
Terra Grain Fuels
SYSTEM DESIGN SPECIFICATION ATTACHMENT 6 (continued)
Project 61141
Hazardous (Classified) Location in Accordance with Article 500, National Electrical Code Class I Combustible material in the form of a gas vapor. Class II Combustible material in the form of a dust. Class III Combustible material in the form of a fiber, such as a textile flyings. The Group sub-divides the Class: Division 1 locations are those places where ignitable concentrations of flammable gases or vapors exist Group A Atmosphere containing acetylene. under normal conditions, or may frequently exist because of leakage or maintenance operations or Group B Atmospheres containing hydrogen, where malfunctions may release ignitable vapors and gases or vapors of equivalent simultaneously cause failure of hazards, electrical equipment. such as manufactured gas. Division 2 Group C Atmospheres containing ethyl ether locations are those where vapors, ethylene or cyclopropane. flammable liquids or gases are present but are normally confined and can escape only through Group D Atmospheres containing gasoline, accident or abnormal operation. hexane, naphtha, benzene, butane, Also included are areas made safe propane, alcohol, acetone, benzol, by mechanical ventilation, but lacquer, solvent vapors, or natural might become hazardous because of failure or abnormal operation of gas. the equipment. A third division 2 situation is an area adjacent to a Group E Division 1 location where ignitable Atmospheres containing metal concentrations of gas or vapor dust, including magnesium and their commercial alloys, and other might be occasionally communicated. metals of similarly hazardous characteristics. Note: The Division defines the probability Group F of an explosive mixture being Atmospheres containing carbon present (e.g. A hazardous mixture black coal or coke dust. is normally present in a Division 1 area, Group G but will only be accidentally present Atmospheres containing flour, in a Division 2 area. starch or grain dust.
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Project 61141
ATTACHMENT 7 EQUIPMENT NUMBERING

The following standard format will be used for equipment identification on all project drawings and documentation:
AG-1301A M
Where: AG 13 01 A M Equipment Abbreviation (from the following chart) Area Number (from Section 4, first two characters only) Sequence Number Optional - Unit Identifier (for multiple units) Optional - Auxiliary Equipment Identifier (eg. motor)
Equipment Designation Abbreviations AC AG AL B BD BE BH BL BN C CF CH CHR CN CP CS CT CY DA DC DR DV E F FA Air Compressor Agitator Airlock Boiler Building Bucket Elevator Bag house Blower Bin Column Centrifuge Chute Chiller Crane Control Panel Classifier Strainer Cooling Tower Cyclone Deaerator Dust Collector Dryer Diverter Valve Exchanger Filter Fan FL GC HM M ME PM PC RV S SA SC SG SP SR ST SU T TK TR VE VS Y Flare Graduated Cylinder Hammer mill Motor, Electric Miscellaneous Equipment Metering Pump Centrifugal Pump Rotary valve Stack, Chimney Sampler Scale, Weighing or Measuring Gate, Slide Sparger Screen Strainer Sump Turbine Tank, Silo, Hopper Trap Vacuum Eductor Vessel, Drum, Sphere, Bullet Conveyor
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Project 61141
ATTACHMENT 8 LINE NUMBERING SYSTEM

The following format will be used for line numbering on all project drawings and documentation:
6" - WW - XXXX - YY - CS1 T"Z

Where: 6" WW XXXX YY CS1 T" Z Line Size (in inches) Service (from the following Table) PID Number Line Sequence Number Material Specification (from the following Table) Insulation Thickness, inches Insulation Function Heat Tracing Symbol From following table
Insulation and Heat Tracing Symbols A C E H P Acoustic Cold Electrically Traced Heat Conservation Insulated for Personnel Protection (safety) Material Specification Abbreviations CS1 CS2 SS1 CU PVC FH C20 Carbon Steel - Boiler Carbon Steel Stainless Steel Copper PVC or CPVC Flexible Hose Carpenter 20
Line Commodity Designations AD AL AV AP CF CI CW DN FS IA MA OT PC PV PW SA SC SL ST WW Denatured Alcohol Alcohol Liquid Alcohol Vapor Alcohol Product Chemical Feed (all services) Clean in Place Cooling Water & Chilled Water Denaturant Fuel Service Instrument Air Mash Other Process Condensate Process Vent Process Water Service Air Steam Condensate Stillage Steam Supply Waste Water
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Project 61141
ATTACHMENT 9 PROCESS UNIT IDENTIFICATION NUMBER

Process Unit Identification Number 1000 1100 1200 2100 2200 2300 3100 3200 4100 4200 4300 4400 4500 4600 5100 5200 5300 6100 7100 7200 7300 7500 7600 7700 7800 7900 8100 Description General Identifier (used for Standard Drawings) Grain Receiving & Storage Grain Handling & Milling Mash Preparation Mash Liquefaction & Cook Heat Recovery Yeast Propagation & Fermentation CO2 System Distillation, Beer Distillation, Rectifier & Stripper Dehydration Acid Reduction Evaporation Syrup Separation & Stillage Dryer DDGS Storage & Load out Ethanol Storage & Load out Cooling Water Steam & Condensate Water Supply & Distribution Compressed Air Process Condensate and CIP System Chemical Storage Fire Protection Waste Water Natural Gas and Propane
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Project 61141
ATTACHMENT 10 INSTRUMENT & VALVE IDENTIFICATION

A typical instrument tag number consists of three parts Process unit identification number Tag identification letters Loop number This format is illustrated below: Instrument Tag format: where:
XXXX 1122 A
XXXX ISA Instrument Identification (per ISA S5.1) 11 Area Identification (plant/area/unit) 22 Sequential number A Multiple Identifier (A-Z) Assigning instrument tag numbers will be the Delta-Ts responsibility, with approval of client. Instrument symbols and nomenclature on P&ID's are derived from the Instrument Society of America (ISA) Standards. The following are notes and general guidelines that reflect preferences for assigning instrument tag numbers. This information is not all encompassing nor does it cover every possible situation. For those situations that are not covered specifically, or where there are questions about the appropriate Tag number(s), client will be consulted.
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ATTACHMENT 11 DRAWING NUMBERING SYSTEM

This document describes the numbering system to be used for identification of all drawings and sketches for this project. All drawings will have a unique number in the following format:
AAA - BBB 1234

Where: AAA BB 12 34 Project number (optional) Drawing type, Engineering Identification according to the following table Unit Number (from Attachment 9 first two characters only) Sequential drawing number within the process area
Drawing Type Abbreviations Engineering Drawings A Drawing Index and Legend B Buildings C Civil E Electrical F Fire Protection GA General Arrangements I Instrumentation ISO Piping Isometrics L Equipment Arrangement P Piping PFD Process Flow Drawing PI Piping and Instrumentation Drawing Q Equipment Details SF Structural / Foundations SS Structural / Steel UFD Utility Flow Drawing Piping Isometric Drawing Format Sketches BSK CSK ESK FSK ISK LSK PSK QSK SSK Buildings Sketch Civil Sketch Electrical Sketch Fire Protection Sketch Instrumentation Sketch Equipment Arrangement Sketch Piping Sketch Equipment Sketch Structural Sketch
AAA - BBB - ## - XX-YYYYY

Where: AAA BBB ## XX YYYYY Project number (optional) Drawing type, according to the following table Unit Number (from Attachment 9, first two characters only) Fluid Service P&ID Sequential Line Number
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Project 61141
ATTACHMENT 12 UNITS OF MEASURE

The SI system of units will be used for all documentation. In general, the units of measure for the project will be based on the table below: Unit Area Density Flange rating Flange size Fouling factor Heat exchanger duty Heat flux Heat input per volume Heat transfer coefficient Latent heat Length Liquid holding capacity Mass Molecular weight Power Pressure, absolute Pressure, differential Pressure, gage Rate, liquid flow Rate, mass flow Rate, vapor flow Specific heat (Cp) Surface Tension Temperature Thermal conductivity Velocity Viscosity, dynamic Viscosity, kinematic Volume Description Square meters Kilograms per cubic meter Pounds per square inch Inches Square meters Kelvin per Watt Gigajoules per hour Watts per square meter Gigajoules per litre Watts per square meter per Kelvin Kilojoules per kilogram Meters or millimeters Liters or cubic meters Kilograms Moles Kilowatts Kilopascals, Bar* Kilopascals, Bar* Kilopascals, Bar* Litres per minute Cubic meters per hour Kilograms per hour Standard cubic meters per hour Kilojoules per kilogram - Kelvin Dynes per centimeter Degrees Celsius Watts per meter - Kelvin Meters per second Centipoises Centistokes Liters or cubic meters Abbreviation m2 kg / m3 psi in 2 m K/W GJ / hr W / m2 GJ / L W / m2 K kJ / kg m, or mm L, or m3 kg mol kW kPa(a), Bar(a)* kPa, Bar* kPa(g), Bar(g)* L / min m3 / hrkg / hr SCMH kJ / kg K Dyne/cm C W/mK m/s CP CSt L, or m3
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Project 61141
ATTACHMENT 13 STORAGE TANKS DESIGN CRITERIA AND CAPACITIES
Storage Tank TK-2101 Slurry Mix Tank #1 TK-2102 Slurry Mix Tank #2 TK-2201 Liquefaction Tank TK-3101 Yeast Mix Tank TK-3102 Yeast Propagation Tank TK-3104,05,06 and 07 Fermenters (4) TK-3108 Beer Well TK-5101 Thin Stillage Collection Tank TK-5102 Whole Stillage Tank TK-5103 Thin Stillage Tank TK-5104 Syrup Storage Tank TK-6101, 02 Ethanol Day Tanks (2) TK-6104 Denaturant Tank TK-6105,06 Product Storage Tank (2) TK-7601 Process Condensate Tank TK-7602 Dilute Caustic Tank TK-7701 Caustic Tank TK-7702 Sulfuric Acid Tank TK-7704 Ammonium Hydroxide Tank TK-7705 Urea Tank TK-7706 Alpha Amylase Tank TK-7707 Gluco Amylase Tank TK-7708 Beta Gluconase Tank TK-7901 Waste Water Tank
Design Criteria Retention Times or Capacity Minutes 30 Minutes 30 Minutes 90 Hours Hours (each) Times the size of the Fermenters Minutes Hours Hours Hours Hours (each) Days Days (each) Hours CIP rate Fermenters on 8 50 1.3 5 12 12 24 24 5 7.5 12
Capacities Gallons Liters 27.500 104,090 27,500 104,090 77,900 294,850 840 3,180 131,600 498,100 718,600 2,719,900 850,000 1750 423,900 274,200 183,800 158,900 29,100 970,000 396,500 47,600 10,000 10,000 32,300 10,000 8,000 8,000 8,000 27,400 3,217,400 6,625 1,604,400 1,037,850 695,700 601,440 110,000 3,671,850 1,500,750 180,200 37,850 37,850 122,260 37,850 30,280 30,280 30,280 103,700

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