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SECTION 1: BIODIESEL PRODUCTION SYSTEM DESCRIPTION Process Flow Description The basic process for any catalyst induced transesterification process involves migrating ester chains from a triglyceride molecule, and reconnecting the ester chains with a methanol or ethanol molecule, thus creating a methyl ester molecule. It is this methyl ester molecule that is Biodiesel. Various chemical and mechanical actions work together to make the transesterification process occur. The catalyst used is a strong base, either sodium or potassium. Once the ester chains are broken off, the left over glycerin molecule is a byproduct of the reaction. The mass balance is shown under Section 4. 1. Raw materials holding tanks: (not included) a. Vegetable feedstock, (soy, rapeseed, etc.) b. The second feedstock tank (optional) contains blending oil, (rendered fats, waste cooking oil, or other suitable material). This tank may also be used to store a secondary vegetable oil. c. Catalyst or methoxide can be either potassium or sodium and is mixed with methanol forming a methylate. In case a catalyst mixing station is used, there is no methylate tank. d. Methanol 2. Centrifuge and Blending Module: (optional) The system can process two or more feedstock of similar or dissimilar acid values, by using the optional blending module. The combined acid value must be <= 5. Acid value is an indicator for FFA (free fatty acid) level. FFA is approximately 50% of acid value. For example, this combination would be used when working with a combination of soybean oil and chicken fat. 3. Catalyst mixing station: Just below the methanol tank is the methanol-catalyst mixing station. The catalyst (concentrated methoxide solution) is obtained by mixing the potassium hydroxide fed into a tank with methanol at low temperature conditions. 4. Dosing Module: It is at this station that the concentrated methoxide solution is blended with methanol to the exact proportions needed for the specific process recipe. Metering is done via closed loop control from the computer module. Process parameters and real time feedback are available on the computer control screen where operators can monitor flow rates at any given moment. Dosing ratios are metered using mass flow meters that are keyed into the mass of feedstock entering the system. 5. Drying Station: (optional) Water has been described as the bane of the Biodiesel industry. It causes soap to be formed in the transesterification process, and also causes the finished fuel to be unstable. The Greenline process in totally waterless, and to further deter any moisture contamination, Greenline may use a drying station. The drying station, following the line from the blending unit, re-circulates and heats the oil under vacuum to remove any residual moisture in the incoming feedstock. 6. First Pass Transesterification Reactor: Immediately after the drying station the dosing mix of methanol and catalyst enter a special mixing tube and then enter the reactor. Our system features a two stage transesterification process which accelerates conversion efficiency and maximizes yield. Approximately 90% of the feedstock oil is transesterified in the first pass. With other Biodiesel processes there is always a trade off between quality fuel and increased throughput. With the Greenline dual station transesterification process there is no trade off or sacrifice of fuel quality for throughput. The secret involves the proprietary reaction tank design, and in the cutting of the fuel after the first transesterification reactor. The result is high throughput and high quality fuel. 7. Glycerin Removal: Initial separation of glycerin from product stream is done using a settling tank. It is located directly after the first reaction station. The glycerin is then pumped to the glycerin storage tank. Glycerin contains methanol. This helps to keep the glycerin liquid as ambient temperatures drop. 8. Second Pass Transesterification Reactor: Immediately after the glycerin removal station the second dosing mix of methanol and catalyst enter a special mixing tube and then enter the reactor. This mix is a slightly different mixture of catalyst. All metering is computer controlled. The second pass reactor further pushes the reaction enabling the process to fully react any remaining mono-, di-, or triglycerides. 9. Glycerin Removal / Settling Tanks: This step sends the product mix on to settling tanks after second pass reactor. Trace amounts of biodiesel and catalyst, and the remaining methanol are carried away with the glycerin byproduct to the glycerin holding tank in the upper right area of the diagram. 10. Ion Exchange Waterless Wash: Following the settling tanks, the biodiesel moves to the ion exchange towers. One of the principal reasons many customers choose the Greenline system is the waterless wash. Greenline pioneered the waterless wash in collaboration with the Rohm & Haas Corporation to create a unique active ion resin material known as Amberlite. This material was specifically designed to work with the Greenline system. Greenline has expended a great amount of research and development in our collaboration with Rohm & Haas and their extensive experience in ion technology, to create our proprietary purification system. Amberlite resembles coffee grounds and functions much like coffee grounds in a percolator. The biodiesel stream enters the top of the percolator and trickles down through the cylinder of Amberlite. The active Ion material on the Amberlite reacts with the unwanted material in the biodiesel. The chemical reaction renders the catalyst neutral, and the resultant material attaches itself to the Amberlite, thus removing it completely from the fuel. The final product is pure and absolutely dry. The Amberlite needs replacing at the rate of about 1 kg for every 1 metric ton of biodiesel processed. Once its lifespan is over, Amberlite is neutral, and non-toxic. It is not a hazardous waste, and may be used as landfill. The Amberlite can be changed without shutting down the process. Tanks are arranged in a configurable series and may be serviced with out shutting down the process. 11. Resin Polish Filter: The polishing filter removes any particles that may have passed through the ion exchanger. Various levels of particulate filters are available. Filters are configured such that filter elements can be changed with out shutting down the process. 12. Methanol Recovery: Following the polish module, the product stream enters the methanol recovery unit. This unit heats the oil to over 100°C while under vacuum. The oil then filters down over heated dispersion plates to facilitate removal of methanol. Recovered methanol is then routed back to the main methanol storage unit. 13. Polish Filter: The polishing filter removes any extremely fine particles that may have passed through the processor. Various levels of particulate filters are available. Filters are configured such that filter elements can be changed with out shutting down the process. 14. Methanol removal from glycerin: (optional) The separated glycerin is a mixture of glycerol, methanol, FFA and catalyst. The methanol content can be as high as 15% of the glycerin by weight, and makes the glycerin liquid. In order to avoid the losses of selling methanol at the lower glycerin value, and to reduce environmental or safety hazard, it may be useful to reduce the methanol content in the glycerin to below 10%, and recycle it into the processing. The glycerin will still be liquid. 15. Storage Tanks: Following the methanol recovery, the biodiesel is ready for sale or storage. Typical parameters for storage require the fuel to be kept at temperatures above 3°C. Biodiesel should not be stored for more than six months prior to use. Nitrogen blankets may be used to help protect your finished product. Heated tanks may be necessary if fuel is to be stored for any length of time in climates colder than 3°C. SECTION 2 SUPERVISORY SERVICES 2.01 The price mentioned under "Quotation" includes provision for supervisory services to supervise the erection, assembly and start-up of the specified plant for a maximum period-volume of: All Sections: 80 man days (see Note below) All expenses incurred beyond this period-volume will be charged to the Buyer at the daily rate of € 625,- per man day. 2.02 All the hours spent by the Seller's engineers will be noted in a log book that will be kept at the Buyer's disposal. 2.03 This supervision to include the training of the Buyers experienced personnel in the specific operation and safety aspects of the Seller's plant. 2.04 The above rates are for services rendered within 18 months from signing of Contract. 2.05 The price quoted for these services excludes the following, which shall be to the Buyers account: a. All airline tickets if required. b. All travel within the country of the installation if required. c. All local living expenses. d. Accommodation in a suitable hotel or furnished accommodation including the provision of all food, (three meals per day) heating, air conditioning, laundry etc. e. Any taxes which may be levied within the country of the site whether this charge be on a personal or company basis. 2.06 The stipulations under this Section 2 refer to the "Conditions of Site Engineering Services" (GLI/320) attached to this proposal. 2.07 The supervisory services are executed whether or not the Buyer chooses to execute the on-site assembly of the Processor, as described under Section 3, by himself or has it executed by the Seller. 2.08 Note: i. The period from beginning of installation to a fully commissioned operating plant will be approximately three (3) months depending upon local factors such as labor quality, weather conditions and availability of construction equipment. ii. Additional man-days can be supplied at the daily rate applicable at the time of the request if after Contract signing. SECTION 3 ON-SITE PROCESSOR ASSEMBLY This service is optional. The following tasks are executed by and the following responsibilities are carried by either the Buyer if the On-Site Processor Assembly is contracted, or by the Seller if it is not. 1. On-site unpacking and storing of the delivered processor equipment, installations, components, parts, supplies and assembly material, tools and equipment. 2. Placement, fastening and fixing of all components on their precise final place in the processor building. 3. All erection, construction, welding, connection, and mounting work related to the complete assembly of the processor, including piping and wiring within the processor and up to the tank farm and utilities supplies of the Buyer. Independently of the option chosen to have the Processor's assembly carried out by Buyer or by Seller, the following will apply: A. The cost of piping and wiring connections from the biodiesel processor to the external installations of the Buyer is limited to 8 running meters. B. All adjustments of designs, lay-outs and drawings as inevitably required by the circumstances of the assembly as they appear will be duly documented. C. All adjustments that are required by errors and omissions in the site preparation, site description and lay-out, utilities specifications, and other essential technical characteristics influencing the processor's assembly and operation, will be subjected to an estimate of additional costs and these costs will be paid for by the Buyer. D. All packing material, waste and left over material and products, delivered on site or used in the frame of the processor's assembly, testing and start-up, will be stored separately on the Buyer's premises as indicated by the Buyer. The Buyer will be responsible and carry the costs of disposing of all such waste material. E. As from the day the Buyer has declared the site to be entirely ready to start the assembly of the processor, the processor's assembly, tests and start-up will take no longer than 90 (ninety) calendar days. This period is calculated without interruptions due to broken or missing parts, unexpected difficulties and delays due to shortages of all kind. SECTION 4 TECHNICAL INFORMATION DATA 4.01 The information given in this section in respect of utility consumption is based upon the following assumptions:- Altitude : Up to 1000 meters above sea level Ambient Temp : 0ºC min to +45ºC max Power Supply : 400 Volts, 3 Phase, 50 Cycles Steam Supply : 1200C, 11 bar. Dry and Saturated (at boundary of processes) Compressed Air Supply : 6 bar. Dry and Oil free (at boundary of processes) Water Temperature : 30ºC max Note: The figures given below are approximate and based upon NORMAL continuous operation of the plant running at its design capacity on a continuous process of raw material. All utilities being supplied at a constant rate and quality without interruption. 4.02 The incoming products shall have the following specification (% by weight): Feedstock: The processor will accept vegetable oil or animal fat with the following specifications: a. Free Fatty Acid ............................... max. 2.50%. b. Water ................................... max. 0.20% c. Phosphorus Content ..............……... max. 10PPM d. Sulfur Content................…………….. max. 15PPM e. Inert particulate content..................... max. 0.30% f. Iodine number .................…………… max. 120 Methylate: The processor will accept Sodium Methylate catalyst with the following specifications: a. Technical Quality concentration…….. 32% b. Water ............................... 0.1% Dry catalyst: In case the processor is equipped with a catalyst mixing station, the processor will accept dry Potassium Hydroxyde with the following specifications: Appearance……………………………….white flakes Assay………………………………………90.0% min Carbonate…………………………………0.5% max. Sulphates………………………………….10ppm max. Iron…………………………………………3 max. Heavy metal……………………………….10ppm max. Nickel……………………………………….5ppm max. Methanol: The processor will accept methanol with the following specifications: a. Technical quality, minimum purity…… 99.80% b. Methanol: maximum water content…. 0.10% c. Specific gravity at 20ºC………………. 0.792 4.03 Utility Consumptions - Biodiesel Plant All utilities based per ton of material at intake to plant except for Air * consumption. a Steam at 11.0 bar. - 106 MJ/t b Water consumed - 0.0 m³/t c Power - - 50 Kwh/t d Air for Filter at 6 bar. - 15 m³/h 4.04 Mass Balance Calculation The following table contains the mass balance for the Greenline transesterification process. All values are in weight as indicated and are approximate and expected values based on the specifications mentioned under this section, including a feedstock FFA value of 2.5%. MASS BALANCE CF 10-CF15 with KOH catalyst mixer Without methanol removal from glycerin INPUT kg kg % Feedstock 1.000,00 Methanol 130,00 Catalyst (dry) KOH 12,00 Ion resin 0,80 TOTAL INPUT 1.142,80 OUTPUT kg kg % Biodiesel 972,50 Glycerin 167,50 100,00% glycerol 103,00 61,49% methanol 25,00 14,93% catalyst 12,00 7,16% FFA 25,00 14,93% water 2,50 1,49% Waste resin 2,80 TOTAL OUTPUT 1.142,80 MASS BALANCE CF 10 – CF15 with KOH catalyst mixer With methanol removal from glycerin INPUT kg kg % Feedstock 1.000,00 Methanol 119,00 Catalyst (dry) KOH 12,00 Ion resin 0,80 TOTAL INPUT 1.131,80 OUTPUT kg kg % Biodiesel 972,50 Glycerin 156,50 100,00% glycerol 103,00 65,81% methanol 14,00 8,95% catalyst 12,00 7,67% FFA 25,00 15,97% water 2,50 1,60% Waste resin 2,80 TOTAL OUTPUT 1.131,80 SECTION 5 PERFORMANCE DATA 5.01 Biodiesel capacity Based on the above mass balance, the plant as specified shall have a capacity as follows : 43,762 metric tons per year of 350 days or 125 metric tons per 24 hours. 5.02 Biodiesel quality Based upon conditions as stated, the plant as specified will produce Biodiesel meeting the following specifications: EUROPEAN STANDARD FOR BIODIESEL EN 14214 Limits Property Unit Min Max Test method Ester contect % (m/m) 96.5 prEN 14103 Density at 15°C kg/m3 860 900 EN ISO 3675EN / ISO 12185 Viscosity at 40°C mm2/s 3,5 5,0 EN ISO 3104 Flash point °C 120 - ISO / CD 3679 Sulphur content mg/kg - 10 Carbon residue (on 10% distillation residue) % (m/m) 0,3 EN ISO 10370 Cetane number 51,0 EN ISO 5165 Sulphated ash content % (m/m) - 0,02 ISO 3987 Water Content mg/kg - 500 EN ISO 12937 Total contamination mg/kg 24 EN 12662 Copper strip corrosion (3h at 50 °C) rating Class 1 Class 1 EN ISO 2160 Oxidation stability, 110°C hours 6 pr EN 14112 Acid value mg KOH/g 0,5 pr EN 14104 Iodine value 120 Pr EN 14111 Linolenic acid methyl ester % (m/m) 12 pr EN 14103 Polyunsaturated (>= 4 double bonds) methyl esters % (m/m) 1 Methanol content % (m/m) 0,2 pr EN 14110 Monoglyceride content % (m/m) 0,8 pr EN 14105 Diglyceride content % (m/m) 0,2 pr EN 14105 Triglyceride content % (m/m) 0,2 pr EN 14105 Free glycerol % (m/m) 0,02 pr EN 14105 / pr EN 14106 Total glycerol % (m/m) 0,25 pr EN 14105 Alkaline metals (Na+K)n mg/kg 5 pr EN 14108 / pr EN 14109 Phosphorus content mg/kg 10 pr EN14107 The above parameters are to be used as the basis for the signing of the "handing over" certificate by the Seller and the Buyer, as referred to under clause 3 of the Conditions of Site Engineering Services and clauses 5.01 and 5.02 of Section 5 Performance Data and the subsequent payment of the final amount as stated under "Terms of Payment". 5.03 Glycerin quantity Based on the above mass balance, the plant as specified shall have a capacity as follows : o 7,537 metric tons per year of 350 days without a methanol removal system, or o 7,042 metric tons per year of 350 days with a methanol removal system. SECTION 6 DESIGN ENGINEERING SERVICES The IPT Quotation includes only the items specified, together with the following engineering services supplied on execution of the Contract and applicable only to the items supplied. Wherever possible all drawings, instrument calibration and documentation are according to the metric system. All documentation will be in the English language (1 hard copy and 1 soft copy). (a) Plant and equipment arrangement drawings showing positional relationship of the items to be supplied and indication of any necessary access walkways and platforms. (b) The above mentioned arrangement drawings will provide indications of static and dynamic loads and the type of equipment 'anchoring' methods to be used. These drawings to provide sufficient information to allow for the Buyer to design the building and foundations. (c) Flow diagrams for both process and utilities showing the main process flow, pipeline sizes, valves and fittings and instrumentation. Indication of where insulation is necessary will be marked on these drawings. (d) Specification for piping, given material of construction for pipes, valves and fittings and miscellaneous items for the various services. This documentation to include methods of construction to be used for the piping. (e) Specifications in terms of material and thickness etc. for insulation. (f) Drawings showing the outline dimensions, connection orientation and weights. (g) Electrical schematic drawings and elementary wiring drawings showing the control of the plant with process and safety interlocks. (h) Where requested two dimensional piping drawings are supplied at an extra charge. Such drawings show location of main pipe runs within the process and utility systems. (i) A nominated Project Engineer and/or Manager responsible for project co-ordination during the term of Contract is provided within the Contract price and, in conjunction with any of Seller's site supervisory personnel, will be the point of liaison between Buyer and Seller. (j) Operating manuals regarding the safety aspects and the process control (including software) of the plant. (k) Fully accessible and authorized process control programs. SECTION 7 LIMITS OF SUPPLY The following services and equipment are EXCLUDED from the Seller's supply unless they are otherwise specifically included in the Specification provided by the Seller. 7.1 Independent insurance inspection and/or non-destructive testing of any pressure vessels or pipe work or any other items that such testing may be deemed necessary by the Buyer or his relevant Authorities. 7.2 Civil works of any kind such as but not limited to buildings, foundations, structural supports, ladders or platforms. 7.3 Pipelines and/or equipment necessary for supplying the required process materials/feedstock and utilities (water, steam, air etc.) to the process building/s. 7.4 Insulation, cladding lagging materials or lagging brackets for either vessels or piping. 7.5 The removal of products, water, condensate or any other substance from the building/s housing the equipment. 7.6 Electric cable, wiring and its fittings, mains isolators, earthing and lightning protection, internal or external artificial lighting etc. 7.7 Any fire equipment for the plant whether this is fixed or portable appliances, sprinkler systems, water ring main and hydrants. 7.8 All expenses for labor, material, welding equipment, tools, temporary platforms, cranes or any other equipment required to assemble, erect or install the equipment on site except if otherwise specified in the Contract. 7.9 Pipe supports. 7.10 Any consumables and/or chemicals for the process such as the first filling of gearboxes, lubrication oils and greases, heat transfer mediums, ion resin, etc. 7.11 Any painting for any buildings, vessels and pipe work other than protective coating suitable for transport. 7.12 Any other equipment, information or services not specifically referred to as being included in the supply specified in the Quotation by the Seller. 7.13 All costs associated with fuel quality during startup. (Ex: testing, reprocessing costs) 7.14 All costs associated with the certification process of pressure vessels or other equipment as required by local authorities. Annex 1 to the New detailed offer Comagrotex V5.doc EQUIPMENT SPECIFICATIONS +220 – Catalyst Mixing Station: Item Qty Description BKMV one Methanol buffer tank Function: To accumulate less two cubic meter methanol for recirculation with the catalyst until the mixture is ready to be used in the process. Construction: Carbon Steel Type: Fabricated horizontal tank. Flanged inlets, outlets and instrument connections. Bolted access door. Fabricated support feet. BKM one Catalyst mixing tank Function: The potassium hydroxide fed into the tank is mixed with methanol in low temperature conditions. Construction: Carbon Steel Type: Fabricated vertical tank. Flanged inlets, outlets, cooling serpentine and mechanical seal and instrument connections. Access door. Fabricated support feet. PKM two Catalyst mixing pumps Function: To circulate and provide methanol in the mixing tank and to provide methanol for the Ion exchanger cleaning process. Construction: Cast Iron/Carbon Steel Type: Centrifugal, electric. All iron body with mechanical seal. Mounted on fabricated base plate with motor, coupling and guard. +241 – Feedstock Dosing: Item Qty Description FR1-2 two FILTER, VEGETABLE OIL, INCOMING Function: To remove small impurities from incoming oil. Construction: Carbon Steel/Stainless Steel Type: Fabricated shell with flanged inlet/outlets. PMPR ONE PUMP, VEGETABLE OIL, INCOMING Function: To pump vegetable oil to drying system. Construction: Cast Iron/Carbon Steel Type: Centrifugal type with semi-open impeller. All iron body with mechanical seal. Mounted on fabricated base plate with motor, coupling and guard. +303 – Feedstock preheating : Item Qty Description HE1 HEAT EXCHANGER, WASTE HEAT RECOVERY Function: To recover heat from outgoing biodiesel and heat incoming oil. Construction: Carbon Steel/Stainless Steel Type: Fabricated shell and tube heat exchanger with flanged inlet/outlets. Fabricated support feet. +305 – Feedstock heating, probing and measuring : Item Qty Description HE2 HEAT EXCHANGER, WASTE HEAT RECOVERY Function: To recover heat from outgoing biodiesel and heat incoming oil. Construction: Carbon Steel/Stainless Steel Type: Fabricated shell and tube heat exchanger with flanged inlet/outlets. Fabricated support feet. +243 – Dosing, 1st Transesterification: Item Qty Description PxM1 two PUMP, DOSING, 1st TRANSESTERIFICATION Function: To accurately measure and discharge methanol into reactor. Construction: Cast Iron/Carbon Steel Type: Rotary type positive displacement with hardened steel gears. All iron body with single mechanical seal. Mounted on fabricated base plate with motor, coupling and guard. PxK1 two PUMP, DOSING, 1st TRANSESTERIFICATION Function: To accurately measure and discharge catalyst into reactor. Construction: Cast Iron/Carbon Steel Type: Rotary type positive displacement with hardened steel gears. All iron body with single mechanical seal. Mounted on fabricated base plate with motor, coupling and guard. +245 – 1st Reactor, Transesterification: Item Qty Description SMxM1 ONE REACTOR, 1st TRANSESTERIFICATION Function: Receive, mix and react dosing oil and methanol with catalyst. Construction: Carbon Steel Design Code: BS5500/ASME Type: Horizontal cylindrical fabricated vessel with dished ends. Flanged top for access. Necessary inlet, outlet drain and instrument connections. Internal vertical mixer shaft with paddles driven by integral motor and gear reducer. Supporting steel legs. +307 – Biodiesel heat exchanger : Item Qty Description W2 HEAT EXCHANGER, WASTE HEAT RECOVERY Function: To recover heat from 1st Transesterification outgoing biodiesel and heat second transesterification incoming biodiesel. Construction: Carbon Steel/Stainless Steel Type: Fabricated shell and tube heat exchanger with flanged inlet/outlets. Fabricated support feet. +247 – Intermediate Settler: Item Qty Description BA11 ONE SETTLER, INTERMEDIATE Function: To separate majority of glycerin from 1st transesterification reaction. Construction: Carbon Steel Type: Horizontal fabricated tank with dished ends, Complete with inlet, outlet, and drain level and instrument connections. Support feet. +253 – Dosing, 2nd Transesterification: Item Qty Description PxM2 two PUMP, DOSING, 2nd TRANSESTERIFICATION Function: To accurately measure and discharge methanol into reactor. Construction: Cast Iron/Carbon Steel Type: Rotary type positive displacement with hardened steel gears. All iron body with single mechanical seal. Mounted on fabricated base plate with motor, coupling and guard. PxK2 two PUMP, DOSING, 2nd TRANSESTERIFICATION Function: To accurately measure and discharge catalyst into reactor. Construction: Cast Iron/Carbon Steel Type: Rotary type positive displacement with hardened steel gears. All iron body with single mechanical seal. Mounted on fabricated base plate with motor, coupling and guard. +255 – 2nd Reactor, Transesterification: Item Qty Description R2 ONE REACTOR, 2nd TRANSESTERIFICATION Function: Receive, mix and react dosing oil and methanol with catalyst. Construction: Carbon Steel. Type: Horizontal cylindrical fabricated vessel with dished ends. Flanged top for access. Necessary inlet, outlet drain and instrument connections. Internal vertical mixer shaft with paddles driven by integral motor and gear reducer. Supporting steel legs. +257 – Final Settling: Item Qty Description BA21 ONE SETTLER, FINAL Function: To separate remaining glycerin from 2nd transesterification reaction. Construction: Carbon Steel Type: Horizontal fabricated tank with dished ends, Complete with inlet, outlet, and drain level and instrument connections. Support feet. BA22 ONE SETTLER, FINAL Function: To separate remaining glycerin from 2nd transesterification reaction. Construction: Carbon Steel Type: Horizontal fabricated tank with dished ends, Complete with inlet, outlet, and drain level and instrument connections. Support feet. BA23 ONE SETTLER, FINAL Function: To separate remaining glycerin from 2nd transesterification reaction. Construction: Carbon Steel Type: Horizontal fabricated tank with dished ends, Complete with inlet, outlet, and drain level and instrument connections. Support feet. +270 – Ion Exchange: Item Qty Description BI1 ONE TOWER, ION EXCHANGE Function: To filter and remove residual glycerin and catalyst from biodiesel. Construction: Cast Iron/Carbon Steel Type: Vertical, all iron bodies with mechanical seals. Mounted on fabricated base plate and legs. BI2 ONE TOWER, ION EXCHANGE Function: To filter and remove residual glycerin and catalyst from biodiesel. Construction: Cast Iron/Carbon Steel Type: Vertical, all iron bodies with mechanical seals. Mounted on fabricated base plate and legs. BI3 ONE TOWER, ION EXCHANGE Function: To filter and remove residual glycerin and catalyst from biodiesel. Construction: Cast Iron/Carbon Steel Type: Vertical, all iron bodies with mechanical seals. Mounted on fabricated base plate and legs. BI4 ONE TOWER, ION EXCHANGE Function: To filter and remove residual glycerin and catalyst from biodiesel. Type: Vertical, all iron bodies with mechanical seals. Mounted on fabricated base plate and legs. PIM ONE PUMP, WASH Function: To pump clean methanol to Ion Exchange Towers. Construction: Cast Iron/Carbon Steel Type: Centrifugal type with closed impeller. All iron body with single mechanical seal. Mounted on fabricated base plate complete with motor +271 – Resin Filtering: Item Qty Description ONE Filters, Biodiesel, Outgoing Function: To remove small impurities of Resin from biodiesel. Construction: Carbon Steel/Stainless Steel Type: Sock, screen basket. +281 – Methanol Dryer: Item Qty Description HEMD1 one HEAT EXCHANGER Function: To recover waste heat from outgoing biodiesel and heat entering biodiesel. Construction: Carbon Steel/Stainless Steel Type: Fabricated shell and tube heat exchanger with flanged HEMD2 one HEAT EXCHANGER Biodiesel Function: To heat biodiesel for methanol recovery unit Construction: Carbon Steel/Stainless Steel Type: Fabricated shell and tube heat exchanger with flanged inlet/outlets. Fabricated support feet. BK ONE Falling film Evaporator Function: The hot biodiesel sucked in by vacuum fall in a thin film inside the column and enlarges the surface of the liquid biodiesel which allows the water and methanol to evaporate easy. The biodiesel will run twice through the failing film evaporator in order to reach the calculated purity. Construction: Carbon Steel Type: Fabricated shell and tube heat exchanger with flanged inlets/outlets. Large diameter swirling type vapor dome mounted on top of vessel. Operated under partial vacuum. Fabricated support feet. HEMD3ONE SET VAPOR DUCTING (CONDENSERS) Function: To transfer hot vapor to Condensers Construction: Stainless Steel Type: Fabricated ducting or piping with fixings, flanges and gaskets where necessary. PV1 ONE PUMP, VACUUM, METHANOL Function: To collect, compress and condense methanol vapors into methanol fluid. Construction: Cast Iron/Carbon Steel Type: Piston. All iron body with mechanical seal. Mounted on fabricated base plate with motor, coupling and guard. BV ONE ACCUMULATOR, METHANOL Function: To collect condensed methanol vapor. Construction: Carbon Steel Type: Vertical with fabricated shell. ONE ACCUMULATOR, METHANOL Function: To collect condensed methanol vapor. Construction: Carbon Steel Type: Vertical with fabricated shell HEMD4 ONE COOLER, METHANOL, VAPOR Function: For cooling methanol vapors after leaving methanol evaporator. Construction: Carbon Steel/Stainless Steel Type: Horizontal, Fabricated shell and tube condenser. Cooling fluid on inside of tubes, vapors on outside. Flanged inlets/outlets. Fabricated support feet. +285 – Condensate Separator: Item Qty Description TCS ONE Separator, Condensate Function: To separate vapors from liquid methanol Construction: Carbon Steel Design Code: Type: Vertical, Fabricated shell and tube heat exchanger with flanged inlets/outlets. Large diameter swirling type vapor dome mounted on top of vessel. Operated under partial vacuum. Fabricated support feet. +957 – Filtering, Fine, Finished: Item Qty Description ONE Filters, Biodiesel, Outgoing Function: To remove small impurities from finished biodiesel. Construction: Carbon Steel/Stainless Steel Type: Sock, screen basket. +293 CHILLER Item Qty Description Chiller TWO INDUSTRIAL COOLER Function: Industrial coolers are compact cooling units which are tested at the manufacturer’s according to EN 378-1 cool liquid media including all necessary components for fully automatic operation. The cooling medium is delivered through the evaporator (heat exchanger) and the heat is transferred in the contrary flow system to the evaporating refrigerant. The compressor is compressing the refrigerant-gas at a higher temperature and pressure level. In the condenser the air-flow or the condenser cooling liquid is transferring out the condenser heat load and the gas becomes liquid. The expansion valve decreases the high pressure and the refrigerant can become gas again in the evaporator, where the circuit process can start again. With the help of the digital controller, the outlet medium temperature is controlled by switching the compressor or the hot gas bypass valve (optional). The installed or the external tank serves for limiting theallowed switching frequency. Construction: Carbon Steel/Stainless Steel Type: Horizontal fabricated. Complete with inlet, outlet, and drain level and instrument connections. Support feet. HEC TWO HEAT EXCHANGER, Function: To cool the cooling agent. Construction: Carbon Steel/Stainless Steel Type: Fabricated shell and tube heat exchanger with flanged inlet/outlets. Fabricated support feet. PC1 ONE PUMP, Cooling agent Function: To recirculate the cooling agent between the heat-exchangers and cooling agent tank. Construction: Cast Iron/Carbon Steel Type: Centrifugal type with semi-open impeller. All iron body with mechanical seal. Mounted on fabricated base plate with motor, coupling and guard. PC2 ONE PUMP, Cooling agent Function: To pump the cooling agent in catalyst mixing station. Construction: Cast Iron/Carbon Steel Type: Centrifugal type with semi-open impeller. All iron body with mechanical seal. Mounted on fabricated base plate with motor, coupling and guard. PC3 ONE PUMP, Cooling agent Function: To pump the cooling agent in methanol recovery stations from glycerin and biodiesel. Construction: Cast Iron/Carbon Steel Type: Centrifugal type with semi-open impeller. All iron body with mechanical seal. Mounted on fabricated base plate with motor, coupling and guard. +291 METHANOL REMOVAL FROM GLYCERIN 400 - Power Distribution Section: Note: Items specified below include for power distribution within the boundary limits of the plant and therefore excludes any cabling or boards outside of or between the sections and main cable from power generator or high voltage feed and transformer. ONE MOTOR CONTROL CENTER (Buyers Supply) For power circuits and control of all motors outside of biodiesel processor supply. Floor standing, carbon steel fabricated cabinet with front opening access doors, including all Star Delta/DOL starters, bus bars, isolators and voltammeter/ammeter (where necessary), with wiring, motor overload lights and individual isolators. This MCC suitable for location OUTSIDE the safety area or within a pressurized room. ONE CONTROL PANEL Function: To control all motors for the biodiesel processor. Construction: Carbon Steel/Cabling Type: Fabricated panel complete with necessary stop/start buttons, motor stop/running lights and audio/visual alarms. Graphic display shows basic flow diagram. Located in the control area of the Biodiesel Processor. ONE SET ELECTRIC CABLES For interconnecting the above motor control center, operator control panel with the various motors, emergency stop buttons, instruments, lights and switches. Necessary cable and armored PVC covered multi-core cabling including cable glands, shrouds, locknuts and telcleats. ONE SET CABLE TRAYS Comprising: Random lengths of galvanized open cable trays, trunking, corners, tees and ends. EXCLUDING supports. ONE SET STATIC PROTECTION Comprising: Rolls of copper strip or wire for forming on site and locating over flanges on all solvent/miscella lines. ONE SET EXPLOSION PROOF LIGHTING (Buyers Supply) For lighting within the building and also on the process building sight/light glasses. Specifically EXCLUDES any area outside building or perimeter lighting. Comprising: Fluorescent light strips, lamp light switches, terminal boxes, glands and connectors all suitable for hazardous area installation. Complete with distribution panel suitable for location OUTSIDE the safety area. 500 - Ancillary Equipment: Item Qty Description TEN PRESSURE RELIEF VALVES Function: To protect biodiesel processor from excess pressure/vacuum. Construction: Aluminum/Stainless Steel Type: Cast body with flanged inlet and outlet. Internal guide posts with lifting diaphragms. ONE SET CONTROL INSTRUMENTS Function: All necessary field mounted instruments including flow, level and temperature control loops, pressure transmitters and flow meters. Design and specification suitable to operate the plant in accordance with the Seller's Standard Control Philosophy. Type: According to function ONE SET LOCAL INDICATORS Function: Field mounted temperature, vacuum, flow, level and pressure indication. Type: Gauge with screwed connections. Complete with U-tube/pigtail and isolating valve, as required. ONE SET CONTROL VALVES Function: All necessary control valves required for fully automated operation of the plant in accordance with the Sellers standard Control Philosophy. Including any necessary pressure relief/pressure safety valves. Excludes any steam reducing station for main incoming steam. Type: On/off/modulating Construction: According to function ONE SET MANUAL VALVES AND FITTINGS Function: All necessary manual valves for on/off and throttling services Type: Butterfly or Ball Valves on process lines (depending on size) Gate Globe Valves on condensate lines butterfly/Diaphragm valves on water lines (depending on size) Construction: According to function. No bronze/brass on oil or miscella lines ONE SET PIPES & FITTINGS Function: For interconnecting all the above specified equipment according to our recommended layout within the boundary walls of the building. Including all process, condensate, water and air lines. Piping supplied in random lengths for cutting to size and screwing or welding on-site. Complete with all necessary flanges, gaskets, nuts/bolts, bends, tees etc. supplied loose for fitting on-site. Type: According to function Construction: Carbon Steel/Galvanised Steel/Nylon Tube/Stainless Steel 600 - Insulation and Cladding Material: ONE LOT INSULATION MATERIALS (Buyers Supply) For insulating the process vessels and process/steam piping where necessary. Process Vessels: Comprising 50mm thick foil covered fiber glass material fixed to the vessel with 3mm dia. carbon steel welded rods with washer on rod end to hold insulation in place. Rolls of aluminum foil tape to seal joints and cover washer ends. Bottom and top of vessels with slabs (80 kgs/m3 density) fixed as above. Piping: Comprising pre-formed fiber glass pipe insulation 40mm thick, foil covered, to suit diameter of pipe. Rolls of aluminum foil tape for all butt and longitudinal joints. Slabs, as above, for ends of pipe. Note: Sellers’ supervisors are NOT responsible for fitting this material. ONE LOT CLADDING (Buyers Supply) Materials: Aluminum sheets supplied in standard sizes for cutting and fitting on site by local contractor. Note: Sellers’ supervisors are NOT responsible for fitting this material. 700 – Miscellaneous: ONE SET MAINTENANCE TOOLS (Buyers Supply) Function: Tools and devices to facilitate easy maintenance of the plant. ONE EMERGENCY EYE WASH/SHOWER (Buyers Supply) Function: For use by operators in event of caustic splashes. Construction: Carbon Steel/Stainless Steel. Type: Vertical shower in galvanised steel, floor mounted with high level shower head and twin-spray eye/face wash. Quick pull handles. ONE SET ESSENTIAL START-UP SPARES Function: For use by Sellers commissioning engineers during start-up Type: Essential pump seals, gaskets, control valve seats, regulating valve seats, springs and standard kits for instruments Note: Sufficient for start-up only ONE SET ACCESS AND SUPPORTING STEELWORK (Buyers Supply) Function: To support and give access to the items of equipment specified inside the building. Construction: Carbon Steel Type: Pre-fabricated steelwork sections of bolted or welded construction for site erection. Open grid flooring where necessary. Access ladders, staircases and handrails, where necessary. ONE SET HOLDING DOWN BOLTS (Buyers Supply) Function: To anchor the various items of equipment to Buyer’s support structures and foundations. Construction: Appropriate to equipment Type: Screwed nuts/bolts and flat/tapered washers, para-bolts, indented foundation bolts as required. NOTES APPLICABLE TO ALL BIODIESEL PLANT SECTIONS MOTORS All motors as specified for the above equipment shall be 3 phase, 50Hz, 400 volts, hazardous area specification and common manufacturer, wherever possible. Motor powers (if stated) are approximate until plant is fully designed. MATERIALS All materials used shall be compatible with the nature of the process and no bronze, brass or copper based materials shall be used where in contact with vegetable oil. PUMPS Pumps have impellers and internals where stated. SAFETY Plant design standards are to NFPA 36 (2004 edition). PAINTING: All equipment is primed painted only in grey GENERAL and PROCESSOR LAYOUT a. General layout b. Processor layout PIPING & INSTRUMENT DIAGRAM ESSENTIAL START-UP SPARE-PARTS A. Spare parts for pumps: DESMI ROTAN HD66EMR-1U3B2 Quantity Order Cod Pos./Dsignation 2 0030-126BA904 B Gasket/O-ring 329 1 0031-115AA904 C gasket 329 1 704348 BC ball bearing 6307-2RS1 1 704010 CU ball bearing G306-2RS1 1 1066-020AA050 BV shaft/ST.60-2 SERA PUMPS RF-411.1-640KDM 100 CODE:298540-298543 Quantity Order Cod Pos./Dsignation 1 90001028 O-ring AU 89.2-5.7 1 90025940 Membrane Set PTFE PTFE dl40 1 90003091 Radial sealing ring 25-40-7 1 90004510 Radial sealing ring 5-62-10 BA R 409.1-150 CODE 298539 Quantity Order Cod Pos./Dsignation 1 90025937 Membrane Set PTFE-k PTFE dl178 1 90005082 Radial sealing ring 12-45-4 BA RF 409.1-68 KDM/40 CODE: 298544-298547 Quantity Order Cod Pos./Dsignation 1 90000084 O-ring A W 34.2-3 1 90025938 Membrane set PTFE PTFE d78 1 90005082 Radial sealing ring 12-45-7 BA STERLING PUMP AKHA 3602 AA AFJ 0A E Quantity Order Cod Old Code Pos./Dsignation 1 65000266 19801647720150 Shaft spare part 1 43000817 10100171030095 Grooved ball bearing 1 20054728 19001847720150 Shaft ZLKD032160 Quantity Order Cod Old Code Pos./Dsignation 1 20025379 904708021-150 Shaft 1 20049556 656780200-003 Impeller 1 43000942 10060197 Grooved ball bearing ZLKD032200 Quantity Order Cod Old Code Pos./Dsignation 1 20025519 904806023-150 Shaft 1 20049628 856700100-003 Impeller -Mechanical seal type BU MG1-G6 025 S Q1R1 VGGQ1Q1VGG Pump P1M1-trans I+II -need 1 piece -Mechanical seal type BU MG1-G6 025 S Q1 AEGG Pump P2M1-trans I+II –need 1 piece B. Spare parts for sensors: -Temperature sensor RTD TR11 4-20 Ma-need 1 piece -Pressure sensor - CERABAR S PMP 71 (4-20 Ma)(DVM1)-1 piece -Level probe : -type FTL 50/51- 1 piece(12 m3) - type ENDRES HAUSER 11363Z(Settling tank) C. Spare parts for valves: Quantity Order Cod Pos./Dsignation 2 Gasket ECO-FLEX Plate gasket 2 Heat exchanger Port ring 1 Actuator EE620x52 Pneumatic actuator 2 Gasket Viton Universal Gasket 2 Gasket EPDM Universal Gasket