Original #s

59,845,000 59,845,000

59,845,000 59,845,000

81,565,410 81,133,000

119171447 119,171,446.90

16,630,762 12,649,000

1.627 $1.72

Name Unit Cost ($)

101MH 121,000

979,000

104M 98,000

105V 33,000

106W 51,000

107V 44,000

307V 133,000

305V 9,000

303V 28,000

301V 50,000

302P 4,000

310V 161,000

321V 103,000

317V 84,000

319V 19,000

401E 285,000

402E 85,000

404P 7,000

405V 2,811,000

Capital Investment Charged to This Project $

Operating Cost $/yr

Economic Evaluation Report

2022 Vanilla Plant

1. EXECUTIVE SUMMARY (2007 prices)

Total Capital Investment $

Ethanol Production Cost $ / Gallon

Production Rate kg MP/yr

CoProduct Credits $ /yr

Steam Energy usage is difference between 2022 CHP thermal energy usage and drying (Nat. gas) energy

Notes:

Drying Energy (Nat. gas consumption) reduced by 26% - difference between baseline and 2022 Vanilla energy usage

2. MAJOR EQUIPMENT SPECIFICATION AND FOB COST (2007 prices)

Quantity/

Standby/

Staggered

Description Cost ($)

1 / 0 / 0 Silo/Bin 979,000

Vessel Volume = 18540.14 m3

1 / 0 / 0 Belt Conveyor 121,000

Belt Length = 100.00 m

1 / 0 / 0 Receiver Tank 33,000

Vessel Volume = 76.90 m3

1 / 0 / 0 Grinder 98,000

Size/Capacity = 46211.30 kg/h

1 / 0 / 0 Receiver Tank 44,000

Vessel Volume = 76.90 m3

1 / 0 / 0 Hopper 51,000

Vessel Volume = 100.93 m3

1 / 0 / 0 Hopper 9,000

Vessel Volume = 4.02 m3

1 / 0 / 0 Blending Tank 133,000

Vessel Volume = 45.29 m3

1 / 0 / 0 Receiver Tank 50,000

Vessel Volume = 12.19 m3

1 / 0 / 0 Receiver Tank 28,000

Vessel Volume = 8.77 m3

1 / 0 / 0 Blending Tank 161,000

Vessel Volume = 141.30 m3

1 / 0 / 0 Gear Pump 4,000

Power = 0.20 kW

1 / 0 / 0 Receiver Tank 84,000

Vessel Volume = 17.57 m3

1 / 0 / 0 Stirred Reactor 103,000

Vessel Volume = 52.10 m3

Heat Exchanger 285,000

Heat Exchange Area = 197.87 m2

1 / 0 / 0 Receiver Tank 19,000

Vessel Volume = 18.87 m3

12-May-09

1 / 0 / 0 Gear Pump 7,000

Power = 0.06 kW

1 / 0 / 0 Heat Exchanger 85,000

Heat Exchange Area = 190.05 m2

1 / 0 / 0

1 / 0 / 0 Fermentor 2,811,000
409V 91,000

410P 7,000

413E 459,000

608T 92,000

411P 16,000

501T 597,000

MX-1010

503T 254,000

507T 168,000

511V 93,000

509V 34,000

513V 308,000

601V 197,000

605V 230,000

604MH 56,000

610D 2,268,000

612MH 123,000

FSP-1010

MX-1030

MX-1040

313E 19,000

312E 105,000

304P 4,000

318P 4,000

320P 4,000

403V 115,000

611X 918,000

514P 40,000

510P 5,000

314V 174,000

412V 62,000

408E 19,000

Vessel Volume = 10446.33 m3

1 / 0 / 0 Absorber 91,000

Power = 3.16 HP

1 / 0 / 0 Heat Exchanger 459,000

Absorber Volume = 13.41 m3

1 / 0 / 0 Centrifugal Pump 7,000

Vessel Volume = 451.07 m3

1 / 0 / 0 Centrifugal Pump 16,000

Heat Exchange Area = 402.34 m2

1 / 0 / 0 Receiver Tank 92,000

Column Volume = 96.57 m3

1 / 0 / 0 Mixer0

Power = 50.00 HP

1 / 0 / 0 Distillation Column 597,000

Column Volume = 113.57 m3

1 / 0 / 0 Distillation Column 168,000

Size/Capacity = 34233.06 kg/h

1 / 0 / 0 Distillation Column 254,000

Vessel Volume = 481.39 m3

1 / 0 / 0 Flat Bottom Tank 34,000

Column Volume = 3.72 m3

1 / 0 / 0 Flat Bottom Tank 93,000

Vessel Volume = 3392.22 m3

1 / 0 / 0 Blending Tank 197,000

Vessel Volume = 339.24 m3

1 / 0 / 0 Flat Bottom Tank 308,000

Vessel Volume = 481.39 m3

1 / 0 / 0 Belt Conveyor 56,000

Vessel Volume = 755.41 m3

1 / 0 / 0 Blending Tank 230,000

Drying Area = 1235.35 m2

1 / 0 / 0 Belt Conveyor 123,000

Belt Length = 100.00 m

1 / 0 / 0 Rotary Dryer 2,268,000

Size/Capacity = 79164.08 kg/h

1 / 0 / 0 Mixer0

Belt Length = 100.00 m

1 / 0 / 0 Flow Splitter0

Size/Capacity = 135779.87 kg/h

1 / 0 / 0 Heat Exchanger 19,000

Size/Capacity = 14697.18 kg/h

1 / 0 / 0 Mixer0

Heat Exchange Area = 112.94 m2

1 / 0 / 0 Gear Pump 4,000

Heat Exchange Area = 61.96 m2

1 / 0 / 0 Heat Exchanger 105,000

Power = 0.25 HP

1 / 0 / 0 Gear Pump 4,000

Power = 0.25 HP

1 / 0 / 0 Gear Pump 4,000

Vessel Volume = 2.97 m3

1 / 0 / 0 Wet Air Oxidizer 918,000

Power = 0.02 kW

1 / 0 / 0 Blending Tank 115,000

Power = 1.79 HP

1 / 0 / 0 Gear Pump 5,000

Vessel Volume = 13.18 m3

1 / 0 / 0 Gear Pump 40,000

Vessel Volume = 14.16 m3

1 / 0 / 0 Flash Drum 62,000

Power = 5.00 HP

1 / 0 / 0 Receiver Tank 174,000

Condensation Area = 58.68 m2

Vessel Volume = 14.32 m3

1 / 0 / 0 Condenser 19,000
316E 614,000

308P 25,000

311P 15,000

322P 15,000

406P 76,000

407P 15,000

502P 13,000

506P 6,000

508P 5,000

505P 4,000

606P 11,000

602P 13,000

609P 12,000

512P 5,000

315E 51,000

306P 4,000

MX-105 0

309E 28,000

MX-102 0

607Ev 3,259,000

103MH 61,000

504X 1,718,000

603 849,000

split 0

MX-106 0

FSP-103 0

MX-107 0

GBX-101 850,000

614E 0

TOTAL

Original #s

1 / 0 / 0 Heat Exchanger 614,000

Power = 14.82 kW

1 / 0 / 0 Centrifugal Pump 15,000

Heat Exchange Area = 490.85 m2

1 / 0 / 0 Centrifugal Pump 25,000

Power = 50.00 HP

1 / 0 / 0 Centrifugal Pump 76,000

Power = 50.00 kW

1 / 0 / 0 Centrifugal Pump 15,000

Power = 12.76 HP

1 / 0 / 0 Centrifugal Pump 13,000

Power = 25.33 HP

1 / 0 / 0 Centrifugal Pump 15,000

Power = 20.00 HP

1 / 0 / 0 Centrifugal Pump 5,000

Power = 50.00 HP

1 / 0 / 0 Centrifugal Pump 6,000

Power = 0.35 HP

1 / 0 / 0 Centrifugal Pump 11,000

Power = 10.00 HP

1 / 0 / 0 Centrifugal Pump 4,000

Power = 50.00 HP

1 / 0 / 0 Centrifugal Pump 12,000

Power = 20.00 HP

1 / 0 / 0 Centrifugal Pump 13,000

Power = 10.00 HP

1 / 0 / 0 Heat Exchanger 51,000

Power = 20.00 HP

1 / 0 / 0 Centrifugal Pump 5,000

Power = 5.00 HP

1 / 0 / 0 Mixer 0

Heat Exchange Area = 179.12 m2

1 / 0 / 0 Gear Pump 4,000

Heat Exchange Area = 52.14 m2

1 / 0 / 0 Mixer 0

Size/Capacity = 15046.90 kg/h

1 / 0 / 0 Heat Exchanger 28,000

Evaporation Area = 684.51 m2

1 / 0 / 0 Flow Splitter 61,000

Size/Capacity = 39800.21 kg/h

1 / 0 / 0 Evaporator 3,259,000

Size/Capacity = 19431.52 kg/h

1 / 0 / 0 Disk-Stack Centrifuge 849,000

Size/Capacity = 46350.35 kg/h

1 / 0 / 0 Component Splitter 1,718,000

Size/Capacity = 108014.97 kg/h

1 / 0 / 0 Mixer 0

Throughput = 1725.62 L/min

1 / 0 / 0 Component Splitter 0

Size/Capacity = 83965.63 kg/h

1 / 0 / 0 Mixer 0

Size/Capacity = 24049.33 kg/h

1 / 0 / 0 Flow Splitter 0

Size/Capacity = 17854.00 kg/h

9 / 0 / 0 Heat Exchanger 0

Size/Capacity = 83965.63 kg/h

1 / 0 / 0 Generic Box 850,000

3. DIRECT FIXED CAPITAL COST (DFC) SUMMARY (2007 prices in $)

Section Name DFC ($)

Heat Exchange Area = 96.54 m2

Unlisted Equipment 0

19,215,000
0

4,161,000

4,959,000

12,141,000

9,750,000

26,634,000

2,200,000

59,845,000

0.00 0 0

52.00 47,520 2,471,040

47,520 2,471,040

Original #s

0.141 367,094,784 51,917,691 50,567,306

0.090 438,190 39,437 39,437

0.220 733,337 161,334 161,334

2.250 257,139 578,562 578,562

2.250 371,408 835,669 835,669

0.110 733,337 80,667 80,667

0.012 18,423,742 223,296 223,296

1.860 96,466 179,426 179,426

0.000 157,719,657 6,940 6,940

0.723 2,383,429 1,722,266 1,722,266

0.000 272,159,431 0 0

0.021 20,200,617 431,283 431,283

840,611,535 56,176,571 54,826,186

Annual Amount Reference Units Original #s

26,404,692 kWh 1,742,710 36,065,811

281,339,518 kg 7,156,839 0

1,249,392,804 kg 124939 1,249,392,804

0 kg 0 0

8,614,248 kg 4,301,537 11,640,876

5,295,747,600 kg 370,702 5,295,747,600

13,032,037,028 kg 0 13,032,037,028

361,033,783 kg 25,272 361,033,783

3,171,803,970 kg 222,026 3,171,803,970

0 kg 0 0

0 kg 0 97,727,110

0 kg 0 32,533,206

0 kg 0 175,958,929

95,434,704 kg 0 95,434,704

10,654,669 kg 266,367 10,654,669

153,266,788 kg 0 153,266,788

Starch to Sugar Conversion 4,959,000

Fermentation 12,141,000

Main Section 0

Grain Handling & Milling 4,161,000

Common Suport Systems 2,200,000

Plant DFC 59,845,000

Ethanol Processing 9,750,000

CoProduct Processing 26,634,000

4. LABOR COST - PROCESS SUMMARY

Labor Type

Unit Cost

 ($/h)

Annual Amount

 (h)

Annual Cost

 ($) %

TOTAL 100.00

5. RAW MATERIALS COST - PROCESS SUMMARY

Operator 0.00

Plant Operators 100.00

%

Corn 92.23

Lime 0.07

Bulk Raw Material

Unit Cost

($/kg)

Annual Amount

(kg)

Annual Cost

 ($)

Glucoamylase 1.52

Sulfuric Acid 0.15

Liq. Ammonia 0.29

Alpha-Amylase 1.06

Water 0.01

Octane 3.14

Caustic 0.41

Yeast 0.33

TOTAL 100.00

6. VARIOUS CONSUMABLES COST (2007 prices) - PROCESS SUMMARY

Air 0.00

Steam 0.79

THE CONSUMABLES COST IS ZERO.

7. UTILITIES COST (2007 prices) - PROCESS SUMMARY

Utility

Annual Cost

 ($) %

Cooling Water 0.83

Chilled Water 0.00

Electricity 14.30

Steam 0.00

CT Water NoCost 0.00

CT Water 35Cout 0.17

Natural Gas 28.43

CT Water 2.45

Steam 50 PSI 16.15

Steam 6258 BTU 5.38

CT Water 31Cout 1.47

Well Water 0.00

Steam (High P) 1.76

Air 0.00

Steam 2205 BTU 29.07

Rectifier OH 0.00
14,210,392

$ Original #s

56,176,571 54,826,000

2,471,000 2,471,000

8,707,448 8,705,000

0 0

14,210,392 15,130,000

0 0

0 0

0 0

81,565,410 81,133,000

Original #s

59,845,000 59,845,000

0 0

0 0

0 0

0 0

59,845,000 59,845,000

59,845,000 59,845,000

112,009,521

119,171,447

121,203,097

Original #s

0.684 0.68

Original #s

0.000 0.00

0.690 0.65

0.137 0.10

8. ANNUAL OPERATING COST (2007 prices) - PROCESS SUMMARY

Cost Item %

Raw Materials 67.58

TOTAL 100.00

Consumables 0.00

Utilities 18.65

Labor-Dependent 3.05

Facility-Dependent 10.73

Failed Product Disposal 0.00

TOTAL 100.00

Advertising/Selling 0.00

Running Royalties 0.00

9. PROFITABILITY ANALYSIS (2007 prices)

A. Direct Fixed Capital $

B. Working Capital $

C. Startup Cost $

D. Up-Front R&D $

E. Up-Front Royalties $

F. Total Investment (A+B+C+D+E) $

G. Investment Charged to This Project $

Total flow in ETHANOL kg/yr

Total flow in Pellets kg/yr

H. Revenue Stream Flowrates

Total flow in CO2 kg/yr

J. Selling / Processing Price

Total flow in CO2 $/1000 kg

I. Production Unit Cost

ETHANOL $/kg

Total flow in ETHANOL $/kg

Total flow in Pellets $/kg
Original #s

00

82,244,586 77,461,000

16,630,762 12,649,000

98,875,347 90,110,000.00

Original #s

81,565,410 81,133,000

Original #s

17,309,937 8,978,000

6,923,975 3,591,000

16,370,462 11,369,000

Original #s

17.51 9.96

27.35 19.00

3.66 5.26

K. Revenues

CO2 $/yr

Total Revenues $/yr

L. Annual Operating Cost

ETHANOL $/yr

Pellets $/yr

AOC $/yr

M. Gross Profit (K-L) $/yr

N. Taxes (40%) $/yr

O. Net Profit (M-N + Depreciation) $/yr

Payback Time years

Gross Margin %

Return On Investment %
$0.218

$1.825

$0.417

$1.627

Co-Product Revenue Per Gallon

Total Cost Per Gallon

P. Cost Per Gallon Ethanol

Capital Cost Per Gallon

Operating Cost Per Gallon
cost per gal% of per gallon cost

0.88 0.54342 Corn - DDG -0.42 DDGS Sale

0.11 0.06559 Chemicals/enzymes 0.88 Corn minus DDG

0.06 0.03805 Labor 0.36 Utilities

0.22 0.13410 Facility 0.22 Facility Cost, Maintenance

0.36 0.21884 Utilities 0.11 Chemicals and Enzymes

1.63 1 0.06 Labor

0 DDGS Sale

-0.42

0.88

0.36

0.22

0.11

0.06

-0.50

-0.25

0.00

0.25

0.50

0.75

1.00

1.25

1.50

1.75

1

$/gal

Labor

Chemicals and Enzymes

Facility Cost, Maintenance

Utilities

Corn minus DDG

DDGS Sale


2,163,949

0

124,939

0

4,301,537

370,702

0

25,272

222,026

0

2,443,178

813,330

4,398,973

0

266,367

0
15,130,273
Assuming a 10 Year Straight Line Depreciation

Total Investment / Net Profit
Natural Gas Case

Inputs & Outputs

Operatig Hours / Year 7920 Hours / Year

Final Product 150 Psig Steam

Quantity 78,150 pounds / hour

Energy in Product 1,200 BTU/ Pound

System Efficency 88.0%

Steam Energy Required (to process) 742,736

Energy Required (w/efficiency loss) 844,019

Fuel Natural Gas

BTU Content 1,030,000 BTU / MCF

Amount Required 103.4641 MCF / Hr

Fuel Cost $7.98 $ / MCF

$7.75 $ / MMBTU

Electricity

Amount Required 22.66346117 kWh

Electricity Cosy 0.066 $ / Kwh

Make Up Water

% Loss to Make Up - 2.7% 2110.046385 Lbs / hr

Cost of Boiler Make Up - $25 / MCF $0.0004 $ / Lb

Capital Cost

Pkg Boiler 800,000

FD Fan Included above - Use 25 HP above

Stack 25,000

Deaerator 50,000

Pumps 25,000

Controls 75,000

Instalation - Allowance 400,000

Engineering 8% all above 110,000

Misc Electrical Ereqd

Material Handling & Storage None

 Conveyors

 Unloading Breakdown

 Storage Areas
Ash Handling & Treatment None

 Conveyors

 Ash Handling disposal 

Total Capital Cost 1,500,000

Use

Annual Operating Cost

Fuel & Utilities

Natural Gas 6,541,144

Electricity 12,000

Make Up Water 6,695

Operating Labor

 Use 1 Men at $50 / hr 396,000

Maintenance - Labor & Matl 30,000

 Use 2% Capital Cost

Overheads & Misc -5% Labor & Maint 21,000

Depreciation - 10 Yrs straight line 150,000

Annual Steam Production $7,156,839 Cost Per Year

Unit Steam production Cost $11.56 Cost per 1,000 pounds of steam

Unit Steam production Cost $25.48 Cost per MT of Steam

Use $25.00 MT Steam
7920

150

90000

1200

0.88 Energy in Steam / Energy in Fuel

855360

972000

Natural Gas

1030000

119.15269

7.4263 $7.21 $/MMBtu

27 See calcualtion below

0.061

2430

0.0004006

800000 Richardson 2001 Pkg boiler plus escallation

above 18.85

25000

50000

25000 14.0 kw Total 18.7322008 Theoretical Pump Hp Reqd

75000

400000

110000

10 KW

None
None

1500000 42.842954 kw / 1500000 lbs steam

0.29 Kwh per 1,000 pounds of steam

7008120

13000

7710.5769

396000

30000

21000

150000

7625830.6

10.698416

23.579308

24
Energy Costs from AEO 2009 (2022 Projections - in 2007 $) Need Updated

0.066 $/kWh

7.75 $/MMBTU Natural Gas

21,300 BTU/lb Natural Gas

Capital Costs (Installed)

3,600,000 From Mueller Report, Done with Midwest CHP center (DOE)

Energy Use Changes with CHP (From USDA Models/My Calculations)

0.354 kWh/gal Electricity Decrease

2239 BTU/gal Natural Gas Increase

Co-Product Prices (2022 Price from FASSOM)

124.74 $/ton DDGS

0.137214 $/kg DDGS

Corn Price (2022 Price from FASSOM)

3.60 $/bushel corn

0.141 $/kg corn

Ethanol Selling Price (AEO 2009 - 2022 Projections in 2007$)

2.061 $/Gal EtOH (Wholesale)

0.690 $/kg
(Not Real Numbers)