Presenters Scott A. Lucas Scott A. Lucas PE PE Founder & Managing Director of Kansas-based Lucas E Lucas E 3 , LLC , LLC (Ethanol (Ethanol Expansion Expansion Engineering) Engineering) Jason Jason A. Cook A. Cook PE/SE/MBA PE/SE/MBA President & Founding Principal of Kansas-based J.COOK J.COOK Structural Structural Engineeri Engineering LLC ng LLC
Presentation Outline Section 1 - Section 1 - Introdu ntroduction ction & Presen & Presentation Outline tation Outline Section 2 - Section 2 - Ethanol Prod thanol Production uction & Plant Issues & Plant Issues ucas E 3 Philosophy of Service Section 3 - Section 3 - Lucas E Philosophy of Service Section 4 - Section 4 - Service Packages ervice Packages Section 5 - Section 5 - Example Customer & Project xample Customer & Project Section 6 - Section 6 - Energy Efficient Projects - nergy Efficient Projects - Looking Forward ooking Forward Section 7 - Section 7 - Comments and Questions omments and Questions
Ethanol Production & Economic Impact For 2012 U.S. had For 2012 U.S. had 21 211 active ethanol plants 1 active ethanol plants producing 13.3 BGY producing 13.3 BGY at 90% of current national at 90% of current national nameplate capacity of 14.7 nameplate capacity of 14.7 BGY BGY Minnesota Minnesota had 21 plants had 21 plants producing producing 1.0 BGY 1.0 BGY at at 100% nameplate capacity accounting for about 100% nameplate capacity accounting for about 7.7% of U.S. production 7.7% of U.S. production Minnesota plants use about 400 m Minnesota plants use about 400 million bushels of corn annually illion bushels of corn annually, , account for about 4,300 jobs, and account for about 4,300 jobs, and have an have an estimated annual total estimated annual total economic impact of about $2.2 billion economic impact of about $2.2 billion Due Due to size and to size and distribution all Mi distribution all Minnesota ethanol plants can benefit nnesota ethanol plants can benefit significantly f ificantly from s om specific ific targeted targeted process improvements process improvements
Plight of the Smaller Ethanol Plant Few ethanol plants have a Few ethanol plants have a pr process engineer on staff, ocess engineer on staff, which some estimates put at about 20% which some estimates put at about 20% Even with a Even with a process engineer process engineer, duties can preven duties can prevent the in- t the in- house design of simple and readily available projects house design of simple and readily available projects Many opportunities exist for the small, targeted project Many opportunities exist for the small, targeted project that can improve energy efficiency at the plant, often that can improve energy efficiency at the plant, often with less than a with less than a $300,000 capital investment $300,000 capital investment This type of This type of project is of project is often revealed after a detailed ten revealed after a detailed optimization process using common engineering methods optimization process using common engineering methods
Plight of the Smaller Ethanol Plant Large consulting design firm Large consulting design firms are often engaged on new s are often engaged on new plants and large additions or remodels plants and large additions or remodels These firms focus on larger projects in excess of These firms focus on larger projects in excess of $1,000,000 and they tend not to approach small plants $1,000,000 and they tend not to approach small plants for proposals with minor upgrades and additions for proposals with minor upgrades and additions When engaged on a When engaged on a smaller pl smaller plant they may come to the ant they may come to the table with a predetermined so table with a predetermined solution that has more than lution that has more than what the Owner really needs what the Owner really needs Smaller firms can work more closely but may lack the Smaller firms can work more closely but may lack the breadth of experience, breadth of experience, relying more on past projects relying more on past projects
Lucas E3 Philosophy of Service As Scott Lucas worked for one of the largest ethanol As Scott Lucas worked for one of the largest ethanol design firms, he came to see design firms, he came to see this plight of the small to this plight of the small to mid-size plant as mid-size plant as unacceptable and unnecessary unacceptable and unnecessary In 2010 Scott founded Lucas E 3 and quickly began to In 2010 Scott founded Lucas E and quickly began to associate with other experienced and like-minded associate with other experienced and like-minded designers, contractors, suppliers in order to offer Owners designers, contractors, supplie rs in order to offer Owners the same types of service – the same types of service – but with a ut with a twist twist The twist? The twist? We do what our clients need us to do do what our clients need us to do regardless of plant size and project scope regardless of plant size and project scope
Lucas E3 Philosophy of Service We start by focusing start by focusing our efforts to determine what the our efforts to determine what the Owner needs and develop solutions from there Owner needs and develop solutions from there We spend time with the Owner spend time with the Owner, usually in face-to-face , usually in face-to-face meetings, to foster a close working relationship meetings, to foster a close working relationship We educate the Owner on readily-available methods and educate the Owner on readily-available methods and projects that increase energy and operational efficiency projects that increase energy and operational efficiency We develop solutions with develop solutions with significant Owner input significant Owner input
Service Packages Plant Evaluation & Plant Evaluation & Report Report Engineering Design Engineering Design Owner Representation & Owner Representation & Coordination Coordination
Service Packages Plant Evaluation & Plant Evaluation & Report Report 1. 1. Plant W Plant Walk-Through lk-Through 2. 2. Baseline Model Baseline Model 3. 3. Improved Model Improved Model 4. 4. Model Comparison Model Comparison 5. 5. Issue Report with Recommendations Issue Report with Recommendations
Service Packages Plant Evaluation & Plant Evaluation & Report Report 1. 1. Plant W Plant Walk-Through lk-Through a. a. Physicall Physically walk the plant to develo y walk the plant to develop a p a more complete understan more complete understandin ding of of operations and begi opera and begin to to identify bo identify bottlenecks ttlenecks b. b. Col Collect ct opera operational inf inform ormation tion, data, drawings , data, drawings, etc. , etc. c. c. Interv Int rview opera w operational sta staff to discu to discuss s ss specific i ecific issues t sues to be be addr addressed essed 2. 2. Baseline Model Baseline Model 3. 3. Improved Model Improved Model 4. 4. Model Comparison Model Comparison 5. 5. Issue Report with Recommendations Issue Report with Recommendations
Service Packages Plant Evaluation & Plant Evaluation & Report Report 1. 1. Plant Walk-Through Plant W lk-Through 2. 2. Baseline Model Baseline Model a. a. Material & Energy Balance to Material & Energy Balance to est establish curr curren ent proces process flows flows b. b. Defi Define proces process flow int flow into and out o and out of each of each piece piece of equ of equipm pmen ent c. c. Model Model will more accu will more accuratel rately rep represent c resent current plant o rrent plant operations erations 3. 3. Improved Model Improved Model 4. 4. Model Comparison Model Comparison 5. 5. Issue Report with Recommendations Issue Report with Recommendations
Service Packages Plant Evaluation & Plant Evaluation & Report Report 1. 1. Plant Walk-Through Plant W lk-Through 2. 2. Baseline Model Baseline Model 3. 3. Improved Model Improved Model a. a. Use baseline mo e baseline model t del to i introduce pr roduce process mo ess modifications difications b. b. Create modified P&IDs an Create modified P&IDs and M&EBs to qua d M&EBs to quantify tify impact impact 4. 4. Model Comparison Model Comparison 5. 5. Issue Report with Recommendations Issue Report with Recommendations
Service Packages Plant Evaluation & Plant Evaluation & Report Report 1. 1. Plant W Plant Walk-Through lk-Through 2. 2. Baseline Model Baseline Model 3. 3. Improved Model Improved Model 4. 4. Model Comparison Model Comparison a. a. Evaluate changes between Evaluate chan ges between Base Baseli line Model Model and Improved Model and Improved Model b. b. Summarize compari Summari ze comparison sons for inclu for inclusio ion in Report in Report 5. 5. Issue Report with Recommendations Issue Report with Recommendations
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