Modular Ethanol Plant Segmentation for Rapid Deployment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The high cost and labor-intensive construction process of traditional ethanol plants built from scratch hinder the widespread adoption of ethanol production technology due to the need for extensive on-site fabrication, plumbing, and wiring.
Innovation Solution
A modular ethanol production plant composed of identically sized modules, including fermentation, distillation, and ground grain modules, pre-built and pre-wired in a factory, allowing for easy assembly and minimal on-site labor, with each module resembling a shipping container for efficient transportation and connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ethanol plants are built from scratch on site with traditional construction methods, then the plant can be constructed with custom-designed components, but the construction cost and labor requirements greatly increase
Solution Approach 1:
The ethanol production plant is divided into multiple modular units, each containing specific equipment and functionality (e.g., fermentation module, distillation module, grain handling module). These modules are manufactured separately in controlled factory environments and then assembled on-site, reducing construction complexity while maintaining manufacturing flexibility.
Solution Approach 2:
Equipment and components are pre-installed, pre-wired, and pre-plumbed within each module during factory manufacturing before delivery to the construction site. This preliminary preparation significantly reduces on-site construction labor and time requirements while ensuring quality control during manufacturing.
2Productivity
If traditional on-site construction methods are used, then custom design flexibility is maintained, but the construction time and labor costs greatly increase
Solution Approach 1:
The plant is segmented into factory-manufactured modules that can be produced simultaneously in parallel, dramatically accelerating the overall construction timeline compared to sequential on-site building while maintaining custom design capabilities.
Solution Approach 2:
All necessary installations (piping, wiring, equipment mounting) are completed in advance during module fabrication, eliminating time-consuming on-site construction activities and reducing the overall project timeline.
3Ease of operation
If modules are designed to be transportable like shipping containers, then transportation and assembly efficiency improve, but the size and capacity of each module are constrained
Solution Approach 1:
The modules are designed with standardized interfaces and dimensions that allow them to function as both transportable units (similar to shipping containers) and scalable building blocks. Multiple modules can be connected in series or parallel to achieve large total capacities while maintaining the ease of handling and assembly of individual standardized units.
Data Source
AI summary
The present invention provides a modular ethanol production plant constructed of a number of identically sized modules each having a supporting structure main framework to which the components contained in the modules are attached. The plurality of modules includes a fermentation module, a distillation module, a ground grain module, or a sugar source feedstock module, and an optional heating module. Each of the modules are sized to occupy the same approximate space as a standard sized ocean going shipping container. Also, each of the modules has a central walkway including piping and electrical control boxes that are aligned for each connection to the next adjacent module.