Industrial facility for deep wheat processing and production of L-lysine HCl, wheat gluten, bioethanol, and auxiliary products

Processing of 250,000 tons of wheat per annum

Project structure

The site

50 hectares of free land plot in Balashov, Saratov region

Raw material

Wheat grown in Saratov region. Output: 250,000 metric tons per annum

Production

Grain elevator (storage capacity of 110 000 tons)
Grinding mill
Starch and gluten plant
L-lysine HCl plant
Bioethanol plant

Products 223,000 tons per annum

L-lysine HCl 65,200 tons per annum
Feed supplement 95,200 tons per annum
Gluten 19,500 tons per annum
CO2 (carbon dioxide) 22,100 tons per annum
Bioethanol 20,600 tons per annum

L-lysine (monohydrochloride 98.5%)

Production output: 65,200 tons per annum.

Area of application: Cattle breeding. Protein is not produced and there is no muscle gain when lysine is deficient. It is used in manufacture of mixed fodder and as a mono-supplement.

Feed supplement (DDGS)

Production output: 95,200 tons per annum.

Area of application: Cattle breeding. Natural muscle gain without application of antibiotics/with reduced application of antibiotics.

CO2 (carbon dioxide)

Production output: 22,100 tons per annum.

Area of application: Food industry.

Gluten (wheat gluten)

Production output: 19,500 tons per annum.

Area of application: Baking industry, fish farming.

Bioethanol (industrial alcohol, 99%)

Production output: 20,600 tons per annum.

Specifics: Produced from the waste of core operations, thus increasing the efficiency of the facility as a whole.

Area of application: Oil refineries – a fuel additive that increases the octane number. Chemical industry – manufacture of detergents, paints & varnishes.

Product line of the plant

Product Demand Technical Data Sheet
L-lysine HCl Fodder production, cattle breeding PDF
Bioethanol Paint and coatings industry, chemical factories, oil refineries PDF
Feed
supplement (DDGS)
Cattle breeding PDF
Gluten Baking industry, feed production for fish farming PDF
CO2 (carbonic acid) Food industry, metallurgy, chemical industry PDF

Process flow diagram

  • An alternative facility configuration assumes processing 250,000 tons of wheat per annum for production of L-lysine Monohydrochloride, dry wheat gluten, bioethanol, and feed supplement.

    It is planned to build a grain elevator with a storage capacity of 100,000 tons of wheat grains within the facility’s territory. The elevator is designed to receive wheat from motor vehicles and rail transport and to prepare it for storage (the wheat is cleaned and dried). The grain is fed from the main storage silos to the main production building for deep wheat processing or shipment.
  • In the facility’s main production building, the wheat is subjected to dry grinding and divided into wheat flour and bran fraction.

    The wheat flour is supplied to the wet milling line where starch is separated from gluten and fiber (pulp and soluble substances) and is then fed for glucose production.

    In the glucose production line, the starch is turned into glucose with enzymes and is fed for L-lysine Monohydrochloride production after filtration.

    Besides the above-mentioned products, the facility produces dry wheat gluten and bioethanol. The wheat gluten is fed to the gluten drying line, then packaged in its dry form and placed in a storehouse.
  • The bran fraction after dry grinding, low-grade B starch and other components without starch which are received during wet grinding are mixed and fed for bioethanol production.

    The facility’s main production building comprises the following process sections: — grain receiving and storage
    — grain milling
    — starch and gluten separation
    — gluten drying and packaging
    — glucose production
    — L-lysine HCl
    — bioethanol production
    — CO2 production
    — feed supplement (DDGS) production

Site plan

  • 1 Administrative building
  • 2 Cereal laboratory with truck scales
  • 3 Main production building
  • 3.1 Utilities building
  • 3.2 Process tanks room
  • 4 Grain storehouse
  • 4.1 Grain terminal for motor vehicles
  • 4.2 Grain terminal for rail transport
  • 4.3 Grain-cleaning station
  • 4.4 Grain-drying station
  • 4.5 Grain storage station
  • 4.6 Control room
  • 4.7 Transformer substation. Switch room
  • 4.8 Aspiration waste hoppers
  • 5 Finished product drying, packaging and storing building
  • 5.1 Feed supplement storage hoppers
  • 6 Bioethanol fermentation section
  • 6.1 Bioethanol distillation and fractionation section
  • 7 On-site chemicals storage
  • 8 Carbon dioxide recovery area
  • 9 Bioethanol storage
  • 10 Acid offloading area
  • 10.1 Ammonia offloading and storage area
  • 10.2 Station for bioethanol loading to rail transport
  • 11 Main step-down substation
  • 11.1 10 kV closed dividing device
  • 11.2 Transformers and arc-suppression coils
  • 11.3 Outdoor switchgear
  • 12 Boiler room
  • 13 Gas distribution plant
  • 14 Water supply pump station with water storage tanks
  • 15 Water treatment
  • 15.1 Process water storage tank
  • 16 Utility unit (compressor room, chiller room, distribution transformer substation)
  • 17 Cooling tower
  • 18 Stormwater treatment facilities
  • 19 Effluent treatment facilities
  • 19.1 Sludge tanks
  • 20 Transformer substation
  • 21 Railroad scale
  • 22 Checkpoint
  • 23 Road transport department
  • 24 Mechanical repair department

Main European
and Russian technologies
of the project

Buhler

Collection and preparation of grains.Transportation equipment, dryers and cleaners.

Buhler

Dry grinding of grain. Solutions of companies adapted for plants of deep processing of grain. Output: flour of specified fractions.

Alfa Laval, GEA, Flottweg

Flour separation processes.Maximum-efficiency technologies on gluten and starch extraction. Minimal energy demand and sewage water volumes.

Vettertec

Dryers technologies.Provide the lowest power consumption per product unit.

VogelBusch

Production of glucose and bioethanol.The lowest operating costs in the industry.

Novasep, State Research Institute of Genetics and Selection of Industrial Microorganisms of National Research Center “Kurchatov Institute”

The production of L-lysine Monohydrochloride.Leader in ion exchange chromatography with the most extensive reference base and the most energy efficient technologies.

Prospective products of the plant —
bio-degradable plastics

The facility is being designed as «an open structure». It presupposes simplified expansion of the product line in the future. Availability of a resource stockpile makes it possible to create a biotechnological cluster with a wide range of opportunities. Creation of facilities to produce biodegradable polymers is considered the most promising one. The integrated textile mill in Balashov will enable to build a chain from the polymer to the final product.

Types of plastic

PLA

(lactic acid )

Packaging of fruit and vegetables, eggs, delicacies and bakery products

Films for packaging of sandwiches, sugar candies and flowers

Nonwoven fabric

PHA

(hydroxyalconoates)

Biodegradable packaging materials and shaped goods

Nonwoven fabric

One-use wipes and personal hygiene items

Films and tissues, binding agents and coatings

Binding materials for metal and ceramic powders

Water-repellent coatings for paper and carton

Project advantages

01

Innovative technology

02

High quality products

03

Efficient personnel

04

Low costs of row
materials

05

Individual attention to customers

06

Worldwide service

07

Non-waste and environmental friendly production

Industry updates

07 12 2019

The first agreement for the supply of equipment

The delegation of «SaratovBioTech» visited the company Bühler in Switzerland. The concern occupies a leading position in the world market in the field of technologies and methods of grain processing. 65% of the mills in the world are equipped by Bühler.

The annual turnover of the concern is $ 3.27 billion, the number of employees is 12 thousand people.

An agreement was signed on the supply of equipment and technologies for the enterprise in Balashov. We will have the most advanced mill complex in Russia!

06 12 2019

Equalization to the world experience

Today, a delegation » Saratovbiotech» visited the AGRANA biotechnological cluster in Vienna.

AGRANA Beteiligungs AG is the leading company in Central and Eastern Europe for the production of sugar and starch, the world market leader in the production of fruit juice concentrates and fruit preparations, and the largest supplier of bioethanol.

The study of modern developments in the field of biotechnologies, production technologies and management will allow the company to successfully develop and compete in the world market.

04 12 2019

Start of construction of the complex!

On December 4, the first stone was laid in Balashov, marking the beginning of construction of a production complex for deep processing of wheat and production of the amino acid L-lysine HCl.

The ceremony of laying the first stone was attended by the Governor of the region Valery Radaev, representatives Of the Department of food and processing industry of the Ministry of agriculture of the Russian Federation, as well as residents of the city.

«This is an innovative project, a very special production that is in demand in our region. We produce a lot of grain, our farmers are able to ensure the loading of the plant, and the food additives that will be produced here are in demand by the Saratov livestock industry, » Valery Radaev said.

At the moment, the most important element in the production of compound feeds — L-lysine HCl is not produced in Russia.

The production capacity of Saratovbiotech will allow to refuse import of lysine chloride and create added value of wheat processing on the territory of the country.
The Ministry of agriculture of the Russian Federation supports this direction and is considering the possibility of state support.

Construction is expected to be completed by the end of 2021.

10 10 2019

Golden Autumn expo of agricultural industry

On 10 October 2019, Sberbank signed a Strategic Cooperation Agreement with Saratov Biotechnologies LLC at the Russian expo of agricultural industry «Golden Autumn».

13 08 2019

«Important Investment Project»

On 13 August 2019, the project of Saratov Biotechnologies LLC received the status of an important investment project for the social and economic development of Saratov Oblast at the Investment Council under the Governor of Saratov Oblast.

16 02 2019

2019 Russian Investment Forum in Sochi

The Governor of Saratov Oblast V. V. Radaev signed a Memorandum of Understanding on Implementation of the Investment Project

Location of the manufacturing facility

A 50 ha area
in Saratov region