Ethanol Plant Installs HRSG for Improved Heat Transfer and Fuel Savings

One leading bioenergy facility produces 54 million gallons of ethanol from 20 million bushels of corn annually. The corn is ground into a meal-like substance and then made into what is termed "beer" because the process is very similar to the fermenting process for consumable alcohol. Steam from two gas-fired, D-type watertube boilers is applied to the material fostering its chemical breakdown. Though the plant's primary objective is the production of ethanol and feed, its executives have a strong desire to conserve finite fuel resources and preserve the environment. 

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Challenge:

The plant desired an energy-efficient solution to capture waste heat from its odor-eradicating thermal oxidizer, which operates at temperatures between 1,000 and 1,500 F, and has a mass flow exceeding 300,000 pounds per hour.

Solution:

Cleaver-Brooks provided a Slant-type Heat Recovery Steam Generator (HRSG) that has a finned watertube design and isolated diagonal downcomers for increased heat transfer and excellent heat absorption, saving valuable energy.

Results:

The Cleaver-Brooks Slant-type HRSG complements the plant's existing fuel-fired, D-type watertube boiler. The HRSG has added processing capacity, increased operational efficiency, reduced fuel, and lowered energy costs. 

HRSG Slant Ethanol Plant

Since ethanol production is a very energy-intensive process, using every BTU generated is critical to the plant's operational efficiency

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