Water Conservation & Treatment Strategies for Ethanol Plants Governors Ethanol Coalition EPA Joint Meeting Kansas City, MO Feb 10, 2006 Bibb Swain, President.
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Water Conservation & Water Conservation & Treatment Strategies for Treatment Strategies for
Ethanol PlantsEthanol Plants
Governors Ethanol CoalitionGovernors Ethanol CoalitionEPA Joint MeetingEPA Joint Meeting
Kansas City, MOKansas City, MOFeb 10, 2006Feb 10, 2006
Bibb Swain, PresidentBibb Swain, PresidentDelta-T Corp.Delta-T Corp.
Topics• External Process Water
Balance• Utility Water Requirements• How It All Fits• Opportunities
ACE ETHANOLStanley, WI
External Process Water Balance
Ethanol
PlantCor
n
Ethanol
DDGS
Basis: 50 mmgpy Typical Corn-Based Dry Mill ethanol Plant
2,233 Bu/ Hr
5,952 Gal/ Hr
20.92 Tons/ Hr2,248 Gal/ Hr
502 Gal/ Hr
18.5 Gal/ Hr
Water In = 2,248 GPH
Water Out = 520 GPH
Cooling Tower Water Balance
Cooling
TowerMakeu
p
Water
Evaporation
Drift
Basis: 50 mmgpy Typical Corn-Based Dry Mill ethanol Plant
14,700 Gal/ Hr
8,820 Gal/ Hr
600 Gal/ Hr
5,280 Gal/ Hr Blowdown
Boiler Water Balance
BoilerMakeu
p
Water
Steam
Basis: 50 mmgpy Typical Corn-Based Dry Mill ethanol Plant
260 – 4,100 Gal/ Hr
13,860 Gal/ Hr
120 + Gal/ Hr Blowdown
Condensate
Deaerator
10,000 – 13,600 Gal/ Hr
138 Gal/ Hr
DDG Dryer/ TO Water Balance
DDG Dryer/
Therm. Oxid.Wet
Cake
w/ Syrup
Water Vapor
DDGS
Basis: 50 mmgpy Typical Corn-Based Dry Mill ethanol Plant
111,892 #/ Hr
70,049 #/ Hr
20.92 Tons/ Hr8,900 Gal/ Hr
502 Gal/ Hr
8,398 Gal/ Hr
Overall Water Balance
Ethanol Plant
Fresh
Makeup
Water
Basis: 50 mmgpy Typical Corn-Based Dry Mill ethanol Plant
Boiler
Dryer
System
Cooling
Tower
Evaporation & Drift = 9,420 gph
Deaerator & Leaks = 140 gph
DDGS =
502 gph
Water Vapor = 8,398 gph
Corn
2,248 gph
13,860 gph
13,860 gph
300 gph
6,631 gph
14,700 gph
Blowdown = 5,280 gph
Blowdown = 120 gph
Water Out = 23,860 gph
Water In = 23,860 gph
Gal Water/ Gal Ethanol = 3.63Ethanol =19 gph
H2O
Water Conservation Opportunities
• Reduce Energy Consumption (less cooling tower evaporation & blowdown)
• Recycle waste and blowdown streams• Treat makeup water (less blowdown)• Use air or groundwater to reject heat
(less evaporation and blowdown)
Water Conservation Opportunities
• <3 – Current Best Practice• 1.5 – Achievable with proven
technology at extra capital cost• 0 – Possible in future with new
technologies
Gallons Fresh Water/ Gallon Ethanol less than:
Water Vapor from DDGS Dryer
Evaporator, Distillation System and Cooling Tower of
Modern Ethanol Plant
Our unique FlexiFerm™ system lets you switch between the greater quality control of batch or the greater production efficiency of continuous fermentation.
Research & Development
Mobile Membrane Test LabMobile Membrane Test Lab
The Ethanol Industry is Doing
Its Part
Clean Water - Clean Environment
Thank You!Thank You!
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