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Water Conservation & Treatment Strategies for Ethanol Plants Governors Ethanol Coalition EPA Joint Meeting Kansas City, MO Feb 10, 2006 Bibb Swain, President Delta-T Corp. Topics. External Process Water Balance Utility Water Requirements How It All Fits Opportunities.

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Water Conservation & Treatment Strategies for Ethanol Plants

Governors Ethanol Coalition

EPA Joint Meeting

Kansas City, MO

Feb 10, 2006

Bibb Swain, President

Delta-T Corp.


Topics
Topics

  • External Process Water Balance

  • Utility Water Requirements

  • How It All Fits

  • Opportunities


Ace ethanol stanley wi
ACE ETHANOLStanley, WI


External process water balance
External Process Water Balance

5,952 Gal/ Hr

Ethanol

Ethanol

Plant

18.5 Gal/ Hr

2,233 Bu/ Hr

Corn

2,248 Gal/ Hr

20.92 Tons/ Hr

DDGS

502 Gal/ Hr

Water Out = 520 GPH

Water In = 2,248 GPH

Basis: 50 mmgpy Typical Corn-Based Dry Mill ethanol Plant


Cooling tower water balance
Cooling Tower Water Balance

8,820 Gal/ Hr

Evaporation

600 Gal/ Hr

Cooling

Tower

Drift

Makeup

Water

14,700 Gal/ Hr

5,280 Gal/ Hr

Blowdown

Basis: 50 mmgpy Typical Corn-Based Dry Mill ethanol Plant


Boiler water balance
Boiler Water Balance

13,860 Gal/ Hr

Steam

10,000 – 13,600 Gal/ Hr

Condensate

Makeup

Water

138 Gal/ Hr

260 – 4,100 Gal/ Hr

Deaerator

Boiler

120 + Gal/ Hr

Blowdown

Basis: 50 mmgpy Typical Corn-Based Dry Mill ethanol Plant


Ddg dryer to water balance
DDG Dryer/ TO Water Balance

70,049 #/ Hr

Water Vapor

8,398 Gal/ Hr

DDG Dryer/

Therm. Oxid.

Wet Cake

w/ Syrup

111,892 #/ Hr

8,900 Gal/ Hr

20.92 Tons/ Hr

DDGS

502 Gal/ Hr

Basis: 50 mmgpy Typical Corn-Based Dry Mill ethanol Plant


Overall water balance

Boiler

Overall Water Balance

Evaporation & Drift = 9,420 gph

14,700 gph

Cooling

Tower

Deaerator & Leaks = 140 gph

300 gph

Blowdown = 5,280 gph

Blowdown = 120 gph

13,860 gph

13,860 gph

Water Vapor = 8,398 gph

Fresh

Makeup

Water

Ethanol Plant

6,631 gph

Dryer

System

DDGS =

502 gph

2,248 gph

Ethanol =19 gph H2O

Gal Water/ Gal Ethanol = 3.63

Corn

Water Out = 23,860 gph

Water In = 23,860 gph

Basis: 50 mmgpy Typical Corn-Based Dry Mill ethanol Plant


Water conservation opportunities
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 opportunities1
Water Conservation Opportunities

Gallons Fresh Water/ Gallon Ethanol less than:

<3 – Current Best Practice

1.5 – Achievable with proven technology at extra capital cost

0 – Possible in future with new technologies




Our unique FlexiFerm™ system lets you switch between the greater quality control of batch or the greater production efficiency of continuous fermentation.


Research & Development greater quality control of batch or the greater production efficiency of continuous fermentation.

Mobile Membrane Test Lab


Clean Water - Clean Environment greater quality control of batch or the greater production efficiency of continuous fermentation.

The Ethanol Industry is Doing Its Part


Thank You! greater quality control of batch or the greater production efficiency of continuous fermentation.


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