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!