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ethanol drawing process

Achieving the ideal yield, producing desirable co-products, and reducing energy usage are a few of the many challenges facing ethanol producers. 

If you need to ensure a maximum yield during the mashing process or want to reduce energy usage per bushel, we have your solution. Replace your heat exchangers and spargers with a product that will improve your product quality, ensure consistency and production efficiency.  

Hydro-Thermal’s patented heating system works by mixing steam and process liquids completely while delivering consistent temperature and instantaneous heating. For more information on our advanced direct steam injection technology, click here.


Heating products utilizing direct steam injection

The type of heater you need is dependent on how it will be used. No matter what your application, Hydro-Thermal has the solution for every application in ethanol and biofuel production.

All of our heaters share unique benefits, including internal modulation, self cleaning ability and rugged design and construction.

Here is what makes each solution unique:

Industrial Hydroheater (Also known as the Jetcooker™)

  • Volume capability: flow rates up to 6,700 gpm [1,522 m³/hr]
  • Precise temperature control ±1°F [.50°C]
  • Available in a variety of alloy materials including: Stainless Steel (316, 316L, 317L, AL6XN, 254SMO & 2205), Hastelloy & Titanium.
  • Adjustable pressure drop to control the shear (high or low)
  • High steam capacity
  • High solids capability
  • Hydroheater has a liquid turndown of 2:1 for starch conversion, and up to 3:1 for water-like fluids. If a greater turn-down is required consult Hydro-Thermal Engineering.
  • Available in sizes from 1/8” to 12”
  • Rating: 1/8” to 2-1/2” NPT (300 psig at 450 F), 2” to 12” flanged (150# 195 psig at 400 F, 300# 300 psig at 450 F, PN16 16 barg at 221 C, PN40 20.7 barg at 232 C)
  • Right angle design
  • All Industrial Hydroheaters include a combining tube. An extended combining tube may be recommended for a large ΔT (high temperature rise). Please contact Hydro-Thermal for more details.
  • For more information on the Hydroheater, click here.


  • Volume capability: flow rates up to 25,000 gpm [5,678 m³/hr]
  • Precise temperature control ±1°F [.50°C]
  • Body materials in a variety of materials, including316/316L SS, 254 SMO, 1.4408 Harmonized, Hastelloy; consult factory for other materials.
  • Straight through design
  • Very low pressure drop
  • Moderate steam capacity, up to 50°F ∆T under most conditions.
  • Handles heavy slurries, medium consistency pulp stock or higher solids content.
  • Up to 10:1 liquid turndown
  • Connections: ANSI Class 150; ANSI Class 300; DIN PN16, PN25, PN40, Others upon request
  • Viscosities up to 40,000 cP, consult factory for higher values
  • Ensures thorough mixing and uniform temperature profile
  • Low shear, maintains chunk size
  • High flow rates
  • Easily plumbs into existing plant utilities.
  • For more information on the Solaris, click here.

EZ Heater

  • Volume capability: 2 up to 1,350 gpm [.5 up to 306 m³/hr]
  • Precise temperature control
  • High temperature rise
  • High turndown capabilities for large flow fluctuations
  • Ability to set more than one temperature
  • Unlimited on-demand hot water at precise temperature
  • Easily plumbs into existing plant utilities
  • Pre-designed and partially stocked for short lead times
  • For more information on the EZ Heater, click here.


Optional Enhancements

Autopilot: The Autopilot automatically adjusts the Hydroheater’s product flow path as process conditions change to maintain a constant pressure drop across the unit. This results in optimized shear, mixing characteristics, and more effective starch conversion, leading to lower enzyme usage and higher yields.


Co-Pilot™: The Co-Pilot™ is designed to complement the K600 Hydroheater and K6 Autopilot, and is used to calibrate the electrical “zero” position of the Combining Tube (CT). Once the Autopilot PLC program is updated for the K600 Hydroheater, the Co-Pilot can be used to calibrate the CT while the heater is offline for maintenance. No further programming is required from Hydro-Thermal of the PLC.


Actuator Options Available

Hydro-Thermal's heaters utilize a Fisher reverse-acting diaphragm actuator (“fail close”). Generally coupled with a filter/regulator and a Fisher DVC 2000 or a DVC 6200 positioner that converts a 4-20 mA DC input signal to pneumatic output signal to the actuator. For high vibration applications remote mount positioners are available. Alternative positioners are available depending on unique processing conditions or upon request. Please contact Hydro-Thermal for more details.


Non-Obstructing Heater (NOH)

  • Volume capacity: 30 up to 6,900 gpm (6.8 up to 1,567.2 m3/hr)
  • Body and stem plugs in 316SS, and diffuser in 316L or 17-4PH (other materials available pending on request or per application)
  • Straight tube design allows unrestricted flow
  • Low pressure drop
  • Trim heating control for high turndown
  • Able to handle abrasive (sand or grit) and large particulate/fibrous materials
  • Available in sizes from 2” to 12”
  • Heater rating of 300 PSIG @ 450°F
  • Raised face flanges designed per ANSI B16.5 with lugged connections
  • For more information on the NOH, please click here.


Fluid Heating Systems

EZ Skid™: Complete skid systems utilizing the EZ Heater®. The EZ Skid is available in 5 standard sizes and is only used for hot water applications. For more information, click here.



ATTEC®: ATTEC or Advanced Fluid Heating Skids are completely customized solutions that are designed, built and installed to individual specs. Hydro-Thermal will provide necessary components including piping and control systems. These skids can be used for processing any type of slurry including starch cooking, food manufacturing, chemical processing and everything in between. For more information, click here.



Applications for Ethanol Production

Blog Articles

From the Desk of a Former Plant Manager

Hydro-Thermal employees an ethanol expert who also happens to be a former ethanol plant manager. He creates blogs with helpful tips on optimizing plant operations. Below are his most recent blogs: 

  • Has your plant increased throughput since your Hydroheater was installed? It may be time to upgrade your equipment to ensure plant efficiency. Read more here. 
  • Jetcooker troubleshooting tips - click here.
  • Tips on how to acheive optimal yield using your JetCooker. Learn more here.
  • Hydro-Thermal offers a variety of maintenance options giving you flexibility during your next shutdown. Read more here.  
  • Are you interested in differential pressures within 0.1 psi? Click here to learn more about the upgraded Autopilot.
  • Is your plant ready for winter? Click here to review our winter heating checklist. 
  • Click here to learn more about Elite Octane's slurry tank installation as well as Dr. Loren Chen's presentation at the FEW. 
  • This blog is written by our CFO from a financial perspective as ways to maximize profits by looking at expenses. Learn more here.
  • An overview of Hydro-Thermal's in-house lab which has been used to test starch conversionusing our JetCooker. Read more here.

Learn More...

For more information on our products, click here.
For more information on our patented direct steam injection technology, click here.
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