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 reduce energy usage per bushel, we have your solution. Replace your heat exchangers and spargers with a product that will improve your product quality and ensure consistency and production efficiency. Hydro-Thermal’s patented heating solution mixes steam and processes liquids completely while delivering precise, consistent temperature and instantaneous heating.
Hydro-Thermal’s proven application expertise.
Liquefaction/Slurry Mash Heating: Achieve the highest possible ethanol yield in either dry or wet milling operations. Heating the corn mash in the Hydroheater (also called the Jetcooker) is the first step to opening the starch molecules so the enzymes can break them down into sugar. The slurry starts and has a targeted temperature of 185°F [85° C]. Once it reaches the Hydroheater, the temperature setpoint has a range between 210°F and 225°F [98°C and 107°C]. It is equally important to maintain a constant pressure drop across the Jetcooker, optimizing shear, mixing characteristics, and overall performance efficiency.
Depressurization Vapor Condenser System (DVCS): Experience a decrease in the BTU load at the sieve vaporizer required by a boiler via recycling depress
urization vapors and reducing the cooling tower load. Achieve a more favorable water balance and a potential improvement in cooling capability through fermentation and distillation.
Slurry Tank Heating: Hydro-Thermal’s turnkey solution reduces viscosity, providing additional flexibility for slurry solids adjustments and reducing downstream equipment load demand. It has also shown an improvement in corn oil yield. Finally, it gives a more uniform heating solution that eliminates mash hot and cold spots within the slurry tank. This will eliminate the need for tank sparging, bringing additional opportunities in potentially reducing enzyme dosing rates.
Cellulosic Pretreatment: A non-shear Solaris Hydroheater can be used to produce cellulosic ethanol. Hydro-Thermal’s technology sufficiently hydrolyzes and opens up the structure of lignin-based biomass feedstocks to allow efficient and effective enzyme hydrolysis of the hemicellulosic sugars. Utilizing the Solaris heater has many benefits, including precise and accurate temperature control, increasing ethanol yield and corn oil production, and reducing energy costs.
Beer Mash Slurry/Beer Mash Column: To achieve more precise temperature control, Hydro-Thermal recommends installing a non-shear Solaris Hydroheater after the beer well but before the beer column of the existing mash stream. The goal is to provide a more consistent/accurate mash temperature to the beer column (135°F [57°C] current to 170°F [76°C] future). Precise temperature control results in a reduction in energy usage, reduced energy usage, more flexibility and efficiency from the beer/mash exchangers, beer bottoms base loss recovery, and a reduction in chemical use.
Corn Oil Production: Hydro-Thermal’s NOH (Non-Obstructing Heater) heats thin stillage/syrup beyond the usually targeted temperatures and helps ethanol producers achieve their minimum feed tag specifications. The result is increasing corn oil production numbers and ultimately increasing revenue. These products provide accurate and consistent temperature control, and the added temperature works as an emulsifier. As a result, ethanol producers may reduce or eliminate their emulsion breaker chemicals while still maintaining or increasing oil production.
Hydro-Thermal is the global leader in the manufacturing and designing direct steam injection heating solutions, including the Hydroheater/Jetcooker. Our patented heating system mixes steam and processes liquids thoroughly while delivering precise and consistent temperature, instantaneous heating, and no scaling or fouling of the product. Our heaters are the industry standard in the ethanol and starch industries. They can be utilized to heat everything from utility water and liquefaction/slurry mash to corn oil, beer column, and slurry tanks.