AI-Corn Clean Fuel 70MMGPY Ethanol Plant Expansion

The expansion of the AI-Corn Clean Fuel plant led to increased production, demanding more power and steam. The current steam generator couldn’t keep up, and a new system design was needed.

Location

Claremont, MN

Industry

Renewable Fuels

Services Provided

Chemical Engineering, Commissioning, Electrical Engineering, Mechanical Engineering, Utility Generation & Distribution

Challenge

The existing steam generator at AI-Corn Clean Fuel didn’t have the capacity to produce the steam required for the increased production rates. To accommodate the demand, a combined heat and power (CHP) generator was selected to produce electricity and steam.

Approach

Low carbon footprint production of motor fuel was crucial to the project and required the installation of a 5.5-MW combustion turbine and HRSG with a supplemental-fired duct burner. KFI supported this project through design, construction, check-out, startup, and commissioning

Outcome

This $146M fuel alcohol plant expansion was completed ahead of schedule and under budget. It increased plant production from 50 million gallons per year, to 120 million gallons per year. A new combustion turbine generates 5.5 MW of power and an additional 150,000 lb/hr of steam. These additions increased the plant-wide steam capacity from 80,000 lb/hr to 230,000 lb/hr.