Overview
A Midwest ethanol producer partnered with RCM Thermal Kinetics (RCM-TK) to execute a high-impact, data-driven revamp of its Distillation, Dehydration & Evaporation (DD&E) system.
Originally designed for 40 million gallons per year (MMGPY), the plant had gradually been pushed to 85 MMGPY through incremental modifications and operational tuning. But to stay competitive, the client needed a step-change—one that delivered major gains without major capital replacement.
Using the NEXT™ Engineering Platform, RCM-TK delivered a strategic revamp that elevated the DD&E system to 105 MMGPY, completing a transformation of more than 250% over the original design while improving efficiency, separation performance, and product quality.
This project demonstrates what’s possible when advanced process design meets real-world constraints. It opens the door for existing plants to dramatically increase output, reduce cost per gallon, and strengthen their competitive position in the renewable fuels market.
Roy Viteri, Chemical Engineer
The Challenge
Despite previous upgrades, the DD&E system had reached its operational ceiling.
At 85 MMGPY, the system exhibited:
- Excessive tower pressure losses
- Undersized pumps, valves, and heat transfer equipment
- Carryover from the Beer Column into the Rectifier
- Hydraulic constraints across liquid and vapor circuits
The overarching objectives were:
- Revamp an original 40 MMGPY system to reliably produce 105 MMGPY
- Reduce carryover and improve ethanol quality
- Minimize CapEx through strategic optimization of existing assets
NEXT™ Engineering Platform Approach
1. Establishing a True Baseline
RCM-TK launched the project with a comprehensive field data campaign using the NEXT™ Platform to uncover true operating constraints, including:
- Detailed walkdowns validating piping, equipment, valves, pumps, and motors
- A comprehensive pressure & temperature survey covering towers, evaporators, and vacuum systems
- Control system data capture to verify flow, level, and performance trends
This accurate “as-is” operational model enabled:
- Identification of hidden bottlenecks
- Validation of process simulations
- Confident, data-driven selection of revamp strategies
2. Simulation & Performance Modeling
Using validated field data, engineers built an accurate digital process model to evaluate multiple revamp scenarios. Key insights included:
- Significant pressure drop in distillation columns and vapor circuits
- Undersized vaporizer and feed preheat capacity
- Pump, motor, and valve limitations restricting hydraulic performance
3. Engineering & Optimization
Using NEXT™, RCM-TK engineered targeted upgrades designed to maximize throughput with minimal capital investment:
- Customized high-capacity distillation trays and downcomers
- Advanced packing to increase Rectifier separation efficiency and ethanol proof
- Expanded heat transfer area for improved energy utilization
- A new vaporizer to increase dehydration capacity
- Larger impellers and/or motors to relieve hydraulic constraints
- A high-momentum vapor-liquid feed device to reduce carryover at elevated rates
Execution
3D laser scanning of the facility—integrated directly into NEXT™ design models—ensured precise fit-up, eliminated rework, and reduced startup risk.
Pre-Shutdown (5 Months)
- Detailed engineering via NEXT™
- Procurement of column internals, vaporizer, condensate equipment, pumps, motors, valves, and instruments
- Replacement of the Beer Column overhead vapor duct
- Multi-vendor coordination and project management
Shutdown (5 Days)
- Tray, packing, and tower internals upgrades in Beer Column and Rectifier (no welding required in towers)
- Heat exchanger and pump capacity improvements
- Piping and control valve modifications
Results
The NEXT™-driven revamp delivered a high-value, low-CapEx transformation:
- Capacity increased from 40 MMGPY to 105 MMGPY (over 250%)
- Improved ethanol proof via enhanced Rectifier separation efficiency
- Significant reduction in carryover
- Maximum utilization of the DD&E asset
- No major equipment replacement required
Lessons Learned
- Accurate field data is the foundation of every successful revamp.
- Pre-shutdown alignment eliminates costly surprises.
- Tight execution planning minimizes downtime and accelerates ROI.
Conclusion
This project demonstrates how the NEXT™ Engineering Platform transforms an aging 40 MMGPY DD&E system into a modern, optimized, high-performance operation producing 105 MMGPY.
By combining field intelligence with petroleum-refining-grade methodology, validated simulation, and targeted engineering, RCM Thermal Kinetics helped the client achieve exceptional throughput gains, improved product quality, and reduced operational risk—all with minimal capital investment.