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PUMPS, VALVES & ACTUATORS


PUMPING SOLUTIONS FOR CORN-BASED ETHANOL


A corn ethanol plant in Brazil is using Sulzer’s process pumps for all of its applications, from initial mash slurry transfer to final ethanol truck loading


phase 1 production started in 2017 with an initial capacity of 250 million litres per year. The facility utilises the latest process technologies from ICM, a company that has become a world leader in biorefining technologies and processes. In addition to bioethanol, some high-value coproducts such as corn oil as well as high-protein and high-fibre dried distiller’s grains are produced. The plant also generates electricity from the biomass, partly for internal use and the surplus for sale. Recognised as one of the most modern and


F


efficient corn ethanol plant in the world, the production facility is equipped with pumping equipment from Sulzer and value-added, patented technologies from ICM. This includes Selective Milling Technology (SMT), Fibre Separation Technology (FST), and Base Tricanter System (BTSTM). Each step of ethanol production from corn


involves pumps with technically demanding applications. The liquids can be complex, have high solids contents, be viscous, corrosive, hot, erosive, or explosive. The right pump materials and optimal sealing systems must be carefully selected to ensure reliable and long- lasting operation. Furthermore, all pumps


S – Fueling Sustainability, located near Lucas do Rio Verde, Mato Grosso, is the first corn-only ethanol plant in Brazil. The


must be highly efficient, both in terms of energy and water savings, so that the complete plant is operating to its full potential. In close cooperation with the customer,


AHLSTAR and SNS pumps were chosen for all applications – from initial mash slurry transfer to final ethanol truck loading. In total, more than 80 single-stage pumps were installed for phase 1. The AHLSTAR pumps in duplex material are handling liquids containing solids and other particles, while the SNS pumps are running on clean liquids. Most of the pumps are equipped with double mechanical seals. Sulzer has thorough experience in pumping


solutions for corn-based ethanol plants worldwide. In the United States alone, more than 200 plants are in operation today, and about 70% of them are equipped with Sulzer pumps. These successful references strengthened the confidence of the client from the very beginning of the project. After careful commissioning and start-up, all


pumps have been working perfectly. For the toughest applications, the AHLSTAR pumps with adjustable side plates provide high performances continuously. For clean liquids, the new SNS pumps have the highest efficiencies on the market – they exceed the benchmark efficiency index MEI 0.7. Both the AHLSTAR and the SNS pumps have open impellers with balancing holes that optimise the shaft seal function. For pumps with double mechanical seals, it was decided after a few months’ operation to switch from API piping plan 54 (external pressurised source) to API piping plan 53


26 NOVEMBER 2023 | PROCESS & CONTROL


(external pressurised reservoir). This change helped to further reduce the water consumption and operational costs. The versatility of the pumps and the dedicated Sulzer service technicians made this upgrade easy and fast. During 2018, a duplicate of the existing plant


was built (phase 2). This doubled the production capacity of the Lucas do Rio Verde site. Extremely satisfied with the collaboration, FS – Fueling Sustainability ordered new similar Sulzer pumps for this extension. The site was further expanded in 2019 (phase 3) with additional Sulzer equipment installed. Today, in total more than 300 AHLSTAR and SNS pumps are running smoothly in the plants. “Top-efficiency. Not only for pumps, but also


for service provided throughout the project,” said Ju


́lio Ce


Fueling Sustainability The corn ethanol site has a total of 307


Sulzer single-stage process pumps in duplex or stainless steel 316 materials. Most AHLSTAR pumps with double seal are equipped with the simple and reliable Sulzer thermosiphon SP8 seal pot system. The AHLSTAR and SNS pump ranges have a wide choice of wet end sizes to cover exactly the required flows and heads, allowing the pumps to always run at duty points close to the best efficiency points. Benefits include: • Recognized supplier in the biofuels market • More than 20,000 single-stage process


pumps installed in bioethanol production plants worldwide. • Close cooperation with the customer


during the whole life cycle of the equipment • AHLSTAR and SNS pumps for demanding


bioethanol applications ensure minimum power consumption, trouble-free operation, and reduced maintenance.


Sulzer www.sulzer.com


́sar Santana, Project Manager, FS –


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