The Challenge
A large-scale ethanol producer was experiencing operational issues and high maintenance costs with their existing jet cooker system. Traditionally, jet cookers are used to heat starch slurry and provide shear to enhance enzymatic conversion. However, advancements in enzyme technology have made mechanical shear largely unnecessary for optimal performance.
Despite this, the facility continued using a jet cooker designed to deliver shear, incurring unnecessary operating expenses. What they truly needed was a reliable and efficient method for thoroughly heating their grain slurry—without the wear and complexity of shear-based equipment.
The plant aimed to:
- Improve operational efficiency
- Lower maintenance costs
- Maintain consistent performance under demanding production conditions
Unfortunately, their jet cooker was difficult to control, required frequent maintenance, and had a high total cost of ownership. The high-shear design resulted in heavy wear, requiring expensive coatings and regular servicing. Complicating matters, limited space in the facility made installing new equipment a challenge.
Key Requirements
- Achieve consistent, optimal slurry heating for enzyme activity without unnecessary mechanical shear
- Reduce maintenance and downtime
- Improve ethanol yield and product quality through stable heating performance
- Fit within space limitations in the production area
- Achieve long-term cost savings and lower total cost of ownership
Solution
ProSonix worked closely with the plant to fully understand their requirements — particularly the need to heat the grain slurry effectively without applying mechanical shear.
We recommended our PSX I-Series Angled Inline Heater, a patented steam injection heater designed to deliver uniform, energy-efficient heating in high-solids, high-viscosity applications.
The I-Series injects high-velocity steam directly into the slurry in a three-dimensional pattern, ensuring consistent, complete heating without hot spots, energy waste, or internal wear. Its robust construction and lack of shear components make it ideal for modern enzymatic conversion processes.
Working with the facility’s engineering team, we tailored the system to existing steam pressures, flow rates, and piping configurations. The compact, inline design allowed for quick installation with only minor plumbing adjustments—minimizing downtime and integrating seamlessly into the plant’s layout.
Results & Benefits
Beyond improved heating performance, the PSX I-Series provided several additional operational advantages:
- Lower Noise – Quieter operation improved the work environment and reduced noise-related safety concerns
- Simplified Maintenance – Durable, low-maintenance construction reduced service frequency and associated costs
- Seamless Integration – Compatible with existing control systems, requiring no proprietary hardware or controls
- Fast Startup – Quick, hassle-free installation and commissioning reduced disruption
- Scalable Design – Internally modulated steam control supports future production increases without equipment upgrades
Summary of Benefits
- Optimized heating performance: Uniform, thorough, and reliable heating of the starch slurry, without the need for grain shear
- Reduced maintenance and downtime: A lack of internal high-wear areas and a robust, low-maintenance design
- Fast, space-efficient installation: Compact, inline design and simple installation requirements
- Improved integration and control: Simple integration with existing control systems
- Quieter operation: Lower noise levels improved workplace safety and comfort
- Scalable for future growth: Internally modulating steam control allows the system to adapt to future production increases
- Long-term cost savings: Energy efficiency, reliability, and lower maintenance needs