Increasing capacity without compromise

The project will help Koch Engineered Solutions to meet a growing market demand for energy efficient bioethanol plants as part of a drive for more sustainable energy. To increase capacity, the plant needed heat exchange technology that could handle complex process media containing solids without compromising efficiency or safety. Minimising potential downtime and ensuring long-term reliability were also critical factors.

Our solution was to provide 19 NT Series plate heat exchangers. These included both standard plate heat exchangers (PHE) and specialised free-flow models, designed specifically to handle fluids containing particles or solids that would clog conventional systems. The NW150 and NF100 wide plate gap models used as mash heaters are critical components in this system, effectively handling media that would normally cause blockages and costly downtime.

In addition, two double-wall plate heat exchangers were installed for critical areas requiring the highest level of safety. These exchangers feature an air gap between the plates to ensure safe circuit separation, providing a similar level of safety as traditional shell and tube designs, but with a more compact footprint.

A long-standing partnership

Kelvion has been a trusted partner of Koch Engineered Solutions since 2003, with a history of successful joint projects. For this expansion, close cooperation and on-site technical support ensured a smooth design and delivery process, with partial deliveries scheduled for late 2024 and full operation by summer 2025.

"Kelvion's technical expertise and commitment to working closely with us on heat exchanger selection and design made a significant difference to the success of this project,” said Dr. Jochen Christmann, Koch Engineered Solutions. “Their ability to provide flexible and efficient solutions perfectly matched our needs.” 

The upgraded heat exchangers significantly improve operational efficiency by optimising heat recovery and reducing energy consumption. By using Kelvion's Free Flow and double-wall PHEs, the bioethanol plant achieves reliable operation with minimal maintenance, while contributing to the environmental goals of the project. The expansion will increase bioethanol production, supporting the industry's ongoing commitment to sustainability.

The result

This bioethanol plant expansion project not only strengthens Koch Engineered Solutions’ capabilities, but also underscores Kelvion's role in advancing sustainable, reliable solutions in the renewable energy sector.