Ethanol Combined Heat and Power Plant Design

Salas O’Brien delivered comprehensive mechanical, electrical, and instrumentation & controls design engineering services for a cutting-edge Combined Heat and Power (CHP) plant at Blue Flint Ethanol’s facility. The project replaced an aging coal power plant to provide an uninterrupted steam supply and reduce purchased power needs.

Our team designed a system featuring two boilers capable of producing 280,000 lb/hr of superheated steam at 560 pounds per square inch gauge and 600°F. The design incorporates a back-pressure steam turbine generator, generating 5 MW of on-site power. Advanced pressure and desuperheater control systems enable flexible steam delivery to the ethanol facility.

Additionally, our team contributed to the design of a 626-ton-per-day carbon sequestration facility, further enhancing the plant’s environmental performance and efficiency.