CASE STUDY:
Al-Corn, Clean Fuel Plant Expansion
PROJECT NAME.
Al-Corn, Clean Fuel Plant Expansion
CUSTOMER.
Al-Corn, McGough CM
MARKET SECTOR.
Industrial & Manufacturing
SERVICES
- $147 million ethanol facility expansion
- Increased production capacity to 120M gallons annually
- Process and utility infrastructure integration
- Completed within an active operating facility
- Cook, fermentation, distillation, and evaporation system upgrades
- Drying, cooling tower, storage, and utility expansions
- 5.5 MW combustion turbine installation
- Heat recovery steam generator (HRSG) integration
- Supplemental duct burner producing 150,000 lbs/hr of steam
- Enhanced long-term plant efficiency and operational reliability
OVERVIEW.
The Pioneer Power team supported the $147 million expansion of the Al-Corn Clean Fuel ethanol facility, helping increase production capacity to 120 million gallons per year. Working within an operating plant environment, the project required the successful integration of new process and utility infrastructure with existing plant systems to support expanded production and improved efficiency.
The expansion included significant upgrades to the cook, fermentation, distillation, evaporation, drying, cooling tower, storage, and utility systems, as well as the installation of a 5.5 MW combustion turbine, heat recovery steam generator, and supplemental duct burner capable of producing an additional 150,000 pounds of steam per hour. Pioneer Power’s expertise in process piping, utility systems, and industrial facility integration helped support the plant’s long-term operational growth and reliability.