Greenfield Corn Ethanol Facility

Indiana, USA

A leading international bioenergy company looked to Roeslein, in partnership with our subsidiary manufacturing facility, Integrated Manufacturing Technologies (IMT), to build a modularization system for the fermentation alley of their Indiana ethanol plant.

Combining customer knowledge of the fermentation process and Roeslein/IMT’s knowledge of the modularization process, the two companies have worked together to create interconnecting piping systems, safer access platforms, cable trays, and other systems into modularized units.

Roeslein’s modularization efforts consisted of but were not limited to lower level piping, process modules, upper area modules, stair tower, upper area access, agitator access platform, operator access, and interconnecting bridges.

This concept enabled a substantially quicker start-up schedule, an average of 34% savings in construction costs, and enhanced safety and productivity.

A quicker start-up was achieved through significantly reducing on-site construction efforts. More work was completed under controlled conditions in the IMT factory,  decoupling process installation from building construction and tank erection, and alleviating interruptions caused by weather.

By utilizing the modularization process, project safety and productivity were also enhanced—Roeslein minimized stacking of trades by shifting pipe and structural fabrication and erection man-hours from the field to a controlled shop. Modularization also led to less site congestion (lifts, equipment, personnel).These factors added to a safer construction effort and on-time start-up process.

Roeslein Scope:

• Delivery of the piping modules to site
• Provide the erection or connection supervision for the piping modules
• Provide all piping materials in order to have a complete system (nuts, bolts, gaskets, and pipe supports).