📋 Case Study

Corn Ethanol Plant Auger Plugging Mitigation

Frequent auger plugging at transition hoppers due to moisture variation and fines accumulation

🏗️ Project Overview

Midwest U.S. ethanol facility processing 120,000 bpd corn

🎯 Challenge

Frequent auger plugging at transition hoppers due to moisture variation and fines accumulation

🔧 Design Approach

Redesigned hopper geometry with 65° walls + vibratory pad integration; installed inline moisture sensor with feed rate modulation

📐 Design Diagram

AI-generated project design illustration

📐 Key Calculations

Critical Hopper Angle

2 × Angle of Repose + 10°

Result: 62°

Prevents arch formation

Fill Ratio Limit

0.45 × (1 − MC/20)

Result: 38%

Avoids torque overload and grain smearing

📊 Results

92% reduction in unplanned shutdowns; 7.3% throughput increase; $210K annual labor savings

💡 Lessons Learned

• •Moisture-driven rheology changes dominate failure modes
• •Real-time feed modulation outperforms fixed-speed control

✅ Key Takeaways

• 1Moisture-driven rheology changes dominate failure modes
• 2Real-time feed modulation outperforms fixed-speed control