With ethanol fast becoming a household word throughout America, and as more and more ethanol production facilities come on line, the need has never been greater for the industry to be seen as a good and conscientious protector of the environment. Attending a local planning board meeting with a proposed ethanol plant on the agenda is all that is needed to understand that environmental impacts of production facilities are a primary concern of citizens.
 
 Fortunately, the ethanol industry is at the forefront of meeting state and federal environmental standards, particularly in the realm of controlling and monitoring stack emissions. These monitoring requirements have created market opportunities for environmental and technology-driven companies to emerge as reliable solution providers.
 
 Why Continuous Stack Monitoring?
 The U.S. EPA requires the continuous monitoring of nitrogen oxide (NOx) at ethanol and biodiesel plants that have steam-generating boilers with a heat input capacity of 100 MMBtu per hour or greater (under 40 Code of Regulations Part 60, Subpart Db). Similarly, facilities with thermal oxidizers and heat-recovery/steam generators (HRSGs) that meet the 100 MMBtu per-hour threshold are also required to have continuous stack monitoring (also under Subpart Db). While there have been cases where operating permits don't explicitly state this requirement, it doesn't obviate the need for the plant to have a continuous stack monitoring system installed, certified and operating within 180 days of plant start-up. Indeed, failure to meet this requirement within the 180-day window could subject the facility to monetary fines for each day beyond the 180 days that a certified system is not in place. 
 
 Although continuous stack monitoring is federally mandated for those facilities meeting the above-mentioned criteria, plants also realize societal benefits from having a system in place that enables plant owners to confidently claim compliance with emission standards. The good will this can engender with local community leaders is a valuable component in keeping a healthy and positive working relationship between ethanol plants, residents and elected officials. The presence of all types of environmental monitoring systems at ethanol plants also speaks to a larger philosophy that the ethanol industry is committed to responsible production and growth within the confines of accepted environmental standards.
 
 Meeting the Need
 Responding to this requirement for continuous stack monitoring, Trace Environmental Systems has become the leading supplier of such systems in the ethanol industry. Trace first provided a continuous stack monitoring system to Little Sioux Corn Processors in Marcus, Iowa. That was followed by projects at several other facilities, all of which were successfully implemented. Soon enough, through the word of mouth of a closely knit industry, Trace became known as a go-to, reliable solution provider for ethanol plants. By 2007, Trace is projected to have its systems contracted at 30 ethanol production facilities, including the four coal-burning plants. 
 

 In explaining the success Trace has seen in the ethanol industry, Dave Martin, the company's president and chief engineer, says, "It was a case of meeting a market need and following through on what we promised. It became clear to us that what folks were looking for was a company that stood behind its commitments, and that had the environmental and technical expertise to get the job done. Ethanol plants wanted a company they could count on to provide a compliant, trouble-free system along with ongoing support of it. That's our ideal client so it was a natural fit. We've done well as a result."
 
 System Make-Up
 A typical system consists of a free-standing Hoffman enclosure that houses the analyzers and programmable logic controller, along with system plumbing. This enclosure can mount within the ethanol plant but is commonly provided in its own walk-in, climate-controlled shelter. The system also contains a stack-mounted probe and a sample umbilical line to transport the stack sample to the analyzers. 
 
 The system is then rounded out with a personal computer and software for monitoring, alarming and reporting in compliance with the regulations. Typically, the system shares data with the plant control system (a distributed control system or supervisory control and data acquisition system) via hardwired signals or serial communications. This enables the plant control system and operators to see emission levels and incorporate them into alarm and control schemes. In the case of Trace Environmental, a turnkey solution also includes preparation of quality assurance and control, and monitoring plans for regulators, and installation and certification, of the system. After commissioning and certification facilities contract Trace for the ongoing upkeep of the system that includes report generation services and quality assurance and control procedures on the system. In this way, compliance is guaranteed, and systems are quickly installed and commissioned since the supplier takes responsibility for a complete, fully compliant, turn-key solution.
 
 What the Future Holds
 Continuous stack monitoring systems will remain an integral part of ethanol production facilities especially in light of the larger plants now coming on line. Users will also bank more years of reliable, trouble-free operation from the systems and, in so doing, remain in full compliance with the regulations. Companies with multiple plants can and will tie together the emissions data at regional or corporate headquarters in order to more easily manage it. Facilities will also continue to bring emission data into their distributed control systems in order to optimize plant performance. Continued environmental monitoring will keep the ethanol industry at the forefront of environmental protection as growth continues to take place. 
 
 Jim Toolen is a principal, and sales and marketing manager, for Trace Environmental Systems. Reach him at jtoolen@traceenv.com or (201) 670-7077.

Shelter exterior of a continuous stack monitoring system

Ethanol Plants: Good, Responsible Neighbors through Environmental Monitoring

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Upcoming Events

2024 International Fuel Ethanol Workshop & Expo

Biodiesel Summit: Sustainable Aviation Fuel & Renewable Diesel

Carbon Capture & Storage Summit

North American SAF Conference & Expo

2024 National Carbon Capture Conference & Expo

Ethanol Plants: Good, Responsible Neighbors through Environmental Monitoring