Case Study: Extending Expansion Joint Service Life Six Times in Ethanol Plant

INDUSTRY

Oil and Gas - Ethanol Plant

OPERATING CONDITIONS

Size: 12” ID x 12” Full Face
Temperature: 194 ̊F (90 ̊C)
Application: Evaporator pump (discharge)
Media: Sodium hydroxide, slurry (35% solids, pH around 4), 5% sodium hydroxide solution, 5-10% sulfamic acid solution, trace amounts of ethanol (negligible)
Pressure: 75 psi (5.17 bar)
 

BACKGROUND

A large North American ethanol manufacturer, uses local non-food grade quality grain and corn to produce more than 130 million liters of ethanol annually. This ethanol is then utilized to manufacture various oil products such as asphalt, light distillate, and distillate kerosene.

CHALLENGES FACED

Mill personnel reported using expansion joints (non- Garlock) that were failing prematurely. The critical joints located on the discharge side of the evaporator system experienced failures in less than 12 months of service, sometimes as early as 6 months. These expansion joints often failed unexpectedly, leading to serious safety concerns and unplanned downtime.

SOLUTION AND BENEFITS

Upon reviewing the operating conditions, Garlock’s Application Engineering team identified abrasion and chemical compatibility as the most significant challenges to service life. To address this, they recommended Garlock Expansion Joint Style 204 with an EPDM tube for chemical compatibility and a stainless-steel flow liner for increased abrasion resistance.

After one year of service, the end user returned the part to Garlock for review and recommendations. It was determined that the joint exhibited normal wear and had not experienced any structural integrity deterioration. With routine in-service inspections, these expansion joints have seen a service life increase from 6 months to over 3 years, thereby reducing overall downtime and safety concerns related to joint failure.

Click here to learn more about Garlock Expansion Joint Style 204 with an EPDM tube.