Safer, Cleaner Evaporator CIP Performance in Ethanol Production Using Non-Peroxide Chemistry

Case Study Summary

This case study examines how a Central Iowa ethanol producer improved evaporator Clean-In-Place (CIP) performance by replacing peroxide-based cleaning chemistry with a non-peroxide alternative. By implementing Apex’s EFX 2540 CIP program, the facility reduced chemical usage by 50%, improved evaporator uptime and throughput, and significantly lowered operator safety risk during cleaning events.

In ethanol production, evaporator performance directly impacts throughput, operational stability, and plant safety. Clean-In-Place (CIP) routines are frequent and time-sensitive, yet many facilities continue to rely on peroxide-based chemistries that require high chemical volumes and introduce handling risks for operators.

A Central Iowa ethanol facility producing approximately 90 million gallons annually was facing ongoing evaporator fouling, extended CIP downtime, and safety concerns related to its existing cleaning program. The operations team needed a safer, more effective CIP solution that could improve cleaning performance without requiring equipment changes or increasing chemical consumption.

Results at a Glance

Facility Background

• Industry: Ethanol/Biofuels
• Application: Evaporator CIP Systems
• Challenge Area: Fouling, downtime, operator safety
• Apex Solution: EFX-2540 Non-Peroxide CIP Chemistry

The facility relied on peroxide-based cleaners that were only moderately effective and required elevated chemical volumes to maintain acceptable cleaning performance. Over time, mineral fouling limited throughput and increased downtime, while the aggressive nature of the chemistry raised safety concerns for operators.

The Challenge

The evaporator system was experiencing persistent mineral fouling, resulting in:

• Decreased throughput and limited run capacity
• Extended and costly CIP downtime
• High chemical consumption
• Increased safety risk due to hazardous peroxide-based reactions

The plant needed a more concentrated, safer solution that could improve cleaning effectiveness while reducing chemical use and operational risk.

The Apex Solution

Apex introduced EFX 2540, a concentrated, non-peroxide CIP chemistry designed specifically for evaporator applications in ethanol production.

Key elements of the solution included:

• Implementation of EFX 2540 with no changes to existing equipment or CIP procedures
• Monitoring of chelant levels during CIP to ensure consistent cleaning performance
• A non-violent reaction profile compared to peroxide-based alternatives
• Reduced chemical demand while improving fouling removal

This approach allowed the facility to upgrade CIP performance immediately while maintaining operational continuity.

Results & Operational Impact

Following implementation, the facility experienced measurable improvements:

• Chemical usage reduced by 50% compared to the previous peroxide-based product
• Operators reported significantly easier and safer handling during CIP events
• Evaporator uptime and throughput improved due to more effective fouling removal
• CIP monitoring was simplified through chelant level tracking

These results demonstrated that improved CIP performance and operator safety could be achieved simultaneously — without increasing cost or complexity.

Applicable To

This solution is relevant for:

• Ethanol and biofuel facilities operating evaporator systems
• Plants using peroxide-based CIP chemistries
• Facilities seeking to reduce CIP downtime and chemical usage
• Operations prioritizing operator safety and system reliability

Conclusion

This Central Iowa ethanol producer’s success highlights the impact of pairing the right chemistry with the right partner. By transitioning to EFX 2540, the facility improved evaporator performance, reduced risk, and lowered operational costs — all without changing equipment or cleaning procedures.

For ethanol and biofuels facilities facing similar CIP challenges, Apex delivers proven solutions that prioritize safety, efficiency, and long-term performance.

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