Plant Expansion Project

Badger State Ethanol recently completed a major expansion by doubling their dry-mill ethanol production to 80 million gallons. This required a new cooling tower and pumps, clarifier, liquefaction tank and new hammer mill for corn grinding. Among the components PDC installed were: a 3000 amp switchboard, five motor control centers, 1,350 feet of cable tray, conduit and wire for 44 motors, conduit and wire for over 400 control connections, two new heat trace monitoring panels and heat tracing on 35 process lines. PDC saved time by using a drone to fly over existing cable trays up to 25 feet to determine new routing and cable fill. PDC had under three weeks to plan this job.