DuPont to Sit on RFA Board

RFANewlogoDuPont will now be sitting on the governing board of the Renewable Fuels Association (RFA). The company has been an associate RFA member for more than 10 years and has now upgraded its membership as its first cellulosic ethanol plant is in its final stages of construction. The biorefinery will be co-located next to Lincolnway Energy in Nevada, Iowa and when complete will produce 30 million gallons per year of ethanol using corn ag waste.

“Next generation cellulosic ethanol is emerging on the market and DuPont is at the forefront of innovation. Their knowledge and expertise in all aspects of the biofuels industry make them a valuable addition to the Renewable Fuels Association,” said Bob Dinneen, president and CEO of the RFA. “I am eager to work together to advance the renewable fuels industry, which is already directly and indirectly employing nearly 400,000 people, reducing GHG emissions, and lowering America’s foreign oil dependence.”

William Feehery, president of DuPont Industrial Biosciences said of their renewed commitment to the ethanol association, “RFA is a leading voice in Washington on issues related to our industry and we look forward to working even more closely together as we reach full cellulosiDuPont Logoc production in the coming year. We acknowledge the hard work RFA has done to promote and defend the Renewable Fuel Standard (RFS) both as an individual organization and as our partner in the Fuels America Coalition. A stable RFS is vitally important to support growth for the existing corn ethanol industry while garnering the investment needed to expand and grow cellulosic ethanol in the United States. We must keep the technology, research, and development here in the United States so consumers can continue to have choices at the pump and America can reduce its reliance on foreign oil.”

NC State Breaks Down Cell Walls

According to Quanzi Li, the greatest barrier to producing biofuels is from stubborn plant cell walls that resist being broken down into biofuel ingredients. Li is the lead author of a paper published in Plant Biotechnology Journal about North Carolina (NC) State’s Forest Biotechnology Group biofuel research progress. Cell walls contain desirable cellulose and hemicellulose, which is “covered up” with lignin, the substance that contributes to the strength of wood but gets in the way of biofuel production.

In the case of wood, the lignin must be removed and then the resulting cellulose is converted to ethanol. Production begins with an expensive pretreatment, followed by enzyme use to release the sugars that can be fermented to produce ethanol. Li and her team are focusing on simplifying the process in various ways.

NC State lignin researchNC State’s team has created genetically modified trees with reduced lignin content. “Normally when you reduce lignin, plant growth is negatively affected, which also reduces biomass production,” explained Li. “However, we now know that we can produce transgenic plants with strong cell walls and normal development but much less lignin.”

Fast-growing trees with high energy content could grow on marginal land without disrupting crop production. NC State has worked extensively with black cottonwood (Populus trichocarpa). Forest Biotechnology Group researchers in the College of Natural Resources have developed engineering models that predict how 21 pathway enzymes affect lignin content and composition, providing the equivalent of GPS directions to guide future research.

This comprehensive approach, which involves genes, proteins, plant chemical compounds and mathematical models, fits into a systems biology perspective that’s the key to future breakthroughs, Li said. She added, “Progress has been made in many areas, but we still lack a complete understanding of how the cell wall is formed. We have to have a better idea of the factors that control its formation to produce better biomass for biofuels.”

Patriot Renewable Fuels Signs Cellulosic Deal

Patriot Renewable Fuels has signed a Professional Services Agreement to install ICM’s Fiber Seperation Technology (FST) as well as their Generation 1.5 Grain Fiber to Cellulosic Ethanol Technology (Gen 1.5) for its biorefinery. According to Gene Griffith, Patriot’s CEO says they are considering beginning construction in February 2015 upon board approval.

According to ICM, FST is a value-added technology that increases ethanol yield and throughput as well as increased oil recovery. Patriot is currently adding a biodiesel plant ICM tank at Patriot Renewable Fuels Biorefinerythat will convert the ethanol’s corn oil to biodiesel. Production is anticipated to begin in early 2015. The FST process separates the fiber from the kernel before the traditional fermentation process.

Once the separation occurs, the Gen 1.5 process then ferments the fiber to produce cellulosic ethanol. With the combined technologies, ethanol production is estimated to increase by six to 10 percent. By removing the fiber prior to the standard fermentation process, FST allows the plant to produce each gallon more efficiently and creates the option of diversified co-products such as high protein feeds.

“With this step, Patriot will be better positioned to help lead the corn-based ethanol industry into increased production of cellulosic ethanol,” said Griffith “With board approval for these projects, Patriot could be the first ethanol plant to produce two Advanced Biofuels [corn-based biodiesel, and cellulosic ethanol]. We believe these processes will not only diversify our plant, but they will also improve ethanol yield of traditional corn based ethanol to over 3.08 gallons per bushel.”

Patriot VP/GM, Rick Vondra added, “We are excited that Patriot’s board approved this next step toward cellulosic ethanol by agreeing to complete the engineering and design for these processes. We appreciate the research and development that ICM has done to develop these new processes along with ICM’s Selective Milling Technology that we installed in 2013. Our team is positioned to continue working with ICM to grow our business. ICM’s ethanol technology is a logical platform on which to build our business as a biorefinery. There are many new products and growth possibilities using corn as our feedstock, and we have identified these as two high potential processes that we can adopt now.”

Pacific Ag Bales Bundles of Energy

Bill Levy Pacific AgLast week Abengoa’s cellulosic ethanol biorefinery went online and is expected to produce 25 million gallons of advanced ethanol per year as well as 21 MW of bioenergy. But how exactly does the corn and wheat residue get from the fields to the biorefinery in a economical and efficient way? Enter Pacific Ag.

The company was founded by Bill Levy in 1998 and began by baling residue for growers and using the biomass for animal feed both in the U.S. and internationally. It was a natural progression for Pacific Ag to get involved in cellulosic production in the U.S. and to become a major supplier to the industry.

I asked Levy to talk about their residue removal model. He noted that since their inception, they have always focused on having a balanced residue program for growers and they are finding value for those products for them. So taking their successful model from the Northwest and applying it to the Midwest was a good fit. “The fundamentals of having residue removed on a timely basis and in a sustainable way is really the same,” explained Levy. Today they are in California, North Carolina, Iowa, Kansas and he says they have innovated to become “energy balers” because of the new bioenergy market for residue.

There has been talk about the best biomass model for the biofuels industry. I posed this question to Levy and he explained how they have refined their model to be financial feasible. “We have tried to make it easy for growers to be part of the program by taking care of the harvest, we own the machinery, we schedule the harvest or the removal of the residue, or energy crop with the grower and then we provide them with an income stream for that product,” Levy answerPacific Ag Hugoton Kansas teamed. “It’s very important that we have the size that allows us to invest in that equipment and a lot of times it doesn’t make sense financially for a grower to to invest in that harvest equipment just to harvest the residue.” Pacific Ag is the largest purchaser and owner of baling equipment in the world.

“So what growers enjoy is being able to sit back and enjoy a residue removal program and the income from that but not have to put a lot of effort into it,” added Levy.

Pacific Ag is looking for growers of rice, wheat, corn and other biomass crops who are interested in working with them. As cellulosic ethanol plants including Abengoa continue to ramp up to nameplate capacity, more biomass will be needed and Pacific Ag is ready to be the advanced biofuels partner to help make the cellulosic industry and the growers who plant the bioenergy crops, successful.

Learn more about Pacific Ag and how to become involved in the biomass energy revolution by listening to my interview with Bill Levy: Interview with Bill Levy, Pacific Ag

Abengoa Cellulosic Ethanol Plant Grand Opening photo album.

Allison Details Abengoa’s Cellulosic Plant

Danny Allison Abengoa Plant ManagerWho better to learn about how Abengoa’s cellulosic ethanol plant works then from Plant Manager Danny Allison. He explained to the standing room only crowd during Abengoa’s grand opening celebration, how the state-of-the-art biorefinery will produce cellulosic ethanol, bioenergy and other byproducts including ash that farmers can use as organic fertilizer on their fields.

Here is how the plant works:

Biomass: biomass harvested from local growers corn and wheat fields by Pacific Ag is delivered to the Abengoa plant to begin the ethanol production process. Each bale is quality tested for moisture, dust and other contaminants that could hinder the conversion process.

Biomass In-take Lines: six-packs of residue travel down conveyor belts to be separated into single bales by a singulator. Each bale goes through a chopper, cutting the biomass Biomass in-take lines at Hugoton Kansas Abengoa biorefineryinto easy-to-handle materials and then fed into a grinder.

Pre-Treatment: The pre-treatment process is where the starch is converted to sugars using Abengoa’s proprietary enzymes. From there fermentation occurs suing industrial yeast to convert the sugar to alcohol. At the end of fermentation, the liquid, now 5 percent alcohol, goes into a 1.3 million gallon tank, or beer well.

Distillation System and Ethanol Holding Tanks: All solids, water vapor and alcohol are removed. The now 95 percent pure ethanol moves to a column while the remaining 5 percent goes to the bottom for reprocessing and reclamation. After all impurities and water are removed, the finished ethanol is pumped to half-million storage tanks and ready for shipment by rail or truck.

Electrical Power Station: The Abengoa bioenergy plant will also produce up to 21MW of renewable electricity used to power the plant. Excess electricity will be fed to the grid for city use.

Learn more about the process by listening to Danny Allison’s remarks: Danny Allison Remarks

Abengoa Cellulosic Ethanol Plant Grand Opening photo album.

Cellerate Receives D3 RIN Certification

The Environmental Protection Agency (EPA) has given D3 Renewable Identification Numbers (RINs) certification to Quad County Corn Processors (QCCP) for its cellulosic ethanol produced with Cellerate Cellerate Processprocess technology. The technology is a collaboration between Syngenta and Cellulosic Ethanol Technologies, a subsidiary of QCCP. The biorefinery earned D3 pathway approval from the EPA on Oct. 7, 2014 and Quality Assurance Program (QAP) certification on Oct. 10, 2014. Clearing these hurdles led to production of QCCP’s first QAP D3 RINs on Oct. 16, 2014.

To qualify as cellulosic biofuel, a renewable fuel must meet a 60 percent threshold (aka reduction) for lifecycle greenhouse gas emissions. RINs are used for compliance with the Renewable Fuel Standard (RFS) program and may be “banked,” traded or sold for use by parties (fuel producers and importers) who must comply with the RFS.

According to QCCP Chief Executive Officer Delayne Johnson, as cellulosic D3 RINs become available on the commercial market, biofuels opponents will no longer be able say there are no D3 RINs as a strategy to weaken the RFS. “The biofuels industry now has the technology available to create two billion gallons of cellulosic ethanol – with no more corn,” said Johnson. “QCCP is proud to be one of the first companies to issue D3 RINs. We look forward to higher D3 RIN requirements in 2015 as new production comes on.”

QCCP expects to produce one million gallons of cellulosic ethanol in 2014 and two million gallons in 2015. Earlier this year.

“Cellerate is designed to increase an ethanol plant’s production by allowing the corn kernel fiber to be converted into cellulosic ethanol,” added Jack Bernens, head of marketing and stakeholder relations for Enogen corn enzyme technology. “Ethanol plants can easily integrate Cellerate process technology into their existing production process. Cellerate, in conjunction with Enogen corn, will deliver notable benefits to ethanol plants beyond what can be achieved through either technology alone.”

Ethanol Industry Applauds Abengoa

abengoaMembers of the ethanol industry joined with government leaders in applauding Abengoa at the opening of its $500 million cellulosic ethanol plant in Hugoton, Kansas last week.

Among those on hand for the celebration was Renewable Fuels Association (RFA) Vice President of Industry Relations Robert White who says Americans should be proud of the new plant “because this phantom fuel, as the naysayers like to call it, is here and it’s here to stay.”

However, White says they are concerned that this third cellulosic plant opening this year could be the last if EPA fails to continue implementing the Renewable Fuel Standard (RFS) as Congress intended. “There may never be another celebration like this and it’s sad but true,” he said. “This promise was made years ago and (the administration) needs to stick to it.”

Interview with RFA's Robert White at Abengoa Opening

Abengoa Cellulosic Ethanol Plant Grand Opening photo album.

DOE’s Moniz Congrats Abengoa on Cellulosic Plant

US Energy Secretary Ernst MonizDepartment of Energy Secretary Ernest Moniz was on hand to help Abengoa Bioenergy celebrate the grand opening of its cellulosic ethanol plant in Hugoton, Kansas. With a beautiful day and a full house, excitement was high as Moniz took the stage to congratulate Abengoa’s achievement.

The $500 million biorefinery was supported, in part, by a DOE loan guarantee. Moniz began his remarks by putting the bioenergy plant in perspective of the larger picture and that is as part of President Obama’s “all of the above” energy strategy.

Moniz said the cellulosic ethanol plant serves three major objectives:

  1. Growing the economy – creating jobs.
  2. Advancing our energy security interests. No only for the United States alone, but also for our allies and friends.
  3. Moving towards the low carbon economy- addressing climate change.

Moniz also noted the importance of the innovation chain, “…and what we’re seeing to today is part of that…But if we’re going to kick start this, we have to work with the private sector with state and local governments with our research institutions and laboratories to get these technologies deployed and drive those costs down to be competitive continued Moniz. So this plant shows all of these features.”

He said that while there will be a few rough spots along the road, what the country is seeing today is the beginning of a new industry.

Listen to Energy Secretary Moniz’s complete comments here:

Listen to Energy Secretary Moniz’s remarks: Energy Secretary Moniz Remarks

Check out the Abengoa Cellulosic Ethanol Plant Grand Opening photo album.

USDA Researchers Advance Advanced Ethanol

usda-logoResearchers for the U.S. Department of Agriculture (USDA) are making advancements on an advanced biofuel, cellulosic ethanol. This article from the USDA says the scientists at the Bioenergy Research Unit in Peoria, Illinois, have recently completed studies on multiple approaches that could help streamline cellulosic ethanol production.

In one study, a team led by ARS chemical engineer Bruce Dien looked at using switchgrass, a perennial grass native to the prairie, for ethanol production. The team concluded that biomass producers could optimize cellulosic ethanol production by planting Kanlow variety—a lowland ecotype—and harvesting at either mid-season or post frost. Results from this study were published in Environmental Technology in 2013.

ARS chemist Michael Bowman led another study of switchgrass xylans, which is challenging to convert to sugars with enzymes because of its complex chemical structure. Bowman determined that structural features of xylan remained the same as the plant matures, even though the amount of xylan changed with maturity. This is good news for biorefiners, because it suggests that they can use the same biomass hydrolyzing enzymes to break down xylans in all switchgrass biomass, no matter when the crop is harvested. Results from this study were published in Metabolites in 2012.

The article also gives progress reports on work with microorganisms needed to ferment xylose—molecules that make up xylans—into ethanol and promising field trials with a yeast strain that grew almost four times faster than other strains that contained XI enzymes and one that could produce ethanol at significantly greater yields than other yeasts engineered to ferment xylose to ethanol.

Abengoa Celebrates Cellulosic Ethanol Achievement

Abengoa Cellulosic Ethanol Goes Into ProductionSpanish-based Abengoa celebrated its cellulosic ethanol achievement today with a celebration of the plant’s grand opening. Thousands of people attended the event with dozens of high profile guests on hand ranging from former and current Senators to governors to the town mayor, to Interior Secretary and Energy Secretary Ernst Moniz who gave the keynote speech.

The bioenergy plant is based in Hugoton, Kansas and when at full scale will produce 25 million gallons of cellulosic ethanol from biomass per year as well as 21 MW of electricity. The plant will use no power from the grid, in fact, it will sell its excess power – a model common in Europe and Brazil.

Javier Garoz Neira Abengoa BioenergyAbengoa announced the plant would be located in Hugoton in 2007 and a lot of has happened since then as Javier Garoz Neira, CEO of Abengoa Bioenergy, said in his remarks. That same year they produced cellulosic ethanol from wheat straw in their pilot facility located in York, Nebraska. In 2009 they built a larger cellulosic demonstration plant in central Spain. In 2011, working with the Department of Energy (DOE) Abengoa was able to secure a loan guarantee to build the plant in Hugoton, Kansas and today the plant is gearing up to produce cellulosic ethanol from corn and what residues at commercial scale.

“It is without a question a major achievement. And we believe it will revolutionize the biofuels industry and our future,” said Neira.

Listen to Javier Garoz Neira’s remarks: Abengoa Bioenergy CEO Javier Garoz Neira

Manuel Sanchez Ortega AgengoaManuel Sanchez Ortega, chief executive officer of Abengoa SA, began his remarks by noting how important today is for everyone in the room. He also addressed the role of the Renewable Fuel Standard (RFS) in providing a platform for the development of second generation biofuels. “Without the RFS, there was no way we would have decided to invest more than $500 million dollars in a project full of risks from both technology and financial without the existence of a solid framework of the RFS.”

Ortega stressed that the role that advanced biofuels will play around the world is not illusive. “The promise of a sustainable and domestic energy is not illusive or imaginary, not anymore. It is right here in front of us. Progress has always come from innovation. And we at Abengoa believe that only through innovation we make make Earth a better place to live.”

Listen to Manuel Sanchez Ortega’s remarks: Abengoa CEO Manuel Sanchez Ortega

Check out the Abengoa Cellulosic Ethanol Plant Grand Opening photo album.