Ansell Installs Biomass Boiler to Reduce Energy Costs

The Ansell factory complex in Biyagama, Sri Lanka has installed its second biomass boiler as part of company initiatives to be greener. The new boiler has a capacity of 12.5MW and will be the largest hot water boiler in Sri Lanka. Ansell Lanka already has a 10.5MW boiler installed at its premises, which reduced CO2 emissions by 11,000 MT per annum. From 2004 to 2012, CO2 emissions have been reduced by 36 percent across all of Ansell’s manufacturing facilities, with the global CO2 emission rate from 2013 to 2014 alone reduced by 6 percent. The company anticipates the reduction of a further 14,000 MT of CO2 emissions annually as furnace oil consumption will now be reduced to the bare minimum.

Screen Shot 2014-10-23 at 10.26.12 AM“This project represents another step forward in Ansell’s business strategy to conducting business ethically, transparently, and in ways that produce social, environmental, and economic benefits for communities around the world,” said Steve Genzer, senior vice president of global operations at Ansell. “We would like to thank the government of Sri Lanka for its continued support, and the more than 4,000 Ansell employees who are the driving force of implementing these green programs.”

The announcement is part of the company’s Green Productivity program, focused on energy management, and implemented within manufacturing operations across Ansell. Energy management at Ansell focuses on achieving the most efficient and effective use of energy and simultaneously reducing greenhouse gas emissions. Programs that have been implemented include the installation of equipment to recover energy from flue gas emitted from boiler chimneys as an energy source to heat water, the installation of energy efficient equipment to provide chilled water for manufacturing site cooling systems and the conversion of fossil fuels to renewable energy sources.

“While the forward progress made in the last 10 years has been incredible, this is only the tip of the iceberg in how Ansell will be doing business differently in the years to come,” added Genzer. “Ansell is committed to a number of sustainable and practical initiatives that are designed to make a positive and lasting contribution to the markets it serves and the community in general.”

Bioenergy Day Recognizes Importance of Biomass

bioenergydayYesterday was the Second Annual National Bioenergy Day, and more than 40 facilities and organizations throughout the U.S. and Canada opened their doors to show folks the benefits of using woody biomass for heating and electrical power production.

U.S. Department of Agriculture Secretary Tom Vilsack has continued to support bioenergy’s role in protecting the health of forests on federal lands, saying, “Renewable wood energy is part of the Obama Administration’s ‘all of the above’ energy strategy. The Forest Service works with its partners to support the development of wood energy projects that promote sound forest management, expand regional economies and create new rural jobs.”

“The continuation of National Bioenergy Day into a second year is truly exciting. We are grateful to our sponsors, particularly the U.S. Forest Service, for their dedication to raising awareness about the role of bioenergy in communities across the nation,” said Bob Cleaves, President and CEO of Biomass Power Association. “Today, all across the country, people are learning about bioenergy and how it helps local economies and forests.”

Some of the National Bioenergy Day sponsors include Biomass Power Association, U.S. Forest Service, Plum Creek, Pellet Fuels Institute, U.S. Industrial Pellet Association, and the Biomass Thermal Energy Council. You can learn more at www.bioenergyday.com.

Cooper Looks to Get Tires & Biofuels from Biomass

cooper-tires1A tire maker is looking to get tires and biofuels to keep those wheels rolling from the biomass of a plant. This news release from Cooper Tire says the company completed tire builds using rubber derived from guayule plants and new guayule related materials and also hopes to get biofuels from those plant materials.

This development was reported by Cooper to its consortium partners—PanAridus, Arizona State University, Cornell University, and the Agricultural Research Service of the United States Department of Agriculture (USDA-ARS)—as the group met recently in Maricopa, Arizona for its third annual meeting and progress report on their $6.9 million Biomass Research and Development Initiative (BRDI) grant, “Securing the Future of Natural Rubber—An American Tire and Bioenergy Platform from Guayule.” The consortium received the BRDI grant in 2012 from the USDA and the U.S. Department of Energy (DOE) to conduct research aimed at developing enhanced manufacturing processes for the production of solid rubber from the guayule plant as a biomaterial for tire applications, as well as evaluating the plant’s residual biomass for fuel applications. The consortium aims to harness biopolymers extracted from guayule as a replacement for synthetic rubbers and Hevea natural rubber used in the production of tires. It is also focused on genomic and agronomic development of guayule and the sustainability impact these biomaterial and bioenergy industries have on the American Southwest, where guayule is grown.

So far, the testing shows the tires are at least equal to tires made of components derived from the more traditional Hevea rubber plant.

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.

Researchers to Turn Biomass into Plastic

While turning biomass into energy has been most of the talk, some researchers are looking at turning biomass into a more valuable product: plastic. This article from the University of Wisconsin-Madison says researchers at that school, along with scientists from the University of Minnesota and Argonne National Laboratory, will use a $3.3 million U.S. Department of Energy grant to explore ways to produce renewable plastic precursors and other substances from biomass.

huber1“We’re trying to make very high-value commodity chemicals from biomass that can be used to make different kinds of plastics and plasticizers,” says George W. Huber, a professor of chemical and biological engineering at UW-Madison. “So many people have been focusing on fuels, which are a pretty low-value product — $600 or $700 per ton — but we’re going to be making products that are worth more than $5,000 per ton.”

Joining Huber on the UW-Madison portion of the grant are Professor of Chemical and Biological Engineering James A. Dumesic; chemical and biological engineering Professor Christos Maravelias; chemical and biological engineering research Professor Bill Banholzer; and chemistry Associate Professor Ive Hermans. This team of researchers, who also are affiliated with the Wisconsin Energy Institute, bring to the project combined expertise in biomass conversion, process design, techo-economic modeling of biochemical and biofuels production, and catalysis.

Researchers at Argonne will provide high-throughput tools for screening large amounts of catalysts used in the biomass-conversion process, and University of Minnesota researchers will contribute expertise in separating products from the reactants and solvents used in their production.

The three-year project involves both elaborating the basic scientific principles involved in converting biomass into useful chemicals that are otherwise petroleum-derived, as well as developing efficient processes that can be scaled up in order to make bio-based production more competitive with petroleum refining.

Tanzania Mini-Grid Project Underway

Continental Energy Corporation, an emerging international energy investment company, announced that its Tanzanian affiliate, Ruaha River Power Company Ltd. has begun construction of the Phase-I development of its Malolo Mini-Grid. They have also begun signing up first subscribers from a waiting list of 400 customers. The Mini-Grids are being installed in an area surrounding the village of Malolo and three nearby villages, all located in the Kilosa District, Morogoro Region, Tanzania.

The Malolo Mini-Grid is the first of four separate, isolated rural “Mini-Grids” to be built, owned, and operated by the Ruaha Power, from which Tanzania flagit intends to generate, distribute, and sell electrical power directly to consumers at pre-payment meters. When complete, the four Malolo Mini-Grids will have a combined generation capacity of 300kW and each Mini-Grid shall directly deliver 75kW of power to a combined total of approximately 2,500 identified residential, commercial, and light industrial customers.

Phase-I of the Malolo Mini-Grid development is expected to begin delivering power by the end of the first quarter of 2015. It involves the installation and commissioning of the first embedded generators, a 25kW hybrid biomass gasifier and a 25kW diesel generation plant, together with more than four kilometers of low voltage distribution network.

The distribution network will be constructed to standards sufficient for connection to the national grid at such time as it may be extended into the Malolo Mini-Grid area. A 21,500 square-foot site near the village of Malolo has been acquired for the first generator house and power line easements have been arranged. Civil works and the construction of the first powerhouse and office has begun and are expected to be complete by year end.

A Phase-II development is planned to add solar PV capacity to complete a hybrid biomass-solar PV-diesel powered Mini-Grid. Ruaha Power plans to duplicate the Phase-I and Phase-II development at each of the other three villages, one after the other, upon completion of Phase-II of the first network.

How to Establish Biobased Production Chains

The Netherlands Enterprise Agency (RV0), Wageningen UR Food & Biobased Research has developed a method that can help companies and government authorities create biobased chains, from source materials to end products. The method was developed out of a need for companies to develop successful production chains for the production of biofuels or biomaterials from biomass-based resources.

According to senior scientist Wolter Elbersen at the institute for Food & Biobased Research, the method is mainly intended for businesses and investors looking to establish a biobased production chain locally, or for export to the Netherlands or other EU countries. “They often have trouble evaluating whether developing a biobased production or export chain is feasible or how it can be done commercially,” said Elbersen. “This method provides an insight into which factors are at play.”

Setting Up International Biobased Production ChainsThe method is a step-by-step plan for the development of a biobased export chain. It includes a classification of the various types of biomass.

Scientist Jan van Dam at Food & Biobased Research explained that an analysis was made of which crops and products are most suitable, and how market demands are expected to develop. “We then described how businesses or investors can use a SWOT analysis to evaluate whether a local crop is a good starting point for the development of a biobased trade chain. This includes factors such as the availability of the crop and the infrastructure, security of supplies, costs and the degree to which the source material can be produced in a sustainable way.”

The method also offers a list of criteria for determining the most suitable location for converting the source material into tradable products. It deals with questions such as which country has the best infrastructure and the most educated employees? Which location offers the lowest operational costs and the best logistics? And where do the co-products or by-products have the most value? This involves issues such as heat for heating networks, CO2 for CO2 fertilisation or lignin for new chemical products.

Is there Enough Feedstock for Gen 2 Ethanol?

Last week Biofuels Digest Editor Jim Lane posed the question: Is there really enough affordable feedstock for the second generation ethanol wave? According to Robert Kozak of Atlantic Biomass Conversions an co-founder of Advanced Biofuels USA, “Yes, if we realistically address the financial realities of feedstock producers and feedstock buyers.” He reviewed the current weaknesses in current biomass development philosophy for feed, fuel, chemicals and biobased products and penned his findings in a white paper.

Advanced Biofuels USA Biomass Crops white paperKozak looked at a several possible biomass feedstocks including switchgrass, miscanthus and other grasses to dandelion roots and carrot and sugar beet residues. He concludes that the combination of saturated markets and increasing production costs may soon cause corn growers to either start returning land to the Conservation Reserve Program (CRP) and other programs (and increasing U.S. taxpayer costs) or to find other crops. In response, he advocates taking a closer look at what we have learned about biomass conversion technologies over the past 10 years along with farm policy.

In the paper he writes, “So, with approximately 20-25 percent of current US corn production being used for fuel ethanol, the questions for growers become: Could portions of this land be used for lower nutrient input biomass crops that would produce comparable income from ethanol or other biofuels and biomaterials? Could corn land not within current shipping distance of existing ethanol refineries also be used for biofuel/biomaterial crops? … I think the right answers to these questions could not only retain current grower incomes but more importantly, could be an opportunity to build the foundation of a true Advanced Biofuel and Biomaterial System.”

Kozak proposes root crops as a viable solution to these challenges. He bases his arguments on cell wall structure, lack of pesky lignin, and potential for over-wintering in situ to address storage logistics, etc. He acknowledges that these are very preliminary thoughts on a complex issue which deserves greater scrutiny. He also suggests convening an action-oriented conference or a series of workshops where experts involved in all aspects of the subject can gather for intense discussions.

Biomass-to-Biofuel Plant Gets USDA Loan Guarantee

coolplanetA Louisiana biomass-to-biofuel operation received a $91 million loan guarantee from the U.S. Department of Agriculture (USDA). This news release from USDA says the agency will back the loan under the Biorefinery Assistance Program to finish building the Cool Planet plant at the Port of Alexandria in Louisiana.

The Cool Planet facilities will produce approximately 8 million to 10 million gallons of reformate per year at full capacity. Often referred to as a “drop-in” fuel, reformate is an ingredient in gasoline and jet fuel that can be added during the regular refinery process. Many biofuels, like ethanol, are fuel additives that are instead blended into a finished product to oxygenate fuel. Reformate enhances the energy content of gasoline, diesel, and jet fuel. Pine chips will be the feedstock source for the Cool Planet facility, but the company can use almost any type of renewable cellulosic material.

Another benefit of Cool Planet’s facility is that it will produce biochar, a bioenergy byproduct that has been noted for its ability to sequester carbon and potentially reduce atmospheric greenhouse gas levels.

Google Ventures, BP, ConocoPhillips, GE, Exelon and NRG Energy are also kicking in on the project, in addition to USDA’s contribution. Cool Planet is putting $50 million in its own equity into the project.

Arizona Pellet Fuel Maker Gains Quality Standard

forestenergyproductsAn Arizona company that makes wood pellets and biomass into residential and commercial-grade pellet fuel gained an important quality acccreditation. Show Low, Arizona’s Forest Energy Corporation is the sixth company to qualify for the Pellet Fuels Institute’s (PFI) Standards Program, a third-party accreditation program providing specifications for those types of fuels.

“We are thrilled to welcome Forest Energy Corporation into the PFI Standards Program,” said Jennifer Hedrick, Executive Director of the Pellet Fuels Institute. “It takes time, effort and dedication to qualify for the program and we are proud to see how much the Standards Program has grown in a year and a half. We thank these companies for leading the way and we look forward to many more program members.”

To meet the criteria of the PFI Standards Program, participants work with an independent accredited auditing agency and testing laboratory. Random monthly audits are performed at production facilities to ensure qualified companies are following a quality assurance and quality control program. Pellets are tested according to the program specifications, also on a monthly basis. By taking these steps, participants ensure that their pellet quality remains consistent.

Forest Energy Corporation joins existing program members New England Wood Pellet, Curran Renewable Energy, American Wood Fibers, Lignetics Inc., and Marth Peshtigo Pellet Co. meeting the standard that now covers nearly half of the pellets manufactured for residential heat consumption within the United States. Those qualifying are able to display the PFI Quality Mark on their pellet bags, showing consumers their qualification to the program requirements.

ReEnergy Lands $289 Mil Biomass Plant Contract

ReEnergyBiomass power plant builder ReEnergy Holdings LLC landed a nearly $289 million contract to provide renewable energy for the U.S. Army’s Fort Drum in upstate New York, home to 37,000 soldiers and family members and employing nearly 4,000 civilians. This news release from ReEnergy says it’s the largest renewable energy project in the history of the U.S. Army.

“This is good news not only for ReEnergy, but for Fort Drum and the North Country region. This will enhance energy security and position Fort Drum as a leader in meeting the military’s ambitious renewable energy goals,” said Larry D. Richardson, the chief executive officer of ReEnergy Holdings. “The ReEnergy team is proud to assist the U.S. Army in meeting its renewable energy goals, and looks forward to enhancing the North Country’s green energy economy.”

The ReEnergy Black River facility, located inside the fence at Fort Drum, has 60 megawatts of generation capacity. Before it was idled in early 2010 by its former owner, the facility primarily burned coal to produce electricity.

Starting November 1st, the facility will turn out all of Fort Drum’s electrical load.

IRENA: Biomass Could be 60% of World’s Renewable Energy

irenareportBiomass could make up 60 percent of the world’s renewable energy sources – one-fifth of the globe’s total energy supply – by the year 2030. That’s according to a new report from the International Renewable Energy Agency (IRENA), which forecasts a major role for modern, sustainable biomass technologies in the report titled, “Global Bioenergy Supply and Demand Projections for the Year 2030.”

“Sustainable bioenergy has the potential to be a game-changer in the global energy mix,” said IRENA Director of Innovation and Technology Dolf Gielen. “Sustainably sourced biomass, such as residues, and the use of more efficient technology and processes can shift biomass energy production from traditional to modern and sustainable forms, simultaneously reducing air pollution and saving lives.”

The new IRENA report shows that approximately 40% of the total global biomass supply potential would originate from agricultural residues and waste, with another 30% originating from sustainable forestry products.

The report also points out that these biomass resources do not compete with food production requirements, such as land and water, and could make significant cuts to global greenhouse gases.

Bugs Way Ahead in Biomass-to-Energy Production

termite1While scientists have been working for years to come up with the best ways to break down biomass for energy production, termites perfected the technique more than 30 million years ago. A new study from the University of Copenhagen and the Beijing Genomics Institute show that termites have been able to use fungus and gut bacteria contributing enzymes for final digestion.

Fungus-farming termites are dominant plant decomposers in (sub)tropical Sub-Saharan Africa and Southeast Asia, where they in some areas decompose up to 90% of all dead plant material. They achieve near-complete plant decomposition through intricate multi-stage cooperation between the Termitomyces fungi and gut bacteria, with the termites managing these symbionts by providing gut compartments and nest infrastructure. Researchers at the Centre for Social Evolution, Department of Biology, University of Copenhagen and Beijing Genomics Institute (BGI, China) discovered this by analyzing plant decomposition genes in the first genome sequencing of a fungus-farming termite and its fungal crop, and bacterial gut communities.

“While we have so far focused on the fungus that feeds the termites, it is now clear that termite gut bacteria play a major role in giving the symbiosis its high efficiency”, says Associate Professor Michael Poulsen, who spearheaded the work.

Experts believe there could be implications for large-scale industrial bioreactors being developed today.

UK Firm Fires Up Straw-Fired Energy Plant

glennmontA renewable energy investment firm has opened a 38 megawatt straw-fired plant in the United Kingdom. Glennmont Partners announced the start of operations at the Sleaford biomass facility.

The plant was built by a consortium of Burmeister & Wain Scandinavian Contractor A/S and Burmeister and Wain Energy A/S. Glennmont purchased 100% of the equity in the project in December 2011, and financed the construction through a debt package provided by NIBC Bank NV, RBS, Siemens Bank GmbH and Unicredit Bank AG.

Sleaford will generate enough electricity to power 65,000 homes as well as providing free heat to local sports clubs and community facilities. It will create and support jobs in local agriculture and has been built to perform to the highest environmental standards.

Joost Bergsma, Managing Partner of Glennmont, said: “Sleaford is a landmark deal not only for Glennmont but for the UK biomass industry as a whole. Glennmont has committed itself to leading the way for institutional investors to realise exceptional value from the renewable energy market, and Sleaford is an excellent example of this.”

Glennmont Partners has a renewable energy portfolio of more than 300MW of biomass, wind and solar power in France, Ireland, Italy, Portugal and the UK.