October 13 Biomass Magazine

OCTOBER 2013 | BIOMASS MAGAZINE 3

INSIDE¦

OCTOBER 2013 | VOLUME 7 | ISSUE 10

POWER

06 EDITOR’S NOTELet Us Be the First By Tim Portz

07 INDUSTRY EVENTS

10 BUSINESS BRIEFS

14 BIOMASS CONSTRUCTION UPDATE

46 MARKETPLACE

ADVERTISER INDEX¦

2014 Fuel Ethanol Workshop & Expo 35

2014 International Biomass Conference & Expo 47

2014 National Advaced Biofuels 13Conference & Expo

Airofl ex Equipment 30

Algae Biomass Organization 4

AMANDUS KAHL GmbH & Co. KG 34

Babcock Power 10

Biomass 24/7 8

Biomass Industry Directory 12

Continental Biomass Industries, Inc. 36

CPM Roskamp Champion 25

CPM Wolverine Proctor 29

Detroit Stoker Company 7

Dieffenbacher 11

Fagen Inc. 2

Himark bioGas 18

Indeck Power Equipment Co. 42

KEITH Manufacturing Company 26

MEGTEC Systems Inc. 43

O.O. Energiesparverband Outsert

Portage and Main Outdoor Boilers 45

PHG Energy 48

Retsch, Inc. 5

SAMSON Materials Handling Ltd. 9

Timber Products Inspection/Bioimass Energy Laboratories 44

U.S. Industrial Pellet Association 22

Wolf Material Handling Systems 23

20

18 NEWS

19 COLUMNUSDA Commits to Biomass By Bob Cleaves

20 FEATURE Modular MasteryAfter perfecting the technology at its R&D center hosting the world’s largest downdraft gasifi er, PHG Energy has completed its fi rst waste-to-energy downdraft gasifi cation installation in Covington, Tenn.By Anna Simet

24 DEPARTMENT The Value of Versatility Ineos Bio's novel biorefi nery in Vero Beach, Fla., gasifi es multiple waste feedstocks to produce power and cellulosic ethanol. By Sue Retka Schill

PELLETS 26 NEWS

27 COLUMNPellet Heat Approaches Liftoff with Residential ConsumersBy Bill Bell

28 CONTRIBUTION Torrefaction: Pre- or Post-Pelletization Researchers at Oakridge National Laboratory have set out to discover the pros and cons to torrefying biomass both prior to and after pelletization. By Shahab Sokhansanj

Biomass Magazine: (USPS No. 5336) October 2013, Vol. 7, Issue 10. Biomass Magazine is published monthly by BBI International. Principal Offi ce: 308 Second Ave. N., Suite 304, Grand Forks, ND 58203. Periodicals Postage Paid at Grand Forks, North Dakota and additional mailing offi ces. POSTMASTER: Send address changes to Biomass Magazine/Subscriptions, 308 Second Ave. N., Suite 304, Grand Forks, North Dakota 58203.

TM

Please recycle this magazine and remove inserts or samples before recycling

COPYRIGHT © 2013 by BBI International

Insight

Influence

Leads

More than 250 companies and organizations are serious about developing algae as a source of fuel, feed, food, and countless other products. Are you?

Joining the Algae Biomass Organization puts you in touch with the entire algae value chain, from suppliers to producers, from engineers to investors, from state government to Capitol Hill.

Learn about our tiered membership programs and the benefits at www.algaebiomass.org or call 507-765-2134 today.


THERMAL

30 NEWS

31 COLUMNSignifi cance of the USDA Wood-to-Energy MoUBy Joseph Seymour

32 FEATURE Thermal Triumphs Through strong and steady R&D, Metso has achieved many milestones in the biomass gasifi cation and fast pyrolysis sectors. By Anna Simet

BIOGAS36 NEWS

37 COLUMNInfrastructure Critical to Biogas as a Transportation FuelBy Amanda Bilek

ADVANCED BIOFUELS & CHEMICALS

38 NEWS

39 COLUMNAlgae Fuel Passes Another Crucial Test By Mary Rosenthal

40 FEATURE Gaining Gasifi cation Ground Numerous companies using a variety of feedstocks and technology platforms are solidifying the foundation of the advanced biofuel market. By Keith Loria

INSIDE¦

OCTOBER 2013 | VOLUME 7 | ISSUE 10

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6 BIOMASS MAGAZINE | OCTOBER 2013

Let Us Bethe First

In mid-July, the U.S. EPA and Ad-ministrator Gina McCarthy announced new emission limits for future power generating facilities. Reactions to these rules were varied, but they generated plenty of “mehs,” as power industry insiders know the pipeline of new gen-eration facilities is relatively small, par-ticularly in the case of new coal plants.

Still, the suggested rule and the pathways available to meet the new limits are telling. In the vast majority of the mainstream coverage of these

new limits, the fi rst technology mentioned as a potential means for producers to achieve compliance is carbon capture and sequestration (CCS). While this technology is promising and should appear on the R&D budgets of every utility that derives a percentage of its power from coal, it is far from proven. So why, then, does the administra-tion—via the EPA—continue to forward this as a means for compli-ance? Because CCS presents one of the only scenarios in which coal-derived power and a legitimate response to increasing levels of carbon dioxide in the earth’s atmosphere can coexist.

Absent, so far, in this larger discussion of the carbon intensity of future power generation in the U.S. is biomass. It is fascinating that a technology without any real commercial deployment, such as CCS, can get more press than a solution that other countries have adopted, and is arguably a central element to their near- and long-term carbon mitigation strategies. The story, in bits and pieces, is told in this issue of Biomass Magazine.

So, let Biomass Magazine be the fi rst to emphatically forward bio-mass-derived power as a near-term option to reduce the carbon inten-sity of power generation in this country. Biomass presents a commer-cially proven and widely deployed means to achieve the same goals the administration is aiming for when it forwards CCS. As this month’s is-sue confi rms with its focus on gasifi cation, biomass continues to refi ne technologies that will facilitate the conversion of an even greater array of input streams into low-carbon power and fuels. These new limits for new production assets are just the beginning of what will likely be a spirited debate about carbon and energy in this country. As the discussion moves forward, it is vital that we all continue to remind poli-cymakers and the general public that a pathway to low-carbon power already exists. We just need to embark upon it.

TIM PORTZVICE PRESIDENT OF CONTENT & EXECUTIVE [email protected]

¦EDITOR’S NOTE

EDITORIAL

PRESIDENT & EDITOR IN CHIEFTom Bryan [email protected]

VICE PRESIDENT OF CONTENT & EXECUTIVE EDITOR

Tim Portz [email protected]

MANAGING EDITOR Anna Simet [email protected]

NEWS EDITORErin Voegele [email protected]

SENIOR EDITORSue Retka Schill [email protected]

COPY EDITOR Jan Tellmann [email protected]

ARTART DIRECTOR

Jaci Satterlund [email protected]

GRAPHIC DESIGNERElizabeth Burslie [email protected]

PUBLISHING & SALESCHAIRMAN

Mike Bryan [email protected]

CEOJoe Bryan [email protected]

VICE PRESIDENT, SALES & MARKETINGMatthew Spoor [email protected]

MARKETING DIRECTORJohn Nelson [email protected]

BUSINESS DEVELOPMENT DIRECTOR Howard Brockhouse [email protected]

SENIOR ACCOUNT MANAGERChip Shereck [email protected]

ACCOUNT MANAGERKelsi Brorby kbrorby@bbiinternational

CIRCULATION MANAGER Jessica Beaudry [email protected]

ADVERTISING COORDINATORMarla DeFoe [email protected]

EXTERNAL EDITORIAL BOARD MEMBERSTimothy Cesarek, Enerkem Inc. Shane Chrapko, Himark Biogas

Stacy Cook, Koda EnergyBenjamin Anderson, University of Iowa

Gene Zebley, Hurst BoilerAndrew Held, Virent Inc.

Kyle Goerhing, Eisenmann Corp.

Subscriptions Biomass Magazine is free of charge to everyone with the exception of a shipping and handling charge of $49.95 for any country outside of the United States, Canada and Mexico. To subscribe, visit www.BiomassMagazine.com or you can send your mailing address and pay-ment (checks made out to BBI International) to Biomass Magazine Subscriptions, 308 Second Ave. N., Suite 304, Grand Forks, ND 58203. You can also fax a subscription form to 701-746-5367. Back Issues & Reprints Select back issues are available for $3.95 each, plus shipping. Article reprints are also available for a fee. For more information, contact us at 701-746-8385 or [email protected]. Advertising Biomass Magazine provides a specifi c topic delivered to a highly targeted audience. We are committed to editorial excellence and high-quality print production. To fi nd out more about Biomass Magazine advertising opportunities, please contact us at 701-746-8385 or [email protected]. Letters to the Editor We welcome letters to the editor. Send to Biomass Magazine Letters to the Contributions Editor, 308 2nd Ave. N., Suite 304, Grand Forks, ND 58203 or email to [email protected]. Please include your name, address and phone number. Letters may be edited for clarity and/or space.


INDUSTRY EVENTS¦

Call Toll Free: [email protected] www.detroitstoker.com

Renewable Energy World Conference & Expo North AmericaNovember 12-14, 2013Orange County Convention CenterOrlando, FloridaBy 2020, at least 15 percent of the world will be powered by renewable energy and this will require investments in the trillions of dollars. This is the only show where utilities, project developers, investors and other stakeholders can ac-cess all their clean energy options in one place. Plus, they can visit with tradi-tional power generation companies at the same time through these co-located events: Power-Gen International, Power-Gen Financial Forum and Nuclear Power International. Look for Biomass Magazine at booth #1129.888-299-8016 | www.renewableenergyworld-events.com

International Biomass Conference & ExpoMarch 24-26, 2014Orange County Convention CenterOrlando, FloridaOrganized by BBI International and produced by Biomass Magazine, this event brings current and future producers of bioenergy and biobased products together with waste generators, energy crop growers, municipal leaders, utility executives, technology providers, equipment manufacturers, project develop-ers, investors and policy makers. It’s a one-stop shop and the world’s premier educational and networking junction for all biomass industries.866-746-8385 | www.biomassconference.com

International Fuel Ethanol Workshop & ExpoJune 9-12, 2014Indiana Convention CenterIndianapolis, IndianaNow in its 30th year, the FEW provides the global ethanol industry with cut-ting-edge content and unparalleled networking opportunities in a dynamic business-to-business environment. The FEW is the largest, longest running ethanol conference in the world—and the only event powered by Ethanol Pro-ducer Magazine.866-746-8385 | www.fuelethanolworkshop.com

National Advanced Biofuels Conference & ExpoOctober 13-15, 2014Hyatt MinneapolisMinneapolis, MinnesotaProduced by BBI International, this national event will feature the world of advanced biofuels and biobased chemicals—technology scale-up, project fi -nance, policy, national markets and more—with a core focus on the industrial, petroleum and agribusiness alliances defi ning the national advanced biofuels industry. With a vertically integrated program and audience, the National Ad-vanced Biofuels Conference & Expo is tailored for industry professionals en-gaged in producing, developing and deploying advanced biofuels, biobased platform chemicals, polymers and other renewable molecules that have the potential to meet or exceed the performance of petroleum-derived products.866-746-8385 | www.advancedbiofuelsconference.com

BiomassMagazine.com Stay top-of-mind. Advertise on the biomass industry’s leading news site.

With 1.175 million page views and 403,000 unique visitors in the last 12 months, BiomassMagazine.com is the industry leading website for the biomass industry. The site is an ever-developing tool biomass pros use to plan, learn and grow their business – whether at the office, in the field or at home.

BiomassMagazine.com is a direct route to producers of biomass power and heat, pellets, biogas and advanced biofuels. The site offers a variety of custom advertising sponsorship opportunities that link to highly engaging editorial platforms.

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PEOPLE, PRODUCTS & PARTNERSHIPSBusiness BriefsLaw firm hires senior council

Michael Best & Friedrich LLP has announced the addition of Angela James as senior counsel in the Environmental Practice group and the Energy and Sustainability Industry Team. James has worked on matters related to industrial regulatory compliance, air and water permitting, water quality trading, utility ratemaking and energy regulation. Prior to joining Michael Best & Friedrich, she was a senior associate at Stafford Rosenbaum LLP and a corporate attorney at Madison Gas and Electric Co. She also served as vice president of government relations at the Wisconsin Paper Council.

Cool Planet adds board member Cool Planet Energy

Systems has added Archie Dunham to its board of directors. Dunham joined Conoco in 1966, eventually serving as chairman, president and CEO, and chaired ConocoPhillips until 2004. He is currently the non-executive chairman on the board of directors of Chesapeake Energy. He is also the past chairman of the United States Energy Association, the National Petroleum Council, the National Association of Manufacturers and a director at the American Petroleum Institute.

Stobart adds chairman U.K.-based Stobart Group Ltd. has announced the appointment of Iain Ferguson as its chairman, effective Oct.

1. Ferguson is chairman of Berendsen plc and a nonexecutive director on the boards of Balfour Beatty plc and Gregg’s plc. He formerly served as CEO of Tate & Lyle plc, and spent 26 years at Unilever.

Viaspace elects board member Viaspace Inc. has

announced the election of Khurram Irshad to its board of directors. He will take an active role in the company and help lead additional Giant King Grass bioenergy project developments, especially in Pakistan. Irshad is a citizen of Pakistan and a resident of California. He heads the agribusiness consulting fi rm Amaanco and is founder of Winergy Pakistan Ltd., which is developing a biogas plant at Landhi Cattle Colony in Karachi, Pakistan. He is

With growing demand for renewable technology for biomass power plants, Riley Power Inc., a Babcock Power Inc. company, responded by taking their 90 plus years of steam generating equipment experience and establishing themselves as market leaders in the planning, designing, fabricating, constructing and commissioning of state-of-the-art chute to stack technology.

Riley Power has provided customers with advanced stoker technology boilers, cutting-edge air quality control systems and innovative modular designs with proven results of optimum performance and

Whether you are building a new plant or converting an existing one, contact the professionals at Riley Power, your source for renewable energy project solutions.

508.852.7100 I www.babcockpower.com I Riley Power Inc., 5 Neponset Street, Worcester, MA 01615-0040

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also chairman and founder of Aquatech Infrastructures Ltd., a water and wastewater treatment company in Pakistan.

Metabolix appoints COOMetabolix Inc.

promoted Johan van Walsem to the position of chief operating offi cer. In the newly created role, van Walsem will be responsible for the management of the company’s biopolymers, biobased chemicals and crops businesses, as well as the key functional areas that enable these businesses to perform. He most recently served as the company’s vice president of manufacturing and product development, and has more than 20 years of experience in the processing industry.

2 companies certified under PFI standards program The Pellet Fuels Institute has certifi ed Massena, N.Y.-based Curran Renewable Energy and American Wood Fibers, with locations in Circleville, Ohio, and Marion, Va., under the PFI Standards Program. This is a third-party certifi cation program that provides standard specifi cations for residential- and commercial-grade fuel.

McGinn confirmed for Navy energy position

Dennis McGinn has been confi rmed as the Assistant Secretary of the Navy for Energy, Installations and the Environment. He most recently served as president and CEO of the American Council on Renewable Energy. McGinn had a 35-year career with the U.S. Navy, where he served as a naval aviator, test pilot, aircraft carrier commanding offi cer, and national security strategist.

Polymer firm releases new sprayable coating

Germany-based Ceramic Polymer GmbH, a provider of coating systems for biogas applications, has launched a new product line of “winter systems,” which can be applied at ambient temperatures of up to -10 degrees Celsius. The combination of specifi c fi llers and reactive hardener compositions enables the use of the new winter product series during dry winter seasons. The coating systems are sprayable and cure within two to three days. After seven days of curing, the coated surface is generally chemical resistant.

BUSINESS BRIEFS¦

SHARE YOUR INDUSTRY NEWS: To be included in the Busi-ness Briefs, send information (including photos and logos, if available) to Business Briefs, Biomass Magazine, 308 Sec-ond Ave. N., Suite 304, Grand Forks, ND 58203. You may also email information to [email protected]. Please include your name and telephone number in all cor-respondence.

Dieffenbacher USA, Inc. 2000 McFarland 400 Blvd. | Alpahretta, GA 30004Phone: (770) 226-6394 | [email protected]

Biomass Pelletizing & Energy SystemsPellet Plants | Dryers | Furnaces | Steam Boilers | Thermal Oil Heaters | Cogeneration

Rotary Dryer Boiler Heat Energy System

www.dieffenbacher.com

NETWORK, LEARN AND TAKE YOUR BUSINESS TO THE NEXT LEVELMake your plans to attend the 2014 National Advanced Biofuels Conference & Expo in Minneapolis, MN. Understand the latest techniques being developed in the industry and continue building relationships that last. Contact us today and to make your reservations.

Email: [email protected]: 866-746-8385

OCTOBER 13-15, 2014Hyatt Minneapolis | Minneapolis, MNwww.advancedbiofuelsconference.com

NEXT GENERATION FUELS & CHEMICALS

Produced by

SAVE THE DATE


Project Complete Port Hawkesbury Biomass Project, Nova Scotia Power Inc.

Location Port Hawkesbury, Nova Scotia CHP Yes

Engineer/builder AMEC, Nova Scotia Power Inc. Government incentives Yes, accelerated

depreciation

Primary fuel Logging, mill residue IPP or utility Utility

Boiler type Stoker Groundbreaking date April 2011

Nameplate capacity 60 MW Start-up date June 2013

The plant is complete and is delivering biomass power to NSP customers in Nova Scotia.

Atikokan Generating Station, Ontario Power Generation Inc.

Location Atikokan, Ontario CHP No

Engineer/builder Aecon, Doosan, Nordmin Government incentives 10-year PPA

Primary fuel Industrial pellets IPP or utility IPP

Boiler type Stoker Groundbreaking date October 2012

Nameplate capacity 211 MW Start-up date Q2 2014

Helical chutes are installed in the storage silos as is the prefabricated conveyor bridge from silos to power house. Project is within budget and on schedule.

DTE Stockton LLC, DTE Energy

Location Stockton, Calif. CHP Yes

Engineer/builder ESI Inc., DTE Stockton LLC Government incentives

Primary fuel Woody biomass IPP or utility IPP

Boiler type Stoker Groundbreaking date September 2011

Nameplate capacity 45 MW Start-up date December 2013

Project is in fi nal construction and start-up phase.

Eagle Valley Clean Energy, Evergreen Energy

Location Gypsum, Colo. CHP Yes

Engineer/builder Government incentives 1603 Program grant

Primary fuel Forest restoration residue IPP or utility IPP

Boiler type Stoker Groundbreaking date November 2012

Nameplate capacity 11.5 MW Start-up date December 2013

Industry Still Hot Despite Cooler Weather BY KOLBY HOAGLAND

With autumn approaching, North American bioenergy projects are rushing to take advantage of agreeable but fading climatic conditions. Projects in the northern U.S. and Canada are generally impeded by winter, with snow and rain making logistics and transportation around construction sites cumbersome, and freezing conditions hampering both concrete curing and plant commissioning procedures. The Q3 Biomass Construction Update lists four newly completed projects and 23 projects that are progressing toward completion.

In the biomass power sector, commissioned Port Hawkesbury Biomass Project now supplies up to 60 MW of power to the grid. DOM Power’s Hopewell and Southampton Power Stations are nearing structural completion, as are DTE Stockton, Rothschild Biomass Cogeneration Plant, Gettysburg Energy & Nutri-ent Recovery Facility, and Eagle Valley Clean Energy. The eight biomass power plants listed represent nearly 500 MW of dispatchable generating capacity.

The pellet sector continues to receive substantial European investment to meet climate change mitigation goals. German Pellets Louisiana recently broke ground in LaSalle, La., and will become the largest North American pellet plant, producing 1.1 million tons/year. Amite and Morehouse BioEnergy also recently broke ground and will supply Drax biomass power plant in Yorkshire, U.K.

The diversifying biogas sector is now supplying transportation fuel along with process heat and electricity. The Sacramento Biodigester by CleanWorld Partners will annually displace 700,000 gallons of gasoline equivalent for its waste-hauling fl eet, while producing 190 kilowatts of power.

Commercial-scale cellulosic ethanol has arrived with the commissioning of Ineos Bio’s Indian River Bioenergy Center, a gasifi cation/fermentation cellulosic ethanol facility in Vero Beach, Fla. This is a standalone facility, as are Abengoa Bioenergy Biomass of Kansas, Project Liberty, DuPont Cellulosic, and Enerkem

Alberta Biofuels. Green Energy Products and Quad County Cellulosic Ethanol Plant are bolt-on projects that will produce renewable diesel and cellulosic etha-nol from conventional ethanol plants. Growth is expected in both standalone and bolt-on technologies, as the cellulosic ethanol industry discovers effi ciencies and mutually benefi cial partnerships.

To list your plant in the BCU, please contact Kolby Hoagland at [email protected].

Biomass Construction Update

Atikokan Generating Station, Ontario Power Generation Inc.

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Biomass Power Pellets Biogas Advanced Biofuel


Gettysburg Energy & Nutrient Recovery Facility, EnergyWorks BioPower, LLC

Location Gettysburg, Pa. CHP Yes

Engineer/builder EnergyWorks, Adolfson & Peterson Construction Government incentives Yes

Primary fuel Egg layer manure IPP or utility IPP

Boiler type Gasifi er and thermal oxidizer Groundbreaking date December 2011

Nameplate capacity 3.2 MW Start-up date Q4 2013

Project construction is in fi nal stage before structural completion. Performance testing is scheduled to begin in October.

Hopewell Power Station, DOM Power

Location Hopewell, Va. CHP No

Engineer/builder Crowder Construction, ESI Inc., Babcock & Wilcox Government incentives Federal PTC, RECs

Primary fuel Wood waste IPP or utility Utility

Boiler type Stoker Groundbreaking date August 2012

Nameplate capacity 50 MW Start-up date October 2013

Woodyard construction and boiler modifi cations are complete. Commissioning activities are ongoing.

Rothschild Biomass Cogeneration Plant, We Energies

Location Rothschild, Wis. CHP Yes

Engineer/builder Boldt Government incentives 1603 Program grant

Primary fuel Urban wood waste, mill residue IPP or utility Utility

Boiler type Circulating fl uidized bed Groundbreaking date June 2011

Nameplate capacity 50 MW Start-up date December 2013

Construction is 90 percent complete and the testing phase has started.

Southampton Power Station, DOM Power

Location Franklin, Va. CHP No

Engineer/builder Crowder Construction, ESI Inc., Babcock & Wilcox Government incentives Federal PTC, RECs

Primary fuel Wood waste IPP or utility Utility

Boiler type Stoker Groundbreaking date. October 2012

Nameplate capacity 50 MW Start-up date November 2013

Wood yard construction and boiler modifi cations are nearing completion. Biomass operations to begin in November.

Amite BioEnergy, Drax Biomass International Inc.

Location Gloster, Miss. Fire prevention technology Fire Eye

Builder Haskell Company Production capacity 450,000 metric tons/yr

Pellet mill Exporting/destination Yes/U.K.

Feedstock Southern yellow pine Groundbreaking date August 2013

Pellet grade Industrial premium pellets Start-up date Q1 2015

Construction is on schedule.

Atlantic Fiber Resources - Chander, Canadian Northern Timber Group

Location Chandler, Nova Scotia Fire prevention technology Firefl y

Builder FW Technologies, Gremmier Production capacity 240,000 metric tons/yr

Pellet mill TBD Exporting/destination Sweden, U.K., Germany, Ireland

Feedstock Softwood Groundbreaking date Q2 2012

Pellet grade Super premium Start-up date Q2 2015

Project is on hold pending an environmental study. Construction is planned to resume shortly.

German Pellets Louisiana, GmbH

Location LaSalle, La. Fire prevention technology German Pellet proprietary

Builder German Pellets Louisiana LLC Production capacity 1.1 million tons/yr

Pellet mill Multiple companies Exporting/destination Yes/Europe

Feedstock Softwood Groundbreaking date August 2013

Pellet grade Industrial and premium Start-up date Q1 2014

Deconstruction of preexisting industrial plant has begun. Equipment has been ordered and construction of new buildings will begin this autumn.

Morehouse BioEnergy, Drax Biomass Inernational Inc.

Location Beekman, La. Fire prevention technology Fire Eye

Builder Haskell Company Production capacity 450,000 metric tons/yr

Pellet mill Exporting/destination Yes/U.K.

Feedstock Southern yellow pine Groundbreaking date August 2013

Pellet grade Industrial premium pellets Start-up date Q2 2015

Construction is on schedule.

CONSTRUCTION UPDATE¦

Hopewell Power Station, DOM Power

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Project Complete Green Whey Energy

Location Turtle Lake, Wis. Biogas production capacity 868 scfm

Engineer/builder Ecolab, Symbiont/Miron Construction Biogas end use Electricity generation

Substrate(s) Waste water Installed power capacity 3.2 MW

Digester type Upfl ow Groundbreaking date January 2013

Gas cleaning technology Unison Gas Conditioning Sys. Start-up date July 2013

Project is complete and operational.

Project Complete Quasar Energy Group - Barberton

Location New Franklin, Ohio Biogas production capacity 195 scfm

Engineer/builder Quasar Energy Group Biogas end use CHP

Substrate(s) Food waste, FOG, biosolids Installed power capacity 810 kW

Digester type Complete mix Groundbreaking date May 2013

Gas cleaning technology NA Start-up date September 2013

The facility became operational on Sept. 20.

FCPC Renewable Generation LLC Waste-to-Energy Facility

Location New Franklin, Ohio Biogas production capacity 195 scfm

Engineer/builder Quasar Energy Group Biogas end use Electricity, heat

Substrate(s) Food waste, FOG, biosolids Installed power capacity 810 kW

Digester type Complete mix Groundbreaking date May 2013

Gas cleaning technology NA Start-up date September 2013

On schedule, working toward substantial completion by Sept. 30.

Hometown Bioenergy LLC, Minnesota Municipal Power Agency

Location Le Seuer, Minn. Biogas production capacity

Engineer/builder Barr Engineering, I&S Group Biogas end use CHP

Substrate(s) Ag and food wastes Installed power capacity 8 MW

Digester type Complete mix Groundbreaking date December 2012

Gas cleaning technology Start-up date December 2013

Structural completion of project is approaching. Installation of the four gensets has been completed. Commissioning is expected to begin imminently.

Sacramento Biodigester, CleanWorld Partners

Location Sacramento, Calif. Biogas production capacity 347 scfm

Engineer/builder Peabody Engineering, Otto Construction Biogas end use Electricity generation and

vehicle fuel

Substrate(s) Pre- and post-consumer food waste Installed power capacity 190 kW

Digester type Three-stage, high-solids liquid digester Groundbreaking date June 2013

Gas cleaning technology BioCNG Start-up date March 2014

Construction continues on schedule. Once complete, the digester will produce electric-ity and 700,000 gal/yr equivalent of renewable transportation fuel.

UC- Davis Renewable Energy Anaerobic Digestion, CleanWorld

Location Davis, Calif. Biogas production capacity 123 scfm

Engineer/builder Peabody Engineering, Otto Construction Biogas end use Electricity generation

Substrate(s) Food and ag. waste, manure, animal bedding Installed power capacity 925 kW

Digester type Three-stage, high-solids liquid digester Groundbreaking date May 2013

Gas cleaning technology Unison Solutions Start-up date December 2013

Construction procedes on schedule.

UW- Oshkosh Foundation, Rosendale Biodigester LLC

Location Rosendale, Wis. Biogas production capacity 380-475 scfm

Engineer/builder BIOFer Energy Systems Biogas end use CHP

Substrate(s) Dairy manure Installed power capacity 1.4 MW

Digester type Complete mix Groundbreaking date July 2013

Gas cleaning technology Biological desulp., moist. removal, carbon fi ltration Start-up date December 2013

Underground piping is complete, CHP is installed, digesters are 80 percent complete, mechanical systems are being installed, and modifi cations at the dairy are underway.

Project Complete Indian River Bioenergy Center, Ineos Bio

Location Vero Beach, Fla. Production capacity 8 MMgy

Engineer/builder AMEC Type of RIN D3

Process technology Ineos Bio (gasifc./ferm.) Coproducts 6 MW of biomass power

Biofuel product Cellulosic ethanol Groundbreaking date Q1 2011

Feedstocks Agriculture/yard waste, MSW Start-up date Q2 2013

Plant commissioning has ended and project has reached completion.

¦CONSTRUCTION UPDATEBiomass Power Pellets Biogas Advanced Biofuel

UW- Oshkosh Foundation, Rosendale Biodigester LLC

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CONSTRUCTION UPDATE¦Biomass Power Pellets Biogas Advanced Biofuel

Abengoa Bioenergy Biomass of Kansas LLC, Abengoa Bioenergy US

Location Hugoton, Kan. Production Capacity 25 MMgy

Engineer/builder Abengoa Type of RIN D3

Process technology Proprietory process Coproducts 21 MW of biomass power

Biofuel product Cellulosic ethanol Groundbreaking date September 2011

Feedstocks Corn stover, wheat straw, switchgrass Start-up date December 2013

Project is 90 percent complete. Boiler and cogen plant commissioning has begun.

DuPont Cellulosic Ethanol - Nevada, DuPont

Location Nevada, Iowa Production Capacity 30 MMgy

Engineer/builder Fagen Type of RIN 90% D3 RINs

Process technology Enzymatic hydrolysis Coproducts Renewable solid fuel

Biofuel product Cellulosic ethanol Groundbreaking date Q4 2012

Feedstock Corn stover Start-up date Q2 2014

Site concrete and steel erection continues. Construction on track for 2014 opening.

Enerkem Alberta Biofuels LP

Location Edmonton, Alberta Production Capacity 3 MMgy

Engineer/builder Enerkem Type of RIN 1.7 D4 RINs per gallon

Process technology Proprietary thermo-chemical Coproducts

Biofuel products Cellulosic ethanol, metha-nol, renewable chem. Groundbreaking date August 2010

Feedstocks Sorted MSW Start-up date 2013 methanol, 2014 ethanol

Construction of the Enerkem Alberta Biofuels facility is nearing completion with 28 permanent employees working full-time at the plant in preparation for commissioning.

Green Energy Products, WB Services

Location Sedgwick, Kan. Production Capacity 3 MMgy

Engineer/builder WB Services Type of RIN 1.7 D4 Rin's per gallon

Process technology Proprietary technology Coproducts Steam and biogas

Biofuel product ASTM spec. bio-based diesel Groundbreaking date Q1 2013

Feedstocks Organic fat, oils and greases Start-up date Q1 2014

Construction is on schedule. Structural steel work is 80 percent complete. Final major pieces of equipment are arriving on site, and piping work continues.

Project Liberty, POET-DSM Advanced Biofuels LLC

Location Emmetsburg, Iowa Production Capacity 25 MMgy

Engineer/builder Poet Design and Construction Type of RIN D3

Process technology Enzymatic hydrolysis Coproducts Biomass power

Biofuel product Cellulosic ethanol Groundbreaking date March 2012

Feedstock Crop residue Start-up date Q1/Q2 2014

Biomass stackyard, saccharifi cation and fermentation tanks, biomass receiving and grinding building are complete.

Quad County Cellulosic Ethanol Plant

Location Galva, Iowa Production Capacity 2 MMgy

Engineer/builder Nelson Engineering Type of RIN D3

Process technology Quad County Corn Processors - ACE Coproducts Solid biomass fuel

Biofuel product Cellulosic ethanol Groundbreaking date July 2013

Feedstock Corn fi ber Start-up date April 2014

Site foundations and fermenters are being constructed.

Southeast Renewable Fuels LLC

Location Clewiston, Fla. Production Capacity 20 MMgy

Engineer/builder Uni-Systems of Brazil Type of RIN D4

Process technology Fermentation Coproducts 25 MW biomass power

Biofuel product Advanced biofuel (ethanol) Groundbreaking date June 2013

Feedstock Sweet sorghum Start-up date January 2014

Foundation work is beginning. All equipment has been ordered and will arrive before the end of the year.

Green Energy Products, WB Services

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PowerNews

New solid biomass sustainability standards are set to go into effect in the U.K. in 2015. According to the U.K. Department of Energy & Cli-mate Change, once the standards take effect, the biomass industry will be required to show its fuel is sustainable to receive fi nancial support under the Renewables Obligation. The require-ments will apply to electricity genera-tors of 1 megawatt (MW) capacity or higher that use biomass or biogas feedstock.

The DECC estimates the 1 MW threshold will cover approximately 98 percent of all biomass power gen-eration in the U.K. Power producers covered by the sustainability standards will also be required to provide an

independent sustainability audit with their annual sustainability report.

In order to provide certainty to investors and developers, the DECC has indicated that there will be no ad-ditional unilateral changes to sustain-ability criteria before April 2027.

“The coalition is committed to delivering clean, affordable and secure energy for consumers,” said Greg Barker, Minister of State for Energy and Climate Change. “This includes an important role for biomass power as part of the UK’s energy mix. The new criteria will provide the neces-sary investor certainty and, crucially, ensure that the biomass is delivered in a transparent and sustainable way.”

The U.S. EPA has updated its RE-Powering Map-ping and Screening Tool. The tool, part of the RE-Powering America’s Land Initiative, provides preliminary screening results for renewable energy potential on contaminated land, landfi ll and mine sites. It now profi les 66,000 locations, up from 34,000.

The tool pulls data from EPA databases of po-tentially and formerly contaminated lands. The RE-Powering Initiative has worked in collaboration with the U.S. DOE’s National Renewable Energy Laboratory to develop screening criteria for biomass, solar, wind and geothermal potential on identifi ed sites.

Currently, the tool identifi es 9,966 potential sites for biopower development. These sites have biomass re-sources of at least 280,000 metric tons per year within 50 miles, are at least 50 acres in size, are less than 10 miles from transmission lines and are close to graded roads and rail. In addition, 1,947 sites are identifi ed as potential locations for landfi ll gas projects, with 9,966 potential sites identifi ed as possible biorefi nery locations.

More than 70 renewable energy projects have already been installed on contaminated lands or landfi lls through the initiative, representing more than 200 MW of combined capacity. Most of these projects to date have been solar, with EPA data highlighting only one 20 MW project currently employing biomass. However, information published by the agency states that biomass potential at EPA’s tracked sites is more than 190,000 MW on a technical basis.

UK announces sustainability standards RE-Powering tool highlights bioenergy potential

12 Greenway PlazaSuite 1100Houston TX 77046

Toll Free: 1 855 8HIMARK (1 855 844 6275)email: [email protected]

U.K. pellet demand (in million metric tons)Consumption Imports Imports from U.S.

2010 1.992011 2.72 1.015 0.2742012 3.38 1.47 0.4752013 (projected) 4.54SOURCE: USDA FAS GAIN, EU BIOFUELS ANNUAL 2013


In mid-September, the USDA made a public commit-ment to support bioenergy, including the biomass, pellet and thermal industries. At a press conference, Deputy Secretary Krysta Harden signed a memorandum of un-derstanding (MoU) with Biomass Power Association and a few of our sister organizations.

Agriculture Secretary Tom Vilsack, who could not be there due to a last-minute emergency, expressed enthusi-asm for the agreement. In a personal statement he issued, Vilsack said, “Today's announcements will help us fi nd innovative ways to use leftover wood to create renewable energy and support good jobs in rural America. Wood-to energy efforts are a part of our 'all of the above' energy strategy. Appropriately scaled wood energy facilities also support our efforts to remove hazardous fuels and reduce the risks of catastrophic wildfi res."

This is a signifi cant step forward for biomass. Public recognition by a federal agency for not only producing renewable energy, but also for our role in reducing the risk of forest fi res, is a big deal. Particularly during a month when wildfi res threatened Yosemite National Park in California, it was gratifying to see the federal government acknowledging the benefi ts of biomass.

Part of the MoU will cover efforts to promote bio-mass to the general public, and part of the agreement will cover increased coordination among federal agencies in ad-dressing biomass, something which could prove especially helpful to us as we prepare for a fi nal ruling by the U.S. EPA on the regulation of biomass emissions under the Clean Air Act.

In the weeks leading up to the announcement, the Biomass Power Association collected stories of success-ful USDA-biomass partnerships around the country. We found some excellent examples of how these public-private partnerships can keep federal lands healthy while generating clean energy, so I thought I would share a few of them here:

• Colorado The Eagle Valley project by Evergreen Clean Energy will open this fall in Gypsum, Colo. It will use woody biomass from 2,500 acres of land ravaged by beetle kill and posing high wildfi re risks, to power nearly 8,000 local homes and businesses. A USDA Stewardship Contract and a $40 million Rural Utilities Service loan guarantee made this possible.

• New York A USDA collaboration in New York with ReEnergy Holdings in the North Country region of New York is helping fund an innovative public/private partnership to invest in energy crops grown on marginal farmland and used as fuel to produce electricity.

• Arizona The White Mountain Stewardship Project is a partnership between Novo Power LLC in Snowfl ake, Ariz., and the U.S. Forest Service, created largely as a result of the Rodeo-Chediski fi re of 2002. The 10-year contract was established to thin approximately 150,000 acres in the Apache-Sitgreaves National Forest. This program provides approximately 155,000 bone-dry tons of ponderosa pine chips annually to the region, enough to power approxi-mately 20,000 homes and businesses.

• California Avista, a biomass company based in northeast Washington, received at its Woodland facility in California logs that were damaged by wildfi re in the Lake Tahoe area as a result of a U.S. Forest Service partnership. The Stockton, Calif., area also yielded wood byproducts from trees infected by light brown apple moth and the pathogen sudden oak death.

• Montana Stoltze Land and Lumber in Columbia Falls, Mont., generates heat for mill operations and sells 2.5 MW of power to Flathead Electric Cooperative. A USDA partnership helped Stoltze replace a 30-year-old wood boiler.

• Oregon Biomass One, a 30-MW wood-fi red biomass power plant, is located in the Rogue River Valley in southern Oregon that includes federally managed lands such as Siskiyou National Forest, the Umpqua National Forest, the Klamath National Forest and the Medford District of the Bureau of Land Management. This year, an estimated 25 percent of Biomass One’s fuel consump-tion will consist of material processed and recovered as a byproduct from forest operations. U.S. Forest Service and Bureau of Land Management stewardship projects combined yield around 30,000 tons of woody biomass in the region each year.

We are looking forward to seeing even more partner-ships following the USDA agreement.

Author: Bob CleavesPresident and CEO, Biomass Power Association

www.biomasspowerassociation.com [email protected]

USDA Commits to Biomass

POWER¦

BY BOB CLEAVES


¦POWER

COVETED TECHNOLOGY: PHG Energy recently completed its fi rst waste-to-energy downdraft gasifi cation installation for the city of Covington, Tenn.PHOTO: PHG ENERGY


POWER¦

PHG Energy has proven its downdraft gasifi cation technology and is ready to scale up. BY ANNA SIMET

Modular Mastery

With a population of just over 9,000 people, the city of Coving-ton in western Tennessee has made a mark on the renewables map. Its recently completed, waste-to-energy gasifi cation

plant installed by PHG Energy went on line in early September, and materials the city has been stockpiling during its development are now being fed into the system for power production.

“Yesterday, Covington was throwing wood waste and sewage sludge into the landfi ll,” explains Chris Koczaja, PHG Energy vice president of sales and engineering. “Today they’re mixing 80 to 90 percent woodchips with 10 to 20 percent sewage sludge and gasifying it into heat energy.”

Previously, the city was spending about $30 per ton in both tip-ping fees and transportation, but is already seeing positive cash fl ow.

The system utilizes PHGE’s proprietary 12-ton-per-day capacity downdraft gasifi er to supply 6 million Btus of producer gas per hour as the central technology. The gasifi er design, which has been vetted through over 40,000 hours of commercial production use, allows the


¦POWER

city to dispose of about 10 tons of urban wood waste and 2 tons of sewer sludge each day, or 360 tons per month.

In a nutshell, PHGE’s plant design in-cludes wood chipping and material handling, chip and sludge mixing and drying, gasifi ca-tion conversion of the feedstock to gas, a thermal oxidizer and an oil heater to pro-vide heat power for a General Electric Clean Cycle heat-to-power Organic Rankine Cycle generator. Direct use of the ORC generator to produce power from a gasifi cation plant was pioneered this year through a research and development project PHGE completed with General Electric.

While just bringing the project on line is exciting—commissioning should be com-plete by late October—the successful instal-lation is particularly noteworthy because it will likely lead to larger projects, which have traditionally utilized updraft gasifi ers.

Up with Downdraft“For larger gasifi cation projects, updraft

gasifi ers have been prevalent, as downdraft gasifi ers have traditionally been limited in size and deemed not scalable,” Koczaja says. “[However] downdraft gasifi ers offer easy operation and low operation and mainte-nance costs—very few moving parts—pow-er density, and a cleaner gas as their output.”

The cleaner gas is a result of air being drawn downward through the feedstock, in the same direction the biomass is moving. Main reactions occur in a throat-like con-striction area where the tars and volatile gas-es are passed through a hot bed of char and broken down into carbon monoxide and hy-drogen, at a much higher temperature than in an updraft gasifi er. As a result, downdraft gasifi ers produce cleaner gas.

Through focused R&D, PHGE has been able to develop a line of gasifi ers that maintain the benefi ts of downdraft while overcoming the issue of scalability.

Rather than scaling up and then looking at symptoms to try to correct them, PGHE approached the core problem—the geom-

GENIUS GENERATOR: Power at the Covington gasifi cation plant is produced via a General Electric Organic Rankine Cycle generator.PHOTO: PHG ENERGY


Tennessee Department of Environment and Conservations. The remainder was fi nanced through a 20-year Tennessee Municipal Bond Fund.

Confi dent in the scalability of its modu-lar design, PHGE is ready to move full speed ahead with larger installations.

Improving Economics“Since the system design is modular, it

can easily be upgraded to accommodate larg-er municipal or industrial facilities,” Koczaja says. “Economies of scale kick in very quick-ly, and savings become substantial. Other such projects now in the development pipe-line are showing payback periods of three to fi ve years. Covington is a small town, and it’s always easier and cheaper to do things bigger. If we can make it work on Covington’s scale, the economics just get better for the cost of the installed equipment.”

As for other current and future endeav-ors, Koczaja says PHGE is currently working

with some islands in the Caribbean on energy options. “I think that is one of the biggest things that gasifi cation can help with…they are already bringing in types of energy and fi lling their landfi lls. We’re trying to help them connect those two dots to make energy, and utilize their tremendous growing seasons and land mass to grow their energy. Those dol-lars going offshore to buy oil are dollars they could keep in the local economy while dra-matically decreasing energy costs.”

There is one very important thing to note about gasifi cation, Koczaja adds. “It’s here, and it’s real. It’s not conceptual with un-realistic goals and unrealistic components…it’s something, that in another month [in Covington], you’ll be able to come and touch, feel, and see that it works.”

Author: Anna SimetManaging Editor, Biomass Magazine

[email protected]

POWER¦

etry in the gasifi er itself—fi rst. “Our theo-retical physicist on staff knew if he could create the right conditions inside the gasifi er, he could change the fundamental design that the industry’s used over the last 100 years, in a way that would be feasible and very easy to operate,” Koczaja says.

That approach proved successful, as PHGE has built what it believes is the larg-est downdraft gasifi er in the world at 64 tons per day and 32 million Btu/hr, located in Greenwood, Miss. Fully functional and oper-ating just like the smaller gasifi er in the Cov-ington project, Koczaja says the company uses this “full-scale, serial #1” for feedstock testing and proof of concept. There, a vast range of feedstocks have been successfully tested, including chips from wood waste or forest residuals, purpose-grown biomass crops, chopped or shredded tires, ag waste such as corn or cotton stalks, food process-ing wastes, municipal or industrial sludge, coal and processed and pelletized municipal solid waste.

Feedstock fl exibility is a noteworthy advantage a municipality would reap from gasifi cation as opposed to a different tech-nology. “New feedstocks can be introduced without having to modify components,” Koczaja says. Additionally, systems are gen-erally easy to operate and can be stopped on a dime by personnel, all of which in Cov-ington’s case are the city’s existing workforce, and not specialized technicians that had to be brought in. “If [Covington] needs to stop it for any reason, they can simply hit the stop button and it shuts down,” he says. “It can be started right back up.”

And perhaps the most obvious advan-tage is that there isn’t a time or space ele-ment, as there is when using other technolo-gies such as landfi ll gas. “You have to wait, and you’re also taking up space in the land-fi ll. [With gasifi cation] you’re skipping that step.”

Via the Mississippi system and three other commercial installations at brick kilns, PHGE was able to prove these advantages and demonstrate the system to Covington, and Mayor David Gordon signed a contract with the company in July 2012. The total cost of the plant was $2.5 million, $250,000 of which was paid for with a grant from the


DEPARTMENT

¦POWER

The staff at Ineos Bio New Planet En-ergy LLC has settled into the daily routine of commercial production at the fi rst-of-its-kind cellulosic ethanol

and renewable power facility near the Indian River Landfi ll outside of Vero Beach, Fla. A steady stream of trucks delivers yard and tree trimmings to the feedstock yard, where the material is shredded and piled for open-air drying in the Florida sun before being moved over to the covered shelter and fed into a dryer and gasifi er. The heat recovered from the cooling gas is used to generate 6 MW of electricity and the cleaned, cooled syngas goes to a patented anaerobic bacterial fermenta-tion process producing 8 MMgy of ethanol.

In the continuous process, feedstock entering into the gasifi er exits as ethanol less than 10 minutes later.

The project is a joint venture between Florida-based New Planet Energy Florida LLC and Ineos Bio, a division of global chem-ical company the Ineos Group. The $130 million project received a $50 million U.S. DOE matching grant in December 2009 and a $75 million USDA loan guarantee in Janu-ary 2011. A groundbreaking ceremony was held a month later. The process design was worked out in over 40,000 hours of opera-tion since 2003 at a fully-integrated pilot plant in Fayetteville, Ark., using a wide variety of feedstocks. Ineos purchased the pilot facility

and technology in 2008 from Bioengineering Resources Inc., forming its IneosBio division to commercialize the process.

The Ineos Group also is relatively new, being formed in 1998 to acquire a petrochem-ical refi nery in Antwerp, Belgium. In a series of acquisitions, Ineos purchased technology rights and production facilities from compa-nies such as Dow Chemicals, Rhodia, BASF, Chevron, Phillips, Monsanto, Hoechst and, in 2006, BP Chemicals. Sales in the past two years have topped $43 billion from 15 Ineos business segments that manufacture a wide range of chemical intermediates. The produc-tion network spans 51 manufacturing facilities in 11 countries.

The Value of Versatility Besides cellulosic ethanol on a commercial scale, Ineos Bio’s Florida biorefinery generates 6 MW of power via a feedstock flexible gasification technology.BY SUSANNE RETKA SCHILL

MEETING A MILESTONE: For a year, Ineos Bio New Planet Energy has been generating renewable power from the biomass gasifi er, shown here with Peter Williams, CEO, left, and Mark Niedershulte, chief operating offi cer, in the foreground. Commissioning the syngas-fermentation-to-ethanol system took 10 months.

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POWER¦

In that context, Ineos Bio’s work in Flor-ida seems small, but it is the fi rst new technol-ogy Ineos has commercialized itself, although it has licensed more than 40 around the world. Peter Williams is CEO of both Ineos Bio and Ineos Technologies, which licenses the com-pany’s technology portfolio. He says the com-pany’s licensees typically take four years from project launch to being operational. “That’s with known technologies and experienced companies,” he adds. Ineos is quite pleased, he says, with the team’s accomplishment in bring-ing a new technology online in just fi ve years.

Mark Niedershulte, explains that at BP Chemicals and other earlier positions, he has worked on six new technologies where each took about 20 years in development. Given that University of Arkansas professor James Gaddy fi rst isolated the ethanol-producing or-ganism in 1992, this project fi ts into that time-line. When Ineos Bio purchased the technol-ogy rights and Arkansas pilot facility fi ve years ago, Niedersholte says they focused their work on optimizing two new technologies, biomass gasifi cation and the microbial fermentation, into ethanol. Other systems such as the gener-ator and distillation unit were well-established technologies purchased from others.

The Ineos Bio gasifi cation process is a two-step, oxygen-blown technology that converts the prepared, dried biomass into a synthesis gas. Feedstocks of different bulk density, particle shape and size may be mixed together to optimize feed rate and minimize entrained air. Upon exposure to the heat in the lower chamber of the gasifi er, further drying takes place followed by pyrolysis, generating a pyrolysis gas that passes through to the upper

chamber where it is mixed with more oxygen, generating more heat from partial combus-tion. The high temperature and residence time crack the pyrolysis gases into carbon monox-ide, hydrogen and carbon dioxide. No tars or aromatic hydrocarbons are present in the syn-gas. The gasifi cation proceeds in a reducing environment, with insuffi cient oxygen present for complete oxidation of the carbon present. This reducing environment suppresses the formation of dioxins and furans, and any di-oxins or furans introduced with the feedstock are destroyed. The gasifi er also operates at slightly negative pressure to prevent the escape of gases.

The hot synthesis gas is quenched and cleaned and the heat recovered to generate re-newable electricity. The cooled, cleaned syngas is compressed as it is introduced to the patent-ed fermentation process at low temperature and pressure where bacteria rapidly convert the carbon and hydrogen into ethanol. Most of the syngas is converted to ethanol and any unconverted vent gas is cleaned and combust-ed to generate additional renewable power. Suffi cient heat and power are generated and recycled in the integrated process to meet the facility’s entire energy needs, with between 1 and 2 MW of surplus power exported to the grid. With all its waste feedstock virtually local, and its ethanol being shipped to nearby Florida terminals as well, Ineos Bio has an impressive energy balance.

Author: Susanne Retka SchillSenior Editor, Biomass [email protected]

701-738-4922

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DIVERSIFIED FEEDSTOCK: Individuals and contractors deliver truckloads of vegetative waste round the clock. Ineos Bio is paid the tipping fee for its feedstock, generated by the 170,000 residents in the two participating counties.


PelletNews

The European Union recently published its annual biofuels report for 2013 with the USDA Foreign Agricultural Service’s Global Agricultural Information Network, reporting European wood pellet consumption is expected to increase mark-edly, reaching 20 to 32 million tons of oil equivalent (Mtoe). The report estimated 2008 consumption at 2.5 Mtoe.

Both domestic production of pellets within Europe and imports have increased in recent years. In 2006, the E.U. produced approximately 3.52 million metric tons of wood pellets. Production is expected to reach 10.15 million metric tons this year, and increase to 10.3 million metric tons in 2014. Imports measured only 800,000 metric tons in 2006, but are projected to grow to 6 million metric tons this year and 7 million metric tons next year.

Consumption has also grown rapidly, from 4.606 million metric tons in 2006 to 14.3 million metric tons last year. In 2013, the EU is expected to consume 16 million metric tons of wood pellets, with consumption growing to 17.1 million metric tons next year.

The U.K. is currently Europe’s larg-est consumer of pellets, with 4.54 million metric tons of demand expected this year. Denmark and the Netherlands round out the top three consumers, with 2.5 million metric tons and 2 million metric tons of consump-tion expected this year, respectively. Sweden, Germany and Belgium also consume large volumes of pellets.

Consumption in the U.K., the Nether-lands and Belgium is dominated by large-scale power plants, while demand in Denmark and Sweden results from household and medium-scale use.

Washington County, Md., recently announced it is forming a public-private partnership with America First Inc. to launch a two-phase waste-to-renewable energy initiative. During the fi rst phase, a facility will be constructed to convert municipal solid waste (MSW) into refuse-derived fuel pellets. That facility will include recycling, sorting, shredding and pelletizing operations, with all nonrecyclable components of MSW pro-cessed into fuel pellets. The proposed phase two component of the project will include the development of a gasifi cation plant to convert a portion of the MSW pellets into drop-in biofuels.

Julie Pippel, Washington County director for environmental management, said the fi rst phase of the initiative is currently expected to break ground in 2014, once all permitting requirements are met. Construction on phase two of the project would commence 18 months after phase one.

According to Pippel, pellets produced at the facility will be sold into various markets, including the industrial sector for use as fuel in boiler systems and kilns. Washington County will provide the facility with the MSW it collects. There are also plans to mine the landfi ll to recover buried MSW in the future.

EU pellet demand, production continues growth MSW pelleting project planned in Maryland

EU pellet production (in million metric tons)2006 2007 2008 2009 2010 2011 2012 2013 (estimated) 2014 (projected)

E.U. total 3.52 5.782 6.294 6.669 9.241 9.62 10 10.15 10.3Germany 1.1 1.46 1.6 1.75 1.88 2 2Sweden 1.36 1.58 1.58 1.65 1.34 1.34 1.35Austria 0.7 0.625 0.695 0.85 0.94 0.89 0.95Portugal 0.4 0.55 0.65 0.65 0.65SOURCE: USDA FAS GAIN, EU BIOFUELS ANNUAL REPORT 2013


“We’re this far from taking off,” said a speaker at a pellet boiler fi rm’s recent sales meeting in Portland, Maine, while holding his thumb and index fi nger two inches apart. At the same time, another major pellet boiler fi rm in Maine is pounding the television airwaves with a commercial comparing the price of pellet fuel to heating oil, and Maine’s state energy agency recently announced an incentive program whereby up to 50 resi-dential pellet boiler purchasers will receive rebates up to $5,000. The boiler fi rms and installers hope that this incentive will prove so popular that it will be extended beyond the initial funding.

Speaking at the 2013 Kedel (a Danish pellet boiler) Summit in Portland, former Biomass Thermal Energy Council Chairman Charlie Niebling was asked what it will take for residential pellet boiler sales in Maine and New Hampshire to achieve liftoff. Niebling suggested that increased tension in the Middle East, thereby spik-ing oil prices, would be an obvious stimulus. Absent such a spike, Niebling stated that while the pellet sector is “poised to signifi cantly expand,” it behooves the industry to undertake a strong education and promotion program.

Other speakers at the meeting cited the need to an-swer consumer questions about bulk delivery, the long-term price outlook for pellets, the resale value of homes with central pellet heat, and greenhouse gas emissions. A panel of customers speaking at the end of the meet-ing emphasized that the desire to “get away from oil,” for both economic and environmental reasons, trumped whatever unanswered questions they had about switch-ing to pellets. A secondary reason cited was a desire to spend their fuel dollars in support of Maine’s forest products economy.

Sales staff at the meeting spoke with confi dence, noting that the 20-year longevity of oil burners means that every year, fi ve percent of Maine homeowners are in the marketplace for a new heating system. The mar-keting pitch is “pellets are half the price of oil, and emit one-tenth the greenhouse gas.”

Will Maine be a signifi cant partner in achieving pellet heat liftoff? According to its critics, the outlook

among some trustees and staff at the state’s energy agency, Effi ciency Maine, is that economic development considerations—the huge multiplier effect of a heating system using a locally produced fuel—are not central to the agency’s mission. In addition, the “insulation uber alles” crowd continues to demand that no home receive funds for a heating system change-out without the building envelope fi rst being secured, a proposition that often leaves the homeowner with only enough funds for a new oil burner.

There are indications that the insulationists’ shrill arguments, threatening legal action if Effi ciency Maine does not interpret an ambiguous section of new state law in their favor, are losing sway at the state agency. Also, Effi ciency Maine recently made a modest grant to assist the Northern Forest Center’s promising Model Neighborhood project, which incentivizes pellet boiler installations in a concentrated area of homeowners.

At any rate, Effi ciency Maine has just announced a wide range of incentives designed to reduce both energy demand and heating costs. Pellet stove purchas-ers will receive a $250 rebate provided the stove is EPA-approved and makeup air is ducted into the unit. Homeowners installing heat pumps or effi cient new gas, propane, or oil furnaces will receive $500 rebates. The fi rst 50 homeowners to install pellet boilers meeting HUD Energy Saver standards—or geothermal heat—will receive a $5,000 rebate, which is approximately the incentive amount that has proved most effective in sell-ing pellet boilers.

Our industry up here obviously hopes that this incentive, sales force enthusiasm, the media advertising being done by one boiler fi rm—Maine Energy Sys-tems—promoting pellet heat in general, and word-of-mouth recognition of our product quality will get us into a sharply upward fl ight path.

Author: Bill BellExecutive Director, Maine Pellet Fuels Association

[email protected]

Pellet Heat Approaches Liftoff with Residential Consumers

PELLET¦

BY BILL BELL


CONTRIBUTION

¦PELLET

Recent developments in densifi cation technologies, including pelletiza-tion, have substantially improved the economics of moving biomass

around the globe. This is one of the reasons that the wood pellet industry has become an inevitable part of the bioeconomy in the U.S., Canada and elsewhere.

To be an effective alternative to coal, increasing the energy density of pellets is as important as increasing bulk density and du-rability. The high heating value of currently marketed pellets is about 19 gigajoule (GJ) per metric ton, which limits the proportion that can be used in cofi ring with coal, with a heating value as high as 28 to 30 GJ per met-ric ton. In this context, removing the low-heat content volatiles from biomass is a promising strategy to increase the overall heat value of pellets and the ability to store them outside brings storage and handling costs on par with coal.

Torrefaction, also known as mild pyroly-sis/carbonization, is a thermal pretreatment

process to upgrade lignocellulosic biomass into a higher-quality energy and carbon car-rier, to augment coal. The process subjects the biomass to temperatures ranging from 200 to 300 degrees Celsius in the absence of oxygen for up to 30 minutes. The slow heating process roasts biomass, releasing volatile compounds and breaking down hemicelluloses. Torrefac-tion has been proposed as a robust strategy to overcome the heterogeneity among different types of cellulosic feedstocks, thus producing a uniform-quality energy commodity with im-proved energy/carbon content and grindabil-ity. The bulk density of the torrefi ed material, however, is generally lower than that of the raw biomass, making transport and storage economically challenging. Therefore, combin-ing torrefaction and pelletization has great po-tential to upgrade raw biomass to a universal energy commodity.

Pellets to the Test In a research project for the Environ-

mental Sciences Division of Oak Ridge Na-

tional Laboratory, two process pathways were investigated to make torrefi ed wood pellets from Douglas fi r wood chips. Both pathways started with dry wood chips as the raw materi-al and ended with torrefi ed wood pellets as the fi nal product. For Pathway I, the chips were ground, pelletized and pellets were torrefi ed. For Pathway II, the chips were initially tor-refi ed and then ground and pelletized. Since there are pros and cons associated with each of these process schemes, a detailed labora-tory experiment was planned to evaluate the characteristics of each operation, along with the compositional and physical properties as well as energy and mass balance.

For the experiments, Douglas fi r wood chips with an average size of 30 to 50 mil-limeter and initial moisture content of 45 to 50 percent were collected from Fibreco Co. located in North Vancouver, British Colum-bia. The material was fi rst dried to 15 percent moisture content for grinding or almost bone-dry condition for torrefaction prior to grind. Both untreated wood chips and torrefi ed

Torrefaction: Pre- or Post-PelletizationOakridge National Laboratory tests identify differing physical and chemical characteristics and energy use of two torrefied pellet pathways.BY SHAHAB SOKHANSANJ

Physical Property Comparison

Pellet typeDiameter

(mm)MC (%) Particle

density (g/cm3)

Bulk density (kg/m3)

High heat value

(MJ/kg)

Durability (% )

Pellets made from untreated wood chips 6.43 6.7 1.16 674 18.82 80.7

Pellets made from torrefi ed woodchips mixed with 7% wheat fl our binder, at 260 degrees Celsius

6.47 8.6 1.21 - - 85

Regular white pellets torrefi ed at 260 C 6.28 1.9 1.14 614 21.08 63.9

Regular white pellets torrefi ed at 280 C 6.12 1.7 1.04 579 21.97 62

Regular white pellets torrefi ed at 300 C 6.12 1.5 0.96 510 23 60.9


PELLET¦

wood chips were ground with a hammer mill under the same experimental conditions (the same feed rate and screen mesh size). Drying, followed by torrefaction, was performed in a Carbolite oven, which operates at tempera-tures ranging from room temperature to 600 C. Torrefaction was carried out in a stainless steel box installed inside the oven with ni-trogen introduced to provide an oxygen-free environment. A lab-scale California pellet mill was used for pelletizing both torrefi ed and untreated materials at 13 percent moisture content.

Comparing SystemsSince biomass is generally fl exible and

tenacious, it is energy intensive to reduce the particle size prior to the pelletization process or to use them in pulverized combustion sys-tems. From the comparison of processes, it is clear that loss of moisture and some of the volatiles during torrefaction process makes biomass more brittle and easier to grind. The torrefi ed material was found to consume near-ly 20 times less energy to grind than untreated wood chips. The torrefi ed material had to be reconditioned, however, to bring it back up to 13 percent moisture from the 2 percent level that followed torrefaction, before pelletiza-tion. Pelletization of the untreated materials was possible without using any binding agents, while the addition of a wheat fl our binder, at

5 percent mass basis, was necessary to enable effective pelletization of torrefi ed material. Pelletization of the torrefi ed material with the use of binder resulted in pellets with relatively higher density, durability and lower moisture absorption than torrefi ed pellets.

In order to understand the stability of the pellets in water, both types of pellets were immersed. Compared to the raw material pellets, which readily disintegrated when im-mersed in water, both types of torrefi ed ma-terial exhibited higher stability in water. How-ever, it was found that the pellets made from torrefi ed wood chips fell apart relatively easily, whereas the pelletized-and-torrefi ed material stayed intact for more than two hours. Simi-lar results were seen when the three samples were subjected to high humidity. It appears that penetration of the water vapor and its subsequent condensation is critically depen-dent on the external surface area of the pel-lets. In the case of pelletized and subsequently torrefi ed material, it appears that torrefaction substantially increased the external poros-ity of the pellets and more water vapor can potentially get condensed in the small pores present in the outer surface of the pellets. In the case of untreated pellets and torrefi ed and subsequently pelletized material, pelletizing could pack the materials tighter with less ex-ternal surface area and less porosity available for vapors condensation.

Pathway I, which involved drying, grind-ing, pelletization and torrefaction, consumed slightly higher amount of energy compared to Pathway II, which consisted of the direct torrefaction of the wet wood chips, grinding and pelletization. However, this lower energy consumption was at the expense of using binders during pelletization. Additionally, the quality of the wood pellets resulting from the pelletization of the torrefi ed material was still poor, including lower heat values and higher moisture content.

Therefore, in order to get the benefi t from the energy savings of Pathway II, we need to develop effective process strategies to improve the binding and pelletability of the torrefi ed material to make it more durable, denser and stronger. Torrefaction following pelletization currently appears to be a promis-ing strategy to obtain torrefi ed wood pellets which are transportable with improved du-rability, reduced moisture content and higher energy value.

Author: Shahab SokhansanjBioenergy Resource and Engineering Systems Group Environmental Sciences Division, Oak Ridge National

[email protected]

University of British Columbia researchers involved in the torrefac-tion project include: Bahman Ghiasi, Takaaki Furubayashi, Linoj Kumar, Tony Bi, Anthony Lau, Jim Lim, Chang Soo Kim and Jack Saddler.


Presentations at the annual Pellet Fuels Institute confer-ence held in July show that the outlook for the industry is still positive, both domestically and internationally. Daniel Saloni, assistant professor in forestry at North Carolina State University, pointed out that both aggres-sive and conservative economic models for the pellet industry are predicting growth.

Although U.S. pellet stove sales dropped when natural gas prices nosedived over the past couple of years, Seth Walker, an associate economist with RISI Inc. estimated the U.S. currently has approximately 845,000 pellet stoves installed. According to

Walker, an additional 50,000 to 60,000 stoves are expected to be added annually over the next several years.

While the EU power market has gotten much attention, the heating market comprises 40 percent of the EU pellet market, with no subsidy required. “Pel-lets are 30 percent cheaper than heating oil,” said Gordon Murray, executive director of the Wood Pellet Association of Canada.

“The consumer market in the EU has grown into a very stable market,” added Arnold Dale with Sweden-based Ekman & Co. “It is no longer seasonal. People prefer to buy pellets in the summer months.”

ThermalNews

Metso has announced it will supply a 10 MW biomass plant for hot water district heating to energy company Elenia Lämpö in Turenki, Finland. The facil-ity will be fi red using locally sourced biomass, such as forest residues and peat and utilize Metso’s advanced BioGrate combustion technology, which enables a wide selection of fuels. The plant is scheduled to be opera-tional in early 2014.

BioGrate is a rotating grate with a conical primary combustion chamber. The fuel input can range from 4 MW to 20 MW and is fed from underneath the center of the grate. Fuel dries in the middle of the grate by the heat radiating from the refractory lining bricks and by the fl ames without disturbing the burning fuel bed in the combustion zone. According to Metso, after the near complete combustion of the residual carbon, the ash falls from the edge of the grate to the ash space fi lled with quenching water.

“Elenia Lämpö's investment in the heating plant is an excellent example of a project that increases the utilization of local Finnish fuels in an energy-effi cient and environmentally friendly manner. The Turenki site highlights the need for a fl exible and highly adjustable plant solution that is able to effectively respond to heat-ing needs throughout the year. The advanced BioGrate combustion technology enables a wide selection of fuels, low internal consumption and highly fl exible adjustability,” says Teemu Koskela, who is in charge of bioheat plant sales at Metso.

PFI conference predicts growth

Metso supplies plant to Finland district heating project

Pellet stoves sold2010 2011 2012

Italy 176,000 182,000 195,000France 27,000 38,000 53,200Spain 16,000 10,000 11,000Germany 15,000 7,000 7,000Austria 3,273 5,000 7,000SOURCE: EUROPEAN PELLET COUNCIL, 2012


Ninety seconds, or 175 words. That was my window for brief speech conveying the positive benefi ts of biomass thermal energy to an audience of reporters, federal agency staff, and forestry groups during last month’s USDA Wood-to-Energy memorandum of understanding (MoU) signing. On the stage to my left were colleagues from the biomass power, pellet, and consumer advocacy sectors, and to my right USDA leadership. We were all there to recognize one thing: the vital role of woody biomass utilization for energy in promoting forest health, rural economies, and energy independence.

Groups such as BTEC, the Pellet Fuels Institute, Bio-mass Power Association, and Alliance for Green Heat have all—to some extent—engaged each other and the USDA on various bioenergy issues, but the signing ceremony on the morning of Sept. 11 formalized each group’s roles and set industry-wide goals. The MoU on Wood Energy had been in development with the aforementioned partners for well over a year, and was carefully tailored to address today’s energy and environmental issues. It was no coincidence that Deputy Secretary Krysta Harden announced the recipients of the USDA’s State-wide Wood-to-Energy Teams prior to the MoU signing. Fighting forest fi res and funding fuels reduction efforts are straining the Forest Service’s resources, and supporting biomass utilization can help meet those needs.

Neither the federal government nor the biomass industry needs an arrangement like the MoU to promote forest health or produce renewable energy, but its presence creates new opportunities for growth and improvement. The purpose of the MoU is straightforward, “to estab-lish the basis for cooperative programs, communications, technological advances, and project development toward an expanded use of wood energy in the U.S.” The words “com-munication” and “cooperation” are used nearly 10 times in the short document. In effect, USDA is creating a two-way street to improve its biomass energy programs, eligibility requirements, and research projects, among others. In turn, bioenergy groups are expected to collaborate with USDA

on their projects, communicate industry advancements, and contribute expertise to agency activities.

The concept of an MoU between the USDA and the agricultural sector is not new. Just this spring, the Innovation Center for U.S. Dairy resigned its agreement with the USDA from 2009.That agreement is also focused on the nexus of energy and environmental issues, with a clear goal of helping the dairy industry increase sustainable practices and the In-novation Center’s own goal of reducing the industry’s green-house gas emissions by 25 percent by the year 2020. While it is diffi cult to tease out whether one caused the other, the dairy industry has seen signifi cant USDA investments and awards since its initial agreement: 140 successful REAP- (Rural Energy for America Program) related loans and grants, 180 awards for biogas systems, conservation planning assistance for 6,000 dairy farmers, 354 on-farm and in-plant energy audits, and 18 conservation innovation grants. With its agreement, the dairy industry went from, “Got Milk?” to “Get-er-Done.”

So what tangible progress will the new Wood-to-Energy MoU yield? That answer lies with the partners and the USDA. From a biomass thermal perspective, I see several near- and longer-term USDA activities like agency participation in BTEC’s thermal effi ciency standard project, quantifying the health benefi ts of hazardous fuels reduction for bioenergy, increased eligibility and awareness of biomass thermal fuels and technologies in agency programs, and ex-ploring new programs and partnerships to further biomass thermal deployment. But again, the MoU is as much about the benefi tting the USDA as it about the bioenergy industry. So, how can you help the USDA improve its bioenergy capabilities? Don’t be shy, we now have an open line of communication.

Author: Joseph SeymourExecutive Director, Biomass Thermal Energy Council

[email protected] 202-457-0868

Significance of the USDA Wood-to-Energy MoU

THERMAL¦

BY JOSEPH SEYMOUR


¦THERMAL

BIO-OIL BRILLIANCE: Metso and VTT will reach a milestone this fall with the completion of a commercial-scale, bio-oil production facility in Joensuu, Finland, at a wood chip-fi red cogeneration facility owned by energy company Fortum.PHOTO: FORTUM


THERMAL¦

Relentless R&D efforts have enabled Metso to successfully commercialize large-scale gasifi cation and fast pyrolysis technologies.BY ANNA SIMET

Thermal Triumphs

Using fast pyrolysis—gasifi cation’s cooler, oxygenless cousin—to eco-nomically produce a bio-oil that serves as a replacement for alter-native fuel oil has been a challenging endeavor. Despite its unusual

properties and typically high capital and operating expenditures, however, there is increased interest around bio-oil production and utilization, and re-searchers and companies are achieving success in solving commercialization barriers.

One of those companies is Metso, whose technology partner, VTT Technical Research Centre of Finland, has been working on bio-oil since 1982. Jussi Mantyniemi, general manager of technology for Metso’s power business line, says the patented, integrated bio-oil production process has three main parts, the fi rst of which is fuel handling. This includes fuel receiv-ing, drying of the biomass to 10 percent moisture, crushing and conveying.

Prepared fuel then enters a fl uidized pyrolysis reactor where the dried biomass is pyrolysed in oxygen-free conditions. “The heat for the reaction is provided by the hot sand from the host boiler,” Mantyniemi explains. “After the reactor, in the cyclones, vapors are separated from the sand and char, which are returned to the boiler.”

Vapors from the reactor are condensed to form bio-oil, and noncon-densable gases are introduced to the boiler for heat and power generation.

The technology has been thoroughly tested in a process demonstra-tion unit at VTT, as well as a 7-ton-per-day scale unit at Metso’s research and development facility in Tampere, Finland. Metso and VTT will reach a milestone this fall, with the completion of a commercial-scale production facility in Joensuu, Finland, at a facility owned by energy company Fortum. “The pyrolysis plant is integrated into the existing CHP (combined-heat-and-power) plant, and will produce 50,000 tons annually of bio-oil,” Man-thyniemi says.

Previously, for proof of concept, around 40 metric tons of bio-oil was combusted in Fortum's 1.5 MW district heating plant in Masala, Finland.

Commissioning of the plant is scheduled for this fall. Though it may serve as proof that bio-oil can be produced and used at commercial scales, there are still hurdles to robust market development.

Market DevelopmentAccording to Mantyniemi and VTT reseachers, the biggest challenge

in commercialization of fast pyrolysis technology is to make bio-oil pro-duction competitive in combustion applications. In other words, the whole value chain from the fuel procurement to the end use must be capable of operating in the margin between the price of the reference fuel and the price of the feedstock. The margin for heavy fuel oil replacement is relatively

¦THERMAL

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small, which makes developing commercial cases very vulnerable. Cases where replacement of light fuel oil is possible are more lucrative, due to the bigger margin.

In case of Joensuu, Fortum is planning on utilizing the produced bio-oil in district heating boilers around the Joensuu and Helsinki areas for peak loads, rather than heavy and light fuel oils.

Another hurdle to commercialization is burner technology devel-opment, as relatively few burner manufacturers have developed com-mercially available burner models for fast pyrolysis bio-oils, and designs are sensitive to the changes in the quality of the bio-oil. This may cause problems in ignition, fl ame detection and fl ame stabilization.

On potential users of bio-oil, Mantyniemi says the main customer segments are the pulp and paper industry and heat and power plant own-ers who have access to biomass. “The integration of the pyrolysis plant energy fl ows, and utilizing the existing infrastructure, are advantages.”

Initial use of bio-oil will be replacement of heavy fuel oil in any current application like industrial boilers, district heating boilers and in-dustrial lime kilns, he adds. “[Bio-oil’s] high-energy density, i.e. transpor-tation cost, is low compared to other forms of bioenergy, and it can be used as a substitute to heavy fuel oil with very limited modifi cations to the existing equipment and process.”

Metso is on track to achieve successes in fast pyrolysis similar to what it has experienced commercializing its gasifi cation technology, which it has spent over 30 years perfecting. According to Bill Partanen, gasifi cation business development manager, the company’s circulating fl uidized bed (CFB) gasifi cation systems are based on many years of

Cymic CFB and Hybex bubbling fl uidized bed system technologies, with over 200 facilities operating worldwide.

Gasifi cation Successes The fi rst CFB gasifi cation system was installed by Gotaverken—

now Metso—at a papermill in Varo, Sweden, in 1987, and is it still in operation at the mill, Partanen says. Nine years later, the power boiler business of Götaverken and Finnish boiler company Tampella were merged by Kvaerner, which was acquired by Metso in 2007. “The con-

GASIFICATION GIANT: Vaskiluodon Voima’s plant in Vaasa, Finland, is Metso’s fi rst utility-scale application of large-scale biomass gasifi cation. Generating 230 MW electricity and 170 MW thermal, the facility has been operating since December 2012.

PH

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: ME

TSO

THERMAL¦

JUNE 9 – 12, 2014Indianapolis, IN

ANNIVERSARY

1984 – 2014

NETWORKING OPPORTUNITIESEXHIBIT.SPONSOR.SPEAK.ATTEND.

tinued growth and development of boilers and gasifi cation with these companies has spanned more than 30 years,” Partanen says.

As a result of lessons learned over the past 30 years, Metso currently has the two largest CFB gasifi cation plants in successful operation in the world. The Vaasa, Finland, facility, cofi res up to 40 percent forest residue in an existing 230 MW electric and 170 MW thermal pulverized coal utility boiler and is the fi rst utility-scale application for Metso. Generating 230 MW electricity and 170 MW thermal, the facility has been in success-ful operation since December 2012.

There are benefi ts to gasifi cation cofi ring, Partanen says, one of which is reusing the existing infrastructure inclusive of the boiler/tur-bine, an investment cost of approximately 30 percent of a new biomass plant. Additionally, cofi ring with biomass provides the option to keep an old, coal-fi red plant in operation by reducing mercury, CO2, and SO2 emission limits that might otherwise require new emissions controls equipment.

The facility Metso completed in the city of Lahti, Finland, uses sort-ed municipal solid waste (MSW) to produce 90 MW of thermal energy and 50 MW of electricity for district heating. “This is Metso’s fi rst dem-onstration facility using sorted MSW, and has been in successful com-mercial operation since December 2011,” Partanen says. “These are the fi rst forest residue and sorted MSW gasifi cation systems to demonstrate that gasifi cation of these feedstocks can be successfully applied in both the industrial and utility sectors.”

Large-scale biomass gasifi cation projects, such as the aforemen-tioned, offer some advantages over small or medium-sized projects, the

biggest of which is economies of scale. “Large-scale gasifi cation can be utilized at large utility and industrial applications where smaller systems would not be cost effective,” Partanen says. “It’s more costly to build and operate multiple small systems than a single large system. The fact that Metso has demonstrated that up to 40 percent of the coal can be displaced with syngas in a utility boiler with no boiler de-rating is an im-portant milestone. Smaller systems don’t make economic sense in utility applications.”

On attributes that have allowed Metso to overcome challenges as-sociated with large-scale biomass gasifi cation, Partanen says it has been Metso’s long history of R&D in gasifi cation technology and persistence that has pushed the technology into commercialization. “[Gasifi cation technologies] must go through a learning cycle, and that takes time,” he adds. “Success is also based on understanding what is required, and then building the equipment and systems that fi t the need. An example is fuel properties, and the effects these properties will have during the gas-ifi cation process. Tars have always been a problem with gasifi ers, and understanding how to deal with these tars is critical…an understanding of fuels and how different fuel characteristics affect fl uidized bed boiler operation is the key to how [Metso] has overcome the challenges associ-ated with gasifi cation.”

Author: Anna SimetManaging Editor, Biomass Magazine

[email protected]


Waste-to-energy fi rm Fiberight LLC could break ground on a waste recycling plant in Marion, Iowa, before the end of the year. The Marion City Council voted unanimously in August to approve a resolu-tion establishing a 15-year waste supply agreement with the company.

Once complete, the facility will process municipal solid waste (MSW) into feed-stocks for the production of compressed biogas and cellulosic ethanol. Equipment at the plant will separate out recyclable materi-als from the MSW. The remaining waste

stream is comprised of soluble organics, which will be fed into a proprietary high-rate anaerobic digestion (AD) system, and cellulosic materials, which will be processed into cellulosic biofuel at a nearby plant in Blairstown.

Biogas generated in the AD system will be compressed for use as transportation fuel. Craig Stuart-Paul, chief executive of Fiberight, estimates the production of bio-CNG will begin during the second quarter of next year.

BiogasNews

Michigan State University recently celebrated the opening of an anaerobic di-gestion (AD) facility that will take in waste from its farms and dining halls, creating energy for several campus buildings. The system will take in approximately 17,000 tons of organic waste and generate 2.8 million kWh of electricity per year. The campus is also home to a small AD system used for research purposes.

According to Dana Kirk, a specialist from MSU’s Department of Biosystems and Agricultural Engineering who is overseeing the project, approximately 20 percent of the energy produced by the new system is used to sustain the anaerobic digestion process. The remaining 80 per-cent is available for on-campus use. “This system is the largest on a college campus in the United States,” Kirk said.

The MSU AD project is one of four on-campus AD systems highlighted during a recent Biomass Magazine webinar. During the event, Kirk spoke about the university’s Anaerobic Digestion Research Education Center, which was founded in 2008 to provide research, evaluation and education related to integrated AD systems for small- and medium-sized facilities.

Fiberight to produce compressed biogas

Michigan State U opens AD facility

TRASH TO GAS: Fiberight LLC’s waste recycling plant in Marion, Iowa, will produce MSW-derived feedstock for biogas production.

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While many of you are familiar with the use of biogas as a means for powering or heating our homes and busi-nesses, I believe that the use of biogas as a transportation fuel is the least well-known and understood application for this versatile and greenhouse gas reducing resource. For this rea-son, my previous columns have focused on the vast potential of biogas as fuel for our vehicles. If this potential is to be reached, however, a critical component of the plan needs to be addressed fi rst: infrastructure.

While current biogas projects can clean and compress biogas into a useable vehicle fuel, new infrastructure is needed to distribute the fuel to our vehicles. Fortunately, the infrastructure needed to use biogas as transportation fuel is enabled by the large infrastructure buildout already occur-ring for compressed natural gas (CNG). Since biogas can be cleaned to a form that is a direct replacement for conven-tional natural gas (referred to as biomethane), new fueling pumps and compression equipment capable of fi lling up CNG vehicles can also dispense blended or pure biomethane. Increasing the amount of biomethane in the overall system not only provides a domestic transportation fuel option, but also decarbonizes the natural gas distribution system, similar to how integration of renewable electricity in the transmis-sion system decarbonizes the electricity grid.

In late August, a new biogas fueling station opened at the Rodefeld Landfi ll in Madison, Wis. The fuel coming out of the nozzle at the bio-CNG fi lling station will come from biogas collected at the landfi ll. Dane County had already initiated the process of converting its county fl eet vehicles to run on natural gas instead of diesel fuel, which has displaced 25,000 gallons of diesel/gasoline and saved Dane County taxpayers an estimated $50,000 annually. Dane County taxpayers will see even greater savings with lower natural gas purchases. Currently, natural gas prices are forecast to remain low, but combining biomethane with conventional natural gas

purchases provides an important hedge in the event natural gas prices spike. Wisconsin joins the ranks of states that have installed dedicated fueling infrastructure for biogas, including Indiana, Ohio, Texas and Pennsylvania.

The blending of biomethane with conventional natural gas is also being pursued by Clean Renewable Fuels. Cur-rently, the majority of gasoline dispensed in the U.S. is a blend of 90 percent gasoline and 10 percent ethanol. This concept can be applied to CNG fueling. Clean Energy Renewable Fuels has developed RNG-10 and RNG-20 to market an even cleaner and low-carbon option to customers, and con-tinues to build out natural gas fueling infrastructure. As the infrastructure improves, we will see a signifi cant increase in vehicles fi lling up with a mix of conventional natural gas and biomethane.

While progress is being made in the U.S., Sweden pro-vides a great illustration of what the future could look like. Nearly half of the vehicles—not just passenger—designed to run on natural gas are fueled by biomethane. Sweden har-nesses biogas from wastewater treatment facilities, agriculture byproducts, household organics and food processing waste to fuel taxis, trains, buses and large fl eet vehicles. The country has built an impressive biomethane distribution system to fuel all these vehicles.

Many exciting developments are occurring in our trans-portation system, and the build out for natural gas refueling infrastructure will bolster increased use of biogas to help meet our transportation needs. Although it is encouraging to see new infrastructure construction, like the bio-CNG fueling station in Wisconsin, there is much more that could be done to fully capture the vast biogas opportunity.

Author: Amanda BilekEnergy Policy Specialist, Great Plains Institute.

[email protected]

Infrastructure Critical to Biogas as Transportation Fuel

BIOGAS¦

BY AMANDA BILEK


AdvancedBiofuelNews

The U.S. EPA has fi nalized the 2013 volume requirements for the renewable fuel standard (RFS), mandating that 16.55 bil-lion gallons of renewable fuels are blended with the U.S. fuel supply this year. At this blend level, biofuels will make up 9.74 per-cent of U.S. transportation fuel.

The 2013 RFS requires 1.28 billion

ethanol-equivalent gallons of biomass-based diesel, accounting for 1.13 percent of the fuel market. The requirement for ad-vanced biofuels is 2.75 ethanol-equivalent gallons, or 1.62 percent of the transporta-tion fuel volume. The cellulosic standard is 6 million ethanol equivalent gallons, which equates to 0.004 percent of transportation

fuel. The remaining 12.514 billion gallons of fuel, on an ethanol equivalent basis, can be met by renewable biofuels.

The EPA also extended the 2013 compliance date to June 30, 2014 and announced it plans to reduce both the advanced biofuel and total renewable fuel volumes in the 2014 RFS rulemaking.

California-based NextFuels has unveiled its strategy to produce advanced biofuels from wet, unprocessed agricul-tural waste via a hydrothermal process originally developed by Shell in the 1980s. The company is currently focused on converting agricultural waste from palm oil production in Southeast Asia into drop-in coal and petroleum replacements.

The technology processes biomass within liquid water at temperatures of 300 to 330 degrees Celsius and pressure of 200 to 230 atmospheres, producing a putty-like GreenCrude. The GreenCrude can either be burned as a coal replacement, or further refi ned into transportation fuels.

NextFuels is in the process of design-ing and assembling a pilot plant in the Netherlands. The facility is expected to be operational by the second quarter of next year. The company also plans to construct a demonstration plant in Asia.

Industry leaders at the National Advanced Biofuel Conference & Expo had an adamant, clear-cut message for at-tendees: if there was ever a time to unite and work together as one force, that time is now.

During the kickoff general session, Advanced Biofuel Association President Michael McAdams urged biofuel industry members—whether biodiesel, renewable diesel, cellulosic or fi rst-generation etha-nol producers—to protect what they have built over the past 30 years. Specifi cally, the renewable fuel standard (RFS). “Dur-ing the next several weeks, we’ll be in the throes [of the RFS’s fate],” he said.

McAdams discussed a key July RFS hearing on Capitol Hill, which he described as “a bit theatrical,” and “tilted against higher blends of etha-nol.” During the hearing, which played out seemingly well for the industry, both

stakeholders and non-industry members in opposition of the RFS were intensely questioned.

As for the ultimate fate of the RFS, McAdams said indications suggest the RFS will not be repealed, but it also won’t be left as status quo. “Everybody in this room has a lot at stake between now and October…for three years I’ve been saying ‘it’s coming, it’s coming,’….and now it’s here. When your industry associations ask you to write a letter or make a call, you need to do it this time.”

Additional speakers during the gen-eral session included Wayne Simmons, ABFA chairman and CEO of Sundrop Biofuels; Joe Jobe, National Biodiesel Board CEO; Gary Haer, Renewable Energy Group vice president of sales and marketing, and Tim Burns, president and CEO of BioProcess Algae.

EPA finalizes 2013 RFS blending volume requirements

NextFuels revives hydrothermal technology

Advanced biofuel industry urged to unite

Cellulosic plants expected to generate RINs for 2013 complianceU.S. EIA forecast

Company Product Capacity Utilization Production (in million gallons)

Ethanol-equivalent production (in million gallons)

Ineos Bio Ethanol 8 MMgy 50% 4 4KiOR Liquids 11 MMgy 50% 5.5 9Various pilot plants Ethanol 1 Mmgy 10% 0.1 0.1SOURCE: U.S. EPA


The big test of any advanced biofuel is whether it can be produced cost competitively, in a way that reduces greenhouse gases and delivers more energy than it requires, while its inputs such as land, water and nutrients can be provided sustainably. For years, we have known that algae is one feedstock that can theoretically meet all those requirements.

In August, the theoretical gave way to real-world data, and the news is even better than expected.

For the fi rst time, researchers conducted a life-cycle analysis (LCA) of pilot-scale operations at an algae-to-fuel facility, and found substantial reductions in greenhouse gases over petroleum and a sustain-able energy return. They also found that algae-based fuels from the pilot plant are on par with commer-cial-scale, fi rst-generation biofuels. It concluded that greenhouse gas reductions and energy returns are set to increase even further once economies of scale in production take hold.

This latest peer-reviewed LCA, published in Bio-resource Technology, examines the cultivation and hydrothermal liquefaction technologies at Sapphire Energy’s Green Crude Farm. This report reinforces a clear trend in the algae industry: During the past few years, the environmental and energy performance of algae-derived fuels has continued to get better.

In 2011, the U.S. EPA qualifi ed algae under the advanced biofuel provisions of the renewable fuel standard after fi nding that algae-based biodiesel could reduce emissions by more than 50 percent compared to conventional fuels.

Last fall, the National Research Council report on the sustainability of algal fuels in terms of land use, water and other factors defi nitively concluded that sustainability concerns are not a barrier to future growth.

The big advantage of this latest analysis is that it addresses one signifi cant drawback of previous stud-ies. Up until now, most peer-reviewed research relied on theoretical production estimates or data available only in the public sphere. Now, a look at one of the fi rst real world operations has given us proof that al-gae-derived fuels can indeed be produced sustainably and competitively.

Meanwhile, the energy return on petroleum fuels has been getting worse. Decades ago, you could ex-pect petroleum to yield 100 times the energy it took to extract the stuff. Today, gasoline will yield as low as four to fi ve times the energy, and prices are near 10-year highs. Furthermore, given that fi nding new sources of oil is increasingly energy intensive, we can expect the energy return to steadily decrease. Talk about diminishing returns.

What does this mean? When the benefi ts of al-gae-derived fuel and other advanced biofuels are get-ting better and the benefi ts of fossil fuels are being eroded to record lows, you know change is coming.

The pilot-scale demonstrations of algae-to-fuel technologies we see today will give way to full-scale production in the next couple of years. Nobody ex-pects fossil fuels to become easier to extract, or to somehow become carbon neutral. And nobody ex-pects gas prices to fall. It all points to a competitive future for advanced biofuels.

We know it’s not a question of “if,” and we can see that the “when” is getting closer every day.

Author: Mary RosenthalExecutive Director, Algae Biomass Organization

[email protected]

Algae Fuel Passes Another Crucial TestBY MARY ROSENTHAL

ADVANCED BIOFUELS AND CHEMICALS¦


¦ADVANCED BIOFUEL

PHOTO: KEN CHILDRESS, KIOR


ADVANCED BIOFUEL¦

Companies focused on producing liquid fuels via biomass gasifi cation are making noteworthy progress.BY KEITH LORIA

Gaining Gasification Ground


Project Alpha in North Carolina is going to commercially test a broad range of purpose-grown energy crops.

Chemtex International Inc. received a $99 million conditional loan guarantee from the USDA a year ago, along with a $3.9 million grant from the USDA through the Biomass Crop Assistance Program, to help establish 4,000-plus acres of miscanthus and switch-grass across 11 North Carolina counties to help supply the new facility. “The Chemtex project in Clinton, N.C., will use a multifeed-stock strategy including switchgrass, high bio-mass sorghum and arundo donax, as well as select hardwood tree species, miscanthus and Bermuda grass residuals,” says Mark Conlon, vice president of sector development for the Biofuels Center of North Carolina.

The push for renewables has fast-tracked the strategic thinking of several biomass com-panies that have turned to biomass resources to explore the viability of gasifi cation for liq-uid fuel, fertilizer and chemical production. All in various stages of development with signifi cantly different technology platforms, each have many common goals, which in-

clude low feedstock and operating costs, com-patibility with the current fuel infrastructure and maximum yield achievements.

One such company making a name for itself in the sector is KiOR Inc., a six-year-old company focused on converting biomass into a renewable crude.

Drop-in Fuels

KiOR Inc. was founded in 2007 by Kho-sla Ventures and a group of catalyst scientists who were looking for opportunities to pro-duce renewable fuels from cellulosic biomass. Using a one-step catalytic process, the com-pany developed a means to convert abundant nonfood feedstocks into a renewable crude oil. Using standard refi ning techniques, the renewable crude oil could be processed into fuels that can drop seamlessly into the existing fuels infrastructure.

The company validated the technology and feasibility of the process at its pilot plant in Pasadena, Texas, and subsequently scaled up 400 times in a demonstration unit. It then built a 13 MMgy cellulosic fuel production fa-cility in Columbus, Miss., which commenced

¦ADVANCED BIOFUEL

PINING FOR BIOFUEL: This year, KiOR brought on line its 13 MMgy facility in Columbus, Miss., which uses southern yellow pine to produce cellulosic gasoline and diesel.

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ADVANCED BIOFUEL¦

provides signifi cantly reduced sizing costs, reduced tar and soot made in the gasifi er, im-proved methane selectivity, and signifi cantly improved duty factor of the feed system,” Goetsch says. “We also have a proprietary oxy-gen injection system that reduces temperature gradients in the injector region. This mitigates the formation of slag in the gasifi er.”

SynGas Technology makes use of a cir-culating solid system that integrates the gasifi er with a fl uid bed combustor to further take ad-vantage of the differences in slagging propen-sity of inorganic material in biomass between

the oxidizing environment of the combustor and reducing environment of the gasifi er. The system is designed to take advantage of cellu-losic feedstock and can handle feedstocks from agricultural residuals to woody biomass.

The company has also developed a pro-prietary, hydrothermally stable, circulating solid catalyst that effi ciently transfers heat into the gasifi er and provides methane reforming ac-tivity and partitions sulfur between the syngas and fl ue gas streams. This design also reduces the amount of oxygen used in the process—since air can be used in the combustor—and

shipments of cellulosic gasoline and diesel in 2013.

KiOR’s technology is feedstock fl exible and has successfully tested a number of dif-ferent biomass sources. Its Columbus facility is focused on southern yellow pine, which is in abundant supply and has a relatively sta-ble pricing history. “We are beginning to see traction on the commercial development of feedstocks other than southern yellow pine, including hardwood, energy crops and waste products such as railroad ties, all of which we expect to be able to procure at lower costs without negatively impacting the overall growth-to-drain in the basin,” says Fred Can-non, KiOR president and CEO. “This has never been done commercially, so KiOR is charting new territory. We have encountered the normal challenges that any startup com-pany would, but are building our on-stream percentage and getting more fuel on the road.”

High Pressure, High ThroughputConversion technologies for syngas de-

rived from fossil fuels are proven and, in many cases, commercially viable to produce fuels and chemicals. Most, if not all, of the con-version technologies operate at high pressure. The challenge has not been making these ma-terials but making them economically.

Duane Goetsch, chief technical offi cer for Elk River, Minn.-based SynGas Technolo-gy LLC, says the focus of SynGas Technology involves the development of a high-pressure, high-throughput gasifi er for biomass. Build-ing a modular gasifi er island will leave few opportunities for future modifi cations to re-duce costs, Goetsch says. “For this reason, we have developed biomass gasifi cation technol-ogy that operates at higher pressure (about 25 standard atmosphere) and signifi cantly shorter residence times than competing technology.”

SynGas Technology approached the gas-ifi er design from the vantage of taking virgin biomass and producing synthesis grade syn-gas.This has led to several unique and propri-etary features, which involve syngas that meets the end users specifi cations regarding the ratio of H2-to-CO, contaminant levels and duty fac-tor with respect to time on stream.

“To do this, we’ve developed a propri-etary feed system that modifi es the composi-tion and morphology of the virgin feed and

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gives lower CO2 content in the syngas stream, which reduces downstream CO2 removal costs. Overall, the gasifi er has a thermal ef-fi ciency of 90 percent and a carbon effi ciency of 51 percent.

This technology traces its roots to the Exxon Advanced Gas Conversion Process developed in the 1980s and 1990s. The gasifi -er section makes use of similar fast-fl uidized bed technology and builds on the original catalyst development. The technology team was reassembled in 2007 at SGT, and it has been advancing the technology using bio-mass at pilot scale. The company estimates capital costs savings associated with the gas-ifi er island of $50 million to $100 million and operating costs savings of about 20 percent compared to lower pressure gasifi cation.

“We are currently raising funds to build a demonstration facility in northern Minnesota. We anticipate that $25 million will be needed to build and operate the facility and we’re at about 40 percent of our goal,” Goetsch says. “Our objective is to complete the data pack-age necessary to generate process guarantees and information needed to minimize or re-duce costs associated with the wrap of a com-mercial scale facility.”

Green GasolineThe most obvious challenge of using

biomass for gasifi cation is that it is an inferior feed compared to natural gas or petroleum-derived fuels. It is hydrogen defi cient and the high oxygen content is undesirable, consider-ing fuels are basically composed of chains of carbon and hydrogen.

Gasifi cation of biomass produces lower-ratio syngas, typically 1.0-to-1.5. Conversion processes that produce fuels typically require ratios around 2-to-1. The higher ratio can be achieved by using more steam in the gasifi er or incorporation of water-gas-shift technolo-gy, but both result in lower thermal effi ciency and reduced carbon effi ciency, which directly translates into lower product yield and higher cost.

As an entry into gasifi cation of biomass, Sundrop Fuels Inc., in Longmont, Colo., is constructing its inaugural facility near Alexan-dria, La. The combined commercial and dem-onstration plant will annually produce about 60 MMgy of fi nished gasoline from natural

¦ADVANCED BIOFUEL

PROCESS CONTROL: Gasifi cation technology developers are experimenting with different levels of pressure and process parameters to develop effi cient biomass gasifi cation technologies.

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gas while providing the platform for Sundrop Fuels to prove its proprietary gasifi cation tech-nology of making renewable “green gasoline” from woody biomass.

“At the center of our advanced biofuels production is the Sundrop Fuels proprietary, ultrahigh-temperature pressurized gasifi cation system. Inside a specially designed thermo-chemical reactor, woody biomass is quickly converted using indirect radiation heat trans-fer to rapidly drive the extremely high temper-atures needed,” Steven Silvers, a spokesman for Sundrop Fuels, says. “Hydrogen from natural gas is added as a secondary feedstock, combining to create a renewable feed stream that is the key ingredient for our biogasoline, which is 100 percent compatible with today’s combustion engines and transportation fuels infrastructure.”

At a molecular level, Sundrop’s biogaso-line will be the same as petroleum-based gaso-line. The renewable feed stream is then con-verted to methanol, and then to gasoline using commercially established processes.

Sundrop Fuels’ innovative production method represents a number of patents re-sulting from work done over many years, culminating with a research and development site that Sundrop Fuels operated in Colorado. This facility was dismantled and will become part of the new plant in Louisiana.

“What makes our process unique from conventional biomass gasifi cation is that it steadily maintains ultrahigh temperatures to drive the endothermic gasifi cation reaction,” Silvers says. “This makes the process oper-ate at extraordinary higheffi ciency, producing more yield of renewable liquid fuel per ton of biomass feedstock than any other produc-tion method. Using natural gas as the power source, temperatures inside the Sundrop Fu-els radiation-driven gasifi er reach more 1,300 degrees Celsius (2,372 degrees Fahrenheit)—hotter than lava fl owing from a volcano.”

The use of natural gas to provide addi-tional hydrogen is also a unique aspect. Ad-vanced biofuels production has historically been limited because plant material feedstock has generally about a 1-1 ratio of hydrogen to carbon, while gasoline used in today’s combus-tion engines must have twice as much hydro-gen as carbon. To correct this imbalance, Sun-drop will add hydrogen obtained from natural

gas to the production process, which will result in virtually 100 percent of all the carbon in the plant material being converted into biogasoline.

The company expects to formally break ground on the site at the end of the year and to build several biofuels megaplants over the next decade.

5-Way CollaborationEarlier this year, Haldor Topsoe Inc.

teamed with Andritz Carbona, Gas Technology Institute, Phillips 66 Co. and UPM-Kymmene in completing the fi rst production of gasoline from woody biomass in an integrated 20-bar-rel-per-day (840 gallons per day) demonstration plant located near Chicago.

Henrik Udesen, business development manager of Haldor Topsoe, explains that the Des Plaines, Ill., plant is gasifying wood pellets into biofuel via the company’s TIGAS (Top-soe integrated gasoline synthesis) process. “We supply the technology but we are not directly involved with the gasifi cation ourselves, and are

relying on the other companies for that part,” he says. “Once the gasifi er has produced a syn-gas, our technology comes into play to convert the syngas gas into something useful.”

The combined technologies include gas-ifi cation by Andritz Carbona, GTI/Uhde’s Morphysorb process to capture acid gases, the woody biomass supplied by UPM-Kymmene. Collaborator Phillips 66 Co. is conducting single-engine emission tests and moderate fl eet testing of the renewable drop-in gasoline.

“We are ready to help this development, but also realize we’re still at the beginning of this and are looking at the importance of work-ing in this fi eld,” Udesen says. “Our challenge is to develop new ways to be part of the solution for the future of fuel supply.”

Author: Keith LoriaCalifornia-based freelance writer

[email protected]

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