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Ineos bio ethanol 3rd gen technology

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Foreshortened bit from "Domestic Fuel"

 

Florida Waste to Biofuel Plant Progress

 

Comment on this post Posted by Cindy Zimmerman – October 15th, 2010

 

A Florida company has announced today that it is three permits closer to opening the BioEnergy Center, the first commercial waste to energy facility in the US.

 

INEOS Bio’s first commercial project in the United States has secured key permits to build its waste to bioenergy facility in Indian River County, Florida.

 

The BioEnergy Center will generate eight million gallons of third-generation bioethanol each year from renewable biomass including yard, wood, agricultural and vegetative wastes. The Center will also generate six megawatts of renewable electricity. The facility will be the first to use INEOS Bio’s advanced BioEnergy technology, the world’s leading feedstock flexible technology for advanced biofuels. At the heart of the INEOS Bio technology is a patented anaerobic fermentation step, through which naturally occurring bacteria convert gases derived directly from biomass into bioethanol.

 

Unlike other technologies that rely on one primary source of feedstock, the INEOS Bio process can produce bioenergy from numerous feedstocks, including forestry and agricultural waste, sustainable energy crops, construction waste and municipal solid waste. This flexibility allows facilities to be built anywhere that a renewable biomass feedstock is available, providing jobs and locally sourced energy for urban and rural communities. The Indian River facility is scheduled to begin construction in 4th quarter of 2010 and begin production in 2012.

 

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http://www.ineosbio.com

 

The process review

 

 

1 Feed Handling

 

The INEOS Bio process is feed flexible. Organic materials are economically dried using heat from the process before being fed into the gasifier. The process is fully compatible with high recycling rates.

 

2 Gasification

 

Organic material is gasified with oxygen at high temperature under controlled conditions to produce synthesis gas, or syngas, a mixture of principally carbon monoxide and hydrogen. Syngas has valuable chemical energy.

 

3 Energy Recovery

 

The hot syngas is cooled and cleaned before being introduced to the fermenter. The heat recovered from the hot syngas is used to generate renewable power for use in the process.

 

4 Fermentation

 

The cool, clean syngas is introduced to our patented bacteria, which convert it selectively to ethanol. The bacteria biocatalyst is far more effective than all known conventional catalysts for syngas conversion to fuels.

 

5 Bacteria

 

Our naturally-occurring bacteria are at the heart of our process. The bacteria are found in nature where they have evolved to efficiently convert carbon monoxide and hydrogen to ethanol. They are maintained in a healthy state with the help of small amounts of essential nutrients to achieve a high yield of ethanol.

 

6 Ethanol Purification

 

Most of the water is removed from the ethanol to produce hydrous ethanol, which is around 96% ethanol in 4% water. The water is returned to the fermenter.

 

7 Ethanol Drying

 

Finally, the ethanol product is refined to produce anhydrous ethanol (>99.7% ethanol), which can be used as a clean, green transport fuel or as a renewable chemical intermediate for the production of a variety of plastics.

 

8 INEOS Bio Ethanol use

 

The INEOS Bio Ethanol delivers 90% Greenhouse gas savings compared to burning petrol (gasoline) in a car and it is potentially cheaper than petrol. The INEOS Bio Ethanol process can convert wastes generated locally into clean, renewable, cost-competitive transport fuel for use locally.

 

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Another process review

 

NEOS Bio Ethanol technology

 

The Ineos Bio Ethanol technology efficiently converts a wide range of low cost, organic materials, including household and commercial wastes into bioethanol for use as a renewable road transport fuel or petrochemical intermediate. The INEOS Bio process is a combined thermo-chemical and bio-chemical process and comprises three main steps:

 

1 Gasification - The prepared organic carbon material is gasified using a controlled amount of oxygen to produce synthesis gas, a mixture of principally carbon monoxide and hydrogen. The gasifier design and operating conditions have been carefully chosen to inhibit the formation of dioxins and furans and to suppress the carry-over of volatile metals. The hot synthesis gas is quenched and cleaned. Heat is recovered to generate renewable power for use in the process.

 

2 Fermentation - The cleaned, cooled synthesis gas is passed into a patented fermentation process, where it is converted selectively into ethanol by naturally occurring anaerobic bacteria (the biocatalyst). The fermentation environment, containing the right quantity and type of nutrients, is maintained at carefully controlled conditions. The bacteria, in this healthy state, achieve an extremely high selectivity to ethanol and high yield of ethanol. The high selectivity and yield translate to outstanding process efficiencies. The off-gas from the fermenter is used to generate additional power and heat.

 

3 Purification - The ethanol solution is purified and refined to make anhydrous ethanol (>99.7% ethanol). This can be blended into gasoline as required for the local, renewable road transport fuel market.

 

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History

 

The heart of the INEOS Bio technology platform is an incredibly innovative biochemical process that began in Arkansas, USA in 1989. A small, highly dedicated team of researchers led by Dr. James Gaddy took the technology from discovery through to integrated pilot plant scale over nearly two decades.  As is often the case with important discoveries, the first production of ethanol from gases using bacteria was detected as an unexpected bi-product during an experiment. The phenomenon was investigated and, over time, an understanding of the science was developed. Progressive stages of laboratory development finally culminated in the construction in 1994 of a significantly sized, purpose built, pilot fermenter with laboratory and offices just outside the City of Fayetteville in Arkansas. A gasifier was added to the pilot plant in 2003 to prove the commercial viability of ethanol production from a variety of low-cost carbon materials. The pilot plant has been operating continuously on a range of waste materials ever since. The sustained passion and commitment of the Arkansas team has produced a long series of innovations, which, progressively has transformed an inspired concept into an outstanding commercial reality.

 

The team in Arkansas has now joined together with INEOS to create a new, stronger, multi-disciplinary and global INEOS Bio team, which has the skills, capabilities and resolve to commercialise the technology quickly.

 

 

 

 

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great news!  It is news such as this that point the way forward for the ethanol industry...  multiple, geographically diverse, small scale production plants...  hopefully distributing to local e85/blender pumps in a 30-50 mile radius. ;D

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The parent firm "Ineos" is self described as a young British International company working primarily within the  petro chemical markets. They do business with Shell oil.  Annual sales at $30 billion. They have lots of technical capability within the chemical field.

 

The Arkansas process can be tweaked to produce bio-diesel, chemicals, and poly ethylene. Although they didn't explain much. Believe they think that it could be accomplished.

 

Note that the gasification process is well known and technical info within public domain. The big challenge to this process, to utilize the waste heat when cooling off the gases. It's energy wasteful to heat up a process. That is why the enzyme process more efficient. Except, if the gasification process can recoup or co-gen the heat for drying and heating purposes thats a game changer. 

 

This process about like Coskata?

 

Also, note gasification is a much cleaner process from emissions standpoint as compared to incineration. Burning organic materials (including wood and coal) will give way to gasification.

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The Center will also generate six megawatts of renewable electricity.

 

Cherry on the Sundae  ;D

 

 

The more diverse our feedstocks the more stable the Industry from price swings.. the more difficult for Nationwide disruptions due to Hurricanes , Droughts , Disease and market manipulation

 

Really exciting to see all these new Companies with Next Gen Ethanol ready to start building and some that have started actual Production..

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A little more on it today: http://www.ethanolproducer.com/article.jsp?article_id=7082

 

I wonder if they plan to use landfill gas as part of their energy requirements.

 

ARTICLE;

Florida approves permits for cellulosic plant

By Kris Bevill

 

Posted Oct. 19, 2010

 

INEOS New Planet BioEnergy, a joint venture between global chemical producer INEOS and biofuel developer New Planet Energy, has obtained the final permits necessary to construct an 8 MMgy cellulosic ethanol plant in Florida. It expects to begin construction by the end of this year and should produce at capacity in 2012. The facility will be located adjacent to a landfill in Indian River County.

 

INEOS New Planet BioEnergy President David King said he is pleased to receive permit approval from the state of Florida, the U.S. Army Corps of Engineers and the U.S. DOE. “We have spent considerable effort to design a state-of-the-art facility to not only ensure compliance but also to minimize our impact on the environment,” he said.

 

The plant will be located within the footprint of a former grapefruit processing plant and will be capable of utilizing forestry and agricultural waste as well as post-recycled municipal solid waste to produce ethanol. The patented technology that will be used at the facility has been under development for more than 20 years and has been tested for the past seven years at the company’s research and development facility in Fayetteville, Ark., according to Dan Cummings, INEOS Bio vice president. It consists of a combined gasification-fermentation process that utilizes naturally occurring bacteria to produce ethanol from the waste-based gas, he said. The conversion process is continuous and requires little time to produce the final product. “It only takes a few minutes between the time you feed it into the gasifier and you get ethanol out the back end … it’s less than 10 minutes,” Cummings said. Energy is the most abundant co-product produced using technology. The facility will produce 6 megawatts of power as a result of the ethanol production process. Ash left behind from the gasification step will likely be utilized at the nearby landfill for daily ground cover.

 

Total cost of the project will be more than $100 million. In 2009, the joint venture was selected to receive a $50 million, cost-matching, DOE grant.

 

INEOS is the largest ethanol producer in Europe, according to Cummings, but the Indian River project marks its first venture into the U.S. market. He said the increasing demand for cellulosic ethanol via the U.S. renewable fuels standard is a motivating factor for INEOS Bio’s entry into the market. The company will also explore licensing its technology to other producers in the future.

 

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