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Arctic Leaf

The best and worst of times for ethanol

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For ethanol it is the best and worst of times. Silos are bursting with a bumper crop and the price of corn has fallen by half, from $7 to $3.50 a bushel over the past year. Refiners are buying feedstock at rock-bottom prices.

“This is the most profitable time I can remember,” Dan Syekh, plant manager at Southwest Iowa Renewable Energy of Council Bluffs, told the Lexington Clipper-Herald of Nebraska. “People are beginning to pay off debt and invest in ever more advanced technologies.”

Yet hanging over all this is the question of what the U.S. Environmental Protection Agency will do about the Renewable Fuel Standard, which specifies how much ethanol the refining industry must buy next year.

“I feel like [the EPA is] playing politics instead of doing what’s right for America,” Iowa Gov. Terry Bradshaw told a Farm Progress Show in Boone last week. “Farmers aren’t buying equipment and John Deere is laying people off. What EPA has done is not only damage farm income but cost us jobs in farm machinery and manufacturing.”

At issue is the EPA’s announcement last spring that it would cut the mandate from the 14.4 billion gallons, originally required by the law, to 13.01 billion gallons, in order to deal with overproduction. With gasoline consumption having fallen since 2007, although numbers are now starting to rise again, the federal requirement had pushed ethanol additives past the 1 percent “blend wall,” where auto and oil companies claim it will damage engines. Many people dispute this but the auto companies are refusing to honor warranties in cars that use blends higher than 10 percent without authorization. Others say the solution is E85 — a blend of 85 percent ethanol and 15 percent gasoline — is the answer but it is not yet widely available outside the Midwest.

The EPA was supposed to make a decision on the mandate last November but has delayed after the furor over its initial proposal. Only last week it sent a final proposal to the White House for review. Rumors are that the EPA has settled on a figure somewhere between the original mandate and its April number, but there is nothing definite. In any case, the Obama administration could take several weeks to approve, even pushing its verdict past the November elections. This is the longest delay in the program’s history.

For several years now the ethanol industry has seen its influence waning in Congress. In 2011, Congress repealed the tariff on foreign biofuels, opening the door to cheaper sugar ethanol. Then it allowed a production tax credit to expire. Perhaps most significant has been the loss of support from large portions of the environmental community. Last year the Associated Press ran a story documenting how the mandate has led to over intensive cropping and the removal of land from conservation soil banks. “Corn ethanol’s brand has been seriously dented in the last 18 months,” Craig Cox, director of the Environmental Working Group in Ames, Iowa, told Politico. “The industry is still politically very well connected but it doesn’t occupy the same pedestal it did two years ago.”

Yet oddly enough, all this is happening at the moment when the industry may be on the verge of a huge breakthrough. On September 3, POET, the South Dakota refiner of ethanol, and Royal DSM, a Dutch maker of enzymes, will hold opening day ceremonies in Emmetsburg, Iowa for the inauguration of what could be the country’s first cellulosic ethanol plant — long considered the holy grail of biofuels. King William-Alexander of the Netherlands is scheduled to be in attendance.

Cellulosic ethanol uses the non-grain parts of the corn plant — the shucks and stalks that cannot be eaten. By cultivating certain enzymes and bacteria from the stomach of cows and other ruminants, several companies now believe they are able to break down the starches in these plant “wastes” and turn them into fuel. Various inventors have made the same claim over the years but have never been able to achieve cellulosic digestion at a commercial level. Now it appears POET may be about to break the barrier.

They aren’t the only ones. In fact, there is now $1 billion worth of cellulosic ethanol investments in the Midwest about to bear fruit:

  • In Nevada, Iowa, DuPont is investing $200 million in a cellulosic plant that will have a capacity of 30 million gallons annually. Operations are slated to begin before the end of 2014.
  • In Hugoton, Kansas, Spain-based Abengoa Bioenergy is spending $500 million on a plant to make ethanol from corn leftovers, wheat straw, milo stubble and prairie grasses. It will produce 21 million gallons of ethanol plus 21 megawatts of electricity.

Should any of these plants succeed, it would change the face of the industry.

So ethanol finds itself in a very strange position. Just as it may be on the verge of a huge breakthrough in production, it finds its markets drying up. Several Midwestern agricultural professors have suggested that the real solution is E85, which readily substitutes for gasoline and would create an almost unlimited demand. There are 15.5 million flex-fuel vehicles on the road — 6 percent of the entire fleet — all of which accept E85. There are also 3,200 gas stations that dispense it. But there is a huge mismatch between them. Most of the stations are in the Midwest where support for ethanol is strong while the flex-fuel vehicles are concentrated in cities on the East and West Coasts. So far no one has come up with a solution for making a better match.

There remains one potential market, however, that could tide over the ethanol industry until better auto markets develop. This is the U.S. Navy. The Department of Defense burns 300,000 barrels of oil a day, 2 percent of national consumption. For some time the Navy has been trying to find “drop-in” biofuels that would substitute for imported oil in jets and other vehicles. This year, for the first time, the Navy will include biofuels in its annual procurements. It is trying to get 50 percent of its fuels from renewable resources by 2020. “Up in the air you don’t have any other choice but liquid fuels,” said Tyler Wallace, professor of agricultural economics at Purdue. “The U.S. uses 21 billion gallons of aviation fuel annually and cellulosic ethanol would make a perfect drop-in.”

So would a huge order from the Navy be able to galvanize an infant cellulosic industry? Or will ethanol have to continue to holds its breath waiting for a decision on the Renewable Fuel Mandate from the White House and the EPA? For the industry, it remains the best and worst of times.

Arctic Leaf

Can algae become the new biodiesel?

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Supporters call it “clean diesel” to differentiate it from “biodiesel,” and indeed, there is a difference. Soybeans, the main feedstock for biodiesel, have only a 2-3 percent oil content. Some species of algae can have up to 60 percent oil content. This reduces the land requirements for growing a crop by a factor of 30.

So is algae biodiesel one of those great ideas that is always just over the horizon? Or has it germinated long enough that it may finally about to become a reality? The outcome still appears to be up for grabs.

The term “algae” actually cover a whole spectrum of organisms, from the 20-foot ribbon-like “seaweed” that grows in ponds and along littoral shores to the mid-ocean, microscopic “plankton” that is the diet of whales. All have one thing in common – they use carbon and sunlight to photosynthesize organic material. And they are good at it. Some species can double their mass within 24 hours. Thousands of species thrive in varying environments. Last summer, a red algae “tide” that feeds on farm runoff at the mouth of the Mississippi River “bloomed” to cover 5,000 square miles of the Gulf of Mexico, killing all manner of birds, fish and marine life, including hundreds of manatees. “If we can figure out how to make energy out of that,” President Obama told an audience at the University of Miami, “we’ll be doing alright.”

The idea of harvesting algae for energy was first suggested by Richard Harder and Hans von Witsch, two European scientists at the outbreak of World War II. Nothing much developed, however, and interest didn’t revive until the Energy Crisis of the 1970s, when the Department of Energy set up an Aquatic Species Program to pursue research.

Funded with $25 million over the next 18 years, the Aquatic Program investigated thousands of species, finding the Chlorella genus the most promising. It also made an important discovery. When Chlorella is deprived of nitrogen, it can increase its lipid (fat and oil) content to a remarkable 70 percent of mass! Remember, soybeans are only 2-3 percent lipids. But this created a conundrum. While depriving algae of nitrogen might may increase lipid content, it also severely inhibited growth. The Aquatic Program had not yet resolved this dilemma when it was disbanded in 1996.

Private companies picked up the research, however, and have tried to overcome it with genetic engineering. While pursuing this, they have developed two methods of cultivation. The easiest is to grow algae in open pools or “raceways” that devour large areas of land, since sunlight can only penetrate a few centimeters into the algal mat. The problem here is that most species are highly sensitive to variations in acidify, temperature and humidity. Their high lipid content also means they synthesize fewer proteins, which makes them extremely vulnerable to invasive species. This makes it very difficult to bring them up to commercial scale.

The more advanced technology is “photobioreactors,” conducted in large networks of glass or plastic tubes. The system overcomes environmental difficulties but is very expensive. In 2009 Exxon combined with J. Craig Venter, the decoder of the human genome, to try to develop a commercial method for developing algae-based fuels. After investing $600 million, however, Exxon pulled out of the enterprise in 2013, saying commercialization was 25 years away.

Nevertheless, several small companies say they are now making progress. Algenol, a Fort Myers, Fla. company, says it has developed a revolutionary “3rd generation” technology that can produce ethanol, jet and diesel fuel 8,000 gallons per acre, 18 times the output of corn-based ethanol, at $1.25 per gallon. Sapphire, a San Francisco company, has opened a 100-acre Green Crude Farm in New Mexico and hopes to be producing 100 barrels a day next year with full-scale commercialization by 2018. And Aurora Algae, a Hayward, Calif. firm which has operated a test facility in Western Australia for the last three years, has just announced an open-pond operation in Harlingen, Texas that it hopes to expand to 100 acres.

There is one great irony to all this. A full-blown algae industry already exists, providing feedstock for food additives, cattle silage and nutritional and pharmaceutical products. Some highly specialized fatty acids derived from exotic species can fetch $10,000 per gallon. In fact, the current industry sees algae-for-fuel as a rather low-grade use. “Until more federal funding is available, my members are going to continue growing for the higher-value products,” Barry Cohen, executive director of the National Algae Association, told Slate’s John Upton. “We have algae companies that are growing for the ingredients industry, the food industry and the nutraceutical industries. If they can grow the right species, those companies will buy every drop they can make.”

What makes these operations viable, of course, is their high-value end products, which cover the costs of growing algae in commercial quantities. An algae-for-fuel industry will either have to: a) develop new species that are much more efficient or b) perfect mass-production techniques that can bring prices down to an acceptable range. Only then will “clean diesel” become a competitor. For now, the industry seems headed in the right direction.