Dow and Algenol producing ethanol from algae and saltwater

When the subject of algae comes up in relation to biofuels, it's usually concerning biodiesel. That's because algae are very high in oil content. However, one of the main reasons for interest in algae is that it grows fast and consumes a significant amount of carbon dioxide. With that in mind, there is no reason algae couldn't also be used to produce ethanol. A company called Algenol has refined strains of algae specifically for ethanol production in salt water. Algenol has submitted a grant application to the Department of Energy to build a pilot plant in cooperation with Dow. The plant, located next to a Dow facility in Freeport, Texas, will consume carbon dioxide produced by Dow's operations to grow the algae in bio reactors.
Dow intends to use ethanol primarily in the production of plastics to replace petroleum. However, the ethanol could be used as a fuel as well. Algenol hopes to get the production price of its algae ethanol down to $1 per gallon. Not only does the process consume carbon dioxide at the net rate of 1.5 million tons of CO2 per 100 million gallons of ethanol, it also transforms salt water into fresh water.
[Source: Algenol, Dow]
Dow Announces Plan to Build and Operate a Pilot-Scale Algae-based Integrated Biorefinery with Algenol Biofuels
MIDLAND, Mich., June 29 /PRNewswire/ -- The Dow Chemical Company (NYSE: DOW) announced today that it plans to work with Algenol Biofuels, Inc. to build and operate a pilot-scale algae-based integrated biorefinery that will convert CO2 into ethanol. The facility is planned to be located at Dow's Freeport, Texas site.
"This project and the innovative technology involved offers great promise in the battle to help slow, stop and reverse the growth of greenhouse gas emissions," stated Andrew N. Liveris, Dow chairman and chief executive officer. We are very excited to be part of this ground-breaking alternative energy project, which is a good example of Dow's holistic approach to CO2 capture and storage by adding value through chemistry."
Algenol's technology uses CO2, salt water, sunlight and non-arable land to produce ethanol. Dow, National Renewable Energy Laboratory (NREL), the Georgia Institute of Technology (Georgia Tech) and Membrane Technology & Research, Inc. are contributing science, expertise, and technology to the project. Their combined expertise offers new and innovative technology, with the opportunity for creating a breakthrough process for ethanol production.
Algenol submitted its formal request last week to obtain a grant from the U.S. Department of Energy for financial support to successfully conduct the pilot. Upon approval of the grant, Dow and the other collaborators will work with Algenol to demonstrate the technology at a level to sufficiently prove that it can be implemented on a commercial scale.
In addition to leasing the land for the pilot-scale facility, Dow plans to develop the advanced materials and specialty films for the photobioreactor system. In addition, Dow will also provide the technology and expertise related to water treatment solutions and will provide Algenol with access to a CO2 source for the biorefinery from a nearby Dow manufacturing facility. The CO2 will be supplied to the algae in the photobioreactors and will serve as the carbon source for the ethanol produced. The result is a CO2 capture process which converts industrially derived CO2 into more sustainable fuels and chemicals.
In line with Dow's sustainability efforts, the project exemplifies the Company's commitment to providing solutions that improve energy efficiency, promote renewable energy and advance the environmental performance of its existing energy sources. According to Rich Wells, Dow vice president, Energy & Climate Change and Alternative Feedstocks, "This is yet another way that Dow is helping to solve world energy challenges with our expertise in sustainable chemistry that is good for the world, and good for business."
About Dow
With sales of $58 billion in 2008 and 46,000 employees worldwide, Dow is a diversified chemical company that combines the power of science and technology with the "Human Element" to constantly improve what is essential to human progress. The Company delivers a broad range of products and services to customers in around 160 countries, connecting chemistry and innovation with the principles of sustainability to help provide everything from fresh water, food and pharmaceuticals to paints, packaging and personal care products. On April 1, 2009, Dow acquired Rohm and Haas Company, a global specialty materials company with sales of $10 billion in 2008 and 15,000 employees worldwide. References to "Dow" or the "Company" mean The Dow Chemical Company and its consolidated subsidiaries unless otherwise expressly noted. More information about Dow can be found at www.dow.com.
About Algenol
Algenol today possesses the most advanced third generation biofuel technology in the United States. Algenol makes low cost ethanol directly from CO2 and seawater using hybrid algae in sealed, clear plastic photobioreactors through its unique, patented Direct to Ethanol(TM) technology -- all powered by the sun. Algenol's research and development efforts have culminated in a process that produces over 6,000 gallons of ethanol per acre per year, compared to corn at 400. Algenol's process achieves an energy balance of more than 5 to 1 and a life cycle carbon footprint that is merely 20 percent of petroleum (an 80 percent reduction from petroleum). For more information about Algenol Biofuels, please visit www.algenolbiofuels.com.
Reader Comments (Page 1 of 1)
Anonymouse 11:52PM (6/30/2009)
How much you think it costs to cover an acre (~210' by 210') of desert in plastic that has to be replaced every several years due to UV degradation (but which must be strong enough to withstand the elements) in order to produce $12,000 of ethanol a year? $12k after refining, storage, shipping, etc costs, that is...
I'm going to guess that the amortized costs are *way* more than $12k a year.
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BoneHeadOtto 12:26PM (7/01/2009)
There are plenty of methods for producing algae without taking up massive acreage. Algae can be grown in large verticle greenhouses and take up far less land. And be grown on any land for that matter. So while this initial approach will not scale to meet the worlds demands it is an interesting small scale test. And yes the algae requires refining but from what ive read the refining is very simple.
But with your father being the "CEO of one of the largest refiners in the US" i can understand your scepticism and criticism of an alternative to oil
But as for algae, why turn it into ethanol. Whynot just turn it into biodiesel which is more energy dense and seems to be easier to produce.
Matt 10:46AM (7/01/2009)
I'd think a great oil man like you would be able to figure this out fairly quickly...
Let's assume they have to buy their plastic from Home Depot, easily a conservative estimate on cost. At 4.45 cents per square foot, an Acre (43,560 sf) of 6 mil polyethylene would only cost $1,938.42. Now, they'll need about 3.14 times that much if they want tubes, making the plastic cost $5,815. Someone would have to spend a week rolling this out and filling them up, add $2,000 = $7,815 installed. If they can harvest $12,000 of fuel from this acre of desert, I'd say they're doing pretty good (54% ROI). Even when you add in the pipeline to the refinery and the cost to extract the ethanol this is a money maker. If they get to $1/gal unsubsidized your dad may be refining ethanol.
Anonymouse 11:08AM (7/01/2009)
"Algae can be grown in large verticle greenhouses and take up far less land."
But no less plastic. Seriously, why do you think hydroponic food costs so much?
Nor, BTW, do vertical greenhouses actually get you any more per unit acre shaded. They get you more per unit acre *that you sit on*, but they do that by shading land that you're not sitting on.
"But with your father being the "CEO of one of the largest refiners in the US" i can understand your scepticism and criticism of an alternative to oil"
Ah, gotta love stereotypes. FYI, I'm going to be one of the earliest owners of an Aptera 2e. Financed through my father.
"Let's assume they have to buy their plastic from Home Depot, easily a conservative estimate on cost. At 4.45 cents per square foot, an Acre (43,560 sf) of 6 mil polyethylene would only cost $1,938.42"
Sorry, but not even close, for three huge reasons.
1) Polyethylene thin film is not sufficient strength for containing large volumes of water.
2) Polyethylene thin film lasts under a year before UV degradation makes it brittle and it falls apart (as well as partly opaque).
3) Polyethylene thin film cannot withstand the elements for any significant length of time.
I know this stuff because I used to build greenhouses. Shock of shocks, I actually have a background in this field. I once built a "home depot" greenhouse glazing. It was in pieces by the next year.
jdtranetzki 3:53AM (9/17/2009)
Ofcourse an oil refinery can produce abundantly, quickly, but not efficiently. And when the supply is used up?
It is actually YOUR comparison that falls short. And I SHOULD know, I worked as a researcher for 'finding the oil', and it is just there that the oil industry commits a mass majority of their resources and energy. The bottom line is, hitting 'pay dirt', with all our technology is still threading the needle. Once hit, the average well is less than 10 years. The number of hits is less than 1 and 100 tries. I think it may be much more. And that's fine for the oil industry, their mentality is that this economy is self sustaining for oil and it will never fall short of large margins profit wise. It's a brutist mentality.
And the simple fact is, in 50 years, oil will turn the way of the dinorsaurs. It served its purpose well no doubt, as if meant to be, but we are going to see it the well dry up in the next 2 generations, that is a fact. That is why 'big oil' likes to promote alternate energy, and show a warm kind side to sidle up to the environmentalist, as if to show a noble cause I guess.
But come on, it's a industry like any other. It shouldn't apologize for that. But it is going to be the independent companies that find the alternatives.
But the simple point to make, and where your fallacy lies, is that producing mass quantities in short time is only the tip of the iceberg. And it is a short stick to measure.
These alternatives are long term. Their development? Is just that, still in development. But that will change and evolve. They are self sufficient. They show the stability that big oil lacks. And by many agencies, they are considered the work horse solution.
And with that evolution in technology will come greater returns over time. That is simply science at work. No different than the oil industry experiences in R&D.
Oh, and I too am going to be the proud owner of the first line of Aptera2e? I am, but I don't think of it as an alternative. It really isn't. But it is cool.
I also drive an old 1965 ford pick up with modified diesel engine to run on bacon fat. Well not really, but it has been done successfully.
Hank 7:35PM (6/30/2009)
Because DOW would have trouble getting plastic at a good price?
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SumideXE 8:39PM (6/30/2009)
Have you ever seen what goes into oil refineries?
How much work it takes to get oil out of the ground these days? ( except for in choice parts of the middle east ).. if you did some research on how much man power, elaborate design, and maintenance go into oil production, a few acres of plastic sheet looks like a drop in the bucket.
This may simple be a PR piece - they have not won an DOE funding grant yet - but there are more and more companies trying to pull this off. Ethanol is a great fuel if we can find a good way to produce it ( hint: not corn! ).
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Anonymouse 11:59PM (6/30/2009)
Have I ever seen an oil refinery? Um, yeah. My father is the CEO of one of the largest refiners in the US. On an acre to acre comparison, their Port Arthur refinery, to pick one, produces the 6,000 gallons of fuel that this facility produces per acre year every nine hours. And most of that used space in the refinery is pipelines and storage tanks. *And*, algae needs to be refined into fuel, too. Completely ridiculous comparison on your part.
polo 12:29AM (7/01/2009)
If they can get the cost down to $1 a gallon this should definitely be heavily subsidized to get production up and stimulate more investments in new facilities. It eats up carbon and produces drinking water, its a win-win. I wouldn't mind seeing a tax on oil refineries that goes right into development of these type of algae refineries.
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gorr 2:02PM (7/01/2009)
I didn't say to subsidize or give grant to algae bio-farming. I have said to invest approx 100 000 $ in an algae plant near where i live and tranform algae in butanol because it's butanol that my neon 2005 need, With the remaining , they can do ethanol too for the fools that have gm flex-fuel sh*t cars and bio-diesel for the poor folks that ruin their life driving tractor-trailers trucks for big-oil, LOL, LOL.
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tony 3:38PM (7/01/2009)
I think this is great... It feeds on the CO2 that these plants produce. A reduction in CO2 while having a usefull by-product that can power my car.
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GTZealot 3:37PM (7/01/2009)
I feel like I need to add a note here about a particular college involved with this project... Go JACKETS!!! (>:
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parking_god 2:12PM (7/03/2009)
Maybe it won't scale up economically, but it might work on a scale large enough to equip individual plants. If I were a plant-owner, I'd be interested in the idea of reducing my CO2 emissions while producing ethanol to use myself or sell to someone else.
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