E3 in the News
Mead Ethanol Plant is One of a Kind
Freemont Tribune
June 29, 2007
MEAD -- For now, this small community is the center of the ethanol world with the opening of a plant that harnesses the newest process for making the corn-based fuel that promises to cut Americans' dependency on fossil fuels.
A special ceremony highlighted that new “closed-loop” process around noon Thursday.
Dennis Langley, president and chief executive officer for E3 BioFuels, refers to the plant just south of here as the Genesis Plant.
He proclaimed the plant “the second generation of ethanol.”
Leading a tour for area media, Brian Barber, director of project development at E3 BioFuels, explained what makes this plant so different.
“There is no byproduct waste from this plant that you get in a traditional ethanol plant,” Barber said. “All of the byproducts are put back into the process.”
There are four components to the Genesis Plant site, he said.
- A 30,000-head cattle feedlot produces manure collected through slatted floors of cattle holding pens. The manure is continuously pumped to a storage lagoon.
- A 2,500-acre corn farm produces part of a special feed mixture for the cattle. About two million bushels of corn will be chopped up each year for the feed mixture.
- A specially designed anaerobic digestion plant allows the organisms to feed on elements in the manure and a thin syrup-like stillage byproduct to produce methane gas. Dry manure that is left is composted to be used as fertilizer on the corn fields.
- An ethanol plant is fueled by the methane gas. An additional eight million bushels of corn is expected to be bought for the plant's production. Distilled grain and leftover corn, called “wet cakes,” are put into the cattle feed mixture. Drained off water from the plant is used to irrigate the fields.
“It sounds bizarre, but it works,” Barber said.
The plant is set to produce about 20 million gallons of ethanol each year, but will be increased to 25 million gallons per year.
“It's a matter of getting this fine tuned,” he said.
E3 BioFuels originally bought 880 acres for the plant site but has recently bought another 1,400 acres. Barber said that will be used for future expansion, which could start later this year. By the time the expansions are complete, the plant could produce more than 60 million gallons of ethanol annually.
Barber explained that the company does not own cattle in the feedlot. The cattle's owners pay for the animals to be held and fed there for about 150 days before being taken to slaughterhouses.
“We refer to it as a cattle hotel,” he said. “We'll have at least two full turnovers in cattle in a year. This takes some of the risk out by not owning the cattle in the feedlot operation.”
In the ceremony, Langley said there are several advantages to the closed-loop system.
“This is a huge step forward to achieving energy independence in the United States,” he said. “We solved the largest water pollution problems (by removing manure from the feedlots). One of the biggest water pollution problems is livestock manure. This system helps reduce the greenhouse gas effect.
“Ethanol isn't the only thing for moving toward energy independence but it's a large component of it,” Langley continued, adding that the process also helps reduce the odor associated with feedlot operations.
The other advantage to the closed-loop system is that it is much more efficient than traditional ethanol plants.
“There isn't much difference in energy efficiency between a traditional ethanol plant and a gasoline plant,” he said. “I wanted to see something that was a dramatic step forward. This does that.”
Langley also praised Gov. Dave Heineman's efforts for getting the company to build the plant near here.
“If not for your governor, this plant would not be here,” Langley said. “He was a champion of the project even when it was just an idea.”
Heineman said this plant is a continued boost to the state's ethanol industry.
“We will be the No. 2 producer of ethanol by the end of the year,” Heineman said. “We will average a new ethanol plant opening from now to the end of the year. Ethanol has proven to be one of the most successful agri industries for this state. This plant is just one example of how our state is leading the way.
“Creating 85 jobs in Mead is very special and very significant,” the governor continued. “This plant sets a new standard for ethanol production in Nebraska and our nation. We are finding new ways of using our natural resources.”