Broin Companies plans on producing its first commercial-scale cellulosic ethanol by 2009 through converting its Emmetsburg, Iowa, ethanol plant. The Sioux Falls, S.D-based company announced today a $200 million conversion project that will boost production at one-year-old Voyager Ethanol to 125 MMgy.

Broin announced its cellulose plans in October, but didn't disclose the location since the project was undergoing permitting. Voyager Ethanol produces 50 MMgy of ethanol and is one of six plants operated by Broin in Iowa. It will undergo a $200 million conversion to a 125 MMgy commercial scale bio-refinery designed to utilize advanced corn fractionation and lignocellulosic conversion technologies to produce ethanol from corn fiber and stover, according to Broin.

Pilot research for the project has been conducted, and the expansion is slated to begin in February 2007. Construction is expected to take 30 months.

Broin applied for matching grant funds through the U.S. DOE to assist with Project LIBERTY, which stands for Launch of an Integrated Bio-refinery with Eco-sustainable and Renewable Technologies in Y2009. Awardees for the $80 million grant will be announced in January.

The project is expected to greatly increase ethanol production efficiency. The project will obtain 11 percent more ethanol from a bushel of corn and 27 percent more ethanol from an acre of corn. The plant is also expected to use 83 percent less energy to operate.

Mike Muston, Broin's executive vice president of corporate development, previously told EthanolProducer.com that the plant will use approximately 25 percent of a field's corn stover, leaving the remainder for erosion control and nutrient replacement. He said the corn stover will likely be stored at the plant.

Technology for the cellulose project has been developed by several parties. In October, Broin announced a partnership that will allow the company to license technology developed by DuPont. Broin also said that efforts for the project were escalated when Broin and the U.S. DOE jointly funded a five-year research initiative to develop and improve dry mill fractionation with the assistance of the National Renewable Energy Laboratory and South Dakota State University. The project led to Broin's trademarked corn fractionation technology, which will be used at Voyager. The plant will also use Broin's trademarked raw starch hydrolysis, BPX.

"We have been working very hard at developing technologies and advancements the past several years to position Broin as a leader in this area, and the project in Emmetsburg is a major step toward reaching that goal," said Jeff Broin, Broin Companies CEO.

Dave Nilles is Online Editor for Ethanol Producer Magazine. Reach him at dnilles@bbibiofuels.com or (701) 373-0636.

Posted: 12:24 p.m. CST Monday, November 20, 2006