Greenstar Products: 90 Biodiesel Reactors, Algae Feedstock

Green Star Products, Inc. (OTC: GSPI)  announced that it has signed an agreement with De Beers Fuel Limited of South Africa to build 90 biodiesel reactors.

Each of the biodiesel reactors, first one shown here, will be capable of producing 10 million gallons of biodiesel each year for a total production capacity of 900,000,000 gallons per year when operating at full capacity, which is 4 times greater than the entire U.S. output in 2006.

The first plant is currently using sunflower seed oil as feedstock, however, it is planned to switch to using algae produced with the Greenfuel Technologies Corporation system and has purchased and removed their bioreactor from Cambridge, Massachusetts, and transported it to South Africa.

Mr. Joseph LaStella, President of GSPI, stated, “The De Beers biodiesel plant is currently in operation and will include some very unique features with modifications to upgrade technology. These are:

1) GSPI reactors, which process raw materials into biodiesel in minutes (versus one to two hours for the rest of the industry), will transform the De Beers plant into a State-of-the-Art Continuous Flow Process to increase efficiency and reduce operating costs.

2) The marriage of the two biodiesel production technologies will allow plants to be constructed at a fraction of the present industry costs and can be built in record time.

Mr. de Beer’s business model also includes a franchising strategy and has already received financial commitments to build 90 biodiesel plants each at 10-million-gallons-per-year capacity.

The 2-ton reactors will be built by GSPI at their Glenns Ferry Facility in Idaho and delivered over the next 18 months. The first reactor was shipped November 8, 2006 by airfreight to South Africa.

Presently, the De Beers plant is now operating at 10,000,000 gallons per year on sunflower seed oil as feedstock and has contracted for additional feedstock for additional plants. However, the final answer for biodiesel feedstock will not be oil crops - it will be algae. For example, soybean produces only 48 gallons of oil per acre per year, canola produces 140 gallons per acre and algae can produce well over 10,000 gallons per acre. This figure has been verified in actual algae field production tests by the US Department of Energy in an 18-year Algae Study Program from 1978 – 1996. This makes algae the only worldwide feedstock capable of replacing crude oil. Making use of algae also means not competing with crops for food sources that would otherwise lead to an increase in food prices.

Mr. de Beer has made great strides to acquire the latest Algae Production Technology. In recent weeks there have been many media articles about the success of the algae bioreactor operating at MIT (see http://web.mit.edu/erc/spotlights/alg-all.html) utilizing the MIT CO₂ exhaust boiler emissions as feed for the algae.

Algae consumes CO2, a major Global Warming Gas. After consumption of the CO2, the algae produces oil (for biodiesel manufacturing) and oxygen. Therefore, the process of using algae creates renewable, sustainable biofuel and reduces global warming gases to better the environment.

Mr. de Beer has entered into an agreement with Greenfuel Technologies Corporation and has purchased and removed the MIT bioreactor from Cambridge, Massachusetts, and transported it to South Africa. It has been reassembled on the biodiesel plant site in Naboomspruit, South Africa, and is now awaiting the arrival of the algae to be inoculated to start production. At the Naboomspruit site construction will soon be underway at the rail spur for a crushing plant to process oil from the planting of sunflowers throughout the region. Mr. de Beer also supports, along with the development of the algae growth technology, the local farming industry that will benefit with the planting of thousands of acres of sunflowers and other feedstocks for oils to be processed into biodiesel fuel.

Most of the 90 franchised biodiesel plants are located close to electric power plants as well as other CO₂ emitters, to utilize their stack emissions (CO₂) to feed the algae farms when they switch over feedstock from oil seed crops to algae.

The franchising plan reduces the initial cost of the biodiesel plant significantly for participants. Franchises will only be paying in the range of 10 cents per installed gallon (depending on location and logistics), while the rest of the industry is paying $0.70 to $1.50 per installed gallon – based on National Biodiesel Board’s Chief Engineer, Steve Howell’s survey report published in Render Magazine - February 2005 issue (see www.rendermagazine.com for complete article).

Comments

[Harvey D.]

This is good news for alternative biofuel.

When will we build the algae version (colocated) with the 100+ (present and future) coal fired generating plants in the USA?

Do we have an application problem?

[marcus]

Although feeding the algae CO2 from coal plants gets more bang for your buck it worsens global warming. Having the algae obtain it from the atmosphere keeps it CO2 neutral.

[George]

What is this stuff going to cost? It is presumably competitive with oil at whatever level the financiers of the project believe will obtain in the relatively near future.

[amazingdrx]

The best technology to provide the extra cO2 would be fuel cell/turbine power generation using the dry algae residue from the oil extraction.

It operates at 75% efficiency versus the typical 30% efficiency of steam turbine power.

This would be a great transitional technology to eventually eliminate fossil fuel. But would treat coal emissions until coal is no longer used when enough renwable distributed generation and storage takes over.

[chris g]

Marcus, "Although feeding the algae CO2 from coal plants gets more bang for your buck it worsens global warming." --- I assume you mean "it still contributes to global warming". Basically getting the CO2 from flue gas of a power plant gives the carbon one extra cycle before being emitted to the atmosphere.

[Cyrus]

Marcus,

Algae experiments are only able to achieve the exceptional photosynthetic efficiencies that have been reported by using concentrated CO2 sources. Using atmosphere, the size of the apparatus would need to be larger. Until it can be profitably demonstrated on a power plant's tailpipe, no one is going to risk the capital to try it at large scale in open atmosphere.

[amazingdrx]

Actually cyrus, even in open ponds with no extra CO2 algae beats any other fuel crop by a couple orders of magnitude.

But can the extra CO2 be provided directly from the atmosphere by merely supersaturating the water/algae mixture with air? I think so.

That would mean extra O2 also, but what difference would that make? It is the availability of extra cO2 rather than a higher concentration.

[amazingdrx]

http://thefraserdomain.typepad.com/energy/2006/06/petrsun_enters_.html

Open pond algae production can yeild 30 times the fuel per acre of other crops.

[Cyrus]

I stand by what I said. If it can be done profitably in open ponds, then it certainly can be done profitably with a concentrated CO2 source. Until the easier one has been successfully scaled up, I doubt we will see the more difficult one tried at large scale.

[Cyrus]

Amazing,

The link you provided states that a firm has just begun to research the problem, and then has lenghthy quotes from the 1970s era DOE study, which used algae in open ponds, but with sparged carbon dioxide as the principal carbon source.

[marcus]

I guess I may have been wrong since its all about the overall flux rate of CO2. Taking it from coal plants that would have emitted it anyway at least reduces the amount of gasoline that would have been burnt. So overall it still reduces GHGs. However the CO2 from coal plants would still be better off underground with the algae helping us to more effectively reduce GHGs directly from the atmosphere.

[marcus]

ps If it is feasible

[amazingdrx]

It's an older article Cyrus. But still shows the inherent enhanced efficiency of biofuel from algae. This much higher growth rate is a function of the design of the algae itself I think.

No roots to grow or leaves for solar collection or respiration, because all the nutrients, gases, and sunlight comes in directly through the cell walls immersed in water. They reproduce like Tribbles! Hehey.

Pure exponential growth. Corn and sugar cane have a harder life.

I doubt it would stay underground reliably marcus. Monitering it would be nearly impossible. When coal is no longer needed the cO2 can come from algae run through fuel cells. And even from the atmosphere itself.

A writer here awhile back suggested using chemical reactions that would increase the amount of cO2 that dissolves in water when air is blown through a mist. This kind of separation powered by wind power could store extra cO2 in the system during high wind periods.

[amazingdrx]

http://uwadmnweb.uwyo.edu/rpc/UWTechs/VariousCO2Technologies.asp

This separation process looks promising. Wind powered compressors could provide the energy to drive the cO2 from air through the membranes. The compressed air would store energy from high wind periods and keep the filtration going continuously.

[Biofuelsimon]

Am I missing something? The reactors appear to be blue and completely metallic. Does this algae grow in the dark? Doesn't photosynthesis need light?

[Tim]

Yes, that confused me too. They are not talking about bioreactors that grow algae, they are talking about a reactor that changes the oil from the algae feedstock to biodiesel. Note that they said that the plant is currently using sunflower seed oil as feedstock. This is just the last step in the process.

[Udo Stenzel]

The best technology to provide the extra cO2 would be fuel cell/turbine power generation using the dry algae residue from the oil extraction.

No, it won't. This way you remove carbon from the cycle and don't replace it, so you obviously end up with nothing in the end.

...still shows the inherent enhanced efficiency of biofuel from algae.

...iff given concentrated CO2. Your math and reading skills are truly amazing, drx.

[amazingdrx]

Well Udo, you forgot a step.

The CO2 from the fuel cell is recycled back through the algae system. The algae system thus makes it's own CO2 for enhanced growth rate.

Half the algae weight is turned into biodiesel and the other half is run back through the fuel cell to produce backup power for the grid and more cO2.

You might turn into a renewable energy booster yet with a bit more science education? Hehehey.

[amazingdrx]

http://thefraserdomain.typepad.com/energy/2006/10/vertigro_algae_.html

Here's the article about the algae system Tim and biofuelsimon.

[Udo Stenzel]

Half the algae weight is turned into biodiesel and the other half is run back through the fuel cell to produce backup power for the grid and more cO2.

I'll try to explain it slowly again, just for you, drx: ALL the carbon in the algae comes from carbon dioxide. About HALF of that is contained in the oil and removed. Only HALF remains and is cycled back through fuel cell and bioreactor. On the next cycle, only HALF remains, which is LESS than ALL.

Does that make sense? Or do you now claim that magic algae are able to transmute photons into carbon atoms?

(You might as well forget about extracting the oil and just burn the algae whole. Then it is a cycle and becomes a solar power plant with in-built storage. It will be a lot less efficient than photovoltaics, though.)

[amazingdrx]

Ahh still not getting it huh?

The algae produces biodeisel, a valuable byproduct that reduces the need for oil. The algae is not burned, it is sent through a fuel cell/turbine that is 75% efficient.

The CO2 from the fuel cell running on the algae increases the level of cO2 in the algae system above that level already attained with cO2 from the atmosphere. It need not replace all the cO2.

But merely increase CO2 level in order to increase the growth rate of the algae.

This whole system is much simpler than a molten salt waste recycling, nuclear reactor, it's surprising that you can't seem to understand it. Maybe you don't really want to?

[Udo Stenzel]

Okay, drx, I give up. Go ahead, build it. See for yourself how much comes out of it at a CO2 concentration of 760ppm. And no cheating with a separate CO2 concentrator that wastes energy!

[amazingdrx]

That's more like it Udo! Actually I would like to build a home sized unit that produces enough fuel for a fuel cell/microturbine plugin hybrid.

If I can convince you, I can convince anyone! Hehey.

But what I'm saying to you is similar, go ahead and build a few experimental nuclear reactors that will render nuclear waste safe in a cost effective process that also generates power economically. Let's make a deal! between nuclear power advocates and renewable energy boosters.

Maybe we can convince the powers that control the research dollars? I know it's a long shot, but why not at least try?

Cheating to use CO2 separation from the atmosphere using wind power? Why is that? We get to use wind, water, and sun, you get to use nuclear fission. That seems fair.

Why can't one use two different systems. One that dissolves air in the algae/water mixture and in a separate paralell stream dissolve mainly cO2 from fuel cell emissions? When the slurry is again mixed together and fed through the algae/solar system the cO2 level will be raisded enough to provide an accelerated growth rate.

[amazingdrx]

http://gristmill.grist.org/story/2006/11/13/15309/906/#9

There it is Udo, biogas from digestors run through the fuel cell is the extra CO2 source. Manure runnoff remediation,clean electric power, clean water, and fertilizer as byproducts.

[Udo Stenzel]

If I can convince you, I can convince anyone!

A big "if". So far you only convinced me that your math skills are inadequate and your reasoning skills non-existent. So please build your algae farm/power plant just to see how it doesn't work.

BTW, you're continually quoting yourself. That's considered a sign of insanity.

[Maarten]

Worldwide oil production is approaching 100 million barrels a day. If all the coal power plants were used to produce algae which would be converted to biodiesel, how much equivalent energy would be produced?

[Skeps]

Is the GSPI company real? Smells like a fraud..

[American Biodieselist]

Speaking of frauds, compare the insulting hype regarding hydrogen and ethanol to the cold sober assertion that "algae [is] the only worldwide feedstock capable of replacing crude oil." This assertion is well said. If and only if you have the strength of character to lay hold of this simple truth and not let go, then you will continue to know what will eventually prevail, despite all the heinous mass hysteria and hypocrisy. Roundly condemning such hypocrisy since it shelters Big Oil at the expense of human life and limb abroad also seems to help...

[amazingdrx]

(3 000 000 000 gallons per day x 365 days per year) / (640 acres per square mile x 150 000 gallons of biodiesel per acre of solar collector) = 11 406.25 square miles to yield that amount of fuel. 100 million barrels per day, aproximately 3 billion gallons of liquid fuel per day.

Cut liquid fuel use to 10% by going to plugin hybrid fuel cell transportation and 1400 square miles of solar collector algae capacity would meet the demand.

so 1400 square miles divided by 57,268,900 square miles land area+139,668,500 square miles water area= .0007 % of the area on earth's surface.

Could that be done from rooftops, over parking lots, and on floating energy collectors on the ocean? I think so.

The ocean platforms could support wave and wind power generation simultaneously. And all the solar collector space could cogenerate electricity and heat.

[Joe McDonald]

We are a UK company manufacturing and supplying our patented photo-bio-reactors into the aquaculture, cosmetic, bio-remediation and biofuel sectors. Unlike most other companies out there who promise they can deliver a system or are still developing a system, we can and do actually deliver! Systems are exported globally, run continuously and operate at up to 36 times the density of conventional production systems.

[Joe McDonald]

We are a UK company manufacturing and supplying our patented photo-bio-reactors into the aquaculture, cosmetic, bio-remediation and biofuel sectors. Unlike most other companies out there who promise they can deliver a system or are still developing a system, we can and do actually deliver! Systems are exported globally, run continuously and operate at up to 36 times the density of conventional production systems.

[yosep]

we wanth to have contact with the Uk company so please contact us by our web page www.yim.com.mx

[Laura]

What's with this company's stock? For such a great product & idea, you would think it would be taking off like wildfire!!!

[bcole]

National Algae Association

Algae: The Next Biofuel

Inaugural

Algae Commercialization
Business Plan and Networking Forum

April 10, 2008

Algae: The New Oil

Early stage algae production algae production companies will showcase their companies at the National Algae Association business plan and networking forum on April 10th. The most promising algae oil production companies will present their new ventures in front of an audience of algae researchers, biodiesel/biofuel companies interested in learning about algae commercialization as well as potential investors and lenders.

Deadline for all business plans and white papers must be submitted by March 28, 2008. Business plans and white papers will be reviewed by the executive committee. Only 6 business plans will be picked to present at the National Algae Association quarterly business plan and networking forum.

www.nationalalgaeassociation.com

[Alan Broadbent]

These company's are infringing on my US patent 6966942 method of purifying exhaust gas utilizing a bubble generator "using algae". they must not have done their homework. Maybe they think independent inventors don't mater as much as money. de beers hands are covered with blood.

[Dr. Rabah Nory From IRAQ]

i think the overall story about theses bioreactor just a great fake why S. affrica what about the diatom used in reaction it needs silicons to be grow up. Belive me it is Number one Fake. the web site desing looks folish and cheap style.