At Borderview Farm in Alburgh, Roger Rainville’s dairy-turned-energy farm makes biodiesel from locally-grown sunflower seeds.
In 2008, when diesel prices rose from $4 to $5 per gallon, Rainville began experimenting with farm-scale biodiesel production. With guidance from UVM Extension and grant funding from the Vermont Bioenergy Initiative, Rainville began planting sunflowers on a portion of his 214 acres and installing biodiesel processing equipment. Oilseed sunflowers (as opposed to confectionary sunflowers that are grown for eating) are the most popular oilseed crop in Vermont, with hundreds of acres planted statewide. The crop is grown in rotation with grains and grasses and yields high quantities of oil.
Harvesting, Cleaning, and Pressing
Following harvest with a combine, a seed cleaner and grain dryer are used to prepare the seeds for storage in a 200-ton grain bin prior to processing. A flex auger system moves the seeds from the storage bin into hoppers on each press, and screw augers push the seed through a narrow dye at the front of the press. Extracted oil oozes from the side of the barrel and is collected in settling tanks while pelletized meal is pushed through the dye at the front and is stored in one-ton agricultural sacks. The oil can then be used as culinary oil for cooking or further refined into biodiesel. The leftover seed meal is used for livestock feed, fuel for pellet stoves, or fertilizer for crops.
The small-scale biodiesel production facility at Borderview Farm is an 800 square foot insulated and heated building (the space does not need to be heated, but the oil should be stored where it will not freeze) that houses an oil press, a BioPro 190 automated biodiesel processor, a methanol recovery system, and a set of dry-wash columns for cleaning the fuel. The clean oil at the top of each settling tank is added to the BioPro 190 processor along with lye, methanol, and sulfuric acid. The automated processor runs through several stages of processing in about 48 hours (esterification, transesterification, settling, washing, and drying), with one break after 24 hours to remove the glycerin byproduct.
Safety equipment in the processing facility includes personal protective equipment like aprons, gloves, eye protection, a ventilation system, gas detectors, and spill containment materials. At Borderview Farm a set of standard operating procedures hangs on the wall and blank check-sheets are in a binder to make the process easy to repeat. The finished biodiesel is stored in 250 gallon pallet tanks making distribution to different farms easier. The installed capacity of the facility can process 100 tons of seeds from 138 acres of sunflowers per year, yielding 10,500 gallons of biodiesel and 64 tons of sunflower meal (assuming the state average yield of 1,500 pounds sunflower seeds per acre and operation of 24 hours per day for 260 days per year).
Rainville switched from purchasing diesel for five tractors and one truck to making his own biodiesel. He wanted to be independent of imported fuel, and liked creating a new way for farmers to diversify. “Using land for making biodiesel is not the most economical option compared to some other crops, but it’s about creating opportunities to try something different,” says Rainville.
Rainville’s annual biodiesel use has ranged from 500 to 3,000 gallons per year. At current prices (over $4 per gallon for diesel and $2.29 per produced gallon of biodiesel) biodiesel has saved him from $500 to $4,000 per year in fuel costs. He also emphasizes energy independence as an added benefit. Plus, any growers that also raise livestock can use the meal, which is leftover after the oil is extracted, as part of their feed rations. Rainville recommends talking with an animal nutritionist to blend this into feed at the right ratio, since sunflower meal has a high fat content.
This story was originally released in a series of energy case studies showcasing farms, businesses, vendors, installers, and technical assistance providers who have made a difference with energy efficiency savings and renewable energy production—all of which are components for helping Vermont reach the renewable energy and environmental impact goals of the Farm to Plate Strategic Plan. Learn more at www.vtfarmtoplate.com.
Algae for biofuel has been a long time component of the local biofuel production for local use model pioneered by the Vermont Bioenergy Initiative. At the forefront of these efforts has been Anju Dahyia, a VBI grantee, lead biofuels instructor at the University of Vermont, and president of General Systems Research (GSR) Solutions. When the Vermont Fuel Dealers Association received a USDA Rural Business Enterprise Grant to utilize waste materials from Vermont farms to produce sustainable distillate fuel, Anju and GRS Solutions were already in a prime positon to conduct the necessary research.
GSR is developing a method of producing algae biofuel to replace traditional fossil fuels in motor vehicles, heavy farm equipment, and even airplanes at Charlotte’s Nordic Dairy Farm as a second tier to the already operational anaerobic digesters contributing to Vermont’s distributed energy generation grid. The process to produce algal biofuel has the potential to prevent nutrients such as phosphorus and nitrogen from making their way into local lakes and waterways. Nordic Dairy Farm’s owner, Clark Hinsdale, explained at a recent press event on his farm: “the best way to capture excess nutrients on farms is to never let them get beyond the boundaries of the farmstead.”
The current anaerobic digestion system “Cow Power,” utilized by Green Mountain Power, functions by using the methane byproduct harvested from constantly produced cow manure to make electricity that then is sold to Green Mountain Power customers. The research done by GSR focuses on another byproduct of digestion – the nutrient dense liquid waste, previously left unused for power purposes.
The oleaginous algae strains that Anju Dahyia has been working with since 2008 thrive on this dense waste and after the algae has consumed the available nutrients, the creation of the distillate fuel can begin. The result makes the process a closed loop system, and means that dairy farmers like Nordic Dairy (whose cows produce up to a ton of manure a day) would be able to sell algae derived biofuel to local fuel dealers and create granular organic fertilizer. According to Dahyia, Hinsdale’s 300 cows alone have the potential to produce anywhere between 20,000 to 30,000 gallons of biofuel each year.
The cost of production is estimated at $20 dollars per gallon, but Dahyia thinks that with increased scale will come a decreased price. At the recent press conference at the Nordic Dairy Farm site early in September, Mary Powell of Green Mountain Power outlined how the company is working with GSR Solutions to help increase scale and add more small refineries that mimic this operation. She went on to note the resiliency a community-sized digester refinery can add to a microgrid.
Speaking to ABC local 22 News, Matt Cota, Director of the Vermont Fuel Dealers Association added, “We know that bio-heat, renewable blended fuel, combined with heating oil works in customers tanks and burners, so if we can source that locally, it would be a great thing for Vermont’s economy, for Vermont famers, Vermont fuel dealers and consumers all across Vermont.”
Richard Altman of the non-profit Commercial Aviation Fuels Initiative was also in attendance and trumpeted that “community-scale digester-refineries in the region might be feasible by 2020,” noting that this project is just a start.
Also on the horizon, GRS Solutions is already working to go further with this technology by incorporating food waste into this digester system. While this system may be in its early stages, one thing is for sure, Vermont energy stakeholders are lining up to show their support and contribute to this more than viable option for local energy production.
For more watch the local WCAX coverage of the September 3rd press conference and to learn more about Algae Bioenergy in Vermont see our other post Algae Biofuel – Vermont’s Search for Viable and Cost-Effective Methods
14 Sep 2015
The Vermont Bioenergy Initiative, a program of the Vermont Sustainable Jobs Fund, aims to foster the sustainable bioenergy through a local production for local use model, proven to work for Vermont. Since 2003 the program has allowed Vermont farms to ease their resilience on inconsistently priced, foreign fossil fuels and other agricultural inputs. This is accomplished by focusing on biodiesel production and distribution for heating and transportation, oil crops for on-farm biodiesel and feed, grass energy for heating, and algae production for biofuels and waste management.
Vermont Bioenergy Initiative grantees have shown just how much the addition of biomass feedstock can contribute to sustainable agriculture. As one of these grantees, John Williamson of Stateline Farm would put it, “100 years ago everyone produced their own fuel; we are just doing that now in a different way.” This is really a novel way to look of what he is doing on his North Bennington farm. John was featured in a recent story in Daily Yonder which outlined his work and how he has begun helping his Vermont neighbors find their path to this form of sustainable, renewable energy.
For more about John Williamson’s on-farm biodiesel production, watch this video of John in self-designed Biobarn. He and Chris Callahan of University of Vermont Extension show us how they can grow oil crops, make biodiesel, feed animals, and save money!
Also, explore the initiative’s extensive and accessible set of bioenergy resources for replication in rural communities across the United States and beyond.
The Vermont Bioenergy Initiative connects diversified agriculture and local renewable energy production for on-farm and community use by supporting research, technical assistance, and infrastructure development in emerging areas of bioenergy including biodiesel production and distribution for heating and transportation, oil crops for on-farm biodiesel and feed, grass for heating, and algae production for biofuels and wastewater management. Explore the initiative’s extensive and accessible set of bioenergy resources for replication in rural communities across the United States and beyond.
A series of informative educational showcase a range of biofuel possibilities; from research and crop farming to feedstocks and fuel. The videos were developed by the Vermont Sustainable Jobs Fund, UVM Extension researchers, KSE Partners, and the Vermont Bioenergy Initiative grantees.
Two calculators, developed by UVM Extension, help connect potential costs and profits associated with oilseed production:
- Grass Biomass Production and Harvest Cost Estimator
- Vermont Oilseed Crop Production Cost and Profit Calculator
- Biomass to Biofuels, University of Vermont: This semester-long course covers liquid and solid biofuels, biogas and bio-electricity, and environmental, social and economic issue related to biofuels. The course includes guest lecturers and field days. Available for variable credits.
- Biomass to Biofuels, Vermont Technical College: The development of this course and associated materials led to an online repository of resources for the classroom covering biomass to biofuels.
- Digester Operations Master Certificate, Vermont Technical College: a twelve week program designed for participants to work directly with operations staff of Vermont Tech’s anaerobic digester and come away with understanding of the mechanics and operations of a digester system, as well as other areas such as permitting, regulatory compliance and record keeping.
- Alternative Fuel Vehicles: Biodiesel, part of the Green Trainings series at Vermont Technical College: This 2-day course covers engine systems, biodiesel blends and biodiesel production, including a demonstration of fuel-making equipment.
- Biofuels Course at Yestermorrow Design/Build School, part of the Green Trainings series at Vermont Technical College: This weekend workshop enables students to begin replacing fossil fuels with biofuels, such as adapting engines to run on straight vegetable oil. 1 credit.
Bioenergy: Biomass to Biofuels; is an innovative new textbook that provides insight into the potential and current advances and benefits of biofuel. Contributions include an extensive list of well-respected university extension programs, such as The University of Vermont Research Extension, as well as numerous national organizations including the US Department of Energy’s National Renewable Energy Laboratories.
A variety of reports are available which cover a range of topics including seed preparation and storage:
- Institute for Energy and the Environment at Vermont Law School.Legal & Regulatory Review of On-farm Biodiesel Production. 2015.
- Chris Callahan and Netaka White,Vermont On-Farm Oilseed Enterprises: Production Capacity and Break-even Economics. July 2013.
- Nell Campbell, Local Production for Local Use to Supply a Portion of Vermont’s Energy Needs.May 2009.
- Emily J. Stebbins. Technical and Economic Feasibility of Biodiesel Production in Vermont: Evidence From a Farm-Scale Study and a Commercial-Scale Simulation Analysis. May 2009.
- Christopher W. Callahan,A Feasibility Analysis of a Mobile Unit for Processing Oilseed Crops and Producing Biodiesel in Vermont. December 2008.
- Emily Stebbins, The Market Potential of Farm-Scale Oilseed Crop Products in Vermont. February 2008. (See also the Executive Summary)
- John Williamson & Tanner Williamson – State Line Biofuels, LLP, Chris Callahan – Callahan Engineering, PLLC, Feasibility Analysis:_Solar Seed Dryer and Storage Bin at State Line Farm, Bennington, VT. October 2008
- Christopher W. Callahan, A Feasibility Study of a Mobile Unit for Processing Oilseed Crops and Producing Biodiesel in Vermont. December 2008
- Kenneth Mulder, Ph.D., Galen Wilkerson, Emily J. Stebbins.Homegrown Fuel: Economic Feasibility of Commercial-Scale Biodiesel Production in Vermont. September 2007.
- The Vermont Biodiesel Project: Building Demand in the Biofuels Sector – Final Report. October 2006. (See also theExecutive Summary)
- Vermont Department of Buildings and General Services, Vermont Biodiesel Pilot Project: Emissions Testing of Biodiesel Blends With #6 Fuel Oil At the Waterbury State Office Complex – Final Report. September 2006.
- Laboratory and Field Testing of Biodiesel in Residential Space Heating Equipment – Final Report. August 2006.
- Vermont Biodiesel Supply Chain Survey – Final Report. April 2006.
- Wilson Engineering,Grass Energy in Vermont and the Northeast, May 2014.
Connect directly with the Vermont Bioenergy Initiative’s technical assistance providers:
Oilseeds for Biofuel
- Heather Darby, Agronomic and Soils Specialist
- University of Vermont Extension, Northwest Crops and Soils Team
- (802) 524-6501
- [email protected]
- Chris Callahan, PE, Agricultural Engineer
- University of Vermont Extension
- (802) 773-3349
- [email protected]
Grass for Heating Fuel
- Sidney Bosworth, Extension Professor
- University of Vermont College of Agriculture and Life Sciences
- (802) 656-0478
- [email protected]
Algae for Biodiesel
- Anju Dahiya, Instructor and Principal
- University of Vermont and GSR Solutions
- (802) 310-1936
- [email protected]
In early 2014 Full Sun Company, a small start-up business was co-founded by Netaka White and Davis McManus. Fueled by an interest to help family farms grow, Full Sun began processing sunflower and non-GMO canola oil crops into specialty food-grade oil and high-protein meal for the farmers. Sunflower and canola oil distribution picked up quickly through local CSAs, farm stores, specialty food shops, health and wellness centers, and direct sales to chefs in the Northeast.
Netaka White previously served as the Vermont Bioenergy Initiative’s (VBI) program director, which directly helped to develop the business model to nurture farm partnerships, both as growers and recipients of oilseed meal – the other product that’s generated from making the oil. At Full Sun oilseeds are pressed with large mechanical machinery, producing oil and a granular meal. The team at Full Sun Company learned a lot about seed storage and oil pressing from the early VBI grantees, such as John Williamson of State Line Farm, and Roger Rainville of Borderview Farm.
The first of the two products, the seed meal, has been used as fuel for pellet stoves, or as is the case with Full Sun, sold as fertilizer for crops, or nutritional meal for livestock. At full operation, Full Sun can pump out one ton of meal per day – necessary to meet the growing demand of such customers as The Intervale in Burlington, Vermont and several local pig, poultry, dairy, and beef producers.
The second product, the oil, is used as culinary oil for cooking. Staying true to their commitment to an extraordinary culinary product, Full Sun Company diverts any of the oil that does not meet their standards to Vermont Bioenergy Initiative biofuel producers to undergo further processing and become biofuel. Approximately 250-300 gallons of off-spec oil for biodiesel has been processed since February, 2014.
In October, 2014, Full Sun Company halted operation to make room for growth to meet the increased demand for their products and scale up to align with Vermont’s accelerating agricultural economy. White and McManus acquired the former Vermont Soap building in Middlebury, Vermont in order to build a full scale mill and achieve their anticipated greater capacity. Over the course of one of the coldest winters in recent history, the Full Sun team made the renovations and adjustments needed to repurpose the building into the first non-GMO verified oil mill in New England. By March of 2015 Full Sun Company had pressed sunflower and canola seeds to make their first batch of specialty oils. The new operation can yield 130 gallons of oil per day – about 2600 gallons per month!
With no shortage of innovation or ambition, White notes, “David and I are in this with the interest of having a transformative effect on local agriculture and food systems.” Well on their way, the operation is certified GMO free, and the next steps are being taken towards becoming certified organic.
As they grow, Full Sun would like to buy from local grower-suppliers and work with local businesses to package and label feed to be distributed to farmers of varying sizes, from backyard chicken growers to larger operations. Collaborating with Vermont breweries and distilleries is also in queue. Full Sun is working with one local distillery to put together “a package” for farmers so they have markets for profitable grain crops throughout four years of rotation (rye, wheat, sunflowers, etc.) and can offer farmers the indexed prices for these locally grown grains and oilseeds.
Coming this fall the University of Vermont will be offering a bioenergy course taught by Anju Dahiya, cofounder of General Systems Research, LLC, lead biofuels instructor at the University of Vermont’s Rubenstein School of Environment and Natural Resources, and Vermont Bioenergy algae for biofuel grant recipient. This course is open to both degree and non-degree students from any background or department, as well as farmers, entrepreneurs, and teachers interested in developing curriculum, or projects at school or college levels. This course is also approved for graduate credit.
Potential participants are offered the option of variable credits, ranging from 0 to 6 credit hours. This allows prospective students to only attend lectures and have access to online course materials for 2 credits; further their experience with the addition of hands-on labs and field trips for 3 credits; or participate in all aspects of the class while additionally applying lessons to a service learning project with a community partner, earning 4 credits. Participants have the ability to add up to 2 more credits, totaling no more than 6, for additional work with the community partner pending special permission from the course instructor.
Lectures will be held twice a week between September 18th and December 9th of 2015. Friday lectures will be on campus from 4:05 pm to 7:05 pm, followed by Saturday morning field trips between 10:00 am and 1:00 pm for those students who elected for 3 credits or more. The course required textbook, Bioenergy: Biomass to Biofuels, was edited by Anju Dahiya less than a year ago and represents a compilation of work from an extensive list of well-respected university extension programs, such as The University of Vermont Research Extension, as well as numerous national organizations including the US Department of Energy’s National Renewable Energy Laboratories.
20 Apr 2015
The State of Vermont 2011 Comprehensive Energy Plan calls for 90% of Vermont energy needs to be met through efficiency and renewable sources by 2050. As Vermont residents witness continued high numbers in clean energy jobs, and advanced renewable energy legislation they will also need to take responsibility for Vermont to meet these goals, as every Vermonter will need to contribute in some way for Vermont to meet this ambitious goal. Enter Brighter Vermont, an action oriented program of the Energy Action Network, to help everyday Vermonters rethink where their energy comes from, how they use it in their daily lives, and what they can do to help the state reach its 90% by 2050 goal.
The Brighter Vermont website is packed with testimonials and videos shared by individuals who describe the financial decisions they are making to positively affect the environment, Vermont’s economy, and their wallets. A family in Rutland reports on small home improvement they have made to keep out the Northeast cold out and share a video about lowering energy costs, with the help of Green Mountain Power, by properly weatherizing their home, changing to energy efficient LED bulbs, electing for a heat pump, and adding solar panels. The overall transition has made them a more energy conscious family and was achievable with a ten year loan the family is pleased to see being offset by reduction in energy costs.
A family in Burlington’s journey towards reducing their carbon footprint is documented in a fun testimonial video where the family picks out their first electric vehicle. They were able to replace one of their family vehicles with a zero emission Nissan Leaf (hyperlink to video) that was available with an affordable two year lease. The switch from a classic Vermont staple vehicle, a Subaru, to the Leaf, has helped the family not only save money at the gas pump, but the, as the family reports, electricity used to charge the vehicle comes from renewable energy. They enjoy educating their friends and neighbors about this carbon footprint transition.
Brighter Vermont also hosts ways for businesses, schools, and towns to become more efficient and promote renewables in their community. Methods for how schools and businesses have become more efficient by transitioning to modern wood heating. A featured video produced by VEIC (hyperlink) features 54 schools from across Vermont currently heating with wood chips and pellets which provides heat for nearly one third of k-12 students across Vermont. Our own Vermont Bioenergy Initiative Vermont on-farm energy videos are also featured for farmers to learn more about the emerging areas of oilseed, grass, and algae biofuel.
There is much that needs to be done in the fight against climate change and moving Vermont away from its reliance on fossil fuels. While this road can be daunting, it is important to remember that we can all make small changes that will benefit us, our community, and our state. And the Brighter Vermont website provides a fun and interactive platform for individuals, families, businesses, and institutions to learn how to contribute and share these efforts with others so Vermont can take steps towards meeting our renewable energy goals for our future.
2014 was a busy year for the Vermont Bioenergy Initiative as we engaged in national outreach efforts to share our work connecting diversified agriculture and local renewable energy production for on-farm and community use in ways that be applicable to rural areas around the country. These rural areas are often at “the end of the pipeline” and are subject to higher and more volatile costs for energy. The Vermont Bioenergy Initiative “local production for local use” model shows that rural communities can produce some of their own energy, thereby improving their energy security and benefitting from more predictable and affordable energy prices. Any farm in any part of the country can grow and process their own fuel, using the best practices developed by the collaborating farms and UVM Extension researchers working in partnership with the Vermont Bioenergy Initiative. Funding for our program work to support research, technical assistance, and infrastructure development in emerging areas of bioenergy was secured by US Senator Patrick Leahy and the US Department of Energy.
Recent news we distributed to local, regional, and national audiences includes:
Visit the Green Energy Times website for our ongoing column, Emerging Frontiers in Bioenergy and follow the Vermont Bionenergy on Twitter for current news, trends, and tweets on renewable energy in Vermont and beyond.
02 Feb 2015
The Advanced Bioeconomy Leadership Conference, to be held on March 11th through the 13th in Washington D.C. serves as a great opportunity to for companies and individuals in the field of biofuels and bioenergy to educate themselves on the most recent advances in the field as well as network with some of its top experts and leaders. This event will open up with a welcome introduction from Jim Lane, Director and Editor of Biofuels Digest and the event’s momentum only promises to build from there. Among other big industry names in appearance, leaders from organizations such as the National Biodesiel Board, American Council on Renewable Energy, U.S. Department of Energy, U.S. Department of Agriculture, the Algae Biomass Organization, and even the U.S. Navy will be speaking and presenting on a variety of policies, advances, and outlooks pertaining to their respective niches.
This conference offers the rare opportunity to receive first hand updates and future outlooks of U.S. bioenergy policies from those who can report best; both Jonathan Male, Director of the U.S. DOE Bioenergy Technologies Office and Harry Baumes, Director of USDA Energy Policy will be speaking on the subjects during the Thursday session of the conference. In addition, conference goers can expect the most up to date reports on current best practices and trends in the field during the ABLC Finance Summit from big investors such as Citiroup and the sessions such as “Due Diligence” in which experts David Dodds of Dodds & Associates and Ron Cascone of NEXANT look at new and emerging companies and technologies.
In addition to conventional biofuel operations and programs, the conference will feature some more advanced military and aviation biofuel related sessions with an appearance by the U.S. Navy’s operational energy director, Chris Tindal. These sessions are organized in partnership with the Commercial Aviation Alternative Fuels Initiative (CAAFI). Altogether, this conference is a great opportunity that can’t be missed for those working with bioenergy of all feedstocks and uses. A complete list of conference sponsors, speakers and events as well as information for registration and lodging can be found on the ABLC website.
Bioenergy: Biomass to Biofuels; is an innovative new textbook that provides insight into the potential and current advances and benefits of biofuel. Contributions include an extensive list of well-respected university extension programs, such as The University of Vermont Research Extension, as well as numerous national organizations including the US Department of Energy’s National Renewable Energy Laboratories. The text is edited by Anju Dahiya, cofounder of General Systems Research, LLC and lead biofuels instructor at the University of Vermont’s Rubenstein School of Environment and Natural Resources, both of which stand as leaders in cutting-edge topics such as microbial fuels and biogas. The chapters of the book are divided into solid, liquid and gaseous biofuels, and further explore cost-effective production as well as discussions covering economics, environment and policy.
Organized into seven accessible sections, Bioenergy: Biomass to Biofuels begins with an in-depth overview of the transformation of biomass into biofuels. Once the basics are covered, readers move on to the technical applications of solid feedstocks, such as wood and grass, and their transformation into biofuels. The following section discusses biomass to liquid biofuels—text focuses on oilseeds, cellulose ethanol, and algae as feedstocks. Anaerobic digestion is explored in a section outlining gaseous fuels and bioelectricity and focuses primarily on livestock manure feedstocks. Throughout the chapters, the tradeoffs and benefits of these different feedstocks are outlined through deeper analysis.
Multiple chapters focus in detail on conversion pathways for cost effective biofuel production. The myriad of topics include basic biodiesel production efficiency, converting petroleum-based infrastructure into biorefineries, reducing enzyme cost through varying combinations, and sustainable aviation biofuels. The text concludes with a robust section that connects biofuels to a big picture perspective—economics, sustainability, environmental implications, and policy are examined closely in relation to renewable resources, future uncertainties, and entrepreneurship.
Bioenergy: Biomass to Biofuels is structured to meet the needs of professionals finding their way in the field, students in need of an introduction, and instructors establishing a course on biofuels. Case studies on provided topics are found at the end of every section and are based on documented implementation projects. Bioenergy: Biomass to Biofuels is available for purchase on the Elsevier publisher website. Editor Anju Dahiya, owner of General Systems Research in Burlington, Vermont and is a Vermont Bioenergy Initiative grant recipient to advance research and applications of converting algae into biofuel.