Emerson Helps Range Fuels Turn Wood Waste Into Gasoline for Your Car 

Imagine filling up your car with a fuel blend made from renewable biomass such as wood waste.  Emerson technology is helping Range Fuels, a  leader in the alternative fuels industry based in Broomfield, Colorado, become the first commercial-scale producer in the United States of fuels from renewable, non-food biomass. This kind of biofuel offers a promising, eco-friendly, alternative energy source that can help reduce our world’s dependence on non-renewable fossil fuels.

Since 2006, Range Fuels has been studying and testing its innovative and proprietary two-step thermo-chemical process, that uses heat, pressure, and steam to convert biomass (plant and plant-derived material, such as wood, grasses, and corn stalks) into synthesis gas, or syngas. This syngas is then transformed into ethanol suitable for blending with gasoline to fuel vehicles. 

Getting from the demonstration plant to a commercial-scale plant is no easy task.  Biofuels processes, by their nature, are highly complex. Range Fuels has built and operated bench-scale and pilot plants in Colorado over a two-year period to test its processes, technologies, and overall operations. Emerson process technology and expertise have played a major role in Range Fuels’ ability to demonstrate the viability of its new technique to produce biofuels as an alternative energy source on a commercial scale.

It's Never Been Done Before.  Range Fuels is currently building its first commercial-scale cellulosic ethanol plant. Located in Soperton, Georgia, this plant will use wood waste from nearby timber operations. When completed and operating at full-scale, the Soperton plant will be able to produce more than 100 million gallons of ethanol and methanol each year.

Range Fuels found that Emerson’s track record of proven “smart plant” technologies and its global reputation for helping companies manage some of the most complex process manufacturing systems in the world made Emerson the logical choice as its automation partner.

Emerson designed and engineered the process control systems (including field measurement devices, control valves, and extensive safety systems) at Range Fuels’ pilot plant in Colorado and at its new Soperton plant. Emerson also helped Range Fuels conduct risk assessments and establish the process control standards for consistent applications in all future plants. 

Using Emerson’s process control technology, Range Fuels has successfully demonstrated to its government partners and financial backers the commercial viability of its technology. Range Fuels was able to collect data from Emerson’s process control and safety systems installed in its pilot plant to demonstrate the company has achieved production goals, lowered risks, ensured safety, and met strict regulatory and safety criteria set by the U.S. Department of Energy and the U.S. Department of Agriculture.

To share real-world experiences and best practices, Emerson is hosting a series of regional alternative fuels summits in 2009 with industry, academic, and government leaders to address key factors and recommendations necessary for successfully translating alternative fuels technology into large-scale commercial production.

Additional information:

Emerson Process Management
Emerson’s energy responsible automation solutions
Range Fuels
Bringing Alternative Fuel Technology into Large-Scale Production (TriplePundit.com blog, December 8, 2008)
Obama administration bets big on biofuels (Wired.com)