Algenol Integrated Biorefinery for Producing Ethanol from Hybrid Algae

254 Pages·2010·6.02 MB·English

ALGENOL INTEGRATED BIOREFINERY FOR
PRODUCING ETHANOL FROM HYBRID ALGAE
Freeport, Texas
Fort Myers, Florida

Final Environmental Assessment

DOE/EA-1786

U.S. Department of Energy
Energy Efficiency and Renewable Energy

December 2010
ALGENOL INTEGRATED BIOREFINERY FOR PRODUCING ETHANOL FROM HYBRID ALGAE
FINAL EA

INTENTIONALLY LEFT BLANK
ALGENOL INTEGRATED BIOREFINERY FOR PRODUCING ETHANOL FROM HYBRID ALGAE
FINAL EA
Table of Contents
1.0  INTRODUCTION AND PURPOSE AND NEED ....................................................................................... 1 
1.1  PURPOSE AND NEED ...................................................................................................................................... 2 
1.2  NATIONAL ENVIRONMENTAL POLICY ACT AND RELATED PROCEDURES ...................................................... 3 
1.3  PUBLIC INVOLVEMENT .................................................................................................................................. 3 
1.4  REPORT CONTENT ......................................................................................................................................... 5 
2.0  PROPOSED ACTION AND NO ACTION ALTERNATIVES .................................................................. 8 
2.1  INTRODUCTION ............................................................................................................................................. 8 
2.2  PROPOSED ACTION ....................................................................................................................................... 8 
2.3  PROJECT BACKGROUND ................................................................................................................................ 8 
2.4  PROJECT TECHNOLOGY AND PROCESSES ...................................................................................................... 8 
2.4.1  Algenol’s Hybrid Algae ........................................................................................................................... 8 
2.4.2  Direct to Ethanol ® Process .................................................................................................................. 10 
2.4.3  Upstream and Downstream Processes .................................................................................................. 11 
2.4.4  Supervisory Control and Data Acquisition System ................................................................................ 13 
2.5  DESCRIPTION OF ALGENOL’S SITE OPTIONS AND PROPOSED FACILITIES .................................................... 13 
2.5.1  Algenol’s Site Options ........................................................................................................................... 13 
2.5.1.1  Freeport, Texas ............................................................................................................................................. 14 
2.5.1.2  Fort Myers, Florida ....................................................................................................................................... 17 
2.5.2  Facility Description ............................................................................................................................... 20 
2.6  CONSTRUCTION .......................................................................................................................................... 24 
2.7  OPERATION ................................................................................................................................................. 24 
2.7.1  Feedstock and Materials Required ........................................................................................................ 26 
2.7.2  Products and Waste Generated ............................................................................................................. 28 
2.7.3  Stormwater Management ....................................................................................................................... 28 
2.7.4  Environmental Health and Safety .......................................................................................................... 29 
2.7.5  Decommissioning ................................................................................................................................... 29 
2.7.6  Permits, Regulations, and Applicant-Committed Measures .................................................................. 30 
2.8  NO ACTION ALTERNATIVE .......................................................................................................................... 37 
3.0  EXISTING CONDITIONS AND ENVIRONMENTAL CONSEQUENCES ......................................... 39 
3.1  LAND USE ................................................................................................................................................... 39 
3.1.1  Existing Conditions ................................................................................................................................ 39 
3.1.1.1  Texas Site ...................................................................................................................................................... 39 
3.1.1.2  Florida Site .................................................................................................................................................... 39 
3.1.2  Environmental Consequences of the Proposed Action .......................................................................... 40 
3.1.2.1  Common Impacts .......................................................................................................................................... 40 
3.1.2.2  Texas Site ...................................................................................................................................................... 40 
3.1.2.3  Florida Site .................................................................................................................................................... 40 
3.1.3  Environmental Consequences of the No Action Alternative .................................................................. 40 
3.2  VISUAL RESOURCES .................................................................................................................................... 41 
3.2.1  Existing Conditions ................................................................................................................................ 41 
3.2.1.1  Texas Site ...................................................................................................................................................... 41 
3.2.1.2  Florida Site .................................................................................................................................................... 41 
3.2.2  Environmental Consequences of the Proposed Action .......................................................................... 41 
3.2.2.1  Common Impacts .......................................................................................................................................... 41 
3.2.2.2  Texas Site ...................................................................................................................................................... 42 
3.2.2.3  Florida Site .................................................................................................................................................... 42 
3.2.3  Environmental Consequences of the No Action Alternative .................................................................. 42 
3.3  CULTURAL RESOURCES .............................................................................................................................. 42 
3.3.1  Existing Conditions ................................................................................................................................ 43 
3.3.1.1  Texas Site ...................................................................................................................................................... 43 
3.3.1.2  Florida Site .................................................................................................................................................... 43 
3.3.2  Environmental Consequences of the Proposed Action .......................................................................... 44 
3.3.2.1  Common Impacts .......................................................................................................................................... 44 
DOE/EA-1786
III
ALGENOL INTEGRATED BIOREFINERY FOR PRODUCING ETHANOL FROM HYBRID ALGAE
FINAL EA
3.3.2.2  Texas Site ...................................................................................................................................................... 44 
3.3.2.3  Florida Site .................................................................................................................................................... 44 
3.3.3  Environmental Consequences of the No Action Alternative .................................................................. 44 
3.4  AIR QUALITY .............................................................................................................................................. 45 
3.4.1  Existing Conditions ................................................................................................................................ 45 
3.4.1.1  Texas Site ...................................................................................................................................................... 47 
3.4.1.2  Florida Site .................................................................................................................................................... 48 
3.4.2  Environmental Consequences of the Proposed Action .......................................................................... 49 
3.4.2.1  Common Impacts .......................................................................................................................................... 49 
3.4.2.2  Texas Site ...................................................................................................................................................... 50 
3.4.2.3  Florida Site .................................................................................................................................................... 50 
3.4.3  Environmental Consequences of the No Action Alternative .................................................................. 50 
3.5  GEOLOGY AND SOILS .................................................................................................................................. 51 
3.5.1  Existing Conditions ................................................................................................................................ 51 
3.5.1.1  Texas Site ...................................................................................................................................................... 51 
3.5.1.2  Florida Site .................................................................................................................................................... 52 
3.5.2  Environmental Consequences of the Proposed Action .......................................................................... 54 
3.5.2.1  Common Impacts .......................................................................................................................................... 54 
3.5.2.2  Texas Site ...................................................................................................................................................... 54 
3.5.2.3  Florida Site .................................................................................................................................................... 54 
3.5.3  Environmental Consequences of the No Action Alternative .................................................................. 55 
3.6  GROUNDWATER .......................................................................................................................................... 55 
3.6.1  Existing Conditions ................................................................................................................................ 55 
3.6.1.1  Texas Site ...................................................................................................................................................... 55 
3.6.1.2  Florida Site .................................................................................................................................................... 56 
3.6.2  Environmental Consequences of the Proposed Action .......................................................................... 56 
3.6.2.1  Common Impacts .......................................................................................................................................... 56 
3.6.2.2  Texas Site ...................................................................................................................................................... 57 
3.6.2.3  Florida Site .................................................................................................................................................... 57 
3.6.3  Environmental Consequences of the No Action Alternative .................................................................. 60 
3.7  SURFACE WATER ........................................................................................................................................ 60 
3.7.1  Existing Conditions ................................................................................................................................ 60 
3.7.1.1  Texas Site ...................................................................................................................................................... 60 
3.7.1.2  Florida Site .................................................................................................................................................... 60 
3.7.2  Environmental Consequences of the Proposed Action .......................................................................... 61 
3.7.2.1  Common Impacts .......................................................................................................................................... 61 
3.7.2.2  Texas Site ...................................................................................................................................................... 62 
3.7.2.3  Florida Site .................................................................................................................................................... 62 
3.7.3  Environmental Consequences of the No Action Alternative .................................................................. 63 
3.8  FLOODPLAINS AND WETLANDS ................................................................................................................... 63 
3.8.1  Existing Conditions ................................................................................................................................ 64 
3.8.1.1  Texas Site ...................................................................................................................................................... 64 
3.8.1.2  Florida Site .................................................................................................................................................... 65 
3.8.2  Environmental Consequences of the Proposed Action .......................................................................... 66 
3.8.2.1  Texas Site ...................................................................................................................................................... 66 
3.8.2.2  Florida Site .................................................................................................................................................... 67 
3.8.3  Environmental Consequences of the No Action Alternative .................................................................. 67 
3.9  BIOLOGICAL RESOURCES ............................................................................................................................ 67 
3.9.1  Existing Conditions ................................................................................................................................ 67 
3.9.1.1  Texas Site ...................................................................................................................................................... 67 
3.9.1.2  Florida Site .................................................................................................................................................... 69 
3.9.2  Environmental Consequences of the Proposed Action .......................................................................... 72 
3.9.2.1  Common Impacts .......................................................................................................................................... 72 
3.9.2.2  Texas Site ...................................................................................................................................................... 72 
3.9.2.3  Florida Site .................................................................................................................................................... 75 
3.9.3  Environmental Consequences of the No Action Alternative .................................................................. 75 
3.10  WASTE MANAGEMENT AND HAZARDOUS MATERIALS ............................................................................... 75 
3.10.1  Existing Conditions ........................................................................................................................... 75 
3.10.1.1  Texas Site ...................................................................................................................................................... 75 
DOE/EA-1786
IV
ALGENOL INTEGRATED BIOREFINERY FOR PRODUCING ETHANOL FROM HYBRID ALGAE
FINAL EA
3.10.1.2  Florida Site .................................................................................................................................................... 76 
3.10.2  Environmental Consequences of the Proposed Action ...................................................................... 76 
3.10.2.1  Common Impacts .......................................................................................................................................... 76 
3.10.2.2  Texas Site ...................................................................................................................................................... 77 
3.10.2.3  Florida Site .................................................................................................................................................... 78 
3.10.3  Environmental Consequences of the No Action Alternative .............................................................. 78 
3.11  UTILITIES .................................................................................................................................................... 78 
3.11.1  Existing Conditions ........................................................................................................................... 78 
3.11.1.1  Texas Site ...................................................................................................................................................... 78 
3.11.1.2  Florida Site .................................................................................................................................................... 79 
3.11.2  Environmental Consequences of the Proposed Action ...................................................................... 79 
3.11.2.1  Common Impacts .......................................................................................................................................... 79 
3.11.2.2  Texas Site ...................................................................................................................................................... 80 
3.11.2.3  Florida Site .................................................................................................................................................... 80 
3.11.3  Environmental Consequences of the No Action Alternative .............................................................. 81 
3.12  TRANSPORTATION AND TRAFFIC ................................................................................................................. 81 
3.12.1  Existing Conditions ........................................................................................................................... 81 
3.12.1.1  Texas Site ...................................................................................................................................................... 81 
3.12.1.2  Florida Site .................................................................................................................................................... 82 
3.12.2  Environmental Consequences of the Proposed Action ...................................................................... 83 
3.12.2.1  Common Impacts .......................................................................................................................................... 83 
3.12.2.2  Texas Site ...................................................................................................................................................... 84 
3.12.2.3  Florida Site .................................................................................................................................................... 84 
3.12.3  Environmental Consequences of the No Action Alternative .............................................................. 84 
3.13  PUBLIC HEALTH AND SAFETY ..................................................................................................................... 85 
3.13.1  Existing Conditions ........................................................................................................................... 85 
3.13.1.1  Texas Site ...................................................................................................................................................... 85 
3.13.1.2  Florida Site .................................................................................................................................................... 86 
3.13.2  Environmental Consequences of the Proposed Action ...................................................................... 86 
3.13.2.1  Common Impacts .......................................................................................................................................... 86 
3.13.2.2  Texas Site ...................................................................................................................................................... 88 
3.13.2.3  Florida Site .................................................................................................................................................... 89 
3.13.3  Environmental Consequences of the No Action Alternative .............................................................. 89 
3.14  SOCIOECONOMICS AND ENVIRONMENTAL JUSTICE ..................................................................................... 90 
3.14.1  Existing Conditions ........................................................................................................................... 90 
3.14.1.1  Texas Site ...................................................................................................................................................... 90 
3.14.1.2  Florida Site .................................................................................................................................................... 92 
3.14.2  Environmental Consequences of the Proposed Action ...................................................................... 94 
3.14.2.1  Common Impacts .......................................................................................................................................... 94 
3.14.2.2  Texas Site ...................................................................................................................................................... 95 
3.14.2.3  Florida Site .................................................................................................................................................... 95 
3.14.3  Environmental Consequences of the No Action Alternative .............................................................. 95 
4.0  CUMULATIVE IMPACTS OF THE PROPOSED ACTION .................................................................. 96 
4.1  EXISTING AND REASONABLY FORESEEABLE PROJECTS .............................................................................. 96 
4.2  ENVIRONMENTAL CONSEQUENCES ............................................................................................................. 97 
4.2.1  Land Use ................................................................................................................................................ 97 
4.2.2  Visual Resources .................................................................................................................................... 97 
4.2.3  Cultural Resources ................................................................................................................................ 98 
4.2.4  Air Quality ............................................................................................................................................. 98 
4.2.5  Geology and Soils .................................................................................................................................. 99 
4.2.6  Groundwater ........................................................................................................................................ 100 
4.2.7  Surface Water ...................................................................................................................................... 101 
4.2.8  Floodplains and Wetlands ................................................................................................................... 101 
4.2.9  Biological Resources ........................................................................................................................... 101 
4.2.10  Waste Management and Hazardous Materials ................................................................................ 102 
4.2.11  Infrastructure .................................................................................................................................. 103 
4.2.12  Transportation and Traffic .............................................................................................................. 103 
DOE/EA-1786
V
ALGENOL INTEGRATED BIOREFINERY FOR PRODUCING ETHANOL FROM HYBRID ALGAE
FINAL EA
4.2.13  Public Health and Safety ................................................................................................................. 103 
4.2.14  Socioeconomics and Environmental Justice .................................................................................... 104 
5.0  SHORT-TERM USES VERSUS LONG-TERM PRODUCTIVITY; IRREVERSIBLE AND
IRRETRIEVABLE COMMITMENTS; AND UNAVOIDABLE ADVERSE IMPACTS ................................ 106 
5.1  THE RELATIONSHIP BETWEEN LOCAL SHORT-TERM USES OF THE ENVIRONMENT AND THE MAINTENANCE
AND ENHANCEMENT OF LONG-TERM PRODUCTIVITY ............................................................................................ 106 
5.2  IRREVERSIBLE AND IRRETRIEVABLE COMMITMENTS OF RESOURCES ........................................................ 107 
5.3  UNAVOIDABLE ADVERSE IMPACTS ........................................................................................................... 107 
6.0  REFERENCES ........................................................................................................................................... 108 

Appendices
Appendix A – Public Correspondence
Appendix B – DOE Consultation Letters and Responses
Appendix C – Wetlands Delineation Study (Texas Site Option)
Appendix D – Listed Species for Florida and the Threatened and Endangered Species
Review for the Texas Site Option

DOE/EA-1786
VI
ALGENOL INTEGRATED BIOREFINERY FOR PRODUCING ETHANOL FROM HYBRID ALGAE
FINAL EA
List of Figures
Figure 2-1. Ethanol from Blue-Green Algae ................................................................................................................ 9 
Figure 2-2. Direct to Ethanol® Process ...................................................................................................................... 12 
Figure 2-3. Texas Site Option (near Freeport, Texas) ................................................................................................ 14 
Figure 2-4. General Location Map of Algenol’s Site Option near Freeport, Texas .................................................... 15 
Figure 2-5. Aerial Photograph of Algenol’s Site Option near Freeport, Texas .......................................................... 16 
Figure 2-6. Florida Site Option (Fort Myers, Florida) ................................................................................................ 17 
Figure 2-7. General Location Map of Algenol’s Site Option in Fort Myers, Florida ................................................. 18 
Figure 2-8. Aerial Photograph of Algenol’s Site Option in Fort Myers, Florida ........................................................ 19 
Figure 2-9. Conceptual Site Layout of the Biorefinery for the Texas Site ................................................................. 22 
Figure 2-10. Conceptual Site Layout of the Biorefinery for the Florida Site ............................................................. 23 
Figure 3.1. Generalized Hydrostratigraphic Column of the Florida Site .................................................................... 53 
Figure 3-2. Wetland Mapping on Texas Site .............................................................................................................. 65 
Figure 3-3. National Wetland Inventory Mapping of Florida Site .............................................................................. 66 
Figure 3-4. Annual Average Daily Traffic Volumes Near the Texas Site Option ...................................................... 82 
Figure 3-5. Annual Average Daily Traffic Volumes Near the Florida Site Option .................................................... 83 
Figure 3-6. Sound Levels of Common Noise Sources ................................................................................................ 85 

List of Tables
Table 2-1. Upstream and Downstream Processes at the Proposed Biorefinery ........................................................... 12 
Table 2-2. Feedstock, Materials, and Waste Streams ................................................................................................. 25 
Table 2-3. Permits, Regulations, and Applicant-Committed Measures ...................................................................... 31 
Table 3-1. National Ambient Air Quality Standards .................................................................................................. 45 
Table 3-2. Air Pollutant Emissions in 2002 in Brazoria County ................................................................................ 48 
Table 3-3. Florida Ambient Air Quality Standards .................................................................................................... 48 
Table 3-4. Air Pollutant Emissions in 2002 in Lee County ........................................................................................ 49 
Table 3-5. Soil Units found at the Fort Myers Project Site. ........................................................................................ 52 
Table 3-6. Federally Protected Species Potentially Occurring in Brazoria County, Texas ........................................ 68 
Table 3-7. Federally Protected Species Potentially Occurring in Lee County, Florida .............................................. 70 
Table 3-8. Typical Nominal Background Sound Levels in Residential Communities ............................................... 85 
Table 3-9. Common Equipment Sources and Measured Noise Levels at 50 feet ....................................................... 87 
Table 3-10. Comparative Population – Texas Site (1990-2008) ................................................................................. 90 
Table 3-11. Population Composition and Poverty Status – Texas Site (2000) ........................................................... 91 
Table 3-12. Housing Characteristics – Texas Site (2008) .......................................................................................... 91 
Table 3-13. Estimated Labor Force and Income Characteristics – Texas Site (2006-2008) ....................................... 92 
Table 3-14. Comparative Population – Florida Site (1990-2008) ............................................................................... 92 
Table 3-15. Population Composition and Poverty Status – Florida Site (2000) ......................................................... 93 
Table 3-16. Housing Characteristics – Florida Site (2008) ........................................................................................ 94 
Table 3-17. Estimated Labor Force and Income Characteristics – Florida Site (2006-2008) ..................................... 94 

DOE/EA-1786
VII
ALGENOL INTEGRATED BIOREFINERY FOR PRODUCING ETHANOL FROM HYBRID ALGAE
FINAL EA
INTENTIONALLY LEFT BLANK
DOE/EA-1786
VIII
ALGENOL INTEGRATED BIOREFINERY FOR PRODUCING ETHANOL FROM HYBRID ALGAE
FINAL EA
LIST OF ACRONYMS AND ABBREVIATIONS

AADT Annual Average Daily Traffic
Algenol Algenol Biofuels, Inc.
APE Area of Potential Effect
APHIS Animal and Plant Health Inspection Service
ASR aquifer storage and recovery
AWWT Advanced Wastewater Treatment
BMP best management practice
CAA Clean Air Act
CEQ Council of Environmental Quality
CESQG Conditionally Exempt Small Quantity Generator
CO carbon monoxide
CO carbon dioxide
2
CO carbon dioxide equivalent
2
CWA Clean Water Act
dBA decibels, A-weighted scale
DOE U.S. Department of Energy
Dow Dow Chemical Company
EA Environmental Assessment
EERE Energy Efficiency and Renewable Energy
EH&S Environmental, Health, and Safety
EISA Energy Independence and Security Act of 2007
EPA U.S. Environmental Protection Agency
EPAct 2005 Energy Policy Act of 2005
FDEP Florida Department of Environmental Protection
FDOT Florida Department of Transportation
FEMA Federal Emergency Management Agency
FIRM Flood Insurance Rate Map
FM Farms-to-Market
FWCC Fish and Wildlife Conservation Commission (for the state of Florida)
GHG greenhouse gas
H-GAC Houston-Galveston Area Council
LOS level of service
DOE/EA-1786
IX
ALGENOL INTEGRATED BIOREFINERY FOR PRODUCING ETHANOL FROM HYBRID ALGAE
FINAL EA
MJ megajoule
MJ megajoule ethanol
EtOH
NAAQS National Ambient Air Quality Standards
NAGPRA Native American Graves Protection and Repatriation Act of 1990
NEPA National Environmental Policy Act
NHPA National Historic Preservation Act
NO nitrogen dioxide
2
NOx nitrogen oxides
NPDES National Pollutant Discharge Elimination System
NRHP National Register of Historic Places
NRCS Natural Resource Conservation Service
NWI National Wetlands Inventory
O oxygen
2
O ozone
3
OSHA Occupational Safety and Health Administration
Pb lead
PDU Process Development Unit
PM particulate matter with an aerodynamic diameter of 10 micrometers or less
10
PM particulate matter with an aerodynamic diameter of 2.5 micrometers or less
2.5
POV privately-owned vehicle
PPA Plant Protection Act
PSD Prevention of Significant Deterioration
psig pounds per square inch gauge
RCRA Resource Conservation and Recovery Act
Recovery Act American Recovery and Reinvestment Act of 2009
R&D research and development
RIN Renewable Identification Number
SCADA Supervisory Control and Data Acquisition
SFWMD South Florida Water Management District
SH state highway
SHPO State Historical Preservation Office
SIP State Implementation Plan
SO sulfur dioxide
2
SPCC Spill Prevention, Control and Countermeasure
DOE/EA-1786
X