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Fiberight Blairstown Operating, LLC

P.O. Box 261 

Blairstown, IA 52209

October 11th 2011

PRODUCER	FACILTY	REGISTRATION – MSW	DERIVED	FEEDSTOCKS

COMPANY	INFORMATION

FIBERIGHT	OF	BLAIRSTOWN,	LLC

2154	78TH STREET

BLAIRSTOWN,	IA		52209

319-454-9937	BUSINESS	PHONE

319-454-9938	BUSINESS	FAX

CRAIG	STUART-PAUL,	CEO

RFS2

RIN	GENERATOR

RFS1	COMPANY	ID	3416

CELLULOSIC	ETHANOL	PRODUCTION	ID	70219	

1. The	types	of	renewable	fuels	that	Fiberight	intends	to	produce.

• Cellulosic	ethanol (D-3)	

• Advanced	Biofuel	(D-5)	As	compressed	biogas

• Renewable	Fuel	(D-6) (Separately	produced	from	waste	seed	corn)

Fiberight	 will	 produce	 renewable cellulosic	 ethanol	 that	 is	 produced	 from	 renewable	

biomass	as	well	as	Compressed	Natural	Gas.		This	transportation	fuel	is	suitable	for use	

in	motor	vehicles,	motor	vehicle	engines,	non-road	vehicles	and	non-road	engines	that	

are	ethanol	fuel	blend	capable or	designed	to	operate	on	CNG.	Fuels	produced	comply	

with	applicable	Federal	renewable	fuel	standards for	the	following	reasons;

• The	facility will	recover	and	recycle	over	70%	of	inbound	waste	that	would	otherwise	

be	landfilled,	as	well	as	support	Iowa’s	aggressive	50%	waste	reduction	target.

• The	 facility	 features	 as	 it’s	 initial	 processing	 step a	 fully	 functional	 recycling	 plant	

that	recovers	recyclable	materials	before	biofuel	production

• All	plastics	and	non-organic	materials	are	 removed	prior	 to	production	of	biofuels.	

Fuels	produced	can	be	tested	using	Carbon	dating	methods	to	affirm	that	the	fuel	is	
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fully	derived	from	renewable	sources.

• The	plant	will	ultimately	be	energy self-sustaining.

• Feedstock	 is	 sourced	 from	 waste	 material derived	 from	 domestic	 and	 commercial	

waste,	and	thus	no	land	is	displaced	for	supply.

• The	plant	will	recycle	virtually	all	process	water with	the	exception	being	an	effluent	

stream	from	the	Reverse	Osmosis	system.

• The	facility will	contribute	to	the	objectives	of	Iowa’s	Solid	Waste	management	plan	

by	recycling	and	re-using	MSW

• Fiberight	employs	 a	 low-temperature	 biochemical	 approach	 to	 bio-fuel	 production	

which will	demonstrate	significant	air	quality	advantages	over	other	waste	disposal	

solutions	such	as	incineration	or	gasification.

• Fiberight	employs	a hydrolysis	and	 fermentation process designed	to	convert	MSW

derived	renewable	biomass to	cellulosic	ethanol in	a	manner	that complies	with	the	

requirements	of	applicable	Federal	Renewable	Fuel	Standards.

• Greenhouse	 gas	 emissions	 from	 the	 Fiberight	 process	 can	 be	 demonstrated	 to	 be	

reduced	 by	 80%	 or	 more	 when	 compared	 to	 fossil	 fuel	 consumption	 or	 landfill	

disposal.

2. List	all	the	feed-stocks	the	facility	is	capable	of	using	without	significant	modification	

to	the	existing	facility.

MUNICIPAL	SOLID	WASTE:		The	 facility	will	 be	 fully	 capable	 of	 using	 renewable	 biomass	 that	

originates	 from	 municipal	 solid	 waste	 (MSW),	 sourced	 from	 community	 refuse	 pick	 up,	

commercial	sources,	municipal	or	county	sorting	facilities	or	landfills.		The	renewable	biomass	is	

composed	 of	 both	 cellulosic	 and	 non-cellulosic	 materials.	 	 This	 renewable	 biomass	 is	 then	

subjected	 to	 various	 specifically	 designed	 recycling	 processes	 in	 order	 to	 separate	recyclable	

paper,	 cardboard,	 plastics,	 rubber,	 textiles,	 metals,	 and	 glass	 from the	 residual	 biomass.		

Fiberight’s	separation	methodology	separates	and	efficiently	converts	residual	cellulosic	wastes	

into	cellulosic	ethanol	thereby	reducing	GHG	emissions	when	compared	to	petroleum,	corn	or	

other	conventional	MSW	disposal	options.

COMMERCIAL	CELLULOSIC	WASTES:	 The	Fiberight	facility	will	be	fully	capable	of	accepting	

commercial	cellulosic	wastes	from	industrial	processors,	such	as	paper	mills	and	book	or	diaper	

manufacturers	that	wish	to	dispose	of	separated	fine	cellulosic	particles	otherwise	impossible	

to	recycle.		Such	materials	are	introduced	in	a	specially	designed	apparatus	to	effectively	

introduce	them	midway	into	the	cellulosic	ethanol	processing	facility.				

WASTE	SEED	CORN:	The	facility	is	currently	able	to	process	waste	seed	corn using	proprietary	

methods.	Approximately	1/5	of	the	ultimate	plant	production	will	be	derived	from	this	source.
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3. For	each	renewable	fuel,	describe	the	facilities	renewable	fuel	production	process,	

which	could	include	a	diagram	of	the	overall	process	train	and	a	description	of	each	

stage	in	the	process,	including	major	and	minor	ancillary	equipment,	process	heat	

fuel,	collection	and	treatment	of	waste	streams,	etc. (Please	note	PFD	Below)

1. Primary 

Shredder/bag 

opener 

4 Trommel 1 

5. Sorting belt !!

7. Autoclave / 

Pulper 

15. Washing 

Tunnel 

17. Fiber 

Screening 

18. Dewatering 

Screw system 

20. Mixing 

Vessel 

21. PreTreatment 

system 

22. Flash 

Vessel 

26. Digestion!!

27. Fermentation!!

30. Primary 

Stripper 

32. Distillation 

Column 

33. Mole Sieves 

34. Cellulosic Ethanol 

Output for Storage and 

load out 

 42. Solids 

Separation 

I. Wet solids to 

waste 

50. Water 

Storage 

 51.Sterilization 

70. Steam 

Boilers 

Flowsheet of Stage 1 

Fiberight MSW to 

Ethanol Process 

A. Inert Fines for 

Disposal 

C. Recycled 

Materials for 

further 

processing 

9. Trommel 2 

(same unit 1) 

Non recyclable 

MSW Feedstock 

B. Large inerts for Disposal, Recyclables 

(Paper,Plastics,Metals) for sale 

6. Sorted MSW 

storage pile !!

14. ScrewPress 40. DAF 

E . Sludge for 

Disposal 

28. Scrubber H. CO2 to 

atmosphere 

45. Gas clean 

up 

D. Flare to 

atmosphere 

10. Sorting belt 

(same unit 1) !!

41. Screen 

16. Mixing tank 

44. A.D. Plant 47. Sludge 

dewatering 

F. purge to Drain 

24. Dewatering 

Screw 

Fresh Water 

Natural Gas Feed 

Heat!to!

process! 13. blender 

Energy!

recovery!to!!

process!

8. Spray 

condenser 

11. Biomass 

storage pile !!

12. feed 

conveyor 

3. Trommel 

feed belt 

2. Feed bunker 

31. Ethanol 

solution 

storage 

46. Flare 

23. Spray 

condenser 

43. A.D. Blend 

Tanks 

25. Blender 

G. Screener 

rejects 

to seed corn 

production 

19. strainer 

Recovery of 

recyclables 
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The	following	are	the	technologies	incorporated	into	the	process:

• MSW	Sorting

• MSW	Pulping

• Biomass	Washing

• Biomass	Thermal	Treatment

• Digestion	(Enzymatic	Hydrolysis)

• Fermentation

• Seed	Culture	Propagation

• Ethanol	Distillation

• Ethanol	Dehydration

• Anaerobic	Digestion

MSW	Receiving	and	Storage:		Municipal	Solid	Waste	(MSW)	will	arrive	on-site	by	truck.		Trucks	

will	 be	 weighed	 as	 they	 enter	 the	 facility	 and	 empty	 trucks	 will	 be	 weighed as	 they	 exit.		

Weighed	 trucks	 will	 be	 directed	 the	 MSW	 receiving	 storage	 area	 where	 they	 will	 unload.		

Unloaded	MSW	will	remain	in	the	receiving	storage	area	until	used.		

MSW	 Pre-Sorting:	 	 MSW	 from	 the	 receiving	 storage	 area	 will	 be	 transferred	 by	 a	 front-end	

loader	to	a	receiving	bin.		The	receiving	bin	is	a	walking-floor	or	belt	type	storage	container	that	

continuously	transfers	MSW	forward.		MSW	from	the	receiving	bin	is	then conveyed	to	a	bagbreaker	 that continuously	 liberates	 the	 waste	 from	 bags	 and containers.	 	 MSW	 is	 then	

conveyed	 to	 a	 rotating	trommel	screen	 where	 the	 waste	 is	 separated	 into	 under-sized,	 midsized	and	over-sized	materials.		

Undersized	materials,	which	are	 too	 small	 to	 be	 properly	 processed,	are	 discharged	 from	 the	

screen	directly into	a	roll-off	container.		This	material	will	be	removed	from	the	site	and	sent	to	

the	landfill.		Other materials,	including	uncontaminated	paper	and	cardboard,	unprocessables,	

rigid	containers,	etc.	are	 transferred	 to	a	belt	conveyor	where	 they	will	be	sorted	into	one	of	

several	bunkers.		These	bunkers will	be	also	removed	from	site either	for	sale	as	recyclables	or	

disposal.	 	 Any	 large,	 but	 otherwise	 acceptable	 materials	 will	 be	 sent	 to	 a	 shredder	 and	

incorporated	into	the	feed	stream	to	process.		Acceptable	mid-sized	materials	will	be	processed	

through	a	magnet	to	remove	any	ferrous	metals.		The	middle	fraction	will	be	combined	with	the	

outlet	from	the	shredder	and	transferred	to	a	pre-sort	stockpile	until	pulping.		

MSW	 Pulping:	 	Pre-sorted	MSW	 will	 be transferred	 from	 the	 storage	 pile	 to	 the	 pulper	 feed	

conveyor	using	a	front-end	loader.		MSW	is	pulped	using	a	high	solids	pulping	(steam	autoclave)	

process	 that	 both	 destroys	 harmful	 biological	 components	 and	 converts	residual	 cellulose	 to	

usable	pulp.		The	pulping	system	is	operated	in	a	batch	mode.		A	load	of	sorted	MSW	is	fed	into	

the	 pulper	 along	 with	 recycled	 process	 water.	 	 The	 pulper	 is	 then	 heated	 and	 held	 at	 the	

required	temperature	 for	a	predetermined	amount	of	time.		This	is	to	insure	that	the	MSW	is	

sufficiently	pulped	and	that	initial	sterilization	has	occurred.		Following	completion	of	the	heat	

cycle,	the	pulped	contents	of	the	vessel are	discharged	to	a	storage	pile	to	be	next	 fed	to	the	

post-sorting	system.		
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Biomass	 Post-Sorting:	 	 The	 pulped	 material	 from	 the	 high	 solids	 pulper	 is	 transferred	 to	 a	

storage	 bin	 with	 an	 integral	 conveyor.	 	 The	 pulp	 is	 conveyed	 to	 a	 rotating	 screen	 (trommel).		

Under-size	 material,	 primarily	 cellulose	 fiber,	 is	 separated	 from	 larger	 materials	 like	 plastics,	

metals	 and	 any	 other	 un-pulped	 components,	 in	 this	 fashion	 the	 biomass	 is	 efficiently	

separated	 from	 plastics	and	 other	 non-organic	materials.		Oversized	materials	are	 discharged	

from	the	screen	and	conveyed	to	an	air	knife	where	plastic	films	are	separated.		The	oversized	

material	is	then	processed	through	a	magnet	to	remove	any	ferrous	materials	and	through	an	

eddy	 current	 separator	 to	 remove	 non-ferrous	 metals.	 	 The	 remaining	 material	 is	 then	

separated	 manually	 to	 remove	 any	 recyclables	 that may	 have	 value,	 including	 for	 example

plastics and	metals.		The	various	separated	materials,	i.e.	ferrous,	non-ferrous,	plastics,	etc.	are	

placed	 in	 separate	 containers	 that	 will	 be	 transported	 off-site	 for	 recycling.	 	 All	 remaining	

material	is	discharged	into	a	container that	will	be	sent	to	landfill.		

Biomass	 from	 the	 screen	 is conveyed to	 a	 screw	 press	 where	 it	 is rinsed	 with	 filtered	 water	

from	 the	biomass	washing	area.		Filtrate	water	 from	 the	press	is	collected	in	a	 tank	and	 then	

pumped	 to	 the	 water	 treatment	 system.	 	 Pressed	 cake	 is	 discharged	 into	 a	 storage	 bin	 that

feeds	the	biomass	washing	area.	

Biomass	Washing:		Biomass	pulp	cake	is	conveyed	to	a	mixing	screw	where	it	is	blended	with	

hot,	 filtered	 water	 from	 the	 outlet	 of	 the	 washing	 process.	 	 The	 pulp	 slurry	 is	 fed	 into	 a	

proprietary	washing	process	where	soluble	and	insoluble	(ash)	impurities	are	removed	from	the	

biomass	pulp.		Water	containing	the	impurities	is	collected,	combined	with	the	recovered	solids	

from	 the	 washing	 screen	 water	 and	 filtered	 to	 a	 dissolved	 air	 flotation	 (DAF)	 system	 that

concentrates	the	insoluble	solids	into	sludge.		Sludge	from	the	DAF	system	is	pressed	in	a	filter	

press	 and	 the	 cake	 is	 collected	 for	 disposal.	 	 Liquid	 from	 the	 filter	 press	 is	 recycled	 to	 the	

autoclave	and	 the	post-sort	screw	press.		Clean	liquid	 from	 the	DAF	is	 recovered,	heated	and	

reused	in	the	washing	process.		

Industrial	solid	wastes will	be	received	by	truck	and	discharged	into	a	storage	bin	with	integral	

conveyor.	 	 Industrial	 biomass	 waste will	 be	 mixed	 with	 filtered	 process	 water	 from	 the	

discharge	 of	 the	 biomass	 washing	 system.	 	Washed	biomass	pulp	 received	 from	 the	 washing	

step	will	be	combined	with	the	industrial	biomass waste	slurry	in	the	mixing	screw.		The	mixing	

screw	 discharges	 into	a	 screen	which	 separates	 larger	 fiber	and	 non-fiber	materials	 from	 the	

mixed	slurry.		The	rejects	are	collected	for	disposal.		

The	fiber	slurry	is	collected	in	a	tank	and	then	processed	through	a	series	of	hydro-cyclones	to	

remove	grit	and	other	smaller	entrained	solids.		Grit	from	the	first	hydro-cyclone	is	discharged	

for	 disposal.	 	 Remaining	 “heavies”	 removed	 in	 the	 hydro-cyclones	 are	 recycled	 to	 the	 DAF	

system	 for	 separation.		 Lighter	 solids	 (fiber)	and	water	are	 collected	and	 then	 fed	 to	 side-hill	

screens	to	remove	excess	water	and	concentrate	the	solids.		The	concentrated	solids	are	then	

sent	 to	a	 screw	 press	 to	 remove	excess	water	 from	 the	 fiber.		Filtered	water	 from	 the	 screw	

press	and	screens	is	collected,	heated	and	recycled	to	the	washing	mixer,	the	screening	mixer	

and	the	industrial	cellulose	mix	tank.			
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Biomass	 Thermal	 Pretreatment:	 	 Washed	 biomass	 pulp	 from	 the	 prewashed	 and	 screened	

storage	 area	 is	 fed	 to	 a	 mixer	 using	 conveyors.	 	 In	 the	 mixer,	 the	 pulp	 is	 diluted	 using	 hot	

process	 water.	 	 The	 diluted	 pulp	 is	 then thermally	 treated	 in	 a	 high-pressure	 reaction	 vessel	

using	 steam.	 	 Reaction	 time	 and	 conditions	 are	 precisely	 controlled	 to	 insure	 that	 product	

properties	 are	 within	 a	 specific	 range.	 	 Following	 the	 required	 reaction	 time,	 the	 pressure	

within	the	reactor	is	released	and	the	solids	are	separated	from	steam	in	a	flash	vessel.		Steam	

from	the	flash	vessel	is	condensed	and	collected	for	reuse	or	treatment	in	the	water	treatment	

system.		Additional	pre-treatment	by	refining	may	occur.

Digestion:		Reacted	solid	biomass	pulp	is	treated	to	the	required	pH	and	adjusted	to	particular	

conditions	 as	 it	 is	 introduced	 to	 the	 primary	 digestion	 vessel.	 	 In	 the	 digestion	 vessel,	 the	

cellulose	is	partially	hydrolyzed	into	monomeric	and	oligomeric	sugars.		Enzymes	are	added	to	

most	efficiently	achieve	hydrolysis	in	the	required	time.		

Fermentation:		Following	completion	of	the	 first	stage	of	digestion,	partially	hydrolyzed	solids	

are	 transferred	 to	 one	 of	 several	 vessels	 where	 they	 are	 heated	 and	 treated	 to	 specific	

operating conditions	 necessary	 for	 optimum hydrolysis	 and	 fermentation	 using	 yeast	 or	 a	

proprietary microorganism.		In	the	fermentation	process,	the	produced	sugars	are	converted	to	

ethanol.		Ethanol,	water	and	any	unconverted	solids	remaining	at	the	end	of	this	step	are	sent	

to	a	temporary	storage	tank	prior	to	being	processed	in	the	distillation	process.		

Fermentation	off-gas,	primarily	carbon	dioxide,	is	vented	from	the	fermentation	vessels	and	is	

treated	by	a	scrubber	system.		The	scrubber	system	removes	a	majority	of	the	volatile	organic	

compounds	 (VOC),	 predominantly	 ethanol,	 from	 the	 off-gas	 before	 it	 is	 vented	 to	 the	

atmosphere.	 	 Liquid	 containing	 the	 organic	 compounds	 is	 collected	 in	 the	 bottom	 of	 the	

scrubber	and	returned	to	the	process	for	recovery.		

Seed	Culture	Propagation:		The	seed	culture	propagation	system	consists	of	a	series	of	vessels	

designed	to	produce	increasing	levels	of	inoculums	to	be	used	in	the	fermentation	system.		Dry	

lab	 medium	 is	 charged	 to	 a	 mixing	 vessel	 and	 diluted	 using	 hot	 process	 water.	 	 The	 liquid	

medium	 is	 then	 charged	 to	 the	 smallest	 of	 the	 culture	 growth	 vessels.	 	 The proprietary

fermentive microorganism	is	 first	grown	in	small	laboratory	vessels	until	sufficient	cell	mass	is	

developed.	 	 The	 laboratory	 culture	 is	 then	 charged to	 the	 first	 culture	 growth	 vessel	 and	

allowed	to	propagate.		Once	the	required	time	and	culture	growth	are	achieved,	the	contents	

of	 the	 first	 culture	growth	vessel	are	 transferred	 to	 the	 second	 culture	growth	vessel.		These	

vessels	 are	 maintained	 at	 the required	 temperature	 using	 steam	 or	 cooling	 water	 that	 is	

circulated	through	external	jackets.		

Hydrolysate	 slurry	 from	 the	 digestion	 step	 is	 charged	 to	 two,	 larger	 culture	 growth	 vessels.		

Following	 the	completion	of	propagation	in	 the	smaller	vessels,	culture	medium	is	charged	 to	

one	 of	 the	 larger	 growth	 vessels	 and	 allowed	 to	 propagate.	 	 Once	 the	 required	 cell	 mass	 is	

achieved,	the	contents	are	again	transferred	to	the	final	growth	vessel	and	the	process	repeats.		

At	 the	 completion	 of	 the	 culture	 growth	 process,	 the	 contents	 of	 the	 final	 growth	 vessel	are	

transferred	to	the	fermentation	system.		The	larger	growth	vessels	are	equipped	with	external	

heat	exchangers	and	pumps	to	regulate	vessel	temperature.		
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Distillation	 &	 Dehydration:	 	 The	 ethanol	 mixture	 (beer)	 from	 the	 fermentation	 system	 is	

separated	 from	 the	 water	 and	 solids	 in	 the	 distillation	 system.	 	 The	 beer	 enters	 the	 first	

distillation	column	where	solids	and	a	portion	of	the	water	are	removed.		The	solids	and	excess	

water	(termed	stillage)	flow to	the	bottom	of	the	distillation	column	and	are	sent	to	the	stillage	

storage	tank	for	further	processing.		Ethanol	and	water	vapor	from	the	top	the	first	column	are	

condensed	in	a	series	of	heat	exchangers	and	collected	in	a	tank	before	being	fed	to	the	second	

distillation	column.		In	the	second	column,	the	ethanol	vapor	is	concentrated	as	it	rises	through	

the	column	eventually	reaching	the	isotropic	point	(95.5	%	v/v)	as	it	exits	the	top	of	the	column.			

A	portion	of	the	column	overheads	are	condensed	and	returned	to	the	column	as	reflux.		The	

remaining	part	of	the	concentrated	ethanol	is	then	fed	to	a	dehydration	system.		Liquid	water	is	

removed	from	the	bottom	of	the	column	and	recovered	for	reuse.		

The	 final	 removal	 of	water	 to	 produce	 fuel	grade	ethanol	is	achieved	in	a	 two-bed	molecular	

sieve	dehydration	system.		Water	is	absorbed	on	 the	sieve	bed	material	while	ethanol	passes	

through	the	bed.		The	dehydration	system	uses	a	pressure	swing	process	that	requires	virtually	

no	external	heat.		Each	of	the sieve	bed	cycles	between	adsorption	and	regeneration	modes	to	

maintain	 maximum	 water	 removal	 capacity.	 	 Adsorption	 takes	 place	 under	 positive	 pressure	

while	 regeneration	is	accomplished	 under	vacuum.		The	adsorbed	water	is	 removed	 during	a	

regeneration	step	and	is	routed	back	to	the	distillation	system.

Water	 Treatment	 and	 Recovered	 Water:	 	 The	 solids	 within	 the	 stillage	 from	 distillation	 are	

separated	using	a	decanting	centrifuge.		The	liquid	stream,	or	thin	stillage,	is	sent	to	the	water	

treatment	 system.	 	 The	 remaining	 stillage	 solids	 are	 a	 byproduct	 of	 the	 process	 that can	 be	

used	in	multiple	pulp	products.

Purge	water	from	the	pulp	washing	and	screening	system	and	the	distillation	system	are	sent	to	

the	 spent	 water	 tank.	 	 The	 spent	 water	 is	 cooled	 and	sent	 to	 an	 anaerobic	 digestion	 (AD)	

system.		This	system	uses	microorganisms	to	digest	suspended	and	dissolved	solids	in	the	water	

and	 produces	 methane	 rich	 biogas	 and	 reduces	 the	 chemical	 oxygen	 demand	 (COD)	 of	 the	

water.		The	use	of	a	reverse	osmosis	(RO)	system	will	be	used	to	produce	a	clean	water	stream	

that	can	be	reused	in	the	process.		The	biogas	produced	by	AD	will	be	used	as	a	supplementary	

fuel	 for	 the	 bio-refinery	 boilers,	 compressed	 for	 vehicle	 fuel or	 used	 for	 power	 generation

depending	on	prevailing	market	factors.

Clean-in-Place:		A	portion	of	the	recovered	water	will	be	sent	to	the	Clean-in-Place	(CIP)	storage	

tank.	 	 In	 this	 tank,	 sodium	 hydroxide	 (caustic)	 is	 added	 to	 the	 water	 to	 produce	 a	 cleaning	

solution	 for	 use	 throughout	 the	 process.	 The	 CIP	 solution	 is	 circulated	 to	 tanks,	 heat	

exchangers	and	other	equipment	to	remove	any	accumulated	solids	and	to	sterilize	equipment	

to	prevent	the	growth	of	bacteria.		Cleaning	frequency	varies	based	on	the	type	of	equipment	

and	monitoring	of	plant	performance.

Ethanol	Storage	&	Load	Out:		Fuel	ethanol	is	pumped	to	one	of	two	shift	tanks,	each	sized	for	

24	 hours	 of	 production	 at	 design	 rate.	 	 The	 production	 rate	 of	 the	 ethanol	 from	 the	

distillation/dehydration	 system	 will	 be	 monitored	 with	 in-line	 instruments,	 while	 moisture	

content	will	be	monitored	with	laboratory	equipment	from	regularly	scheduled	samples.		After	
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the	quality	of	the	ethanol	is	confirmed,	it	is	transferred	to	a	product	storage	tank.		A	blending	

system	will	be	used	to	combine	gasoline	denaturant	with	ethanol,	producing	the	final	product	

which	is	transferred	to	the	product	storage	tank	while	awaiting	shipment.		Gasoline	denaturant	

has	a	separate	storage	tank	on-site.

4. List	the	types	of	co-products	produced.		Ie.	DDGS,	carbon	dioxide,	industrial	alcohols,	

oils,	etc.

• CO2 – This	is	an	off	gas from	fermentation	which	is	first	scrubbed	and	then	

released	to	atmosphere or	compressed	and	sold.

• Residual	solids	– This	material	is	a	combination	of	unreactable	fiber	and	paper

fillers,	primarily	Calcium	Carbonate.		It	is	dried	and	then	fractionated	to	produce	

a	number	of	specialty products	such	as	SMA	fibers	for	asphalt	roads	and	filler	for	

drywall

• Fines	– Predominantly	silicates	and	food	waste; may either	be	land	applied,	land	

filled or	further	screened	and	food	waste	added	to	the	anaerobic	digestion	plant	

feed		

• Recyclables	– Uncontaminated	waste	papers,	plastics, metals	and	other	

materials	which	are	sold	for	beneficial	use.

5. Fiberight’s	independent	third-party	engineering	review	will	be	conducted	by.

Nayes	Associates,	LLC

Terry	Nayes,	P.E.

9133	Preserve	Blvd.

Eden	Prairie,	MN		55346

The	 required	 third-party	 engineering	 review	 is	 attached	 to this	 registration	 document.	 	 The	

engineers	report affirms that	the	facility	has	a	material	recycling	facility	integrated	that	allows	

Fiberight	direct	control	and	 full	capability	to	recover	residual	recyclables	including	marketable	

paper	and	corrugated containers,	as	well	as	plastics	and	metals.		The	 facility	is	capable	of	 resizing	and	sequestering	the	organic	fraction	of	waste	stream	and	there	is	an	efficient	removal	of	

virtually	all	plastics	from	the	bio-fuel	processing	ensuring	no	hydrocarbon	content	in	the	fuel.				
9

6. Process	heat	fuel	supply	plan:

• List	the	types	of	process	heat	fuel	used	(i.e.	natural	gas,	biogas,	coal,	etc.)

o Natural	Gas

o Biogas	(Commencing	2012)

• Name	and	location	of	facility	providing	the	process	heat	fuel	to	the	renewable	

fuel	producer

o Alliant	Energy	

22	Second	Street	NW

Mason	City,	IA		50402

o Fiberight	LLC

2154	778th Street

Blairstown,	IA	52209

For	a	facility	using	biogas	for	process	heat,	provide	an	affidavit	from	the	biogas	supplier	

stating	its	intent	to	supply	biogas	to	the	renewable	fuel	producer

The	 Fiberight	 bio-refinery	 will	 take	 the	 waste	 liquid	 stream	 and	 soluble	 organic	 concentrate

from	 the	 washing	 plant	 and	 process	 them	 to	 produce	 biogas	 through	 microbial	 degradation.	

The	degradation	will	take	place	at	approximately	100oF.

The	 Anaerobic	 Digestion	 “AD”	 facility	 will	 be	 designed	 for	 year-round	 un-manned	 operation,	

with	connection	to	the	main	bio-refinery	control	system	to	provide	warnings	to	the	operators	if	

there	 are	 issues.	 	 The	 bio-refinery	 performance	 will	 be	 monitored	 daily	 by	 the	 laboratory	

though	collection	and	testing	of	samples	of	the	liquid	feed	and	residual	solids	produced.

The	biogas	from	the	AD	plant	will	be	stored	and	used	in	the	process	boilers	to	raise	steam.		In	

the	 event	 that	 there	 is	 excess	 biogas	 or	 a	 process	 interruption,	 the	 biogas	 will	 be	 used	 to	

generate	power,	sold	as	transportation	fuel	or	flared	once	the	storage	capacity	is	full.		The	flare	

stack	 will	 be	 designed	 to	 flare	 the	 entire	 biogas	 production	 in	 the	 event	 of	 an	 unplanned	

outage.

7. Separated	MSW	Plan

Extent	and	nature	of	recycling	that	occurred	prior	to	receipt	of	the	waste	material	by	the	

renewable	fuel	producer

Fiberight’s	facility	is	designed	around	a	“recycling	first”	philosophy	wherein	the	first	part	of	the	

process	involves	processing	MSW	through	a	recycling	plant	(see	artists	rendering	below)
10

The	extent	of	the	nature	of	recycling	will	vary	by	supplier,	however	given	that	most	materials	

will	pass	through	Fiberight’s	front-end	recycling	plant,	it	can	be	demonstrated	that	recycling	of	

waste	material	will	occur	to	a	great	extent	using	the	methods	described	herein	and	below.	

Identification	and	explanation	of	the	available	recycling	technology	and	practices	that	were

selected	to	remove	the	recyclable	materials

Fiberight’s	management	team	has	extensive	experience	in	the	recycling	industry,	which	

experience	has	heavily	influenced	the	design	of	the	facility.	Technologies	and	practices	that	will	

be	used	to	remove	the	recyclable	materials	include;

• Shredding	– methods	to	open	bags	to	release	paper	and	other	recyclables	

contained	therein	while	minimizing	damage	to	the	materials

• Screening	- Bounce	adhesion	and	trommel	screening	to	separate	recoverable	

paper	from	other	materials,	as	well	as	to	recover	biomass	while	separating	

plastics	and	metals

• Pulping	– Proprietary	methods	to	render	biomass	for	conversion	while	

preserving	plastics	and	metals	for	recycling.	This	process	also	makes	it	easier	to	

recover	small	plastics	and	metals	from	the	biomass	using;

• Hydrocyclones	– to	separate	heavy	materials	(metals	etc.)	from	biomass	pulp	

and

• Screen	washing	- for	removal	and	cleaning	of	plastics
11

• Air	separation	– methods	to	remove	rocks	and	other	heavies,	and	“float”	lighter	

plastics	and	paper

• Magnetic	separation

o Electro-magnets	for	ferrous	metals

o Rare-earth	Eddy	Current	for	Aluminum

• Optic	Sorting	(planned)	for	sorting	of	ridged	containers	and	removal	of	PVC	from	

mixed	plastics

• Automated	bunkers	to	store	recyclables	during	shift	and	maximize	efficiency	of;

• Baling	– To	compress	paper,	plastics	and	metals	for	efficient	shipping

• Manual	sorting	will	occur	after	screening	and	in	certain	circumstances	is	still	the	

most	efficient	method	to	recover	recyclables.

Fiberight	 has	 chosen	 to	 utilize	 known	 technologies	 for	 all	 other	 process	 operations.	 	 All	

equipment	will	be	specified	and	selected	based	on	its	applicability	to	the	process	requirements.	

In	addition,	a	significant	portion	of	the	process	will	utilize	the	existing	equipment	assets	of	the	

Blairstown	site	exactly	as	they	were	original	designed,	without	modification.		

Evidence	of	contractual	arrangements	for	paper,	cardboard,	plastics,	rubber,	textiles,	metals	

or	glass	that	is	recycled

Fiberight	will	sell	recyclables	from	the	facility	to	the	following	local	processors;

• Paper	and	Cardboard	– International	Paper, Cedar	River	Mill	- 4600	C	St	SW	

Cedar	Rapids,	IA	52404

• Plastics	(Containers),	glass &	Metals	– City	Carton,	901	Ingleside	Drive	Southwest

Cedar	Rapids,	IA	52404	

• Film	Plastic	&	Rubber – U.S.	Green	Steel

Certification	by	the	renewable	fuel	producer	that	the	recycling	is	conducted	in	a	manner	

consistent	with	goals	and	requirements	of	applicable	state	and	local	laws	relating	to	recycling	

and	waste	management

Fiberight	certifies	that	all	recycling	will	be	conducted	in	a	manner	consistent	with	the	goals	and	

requirements	of	applicable	laws	directed	by	the	State	of	Iowa	and	Benton	County	Iowa.

The	State	of	Iowa,	under	the	waste	reduction	act	(Code	of	Iowa,	Chapter	455D),	has	enacted	a	

requirement	for	50%	waste	diversion,	which	has	yet	to	be	achieved.	Further,	the	State	is	now	

seeking	to	increase	the	waste	reduction	requirement	to	60%	(HSB	74	&	SF249)	which	goal	is	

supported	by	Fiberight.	Please	also	see	attached	letter	from	Iowa	Department	of	Natural	

Resources	concerning	Fiberight’s	role	in Waste	Management	Planning.
12

Fiberight’s	facility	specific	information	(Title	40	CFR	80.1450)

FIBERIGHT	OF	BLAIRSTOWN,	LLC

2154	78TH STREET

BLAIRSTOWN,	IA		52209

319-454-9937	BUSINESS	PHONE

319-454-9938	BUSINESS FAX

CRAIG	STUART-PAUL,	CEO

STEVE	GERBER,	VICE	PRESIDENT	OPERATIONS	– SITE	MANAGER

RFS2

RIN	GENERATOR

RFS1	COMPANY	ID	3416

CELLULOSIC	ETHANOL	PRODUCTION	ID	70219	

New	renewable	fuel	category	(“D”	codes):

Fiberight	is	eligible	 for	D	Code	– 3 (cellulosic	ethanol)	and	D	Code	– 5	 (biogas).	All	other	 fuel	

produced	at	the	facility	will	be	sold	under	D	Code		- 6
13

Fiberight LLC Answers to:

Renewable Fuel Standards (RFS2) Program 

MSW Separation Plan

Supplemental Questions for Renewable Fuel Producers

1. The RFS2 regulation provides that only separated yard waste and food waste may be used to 

make RFS2. How much separated yard and food waste will you need to run your facility on an annual 

basis?

Fiberight anticipates that the 2.5MM GPY plant will be sustained by approximately 330 Tons 

per day of residential solid waste pursuant to modeling data, data extrapolation, and pilot plant 

experience. 330 Tons per day of inbound mixed waste will yield approximately 83.82 tons of 

yard, food and other non-recyclable waste suitable for biofuel production under RFS2 regulatory 

guidelines.

2. What is your planned source of that material?

Fiberight will source Residential Solid Waste from landfill diversion, specifically from Iowa 

landfills generally within a 100 mile radius of the facility. Fiberight considers the name and 

nature of these supply agreements to be confidential, however the agreements will specify that 

material is not collected as part of any recycling program. 2,684,6491 tons of waste was 

landfilled in Iowa in 2010.

3. Describe the collection practices and recycling technologies you are planning to use to separate 

paper, cardboard, plastic, rubber, textiles, metal and glass so that only incidental, de minimus amounts 

that are impracticable to remove are left in the waste stream?

A detailed flowsheet and outline designs have been included as a part of Fiberight’s plant 

registration. However in summary the steps to be taken include;

MSW Receiving and Storage: Municipal Solid Waste (MSW) will arrive on-site by truck. 

Trucks will be weighed as they enter the facility and empty trucks will be weighed as they exit. 

Weighed trucks will be directed the MSW receiving storage area where they will unload. 

Unloaded MSW will remain in the receiving storage area until used. 

MSW Pre-Sorting: MSW from the receiving storage area will be transferred by a front-end 

loader to a receiving bin. The receiving bin is a walking-floor or belt type storage container that 

continuously transfers MSW forward. MSW from the receiving bin is then conveyed to a bagbreaker that continuously liberates the waste from bags and containers. MSW is then conveyed 

to a rotating trommel screen where the waste is separated into under-sized, mid-sized and oversized materials. 

Undersized materials, which are too small to be properly processed, are discharged from the 

screen directly into a roll-off container. This material will be removed from the site and sent to a 

landfill. Other materials, including uncontaminated paper and cardboard, unprocessables, rigid 

containers, etc. are transferred to a belt conveyor where they will be sorted into one of several 

bunkers. These bunkers will be also removed from site either for sale as recyclables or disposal. 

Any large, but otherwise acceptable materials will be sent to a shredder and incorporated into the 

																																																												 1 Source	– Iowa	Department	of	Natural	Resources
14

feed stream to process. Acceptable mid-sized materials will be processed through a magnet to 

remove any ferrous metals. The middle fraction will be combined with the outlet from the 

shredder and transferred to a pre-sort stockpile until pulping. 

MSW Pulping: Pre-sorted MSW with recyclable paper removed will be transferred from the 

storage pile to the pulper feed conveyor using a front-end loader. MSW (food and yard waste 

with other contaminated cellulose) is pulped using a high solids pulping (steam autoclave) 

process that both destroys harmful biological components and converts residual cellulose to 

usable pulp. The pulping system is operated in a batch mode. A load of sorted MSW is fed into 

the pulper along with recycled process water and the pulper is then heated and held at the 

required temperature for a predetermined amount of time to insure that the MSW is sufficiently 

pulped and that initial sterilization has occurred. Following completion of the heat cycle, the 

pulped contents of the vessel are discharged to a storage pile to be next fed to the post-sorting 

system. 

Biomass Post-Sorting: The pulped material from the high solids pulper is transferred to a 

storage bin with an integral conveyor, it is important to note that plastics are little changed 

during the pulping process making their subsequent recovery more practicable. The pulp is then 

conveyed to a rotating screen (trommel). Under-size material, primarily cellulose fiber, is 

separated from larger materials like plastics, metals and any other un-pulped components, in this 

fashion the biomass is efficiently separated from plastics and other non-organic materials. 

Oversized materials are discharged from the screen and conveyed to an air knife where plastic 

films are separated. The oversized material is then processed through a magnet to remove any 

ferrous materials and through an eddy current separator to remove non-ferrous metals. The 

remaining material is then separated manually or by automated optic sorting to remove any 

remaining recyclables, for example plastic containers and films. The various separated 

materials, i.e. ferrous, non-ferrous, plastics, etc. are placed in separate containers that will be 

transported off-site for recycling. All remaining material is discharged into a container that will 

be sent to landfill. Additional sorting and separating occurs during a separate wash process that 

separates soluble organics (generally from food waste) from cellulosic materials (yard waste and 

other cellulose such as vegetable peelings for example), each of which will be processed into 

biofuel using optimized conversion pathways.

4. Specify what you plan to do with the separated paper, cardboard, plastic, rubber, textiles, metal and 

glass.

The materials described in point 4 above, to the extent recovered in processing, will be sold to 

local recycling facilities under contract. It is anticipated that much of the paper and cardboard 

recovered by sorting (to the extent it meets ISRI {International Scrap Recycling Institute} quality 

requirements as conditioned by the end user) will be ultimately sold to International Paper in 

Cedar Rapids, IA, which company operates a large paper mill using recycled paper as feedstock.

5. What are the recycling rates for paper, cardboard, plastics, rubber, textiles, metals and glass your 

collection system and recycling operations are achieving or will be designed to achieve? 

The system is being designed to recover a minimum 70% of recycle grade materials listed in 

point 5 above.

6. Provide a list, by city and county, of the collection practices and recycling technologies being used in 
15

the state or states from which the facility receives waste. Specify the amount of waste coming from each 

as well as the current collection and recycling rates for each of these areas, specifying the rate for each 

category (i.e., paper, cardboard, plastics, rubber, textiles, metals, glass, food waste, and yard waste).

Iowa DNR does not collect the statistics requested above, however please see table 1 below 

showing, County by County, which materials are collected.

Additionally, the State of Iowa conducted a comprehensive waste characterization study in 2005, 

Based upon the results from the 2005 Study, “additional source reduction and landfill diversion 

opportunities were identified for the solid waste stream. The items in the solid waste stream 

representing the greatest potential for source reduction and recovery through recycling and 

composting and the estimated tonnages disposed of each statewide included the following:

• OCC (180,600);

• Mixed recyclable paper (148,200);

• Compostable paper (138,000); (Please note; Fiberight’s process may be viewed as a 

highly evolved, high-rate composting process that accelerates the breakdown of paper, 

amongst other materials)

• Food waste (225,000);

• Film/wrap/bags (139,300); and

• Demolition/construction debris (516,600);

Mixed paper was categorized into the three subcategories of recyclable, non-recyclable, and 

compostable to measure opportunities for both mixed paper recycling and composting.”

In the absence of recycling rate data Fiberight has selected the 2005 Iowa Waste Characterization 

Study (Conducted by R.W. Beck, Inc) as a source of available tonnage that is de-facto not 

recycled. Table 2. Below illustrates the breakdown of materials found in Iowa’s Municipal Solid 

waste.

7. How will you ensure that a sufficient amount of this separated material will be available for your 

operation?

Recyclable materials are already separated from Residential Solid Waste in Iowa thus only waste 

otherwise landfilled will be used at the facility. Please see table 3 below which details Fiberight’s 

“waste-shed”, a term used to describe waste available in a transportation efficient radius from the 

facility. Using this data, and the compositional analysis contained in table 2, the following can be 

extrapolated;

• Using a conversion factor of 85 gallons per ton (feedstock to cellulosic ethanol and/or 

biogas) Fiberight’s plant may be sustained by 330 tons per day of inbound mixed waste.

• 330 Tons per day represents 115,500 Tons per year (at 350 day/yr processing) which in 

turn represents only 6.7% of the total waste landfilled in Fiberight’s waste-shed. Thus a 

significant feedstock surplus is available to the operation.
16

8. What impact will your facility have on the recycling collection and recycling rates for these nine 

materials?

Given that Fiberight then undertakes a series of additional separation steps as described herein 

after waste is received at its facility, it is anticipated that recycling rates for the materials listed 

will be significantly improved concomitant with the total volume of waste processed. Records 

will be kept at the facility and reported to the Iowa DNR quarterly indicating the total amount of 

materials recycled by type, thus empirical audited data will be available to confirm increased 

recycling of paper, cardboard, plastics, rubber, textiles, metals, glass, food waste, and yard waste 

as a result of Fiberight’s facility. Please note that food and yard waste tonnages may be reported 

as a single item given that they will be processed together.

Using the data presented below, it is possible to extrapolate that Fiberight’s facility, running at 

330 tons per day of inbound mixed waste will increase recycling collection in the following 

areas;

• Recovery of food & yard waste & other compostable materials – 29,337 Tons annual 

additional recovery

• Recovery of the nine materials listed herein – 40,829 Tons annual additional recovery.

Further improved recycling rates would be possible should Fiberight increase the capacity of the 

facility.

SUPPLEMENTAL DATA

• Table 1 - List of Iowa Counties and materials recycled

• Table 2 – Iowa MSW composition

• Table 3 – MSW available to Fiberight from targeted waste-shed
17

Table 1 - List of Iowa Counties and materials recycled
18
19
20

Table	2 – Iowa	MSW	Composition	(Source	Iowa/I.W.	Beck	2005	waste	characterization	study)

Material Composition	%

Compostable	paper 6.5

High	Grade	Office 2.5

Magazines 1.8

Mixed	Recyclable	Paper 7.0

Newsprint 4.0

Non-Recyclable	paper 2.8

OCC	and	Kraft	Bags 8.5

Total	paper	(Rounded) 33.0

Yard	Waste 1.6

Food	waste 10.6

Diapers 2.4

Other	Organic 1.5

Rubber 0.5

Plastics 14.9

Textiles	&	Leathers 4.9

Metals 4.7

Glass 1.7

Wood 8.0

C&D	Debris 5.5

Durables 5.1

Household	Hazardous	Materials 0.4
21

Other	Inorganic 2.4

Fines 2.4

Other 0.5

Total	Rounded 100%

Total	Suitable	for	Biofuels	Production 25.4%

Total	Paper,	Cardboard,	Plastics,	Textiles,	Glass,	Metals,	Rubber	available	

for	recycling	and	recovery	from	mixed	waste	stream

50.5%

Potential	Recycling	increase	(as	%	of	total	waste	@	70%	efficiency) 35.35%
22

Table	3 – Waste	disposed	at	landfill,	Fiberight	anticipated	Market	Waste-shed.	

Blairstown	- Surrounding	Counties	Landfill	Tonnage

County Landfill Tonnage

Benton Benton	County	Sanitary	Landfill 12,808

Blackhawk Blackhawk	County	Sanitary	Landfill 162,292

Boone Boone	County	Sanitary	Landfill 48,344

Clarke Clarke	County	Sanitary	Landfill 8,422

Clinton Clinton	County	Sanitary	Landfill 36,621

Dallas North	Dallas	County	Sanitary	Landfill 23,522

Dallas South	Dallas	County	Sanitary	Landfill 13,159

Debuque Debuque	Metropolitan		Sanitary	Landfill 95,089

Debuque John	Deere	Debuque	Works	and	Waste 1,749

Fayette Fayette	County	Sanitary	Landfill 6,265

Hardin Rural	Iowa	County	Sanitary	Landfill 33,523

Iowa Iowa	County	Sanitary	Landfill 9,442

Jasper City	of	Newton	Sanitary	Landfill 26,285

Johnson City	of	Iowas	City	Sanitary	Landfill 120,584

Keokuk Southeast	Multi-County	Sanitary	Landfill 24,059

Linn Cedar	Rapids/Linn	County	Solid	Waste	Agency	Site	#2 188,077

Linn Cedar	Rapids/Linn	County	Solid	Waste	Agency	Site	#1 57,588

Linn Cedar	Rapids	WPCF	Ash	Sanitary	Landfill 1,351

Madison South	Central	Iowa	Sanitary	Landfill 32,155

Mahaska Mahaska	County	Sanitary	Landfill 41,790

Marion South	Central	Iowa	Solid	Waste	Agency 57,216

Marshall Marshall	County	Sanitary	Landfill 31,539

Muscatine Muscatine	County	Sanitary	Landfill 29,916
23

Polk Metro	Park	East	Sanitary	Landfill 498,635

Scott Scott	Area	Sanitary	Landfill 155,883

Tama Tama	County	Sanitary	Landfill 15,286

Total 1,731,600