The CO2 Bomaderry Plant Partnership and the Future

The commissioning of the Bomaderry Plant in partnership with Manildra was a project that has greatly changed the pace for Supagas with an outlook geared towards sustainability in the gas industry and across products like Carbon Dioxide (CO2). Food & Beverage Industry News discovered.

The gas industry as an essential service and the nature of gas as a resource, Supagas seeks to explore ways to source a clean and reliable supply of CO2 for the Australian market and Supagas customers. The topic continues to be an important issue for gas suppliers in Australia, like Supagas.

A partnership with Manildra

Previously, Supagas had several manufacturing Plants’ across Australia that were used to burn natural gas to produce CO2. The CO2 that was produced, also created moisture which Supagas could capture and purify, thereby convert the moisture into Food Grade CO2. However, with the increasing price of natural gas and concerns towards the emission of greenhouse gases into the atmosphere, Supagas identified a way to better source CO2.

The previous method of burning natural gas to produce CO2 was the main option for Supagas in the past. The idea at the time of the Bomaderry CO2 Plants’ development was a move towards greater sustainability to ensure sufficient supply, which still proves true today. The notion was to develop a source that was long term and sustainable to help with the environment and reduce costs, in addition, to meet growing consumer demand for CO2 within in the market.

The ability to have a large source that would produce the level of CO2 required, Supagas needed a facility that was reliable and could support the manufacturing process. One key concern for a CO2 production facility that uses plants is the time period feed suppliers are running maintenance checks. The issue here is the manufacture of CO2 stops, which has a carry-on effect into the market, as companies may not be able to meet customers’ demands.

Manildra was introduced to the Supagas team at the right time, as an Australian producer of food products including protein, fats, wheat and syrups. One of the by-products that was most valuable for Supagas was ethanol. Therefore, the Plant was built at Manildra Shoalhaven Starched integrated manufacturing facility in Bomaderry, NSW. The project took several months to complete with building taking place offsite and final assembly of the Plant onsite.

The Process

The process to produce CO2 starts at the fermentation stage such as wheat, where Manildra is left with the by-product ethanol, which is important for Supagas, because this is where the CO2 is around 90% pure.

The ethanol is captured as a by-product through a blower and cold-water scrubber which dehumidifies the CO2 and removes the remaining alcohol. The blower will then push the CO2 gas through the underground pipelines which funnels into another processing Plant. The CO2 gas will then go through a range of processes and a compressor, which will raise the gas pressure. The CO2 will also filter through a Catox, to remove all impurities and leave only pure CO2.

The CO2 is then dried and liquified, so it can be turned into Food Grade CO2 to be used in Supagas’ market ready products. As you may know, CO2 is versatile in nature, offering different forms including solid (i.e. dry ice), liquid and gas. Dry ice is a product Supagas offers for varying applications and uses, for example the cold chain will use dry ice for freezing food and for the transportation process to keep goods cold.

The topic closely relates to the packaging and processing industry, as dry ice and SupaMap gases are used across varying businesses and client bases. Dry ice is a great product as there is minimal to no waste left behind compared to gel packages. It is also important to consider the use of CO2 for SupaMap gases for food packaging to maintain shelf life and food freshness. CO2 also plays a key role in the Beverage industry for the carbonation of beer and drinks for venues and manufacturers. Businesses vary in size, with larger manufacturers and facilities utilising pack or bulk forms to ensure sufficient gas supply onsite for the production of goods.

Reducing emissions with a move towards sustainability

The Bomaderry Plant is important, on the realisation of the positive impact in reducing Supagas emission footprint. The Plant sought to reduce emissions on a yearly basis of an estimated 18,000 tonnes of CO2 forecasted to double overtime that would not be released into the atmosphere.

It is important to look at the supply chain from beginning to end and the impact of how products such as CO2 are produced, the environmental impact to the delivery of products to customers and businesses. The benefits of the Bomaderry Plant outweighs the costs, as it is a sustainable alternative in reducing waste and direct emissions into the atmosphere. The circular system is environmentally friendly in its operation and output, as the material produced has multiple uses. For example, the syrup and gluten is used to produce ethanol which creates the CO2, therefore, reducing waste.

A high level of water is also left during the process as waste that is removed. However, the excess of wastewater left during production is recycled and used for plants or even for local farmlands for irrigation purposes such as food crops, cattle grazing and farm pastures. The wastewater created during production is treated and circulated into the Manildra Wastewater Treatment Plant, which is located on site.

Supagas expresses how they have come to realise how they could operate in an environmentally friendly and sustainable way for the future. In achieving the same outcome of producing high quality CO2, whilst still operating in an environmentally and sustainable mind frame.

The business outlook such as reducing utility costs such as water and electricity is a benefit to produce CO2 which Supagas needs to facilitate and manufacture other products such as dry ice and SupaMap gases. Overall, the Plant has been highly beneficial since the start of the project. The Plant is providing Supagas with a clean, reliable and sustainable supply of CO2 to service current and future markets, with a growing demand for CO2. Supagas highlights that they will continue to expand and explore other sources to ensure sufficient plant (i.e. wheat) supply to keep generating CO2.

To find out more about Specialty and Industrial Bulk Products and Gases, contact the Supagas Gas Professionals.