ICM/PBS personnel provided design, construction supervision, technical development, start-up and training services for the implementation of the anaerobic Bio-Methanation system at the NEMO Fuel Ethanol Plant in Macon, MO. The turnkey Bio-Methanator plant was designed and built by ICM-Phoenix for Broin and Associates, the constructors of the Fuel Ethanol Plant. 

     The plant consists of a single upflow expanded-bed, 33,000 gal bio-reactor, capable of removing up to 4,000 pounds per day of COD (Chemical Oxygen Demand). The bio-reactor is located out-of-doors, while all control and sampling units are skid-mounted and located inside the plant's utility building.  The two level skid was used as a basic structure to provide an add-on building to the existing utility building, by adding metal skin and insulation to the outside of the skid. 

     The entire anaerobic system was pre-fabricated at the ICM shop in Colwich and shipped to the site in Macon for installation, which required less than one week. The main bio-reactor is pre-molded FRP including all internals.  

     The entire unit was installed in October 1999 and started up in May 2000 along with the main plant. Start-up was completed in five days and the plant was turned over to operating personnel shortly thereafter. The plant has operated successfully since start-up averaging over 85% COD reduction and consistently producing effluent waters suitable for polishing treatment in aerated lagoons and subsequent direct discharge under an NPDES permit.  

     Daily operating costs are extremely low, requiring only one to two hours per day of operator and lab time along with small amounts of nutrient chemicals and less than 17 operating horsepower. Bio-gas produced by the system is piped to the plants' DDGS dryer providing an energy return of approximately $7,000 per year.