Our Process

How Do We Do It?

The Process

Locally sourced feed grade wheat

Locally sourced feed grade wheat

We will use around 1 million tonnes of feed grade wheat (commonly used to feed animals) sourced from local farmers predominantly across Yorkshire and Lincolnshire every single year, providing a sustainable market for arable farmers in Yorkshire and the Humber.

The Plant

The Plant

Our £350m plant will convert the feed wheat – with no waste – into Bioethanol and animal feed. We will be one of the largest producers of Bioethanol in Europe and the largest single source supplier of animal feed in the UK.

Animal Feed

Animal Feed

We will use the protein in the feed wheat to produce up to 500,000 tonnes of protein rich animal feed. This will provide the protein required for 340,000 dairy cows every day.

Bioethanol

Bioethanol

We will use the starch to produce 420 million litres of Bioethanol each year. This will be blended with conventional petrol to make a greener, more sustainable transport fuel.

Green House Gases

Green House Gases

Carbon dioxide (CO2) emitted when the Biofuel is burnt in a vehicle is offset by the CO2 absorbed during the growing of the wheat crop.

Our Bioethanol offers GHG savings 50% over standard petrol – the equivalent of removing 180,000 cars from the road.

Locally Sourced Wheat

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Local farmers supply our 1 million tonnes of feed grade wheat, making us the biggest wheat buyer in the UK

Our location in the heart of the UK’s wheat growing belt, which is one of the highest yielding in the world, offers us easy access to around 1 million tonnes of feed-wheat we will need annually. We are committed to sourcing our wheat from local farmers in the Yorkshire and Lincolnshire area wherever possible.

We will use ‘feed’ grade wheat which is widely grown in the UK and is most commonly used to feed animals. This is different to ‘milling’ wheat which is used in bread making and other core food products. This lower grade feed wheat is ideal for fermentation due to its high starch content. 60% of the wheat we process will be used to produce the Bioethanol. The remaining 40% is protein and that will be converted into animal feed. This type of wheat is widely grown in the area around the Vivergo Fuels plant, wider Yorkshire and Lincolnshire.

Vivergo Fuels continues to work with Frontier Agriculture as our wheat supplier and will source around 1 million tonnes of feed wheat for our production process each year making it the biggest single tip point for wheat in the UK.

Our Plant

We will once again be one of the largest Bioethanol producers in Europe, producing 420 million litres every year from early 2022 onwards

Our plant covers an area the size of 12 World Cup football pitches and can produce the amount of bioethanol equivalent to 1 billion bottles of spirits every single year.

Our £350m biorefinery, based at Saltend near Hull, will use around 1 million tonnes of feed-grade wheat to produce 420 million litres of bioethanol and up to 500,000 tonnes of animal feed per year. This will make us the largest bioethanol producer in the UK and one of the biggest in Europe. We will also be the largest wheat tip in the UK and the biggest single-source suppliers of animal feed. We definitely don’t do things by halves! Once operational in early 2022, our plant will runs 24-hours a day, seven days a week. The whole process begins with locally sourced feed wheat, which is brought to our site by truck. In simple terms, our process is comprised of four key stages – The Mill, The Brewery, The Distillery and The Feed Factory. Read on to discover what happens once the wheat arrives on site…

process-the-plant

The Mill

Wheat is made up of starch, protein and fibre. At Vivergo Fuels we will use the starch to produce the bioethanol and the protein and fibre to make our animal feeds.

The process will start when the wheat arrives at the site. The wheat grains will be tested for quality and ‘tipped’ into one of our six silos, each of which can hold up to 1,500 tonnes of grain. We refer to the wheat milling and storage area of the site as ‘The Mill’, because it works in the same way as a traditional flour mill. Once the wheat has been milled into flour, it will be mixed with water to form a slurry that is then ‘cooked’ with steam. At this point the product will look a lot like thick porridge! We will then add enzymes to thin the mixture and help convert the starch into sugar before brewing.

The Feed Factory

The proteins and fibre will arrive from distillation and will be squeezed to remove most of the water. At this stage the solid product is still relatively moist. We will then transfer it to our three dryers (think tumble dryer on a massive scale) so that it can be dried and pelletised to form the majority of our animal feed product – which is similar to the food pellets you buy at a petting zoo. Some of the solid product is deliberately not sent through the dryers so that it can be sold in a moist form or as a syrup feed.

The animal feed products will be stored in a large warehouse before being delivered to farms across the UK via truck.

The Brewery

The porridge-like product then moves onto ‘The Brewery’, which is comprised of eight fermentation tanks and a beerwell. Here we will follow a similar process to a conventional brewery – but on an even larger scale!

We will start the brewing phase by adding yeast to the porridge-like product to convert the sugars from wheat starch to alcohol. At the end of each fermentation cycle we are left with a ‘beer’, with an alcohol concentration of around 12%. At this point, the protein and fibre from the remains is suspended in the beer solution. At the end of the brewing process the beer is transferred to the beerwell in preparation for distillation.

The Distillery

In the first stage of distillation we will separate the alcohol from the protein and fibre. In the second stage we will concentrate the alcohol to 96% and then further dry it to 99.7% alcohol. At this point it then becomes our bioethanol product and is sent to storage. It will then be transferred to our jetty for loading onto a ship. It will then be transported to refineries around the UK or into mainland Europe where it is blended with regular petrol for use in conventional car engines. Our process is very efficient, with virtually no waste.

Bioethanol

process-bioethanol

We will be one of the largest Bioethanol producers in Europe, producing around 420 million litres every year

Bioethanol is a renewable energy made from carbohydrates in plants – at Vivergo Fuels, we’ll use locally sourced feed wheat, from predominantly Yorkshire and Lincolnshire, which is a very sustainable source.

The UK is committed to meeting the EU wide 10% renewable energy in transport target, via the Renewable Transport Fuel Obligation (RTFO) and sustainable biofuels will be the main ‘vehicle’ for achieving this target. In February 2021, the UK government announced that E10 petrol – a cleaner, greener fuel, will be introduced at UK petrol forecourts up and down the country from September 2021.

E10 contains up to 10% Bioethanol and will cut transport emissions, equivalent to 250,000 fewer cars on the road – or all cars in North Yorkshire, reducing drivers’ environmental impact of every journey taken. Currently, UK forecourts provide E5 petrol which only contains 5% renewable Bioethanol.

At around 420 million litres of Bioethanol per annum, Vivergo Fuels’ production capacity will represent around half of the current UK demands under the RTFO, contributing to a more diverse energy mix, and helping to tackle energy security and climate change both here and across the world.

We will be one of the largest Bioethanol producers in Europe and the biggest in the UK.

Animal Feed

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Our animal feed will provide the protein required for 340,000 dairy cows a day – that’s nearly 20% of the UK's dairy herd. We will make cows happy!

We will transform approximately half of the 1 million tonnes of feed wheat into a protein rich animal feed.

The local feed wheat that Vivergo Fuels will use, was already previously used for animal feed products but much of it was exported to European and International markets.

Our process will take in around 1 million tonnes of this wheat and gives approximately half back to UK agriculture in a form that has more protein, and which is more appropriate to the needs of livestock/dairy farmers.

We will produce 500,000 tonnes of animal feed every year, making us the UK’s largest single source supplier.

We will supply the protein required for 340,000 dairy cows every day (as part of total dietary requirements) – which will equate to around 20% of the UK dairy herd.

The scale of the Vivergo Fuels plant means that we will play an important role in UK agriculture and we are committed to supporting local farmers, as a key part of that. British agriculture has an ambition to reach net zero gas emissions by 2040 and increasing farming’s delivery of renewables is part of this.

Vivergo Fuels will be working with AB Agri to manage the marketing and distribution of our animal feed products – dry pelleted, moist meal, and liquid solubles.