Gross & CO:
Portfolio of Renewable Energy and Waste-to-Value Projects
At Gross & CO, we specialize in providing innovative, large-scale engineering solutions for renewable energy and waste-to-value projects. With a team of experts across various disciplines, we pride ourselves on delivering sustainable, efficient, and cutting-edge solutions. Below is a selection of projects that reflect our team’s collective expertise and commitment to driving positive environmental impact.
Biomass to Sustainable Aviation Fuel (SAF) Feasibility Study
Location: USA
Role: Engineering and Technical Leadership Team
Gross & CO provided comprehensive engineering and technical leadership for a $6 billion project to convert woody biomass into sustainable aviation fuel (SAF). Our team developed the Front-End Loading Phase 2 (FEL2) estimate and feasibility study for an 87-million-gallon-per-year facility. The project integrated advanced gasification and Fischer-Tropsch synthesis technologies with biomass-fueled power generation.
Key Achievements:
• Integrated Feasibility Solutions: Conducted an in-depth FEL2 analysis, combining financial, technical, and operational assessments.
• Advanced Technology Implementation: Delivered expert guidance on SAF production systems, ensuring scalability and efficiency.
• Environmental Leadership: Contributed to the decarbonization of the aviation industry by reducing reliance on fossil fuels.
Dairy Manure to Renewable Natural Gas (RNG)
Location: USA
Role: Project Development Team
Our multidisciplinary team executed a $200 million greenfield project that transformed dairy manure into renewable natural gas (RNG). Gross & CO designed a robust system that integrated multiple dairy operations, captured methane, and injected RNG into the interstate pipeline network.
Key Achievements:
• End-to-End Project Execution: Delivered a turnkey solution, from conceptual design to operational readiness.
• Sustainability Impact: Reduced agricultural methane emissions by converting waste into renewable energy.
• Infrastructure Optimization: Ensured scalability with a future-focused design framework.
Landfill Gas-to-Energy Project
Location: Missouri, USA
Role: Renewable Energy Team
Our team led the technical design and execution of a landfill gas-to-energy project, converting waste gas into a renewable power source. This innovative project generated 15 MW of continuous electricity, directly supplying the local grid.
Key Achievements:
• Energy Resilience: Engineered a reliable system to supply renewable electricity to thousands of homes.
• Technology Integration: Designed and implemented efficient gas collection and cleaning processes.
• Economic and Environmental Benefits: Supported community energy needs while reducing landfill emissions.
Agricultural Waste Biorefinery
Location: North Dakota, USA
Role: Engineering and Owner’s Representation Team
Gross & CO provided engineering and owner’s representation services for a $150 million greenfield biorefinery. This first-of-its-kind facility converted sugar beet and potato waste into biofuels and biogas. The facility reached nameplate capacity within a year, a testament to our team’s expertise and operational excellence.
Key Achievements:
• Innovative Process Design: Developed a state-of-the-art facility to repurpose agricultural waste.
• Operational Milestones: Achieved full production capacity on schedule, exceeding industry benchmarks.
• Circular Economy Leadership: Enhanced resource efficiency by transforming waste into valuable energy products.
Distillery Wastewater Treatment and Biogas Generation
Location: North Dakota, USA
Role: Water Treatment and Energy Recovery Team
Gross & CO designed and commissioned a wastewater treatment and biogas generation system for a leading distillery. The project included advanced equipment to reduce Total Suspended Solids (TSS) and Biochemical Oxygen Demand (BOD) using anaerobic digestion.
Key Achievements:
• Advanced Wastewater Solutions: Delivered a high-performance system that ensured environmental compliance.
• Energy Recovery Leadership: Captured biogas for facility use, reducing operational costs and emissions.
• Process Integration: Successfully integrated multiple technologies for seamless operation.
Cellulosic Ethanol Production Facilities
Propagation Support Skids for Ethanol Facility
Location: USA
Role: Modular Construction and Engineering Team
Our team designed and delivered modular propagation skids to support a next-generation ethanol facility. The skids featured advanced automation for chemical addition, temperature control, and Clean-in-Place (CIP) systems.
Key Achievements:
• Efficient Deployment: Reduced onsite construction time with pre-assembled skids.
• Enhanced Automation: Improved process control, ensuring operational consistency.
• Seamless Integration: Delivered on-time installation with minimal disruption to the main facility.
Pilot Plant Acid Soak Pretreatment Integration
Location: USA
Role: Process Design and Commissioning Team
Gross & CO engineered and implemented a new acid soak pretreatment process at a pilot plant to validate commercial-scale ethanol production. Our team provided comprehensive engineering packages and supported the project through startup.
Key Achievements:
• Process Validation Expertise: Demonstrated scalability of critical pretreatment technology.
• Detailed Engineering Support: Delivered precise engineering documentation to facilitate replication.
• Operational Readiness: Ensured smooth commissioning and operational efficiency.
Food and Beverage Industry Projects
Clean-in-Place (CIP) Automation
Location: Wisconsin, USA
Role: Food & Beverage Process Improvement Team
Our team automated CIP processes for a major beverage producer, replacing manual systems to improve safety and operational efficiency. This upgrade minimized operator exposure to hazardous chemicals while enhancing cleaning cycle reliability.
Key Achievements:
• Safety Enhancements: Implemented systems that significantly reduced occupational risks.
• Process Efficiency Gains: Achieved faster and more reliable cleaning cycles.
• Operational Continuity: Enabled consistent production with minimal downtime.
Refrigeration Retrofit Feasibility Study
Location: Georgia, USA
Role: Energy Optimization Team
Gross & CO conducted a detailed feasibility study for upgrading refrigeration systems at a beverage production facility. The phased implementation plan identified opportunities to reduce utility costs by $150,000 annually.
Key Achievements:
• Energy Efficiency Leadership: Proposed sustainable upgrades to lower energy consumption.
• Cost Savings Realization: Delivered actionable plans with measurable financial benefits.
• Sustainability Alignment: Helped the client meet energy reduction and sustainability goals.