Biofuel is complicated. Most people hear "ethanol" and think of corn fields or a slight discount at the gas pump, but what’s happening at Al-Corn Clean Fuel in Claremont, Minnesota, is actually way more interesting than just grinding up kernels. Honestly, if you look at the tech they’ve bolted onto their facility over the last few years, it’s less of a farm-support business and more of a sophisticated chemical engineering lab.
It works.
They aren't just making fuel; they're trying to figure out how to make the entire process "carbon neutral" or even "carbon negative," which is basically the holy grail of the energy transition right now.
The Reality of Al-Corn Clean Fuel and the Carbon Race
Al-Corn Clean Fuel started as a farmer-owned cooperative back in the 90s. At that time, it was all about local markets and finding a use for surplus corn. Today, it’s a high-output facility producing roughly 125 million gallons of ethanol annually. But the volume isn't the story. The real story is the Carbon Intensity (CI) score.
In the world of clean energy, your CI score is your reputation. The lower the number, the more valuable the fuel is in markets like California or Oregon. Al-Corn has been obsessively driving that number down.
How? They didn't just buy better tractors.
They invested heavily in Combined Heat and Power (CHP) systems. This is basically a way to generate their own electricity while capturing the "waste" heat to use in the distillation process. Instead of letting energy bleed out into the atmosphere, they loop it back in. It saves money, sure, but it also slashes their emissions profile.
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Then there’s the carbon capture and storage (CCS) angle.
Why the Summit Carbon Pipeline Matters Here
You can’t talk about Al-Corn Clean Fuel without talking about the Summit Carbon Solutions pipeline. It’s controversial. It’s in the news constantly. But for Al-Corn, it’s a technological lifeline.
The fermentation process naturally produces a very pure stream of $CO_2$. Usually, this just floats away. By connecting to a pipeline, Al-Corn can capture that $CO_2$, compress it, and send it underground for permanent storage in North Dakota.
If this goes fully live, the ethanol coming out of Claremont won’t just be "green-ish." It will be some of the lowest-carbon liquid fuel on the planet. This isn't just a win for the environment; it’s a massive business play. When you produce low-carbon fuel, you get lucrative credits under the Low Carbon Fuel Standard (LCFS).
It’s high-stakes poker with corn.
Beyond the Fuel Tank: High-Value Co-Products
We need to stop thinking of these places as "ethanol plants." They are biorefineries.
When Al-Corn processes corn, they aren't just getting fuel. They are extracting corn oil, which goes into the biodiesel market—another "clean fuel" win. They are producing Distillers Dried Grains with Solubles (DDGS). That’s a fancy name for high-protein animal feed.
Basically, they take the starch out of the corn for fuel and leave the protein and fat for the cows.
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It’s efficient. It’s circular.
The Corn Oil Evolution
A few years ago, corn oil was almost an afterthought. Now, because of the boom in Renewable Diesel (which is different from traditional biodiesel), that oil is worth a fortune. Al-Corn uses centrifugal technology to pull as much of that oil out as possible.
The tech is so precise now that they can tune the "recipe" of their feed based on what local farmers need while maximizing the oil for fuel. It’s a delicate balance of biology and mechanical engineering.
What Most People Get Wrong About Ethanol
There’s this persistent myth that ethanol takes more energy to make than it gives back. That might have been a valid debate in 1978. In 2026? It’s just not true.
Modern plants like Al-Corn are incredibly lean. Between the CHP systems, better yeast strains that ferment more efficiently, and precision agriculture practiced by the member-owners, the energy return on investment (EROI) is strongly positive.
Another misconception: it "ruins engines."
If you’re running a 1960s chainsaw, maybe stick to ethanol-free. But for modern flex-fuel vehicles or even standard cars running E15 (15% ethanol), the higher octane actually helps engine performance. Al-Corn is a major advocate for E15 because it’s an immediate way to lower tailpipe emissions without waiting for everyone to buy a $50,000 electric vehicle.
The Local Economic Engine
Claremont isn't a huge metropolis. Al-Corn is one of the biggest drivers in the region.
We're talking about a cooperative owned by about 500 local farmers. When the plant does well, that money doesn't disappear into a corporate headquarters in Houston or London. It goes back into the pockets of people in Dodge and Steele counties.
They buy new equipment. They pay local taxes. They keep the local schools funded.
It’s a decentralized energy model. Instead of one massive oil refinery on the coast, you have hundreds of these biorefineries scattered across the Midwest. It’s harder to disrupt and better for rural stability.
The Future: Sustainable Aviation Fuel (SAF)
This is the big one.
The "next level" for Al-Corn Clean Fuel is likely SAF. Planes can’t easily run on batteries. They need liquid fuel because of energy density. Ethanol-to-Jet (ETJ) technology is the bridge.
By cleaning up their ethanol production now—lowering that CI score we talked about—Al-Corn is positioning itself to be a supplier for the airline industry. Imagine a flight from Minneapolis to London powered by corn grown 70 miles south of the airport.
It’s not sci-fi. It’s happening.
Real Challenges to Watch
It’s not all sunshine and high yields.
- Water usage: Biorefineries use a lot of water. Al-Corn has to be a good steward of the local aquifer, or they'll face a PR and regulatory nightmare.
- The Pipeline Fight: If the carbon pipelines get blocked by legal challenges or landowner disputes, the path to "net zero" becomes much, much harder.
- EV Adoption: As more people go electric, the demand for gasoline (and the ethanol blended into it) could drop. This is why the pivot to jet fuel and chemicals is so vital.
Actionable Steps for Stakeholders and Observers
If you’re looking at Al-Corn or the broader clean fuel industry, here is how you actually engage with this shift.
For Consumers: Look for the E15 or "Unleaded 88" pump. It’s usually the cheapest option at the station. It has a higher octane rating than standard 87, and it’s supporting the tech upgrades at plants like Al-Corn. It’s an easy way to lower your personal carbon footprint without changing your lifestyle.
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For Investors and Policy Watchers: Keep a close eye on the GREET model (Greenhouse gases, Regulated Emissions, and Energy use in Technologies). This is the "rulebook" the government uses to decide which fuels get subsidies. Any shift in GREET calculations directly impacts the valuation of facilities like Al-Corn.
For Local Landowners: Stay engaged with the carbon capture conversations. Whether you're for or against the pipelines, the reality is that the "Clean" in Al-Corn Clean Fuel increasingly depends on what happens underground.
The transition to a lower-carbon world isn't going to happen overnight with a single "silver bullet" solution. It's going to happen through incremental, gritty engineering at places like Al-Corn. They are taking a 100-year-old crop and forcing it into the 21st-century energy economy. It’s impressive, it’s messy, and it’s absolutely essential for the Midwest’s economic survival in a greening world.