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Why 2g Sugar Process Should Begin with Wet Feedstock Storage Jim Hettenhaus, cea Inc ABFC New Orleans, LA June 2015
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INTRODUCTION Stover Harvest Experience Harlan, Iowa –1997 Wisconsin and Illinois -- 1998 FIRES HARVEST RISK FOOTPRINT BALE DETERORIATION DIRT etc Has to be a Better Way! June 2015 cea Inc 2
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Bale Loss in Storage Harlan Iowa, 1997 June 20153
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cea Inc Bagasse Bale Storage (1930-1960) June 20154
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cea Inc Non-Wood Pulp Mill Storage Since 1950s June 20155 Dr. Joe Atchison
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Wet Storage Basics 30 to 40% DM.... Serious Decomposition ~50% DM (bagasse).... Some Degradation Pile can develop ‘hot spots’ Corrected by moving the material around E. A. Ritter Method (1950).... > 80% DM Circulates liquor to build and saturate pile Added proprietary microbes to ferment sugars Modified Ritter Method... Wild Microbes June 2015 cea Inc 6
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Ritter Wet Storage Process Flow June 2015 cea Inc 7 Truck Dump Wash- Shred- (pump ) Wet Storage Pad Pulp Process Feedstock Circulation Liquor Process Water Remove Dirt
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cea Inc Multiple Piles Pipe to Top of the Stack June 20158
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cea Inc Stover Storage Validation Imperial, NE 2005-2008 June 20159 USDA Grant
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cea Inc Stover Storage Validation Imperial, NE 2005-2008 Stable Internal T, Fº~ 700 dry tons, 35’ high June 201510
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Wet Storage Composition June 2015 cea Inc 11 Source, Nathan Mosier et al, LORRE, Purdue University Component
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Wet Storage Composition Economic Effect June 2015 cea Inc 12 Source, INL and NREL models, 2013 200506-'07Change Holocellulose59%68%9% Solubles15%5%-10% More Holocellulose.... $0.20/gal EtOH Less Solubles, $2.25 dt/%.. $22.5/dt Improved Yield & Less Process Waste
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cea Inc Wet Storage Removes solubles, volatiles June 201513 Source:Tappi
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cea Inc Wet Storage Increases Feedstock Yield June 201514 Source:Tappi
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cea Inc 15 Collection Dry & Wet Feedstock Dry Collection Problems include: Short, weather dependent collection window Fire hazard to transport Wet collection (for Wet Processing) Reduces collection risk Improves scheduling Increases utilization: equipment and labor Adds Water for Process Increases Load Weight Dec 8, 2014
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Feedstock Moisture Comparison 6X more water collected 50% M is 3 gal H 2 O/gal EtOH ( The same ratio as present dry mill usage RFA ) Additional 76 MGPY for 30 MGPY Basis: 1 dry ton feedstock, 1100 dt/day, 30 MGPY Dec 8, 2014cea Inc 16 Feedstock Moisture Water lbs Water gal EtOH gal/dt gal H 2 O/ gal EtOH Annual Water (Mgal ) 50%2,000240.180.0 3.092.4 15%352.942.480.0 0.516.3
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cea Inc 17 Summary Feedstock Storage June 2015 PARAMETERDRY (Bales)WET (Ritter) Fire Hazard HighNone Dirt & Solubles Remain in BaleRemoved in Pile & Recycled Process Impact of Dirt & Solubles Dust Explosion Hazard Higher Maintenance Process Waste No Dust Less Equipment Wear More Fermentor Utilization Storage Area 10x1x Storage Height Bale Stack LimitsPump Head limit ( >50ft ) Storage Loss >10%<5% Weather Risk Rain, Hot WeatherNone Industry Proven Small, mostly farm useLarge, >100,000 dt/yr (non-wood pulp mills) Project Financing Adds RiskSecure Asset Moisture Limit < 20%Unlimited
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cea Inc Future Outlook Collection & Processing Logistics Shrink residue collection area to local dry mill corn supply Move away from dry bale storage One pass harvest: ear, stalk and/or other Wet Storage Water Management Wet Process Water Source, ~200 to 240 gal/dt residue Return Feedstock P, K, soil to field, not to process Farmer Affordable Business Model Expand local Dry Mill with 2G sugars Manage Residue, improved agronomic systems Debt financing possible w/wet storage asset? June 201518
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Ethanol Plant Locations RFA Dec 8, 2014 cea Inc 19
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Ethanol Plant Locations 1999 Iowa Site Study Dec 8, 2014 cea Inc 20 50, 25 mi radius
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Hay Trailer Fire I-25, Colorado Springs-Denver June 2015 cea Inc 21
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Recent Corn Stover Fires “Couple Sues DuPont” June 2015 cea Inc 22 Abengoa’s Bales Up in Smoke DuPont Fire & Resulting Lawsuit Nevada, Iowa
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cea Inc Dry storage problems Fires ● > 10% yield loss ● 10x space Dust, Dirt ● Liability ● Moisture ● Viable Asset Collection Risk Dry: Field drying risky, schedule uncertain Wet biomass collected in field Downstream Effect: Lower processing cost Less ash, solubles ● Improves feedstock quality More holocellulose ● More production Summarize Value Added Wet Feedstock June 201523
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Economic Effect INL Estimate June 2015 cea Inc 24
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