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2005 OBP Bi-Annual Peer Review Fran Ferraro Merrick & Company Sealaska Corporation Southeast Alaska Ethanol Project Integrated Biorefinery Session November 16, 2005
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Overview Time Line Proj. Start: 6/03 Proj. End: 12/06 55% Complete Stage Stage 3 Development Pilot Testing Barriers Contaminated Feed Mat’l Scale-up Integration Yield/Costs Budget Total Proj. Start: $5,350,021 Project End: $5,350,021 58% Complete Partners Sealaska Corporation Merrick & Company USDOE USDA
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Project Goals and Objectives Select and demonstrate suitable technologies to convert SE Alaska wood residues to Ethanol for the Alaska market. Previous – established project concepts and economics. Select gasification (steam reforming) technology Select ethanol conversion technology Confirm suitable gas cleanup technologies Pilot test technologies on contaminated wood residue Design commercial scale facility Construct and operate wood residue conversion to ethanol
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Project Strategic Fit Relevance to Platform and Pathway Objectives and Barriers Thermochemical Platform – Feed and Thermochemical Processing, Gas Clean-up Products – Fuels, Chemicals, CHP Integrated Biorefineries – Ag Residues, Energy Crops, Pulp & Paper, and Forest Products Mill Improvement Pathways
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Technology Fit and Demo Vision Technology Fit for Sealaska/Merrick Regional timber and lumber processing Residues environmental control Alaska ethanol market Multiple Biomass-to-Ethanol projects Demo Phase Vision by 2008 Design Basis and Costs – early 2006 Financing and Design – 2006 to 2007 Construction – 2007 to 2008 Ready
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Project Approach & Design Technical Barriers Feed -Preparation -Contaminants Gasification (Steam Reforming) -Gas Composition – yield -Gas Cleanliness Conversion -Yield vs. Costs -Fermentation – limitations? -Catalytic Process Efficiency -Waste Energy Utilization -Tail Gas Process Integration Project Design Practical Syngas Quality and Quantity Practical Conversion – Integrated Practical Energy Utilization – Integrated Later – Improve all 3
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Technical Feasibility Feed Preparation Contaminants Gasification (Steam Reforming) Syngas Composition Syngas Cleanliness Conversion Alcohol Yield(s) Heat Utilization Tail Gas
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Project Tasks Select Technologies Basis – yield 70 gal per Dry Ton Compatible with feed and product Risks – readiness, suitability for feed, yield, cost Pilot Demos – Integrated Process Commercial Scale Design Basis and Cost Estimate Design, Build, Run Demo – 2006 – 2008 Adjust designs for other project feedstocks, locations, etc Commercial Operating Plants
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Competitive Advantages Suitable for numerous feedstocks with proper preparation Superior yield vs. costs Integrated heat/energy and potential export Potential Show-Stoppers: Scale-up Demo 200 – 250 DTPD Integration with reasonable costs Initial Projected Economics Future Projected Economics
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Commercial Scale Design Basis Commercial Scale Design Basis and Cost Estimate Basis – 6 mm gal/year AK facility on salt water contaminated wood residue Risks: cost, business Milestones – cost $30 - $40 mm, business/technology useful elsewhere Go/No-Go – Economic Return on net Equity Investment Accomplishments – underway Future Plans – more feedstocks and locations, heat and power integrated
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Project Collaboration Sealaska Corporation with Merrick & Company USDA, USDOE, NREL Technologies – Enerkem Technologies, Inc.; ThermoChem, Inc.; Bioengineering Resources, Inc.; BioConversion Technology, LLC Industry – other similar projects – RDF, Pet Coke, Ag Residues Alaska – AIDEA, AEA, Ketchikan Gateway Borough
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Market & Customers Ethanol Product – fuel blending Heat and Power – users Costs Ethanol @ $0.90/gal. depends on scale and other aspects Current/Future Market Shifts
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Competitive Advantage Window – next few years Competing Technology – gasification and fermentation or other catalytic conversions Ready for commercial demo, yield Market Change – fuel and octane blending value; min. costs from other producers Economic/Investments – multiple interested project developers with suitable economics
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Project Stage Stage 3 – Development Pilot Testing and Commercial Scale Design Basis
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Progress and Accomplishments Pilot Testing – Integrated Platform – Integrated Thermochemical Platform Conversion to Ethanol Project – Technologies and business compatible
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Future Work Final Integrated Pilot runs on AK feed material Commercial Plant Design Basis and Cost Estimate Design, Build Demo Milestones: Pilot Runs – 12/05 Design Basis – 2/06 Cost Estimate – 3/06 Design Underway - 2006
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Contact Information Francis (Fran) Ferraro Senior Technical Specialist Merrick & Company 2450 S. Peoria Street Aurora, CO 80014-5472 Phone: (303) 751-0741 Fax: (303) 368-1299 Email: fran.ferraro@merrick.com
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