innovative methods for providing 2g feedstock - bio hettenhaus.pdfinnovative methods for providing...

SCALING CELLULOSICSInnovative Methods

For Providing 2G Feedstock

BIO Pacific Rim Conference

December 8, 2014

Jim Hettenhaus, cea Inc

cea Inc 2

OVERVIEW

2G Feedstock

• Plant Locations

• Harvest & Collection

• Transport

• Storage Choices

• Preprocessing

• Conclusion

Dec 8, 2014

cea Inc 3

2 G Commercialization

• Site Choices• Co-Locate: e.g. Poet , Sweetwater

• Hub & Spoke: e.g. AFEX, Pyrolysis,

• Greenfield: Hugoton, DuPont

• Feedstock Factors• Supplier–processor Relationship

• Financing

• History

Dec 8, 2014

Ethanol Plant Locations1999 Iowa Site Study

Dec 8, 2014 cea Inc 4

50, 25 mi radius

Ethanol Plant Locations

2014 Iowa Sites


Ethanol Plant Locations RFA


cea Inc 7

Existing Plant“Bolt On”

• Financing

• Add On--Modules

• Farmer Affordable

• Use 2G feedstock as farmer asset for equity

• Feedstock

• Scalable

• Win-Win

• Farmer

• Existing Plant

• Local Economy

Dec 8, 2014

cea Inc 8

TransportSource Closer to Processor

Stover collected within 5 - 15 mi radius

Dec 8, 2014

Collection

radius,

mi

Total

acres

(000)

Stover

Grown

dt (000)

Stover collected

dt (000)

30% 50% 70%

5 50 143 43 71 100

10 201 571 171 285 400

15 452 1,284 385 642 899

Basis: Corn planted acres, 60%

One Harvest index, 1

Bushels per acre, 250

Hub & SpokeRegional Processing to Liquids

July 2010 cea Inc

Imperial, NE Example,

~200 mile pipe gathering system

Farmer Affordable

Process to Sugars,

other Liquids at Center

Supply Liquids

To Biorefinery

15 mile r

~3,000,000 acres total

9

Terrabon’s Mixalco Process

Pipeline Logistics Example

Oil

RefineryCarboxylate Salts Pipeline

Ketones, Acids, or Alcohols Pipeline

Existing Oil Pipeline

MixAlco Plant

Satellite Fermentors

Riv

er

Bayou

Ocean

July 2010 10cea Inc

cea Inc 11

Greenfield Site

• Site• Locate distant from “Bolt on Threat”

• Financing• Highest Capital

• Longer timeline

• Non-Fungible Feedstock Risk

• Feedstock• Proprietary Supply

• Fungible Possibility

• Win-Win Approach

Dec 8, 2014

cea Inc 12

Harvest & Collection

• Sustainable: New agronomic systems to manage better• Data Driven

• SOC Management

• Lower LCA

• More Productivity• Higher yield

• Improved Collection

• Dry and Wet Feedstock

Dec 8, 2014

cea Inc

Harnessing Technology

for Better Farming

Dec 8, 2014 13

Kip Tom, Tom Farms is

as much a CTO as he is

a farmer.

Lebonan Indiana

Farm has grown from

700 ac in the 70’s to

20,000 ac, ~$50 M sales

with 21.2% ROI.

“My growth comes

from farmers who don’t

embrace technology.”

cea Inc

Calmer Corn Heads51,000 seeds/ac 300 bu/ac corn

Dec 8, 2014 14

30 row-12”

and

32 row-15” spacing below

Calmer Agronomic Research Center

“Planting corn in 12 and 15 inch rows since

the 1990’s demonstrates equidistant spacing

between plants improves light interception

and yield while a denser canopy reduces erosion

and weed control costs.

cea Inc 15

CollectionDry & 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

Feedstock Moisture Comparison 6X more water collected

• 50% M is 3 gal H2O/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


Feedstock

Moisture

Water

lbs

Water

gal

EtOH

gal/dt

gal H2O/

gal EtOH

Annual

Water (Mgal)

50% 2,000 240.1 80.0 3.0 92.4

15% 352.9 42.4 80.0 0.5 16.3

cea Inc

Storage

Dry (Bales) vs Wet Storage

Parameter Dry (bales) Wet, >80% moisture

Fire hazard High None

Storage area 10x 1x

Storage Loss >10% <5%

Process Impact Higher capex-opex Consistent

Financing Adds Risk Secure Asset

Non-fermentable

solubles removal

Process

Residue

Storage

Liquor

Weather Risk Rain, hot weather Same as Grain

Dry Density, lbs/ft3 8 to 12 12 to 14

Infrastructure $ Low to High Low to High

Industry

Proven

Small, mostly

farm use

Large,

Bagasse to Pulp & Paper

Dec 8, 2014 17

PREPROCESSING

Ritter Method Process Flow


Truck

Dump

Wash-

Shred-

(pump)

Wet

Storage

PadPulp

Process

Bagasse

Circulation Liquor• Remove Dust, Dirt

& Solubles

• Recycle clean liquor, soil

and nutrients

cea Inc

Wet Storage

Removes solubles, dirt, dust

Dec 8, 2014 19

Source:Tappi

cea Inc

Wet Storage

Increases Feedstock Yield

Dec 8, 2014 20

Source:Tappi

cea Inc

Stover Storage Validation

Imperial, NE 2005-2008

Stable Internal T, Fº~ 700 dry tons, 35’ high

Dec 8, 2014 21

Wet Storage Composition


Year 2005 2006 2007 2008

Incoming Stover %

Annual Storage Samples

% Dry Matter

Glucan 31 42 42 37

Holocellulose 59 68 66 57

Acid Insoluble Residue 12 17 20 22

Acid Soluble Lignin 3.8 1.5 1.8 2.1

Ash 6.0 6.7 6.9 6.9

Solubles 15 4.8 5.5 8.1

Structural mass 84 94 95 86

Dry Matter Balance 99 98 101 94

Source, Nathan Mosier et al, LORRE, Purdue University

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

• Consistent feedstock quality, Higher fermentation

• More holocellulose in pot ● More production

Summarize

Value Added Wet Feedstock

Dec 8, 2014 23

cea Inc

Future Outlook

Collection & Processing

• Farmer Affordable Business Model

• Expand local Dry Mill with 2G sugars

• Manage Residue, improved agronomic systems

• Debt financing possible w/ wet storage asset?

• Logistics

• Shrink residue collection area to local dry mill corn supply

• Move away from dry storage

• One pass harvest: e.g. ear, stalk

• Wet Collection & Storage Liquor Management

• Preprocessing

• Recycle Feedstock Dirt, P, K

Dec 8, 2014 24

Thank You

Jim Hettenhaus

704.541.9500

[email protected]


OVERVIEWSustainable, Economic, Reliable, LCA?

• Removal impact? ● Storage?

• Collection? Fire Risk

• Who? When? Yield

• Condition? Downstream Effect

Compaction? Foot Print

• Will it sell? Debt Financing

• Contract? For how long? Water Management

• Transport

• Field to Storage ● Storage to Process


Dry Storage Cost

• Quantifiable

• Bale Yield shrinkage

• 10 x land

• Non Fermentable Solids Capacity loss

• Process Waste Disposal

• Water management

• Dust hazard—CAPEX and OPEX


Hay Trailer FireI-25, Colorado Springs-Denver


cea Inc

Bale Loss in Storage

Harlan Iowa, 1997

Dec 8, 2014 29

Recent Corn Stover Fires

“Couple Sues DuPont”


Abengoa’s Bales

Up in Smoke

DuPont Fire &

Resulting Lawsuit

Nevada, Iowa

http://3.bp.blogspot.com/-Zr-IAtWX2gs/UcfXUl0ve_I/AAAAAAAAAOk/At4ltUzHh8w/s1600/MoscowFire.jpg

http://3.bp.blogspot.com/-Zr-IAtWX2gs/UcfXUl0ve_I/AAAAAAAAAOk/At4ltUzHh8w/s1600/MoscowFire.jpg

Anderson Cob Fire

Delphi, IN


cea Inc

Bagasse Bale Storage (1930-1960)

Dec 8, 2014 32

cea Inc

“Ritter Process”

Pulp Mill Storage

Dec 8, 2014 33

Dr. Joe Atchison

cea Inc

Multiple Piles

Pipe to Top of the Stack

Dec 8, 2014 34

cea Inc

Stover Storage Validation

Imperial, NE 2005-2008

Dec 8, 2014 35

USDA Grant

cea Inc

Modified “Ritter Method”Biological Basis

• “biological liquor” addition not needed

• Plenty of wild organisms

• pH drops to 4.2 or less

• Sugar in feedstock, 1% to 3%

• Residual in corn stover and bagasse

• Molasses added if needed

• Circulate: Complete Saturation of Fiber

• Compacts Pile

• Anaerobic conditions

Dec 8, 2014 36

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