FEEDING A CELLULOSIC ETHANOL PLANT:

THE FEEDSTOCK LOGISTICS OF POET-DSM’S PROJECT LIBERTY

Adam Wirt – POET BiomassMN Biomass Sustainability Forum – December ‘14

DISCUSSION TOPICS▪ What is Project LIBERTY

▪ Supply Chain Development Parameters

▪ Project LIBERTY Biomass Program Overview

▪ Major Takeaways

▪ 20 million gallon Cellulosic Ethanol Plant, rising to 25 million

▪ Co-located with an existing grain-based ethanol plant

▪ Utilizes existing infrastructure▪ EZ Bales™ are the feedstock▪ Byproduct of cellulosic process (lignin)

is used to generate steam that will power both plants, reducing energy costs

▪ Operated by the POET-DSM Advanced Biofuels Joint-Venture

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▪ 20 million gallon Cellulosic Ethanol Plant, rising to 25 million

▪ Co-located with an existing grain-based ethanol plant

▪ Utilizes existing infrastructure▪ EZ Bales™ are the feedstock▪ Byproduct of cellulosic process (lignin)

is used to generate biogas that will power both plants, reducing energy costs

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STACKYARD

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GROWTH PLATFORM – WHY CORN STOVER▪ POET has 27 biorefineries across the corn belt where we can

co-locate+ 4-plants in Minnesota

▪ Our partner (DSM) wants to help us license this technology, both domestically and internationally.

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POET’S BIOMASS HISTORY

‐ POET researched how to collect and 

store cobs

‐ Single‐Pass Baling was trialed, along 

with cobs

‐ First Commercial Harvest of Biomass Ever for Cellulosic Ethanol with EZ Bale™ being the new feedstock

‐ The Stackyard at Project Liberty was 

built

‐ Second  & Third Biomass Harvest with Expanded 

Acres‐ Roll‐out of the Custom Model

‐ Fourth Commercial Harvest Material from the Fourth 

harvest will be used to make cellulosic 

ethanol

‐ 200,000 BDT of Material Collected‐ 300+ Growers 

involved‐ 10 Custom Baling 

Crews

2006,2007 & 2008 2009 2010 2011 & 

2012 2013 2014

ISU – UDSA: Biomass Removal Soil Research (7 Years)

SUPPLY CHAIN DEVELOPMENT

The questions that needed to be answered:▪ Agronomics of Removal

▪ Take-rates/Collection Rates

▪ Economics - Grower & Biorefinery

▪ Plant Needs/Specs

▪ Equipment Needed

▪ Grower/Community Education

USDA-ISU REPORT: CORN STOVER NUTRIENT REMOVAL ESTIMATES FOR CENTRAL IOWA

Macronutrient Nitrogen Phosphorus Potassium

Lbs./Ton Removal 14 1.4 16

Observed Macronutrient Removal RatesOne Ton/Acre Harvest

- Based on 6 years of Study

▪ No change in Organic Matter seen with EZ Bale™ removal▪ Main drivers of Organic Matter change due to tillage

intensity

NUTRIENT REMOVAL LEVELS ASSOCIATED WITH RESIDUE REMOVAL

ISU/USDA Recommendations:▪ 10-15 lbs of Potassium/acre (based on 1BDT/ac removal rate)▪ No additional Nitrogen or Phosphorus needed▪ No change in OM seen with EZ Bale™ removal

0.0

5.0

10.0

15.0

20.0

25.0

Nitrogen Phosphorous Potassium

Removal Rate (lb

s. /ton stover)

Soil Nutrient

Nutrient Removal by Harvest Scenario (Average) 

 Cob harvest

MOG Bulk harvest

MOG Direct Bale harvest

High‐Cut, below ear stover harvest

Multiple‐pass round bale harvest

Low‐Cut, 4 inch stubble harvest

EZ Bale™

RECOMMENDATIONS FOR FIELD TREATMENTS● Use current grain-based Nitrogen and Phosphorus

fertilizer application rates● Soil test to verify that grain-based fertilizer rate for

Potassium meets sustainability needs● Incorporate effects of cover crops, manure, diverse crop

rotations in future biomass feedstock studies

GOOD CANDIDATES FOR BIOMASS HARVESTING● Slopes of less than 3 percent● Consistent grain yields of >165 bu/acre● Good nutrient-management plans with soil-test records

of at least pH, P and K levels

BOOST YOUR CORN YIELDS ON CORN ON CORN

Work done by USDA - ISU

Residue removal allows for:

Darker, faster warming soils

Better seed to soil contact

Improved germination

Better potential = Better yield

163.8

165.0

164.4

163.2

163.4

163.6

163.8

164.0

164.2

164.4

164.6

164.8

165.0

165.2

Conventional EZ Bale Rake & Bale

Bu/A

c

Grain Yield by Biomass Treatment (Avg 2008‐2012)

Grain Yield by Biomass Treatment

EZ BALES™ = THE NEW “EAR CORN”

Ear corn has been picked for decades sustainably, EZ Bales™ are just a new way of performing the same task.

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WHICH BALE IS BETTER?EZ BALE™ VS. STOVER BALE

▪ EZ Bale™ + 33% cob+ 43% husk/leaf+ 16% stalk+ 8% ash

▪ Stover Bale+ 9% cob+ 42% husk/leaf+ 35% stalk+ 14% ash

EZ Bale™ • 24% more cob, 19% less stalk, 6% less ash per bale• 288 lbs. more cob, 228 lbs. less stalk, 72 lbs. less ash

in every 1200# bale Less nutrients removed per ton of biomass

removed

HISTORY OF CORN PRODUCTION

BIOMASS COLLECTION IS THE NEXT STEP IN THE EVOLUTION OF FARMING.

LIBERTY FEEDSTOCK PROGRAM OVERVIEW

▪ At full production, LIBERTY will consume ~285k bone dry tons of biomass annually.

▪ EZ Bales™ is the feedstock.+ Will collect 1-ton from 285-300k

acres.

▪ Target collection range is 35 miles from plant or ~30% of the total acres.

▪ We estimate 450 – 500 farmers will participate in the delivery of biomass.

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PROJECT LIBERTY BIOMASS PROGRAM▪ Offer grower choice of participation

+ Grower Model + Custom Model

▪ Bale type – We take them all!+ PBM can manage the benefits of both

▪ Quality+ Stover can be too dirty, take rate can be too

aggressive+ EZ Bales™ - Cleaner, grower acceptance

▪ Local Development of Business+ Equipment Dealers+ Custom Contractors

COLLECTION BEST PRACTICES• SOP for sustainable collection• Minimize dirt and stalk• Ensure biomass integrity & value• Drive consistency

This

Not This

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BALER SET UP IS CRITICAL, BUT MANAGEABLE

BIOMASS COLLECTION = OPPORTUNITY FOR IMPROVED FARMING PRACTICES▪ Biomass Removal is an enabler of improved farming

practices.

▪ Soil Carbon levels are the most impacted by tillage intensity.+ By removing some fractional amount of stover, tillage

intensity &/or number of tillage passes should be reduced.

▪ Below ground biomass is the key to increasing soil health by improving soil organic carbon and organic matter levels.

▪ Biomass Removal is a residue management tool. + When aligned with the right practices, soil

health and productive can be enhanced.

SUSTAINABLE

▪ The term “Sustainable” carries multiple personal definitions.+ Many times these do not match.

▪ Lets focus on metrics such as:+ Soil Erosion+ Soil Organic Matter+ Soil CarbonThese factors all associate to “Soil Health”

LANDSCAPE DESIGN▪ Not every site will be as much of a monoculture as the

that of LIBERTY▪ Landscape design has been discussed with future

locations▪ Dedicated energy crops offer great opportunity:

+ Risk mitigation+ Extended harvest scenarios or multiple harvest

periods+ Offer biomass source while also protecting erodible

soils and buffer strips. ▪ The key is to create the bio-economy market.

+ Without a bio-energy plant, a grower will not consider changing their cropping patterns.

MAJOR TAKEAWAYS1. Education is Key.

2. Biomass Harvesting is an important Farm Management Tool.

3. Biomass removal is not the major variable affecting erosion and organic matter change.

4. Continued work is needed to do prescribed biomass removal across fields.

5. Get the growers and community involved.

IN CONCLUSION

▪ Who Wins+ The Growers+ The Bio-refiner+ The Vendors+ The Community+ The Land+ The Consumer

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Thank YouCheck out: www.poetdsm.com