PowerPoint Presentation

Catawba CountyRegional EcoComplex and Resource Recovery FacilityUsing Existing Landfill Gas Project to Produce Additional Renewable EnergyJeff Ramsdell, Ph.D., P.E.Appalachian State University

Barry B. Edwards, P.E.Director of Utilities and EngineeringCatawba County1

The EcoComplex Catawba County, NC

WHERE: Catawba County- located near Hickory NC in WNC, 1 hour northwest of Charlotte.Population 150,0008 incorporated municipalities

2Catawba County EcoComplex & Resource Recovery FacilityEcological-industrial parkSynergetic waste and resource management, renewable energy production, and local economic development Public Private Partnerships 805 acres around Blackburn Landfill 452 tons/day of municipal and 88 tons of construction waste daily. 3MW grid-tied LFGTE - GE-Jenbacher engines.

WHAT: Eco-Industrial Park

31990 NC Waste Reduction Mandate1990 baseline 1.51 tons/capita10% by 2000 (1.36 tons/capita)15% by 2005 (1.28 tons/capita)20% by 2010 (1.21 tons/capita)25% by 2015 (1.13 tons/capita)34% by 2020 (1 ton/capita)

WHY: 1990 Waste Reduction Mandate165,000 TONS/YEAR

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FY 2008-09 at 1.10 tons/capita

STRATEGY:INDUSTRIAL ECOLOGY

HOW: Industrial Ecology6Site Plan

Landfill Gas to Energy

Anchor tenants

Testing site established in 1999LFG flow 1,000 scfmFrom 452 municipal solid wasteNo purification/filtration of gas, top end rebuilds and maintenance in stead8

Average output: 2.3MW +8.1 MMBtus Waste Heat

1MW capacity eachOver 15M BTUs/hr recoverable heat9Blackburn Landfill, Catawba County, NCFacility began producing electricity in November 1999Facility has operations at a 94% up-timeTo date, facility has produced 168,000 MW electrical+ Electrical Sales of $5,698,595+$257,258.00 in REPI+$279,041.00 in RECFacility has provided electricity to approximately 600 average homes annually10Current and Future Uses of Waste Heat from Electricity Production

Biodiesel Research & Production Facility

Algae Growth and Research for Mitigating CO2

Biosolids Management Facility

Solid Waste Digester11Heat energy employed in various capacities. I will touch on each of these in the next few slidesPrivate Industrial Partners

Pallet One

Gregory Wood Products

Public Private Partnerships:Gregory Wood Products: 65,000 BF/hr capacityPallet One: largest new pallet manufacturer in the US (17 facilities in 11 states- 4 in NC)12

1.9MW, + 6.7MM Btus Heat

Wood Waste Gasification15,000-20,000 dry tons of clean wood fuel/year1.9MWWaste heat to provide process heat for Kiln 13

Multi-Feed Anaerobic DigesterAg & Food WastesAlgaeAnimal ManuresMixed PaperWastewater sludge

Organic Waste Anaerobic Digester Facility - The Organic (Sewage, Animal and Food Waste) Anaerobic Digester Facility will consist of two newly constructed anaerobic digesters. One digester will be used to process sewage (wastewater sludge) from wastewater plants and the other digester will process animal and food wastes. Biogas from both digesters will be used to produce electricity and heat through the operation of GE-Jenbacher Generator sets.14Oilseed Feedstock Crops & Processing

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200 acres on EcoComplex buffer area for row cropsDouble crop potential of rapeseed/sunflower in NC: 3.5-5 tons/acre and 220 gal oil/acre/year.(7.7-11.2 tons/Ha/yr and 2,000 Liters Oil/Ha/yr)Sunflower: 2-3 tons/acre 100galoil/AcCanola: 1.5-2 tons/Ac 120gal oil/AcAfter two years, follow double crop with soy/rapeseed or soy/winter wheat.

Feedstock Processing StationCapacity: 100,000 gal oil/year (~400,000 liters oil/year)Crop area (with double cropping): 450 Ac (180 Ha)Material handling: 1900 tons seed/year, 1300 tons of meal

15Oilseed Feedstock CropsDouble crop potential of rapeseed/sunflower in NC: 3.5-5 tons/acre = 220 gal oil/acre/year.(7.7-11.2 tons/Ha/yr = 2,000 Liters Oil/Ha/yr)

Sunflower: 2-3 tons/acre 100galoil/AcCanola: 1.5-2 tons/Ac 120gal oil/AcAfter two years, follow double crop with soy/rapeseed or soy/winter wheat.

16EcoComplex Feedstock Processing StationCapacity: 100,000 gal oil/year (~400,000 liters oil/year)Crop area (with double cropping): 450 Ac (180 Ha)Material handling: 1900 tons seed/year, 1300 tons of meal

Capacity: 100,000 gal oil/year (~400,000 liters oil/year)Crop area (with double cropping): 450 Ac (180 Ha)Material handling: 1900 tons seed/year, 1300 tons of meal17Cellulosic Ethanol/ Algae

Alternative Cap

200 acres of landfill cap, Cellulosic ethanol yield from switchgrass = 400 gal/acre18Gen-Set Heat employment:Injecting CO2 into Algae ponds to facilitate growthBlending Algae with oilseed meal to enhance livestock feedAlgae used as soil amendment in Greenhouse Possible gasification in Bio-Energy FacilityAlgae for Mitigating CO2Algae will be grown in greenhouse setting primarily for mitigating CO2

Too costly to extract oil for biofuel production. However, we will be getting energy from algae in some fashion (gasification, digestion, livestock feed-to-livestock waste). 19

BIOMASS ENERGY POTENTIAL

FeedstockProcessEnergy TypeNet Energy (MW)Net Heat (MMBtus)Annual Energy (MWh)Annual CO2 Reduction (metric tons)MSWAnaerobic DigestionLandfill Gas2.38.0919710.011826.0TriglyceridesTranesterifi-cationMethyl Esters100,000 gal/yearN/A3516.02109.6Wood fuelGasificationSyn Gas1.96.6814979.68987.8Biosolids/algaeAnaerobic DigestionMethane1.03.527884.04730.4Perennial Grass/energy cropsCellulosic EthanolEthanol80,000 gal/yearN/A1758.01054.8TOTALS5.218.347847.628708.5

Appalachian Biofuels Research and Testing Facility A Vision

GOLD LEED CERTIFIED22Biodiesel Production Chain at Catawba County EcoComplex23

ProcessesAnalyticsNIR-spec ProbeGC-MSQA/QC -Reduced Spec ASTM D6751Free & Total GlycerinFlash pointSulfated AshAcid NumberPhosphorousWater & sedimentCold Flow

Process HeatingCatalystsReactant mixingMethanol recovery Fuel washingGlycerol separation & refiningCo-product developmentProcess Efficiency (Energy Balance)Modular TestingCatalyst: acid/baseReactant mixing: pump mix, shear mix, cavitation mixGlycerol refining w/ KOHMethanol recovery: vacuum, energy intensity, Clean-up: Water, magnesium silicate, ion exchange- hybrid washing systemsBy-products- recovered fuel from wash water w/ acidulation24Appalachian Biofuels Research and Testing Facility A Reality

Appalachian Biofuels Research and Testing Facility A Reality

Oil Extraction and Refinement Research and Outreach

Biofuels Emissions Analysis The Need

Source: NREL/TP-580-30004Biofuels Emissions Analysis A Vision

Biofuels Emissions Analysis A Reality

Returns Emissions in g/km, g/kg fuel, g/s, or g/bhp-hr: CO2, CO, SOx, NOx, THC, Particulate Matter

Visit the EcoComplex

Barry B. Edwards, P.E.Director of Utilities and EngineeringPhone 828.465.8261barrye@catawbacountync.gov

Jeremy FerrellBiodiesel Operations & Outreach ManagerAppalachian Energy Centerferrelljc@appstate.edu

Utilities and Engineering site: www.catawbacountync.gov/depts/u&e31