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Why 2g Sugar ProcessShould Begin
with Wet Feedstock Storage
Jim Hettenhaus, cea IncABFC
New Orleans, LAJune 2015
INTRODUCTIONStover 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
cea Inc
Bale Loss in StorageHarlan Iowa, 1997
June 2015 3
cea Inc
Bagasse Bale Storage (1930-1960)
June 2015 4
cea Inc
Non-Wood Pulp Mill Storage Since 1950s
June 2015 5
Dr. Joe Atchison
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
Ritter Wet Storage Process Flow
June 2015 cea Inc 7
TruckDump
Wash-Shred-(pump)
WetStorage
PadPulpProcessFeedstock
Circulation Liquor
Process Water
Remove Dirt
cea Inc
Multiple PilesPipe to Top of the Stack
June 2015 8
cea Inc
Stover Storage ValidationImperial, NE 2005-2008
June 2015 9
USDA Grant
cea Inc
Stover Storage ValidationImperial, NE 2005-2008
Stable Internal T, Fº~ 700 dry tons, 35’ high
June 2015 10
Wet Storage Composition
June 2015 cea Inc 11
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
Component
Wet Storage CompositionEconomic Effect
June 2015 cea Inc 12
Source, INL and NREL models, 2013
2005 06-'07 ChangeHolocellulose 59% 68% 9%
Solubles 15% 5% -10%
• More Holocellulose . . . . $0.20/gal EtOH• Less Solubles, $2.25 dt/% . . $22.5/dt
Improved Yield & Less Process Waste
cea Inc
Wet StorageRemoves solubles, volatiles
June 2015 13
Source:Tappi
cea Inc
Wet StorageIncreases Feedstock Yield
June 2015 14
Source:Tappi
cea Inc 17
SummaryFeedstock Storage
June 2015
PARAMETER DRY (Bales) WET (Ritter)Fire Hazard High NoneDirt & Solubles Remain in Bale Removed in Pile & Recycled Process Impact of Dirt & Solubles
Dust Explosion HazardHigher Maintenance
Process Waste
No DustLess Equipment Wear
More Fermentor Utilization
Storage Area 10x 1xStorage Height Bale Stack Limits Pump Head limit ( >50ft )Storage Loss >10% <5%Weather Risk Rain, Hot Weather NoneIndustry Proven
Small, mostly farm use Large, >100,000 dt/yr (non-wood pulp mills)
Project Financing Adds Risk Secure AssetMoisture Limit < 20% Unlimited
cea Inc
Future OutlookCollection & 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 2015 18
Ethanol Plant Locations RFA
Dec 8, 2014 cea Inc 19
Ethanol Plant Locations1999 Iowa Site Study
Dec 8, 2014 cea Inc 20
50, 25 mi radius
Hay Trailer FireI-25, Colorado Springs-Denver
June 2015 cea Inc 21
Recent Corn Stover Fires“Couple Sues DuPont”
June 2015 cea Inc 22
Abengoa’s Bales Up in Smoke
DuPont Fire &
Resulting LawsuitNevada, Iowa