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

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Bale Loss in StorageHarlan Iowa, 1997

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Bagasse Bale Storage (1930-1960)

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Non-Wood Pulp Mill Storage Since 1950s

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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

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Ritter Wet Storage Process Flow

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TruckDump

Wash-Shred-(pump)

WetStorage

PadPulpProcessFeedstock

Circulation Liquor

Process Water

Remove Dirt

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Multiple PilesPipe to Top of the Stack

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Stover Storage ValidationImperial, NE 2005-2008

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USDA Grant

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Stover Storage ValidationImperial, NE 2005-2008

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

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Wet Storage Composition

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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

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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

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Wet StorageRemoves solubles, volatiles

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Source:Tappi

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Wet StorageIncreases Feedstock Yield

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Source:Tappi

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SummaryFeedstock Storage

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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

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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?

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Ethanol Plant Locations RFA

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Ethanol Plant Locations1999 Iowa Site Study

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50, 25 mi radius

Hay Trailer FireI-25, Colorado Springs-Denver

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Recent Corn Stover Fires“Couple Sues DuPont”

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Abengoa’s Bales Up in Smoke

DuPont Fire &

Resulting LawsuitNevada, Iowa