The Changing Nature of Organics: Emerging Strategies for Managing the Low Hanging Fruit (and other Organics) 12 th Annual Conference on Renewable Energy from Organics Recycling John G. Carlton, P.E., BCEE, Vice President Gershman, Brickner & Bratton, Inc. 1 The Times They Are a- Changin -Bob Dylan 2 Gershman, Brickner & Bratton, Inc. 1
Outline Organic Wastes in the US Waste Conversion Technologies Lots of Companies Lots of Interest Selected Technologies and Projects Summary and Trends for Future Q&A 3 Established in 1980 Solid Waste and Technology Consultants Helping Clients Turn Problems into Opportunities GBB Overview 4 Gershman, Brickner & Bratton, Inc. 2
GBB Waste Waste Technology Services Economic, technical and environmental reviews Procurements Due diligence Waste characterization and sourcing Process planning and design Independent feasibility consultant 5 Organic Wastes in the US 6 Gershman, Brickner & Bratton, Inc. 3
US MSW Management Recovery 34% WTE 12% Landfill 54% Recovery 24% WTE 7% Landfill 69% EPA Estimate: 250 million tons BioCycle Estimate: 389 million tons 2010 2008 7 US MSW Disposal (post recycling) Yard 9% Food 21% Non-Organics 46% Wood 8% Paper 16% Source: USEPA 8 Gershman, Brickner & Bratton, Inc. 4
Waste is A-Changin Material 1994 2009 Difference Paper 32.9% 16.1% -51.1% Plastic 11.8% 17.2% 45.8% Metals 6.3% 8.5% 34.9% Glass 6.4% 5.5% -14.1% Organics 31.5% 37.6% 19.4% Hazardous N/A N/A N/A Source: USEPA, Municipal Solid Waste Generation, Recycling, and Disposal in the United States, 1995 and 2011 9 Waste Conversion Technologies 10 Gershman, Brickner & Bratton, Inc. 5
592 (and counting) Companies Offering Technology and/or Development Services 31 Aerobic Composting 110 Anaerobic Digestion 36 Ethanol Fermentation 175 Gasification 47 Plasma Gasification 52 Pyrolysis 63 WTE: mass burn, modular, RDF 78 Others (agglomeration, autoclave, depolymerization, thermal cracking, steam reforming, hydrolysis) 11 143 Conversion Companies Operating Commercial/Demonstration Facilities 64 Anaerobic Digestion 47 Gasification 13 Plasma Gasification 19 Pyrolysis 12 Gershman, Brickner & Bratton, Inc. 6
Some US Locations Investigating/Advancing Waste Conversion Technologies Ada County, ID Baton Rouge, LA City of Allentown, PA City of Cleveland, OH City of Dallas, TX City of Glendale, CA City of Plano, TX City of San Antonio, TX City of Taunton, MA Columbia, SC Fulton, MS Lake County, IN Los Angeles County, CA Prince William County, VA Salinas Valley, CA San Bernardino County, CA Storey, NV Vero Beach, FL 13 Conversion Technology Processes and Products Conversion Technology Primary Product Product Conversion Secondary Product Pyrolysis Char Extraction Chemicals Gasification Tars & Oils Upgrading Gasoline Feedstock *may be preprocessed Combustion Syngas Heat Synthesis Engine Methanol Anaerobic Digestion Ethanol Fermentation Aerobic Composting Biogas Ethanol Compost Gas Turbine Boiler Ammonia Electricity 14 14 Gershman, Brickner & Bratton, Inc. 7
Selected Waste Conversion Technology Companies and Projects 15 Location Edmonton, Alberta, CA Technology Commercialization Vero Beach, FL Storey, NV Fulton, MS Columbia, SC Technology Gasification/ Catal.Conv. of Syngas Gasification/ Ferment. of Syngas Gasification/ CatalyticConv. of Syngas Acid Hydrol./ Ferment. of Sugars Anaerobic Digestion Developer Enerkem INEOS Bio Feedstock Throughput (TPD) Energy Products Non-recycled MSW Yard, vegetative, resid. waste Fulcrum Bioenergy Post-sorted MSW Bluefire Renewables Wood Waste W2E Organic Power Source-Sep. Organics 300 450 400 720 150 Methanol; Ethanol Ethanol Ethanol; Propanol Ethanol Electricity Cost $80M $130M $120M $334M $23M Federal Grants/Loan Guarantees $23.5M $125M -- $88M -- Start Date Fall 2012 June 2012 June 2013 June 2013 2012 16 Gershman, Brickner & Bratton, Inc. 8
Commercial demonstration facility Westbury, Quebec (since 2009, 1.3 million gallons/year) On going projects on commercial facilities: Edmonton, Alberta- 10 mill gal/year,start-up 2013 Pontotoc, Mississippi & Varennes, Québec, each 10 mill gal/year Feedstocks include MSW, wood chips, treated wood, sludge, petcoke, spent plastics and wheat straw Enerkem s Westbury Facility 17 Enerkem Process 18 Gershman, Brickner & Bratton, Inc. 9
Gasification followed by biocatalyst fermentation and distillation Organics to Bioethanol Plants: Fayetteville, AR- pilot plant Vero Beach, FL o processes150,000 tpy MSW o produce 8 million gal/year ethanol and 6 MW (gross) of electric power Lake County, IN) - under development Indian River BioEnergy Center August 2012 Pilot facility in Fayetteville, AR 19 Feed Handling Gasification Fermentation Ethanol 20 Gershman, Brickner & Bratton, Inc. 10
INEOS Bio s Vero Beach, FL August 2012 21 Fulcrum BioEnergy Sierra BioFuels- commercial plant under construction in City of McCarran, NV o 10.5 million gal/year o Permitting completed o Feedstock and off-take agreements completed o USDA $105 million loan guarantee in August 2012 o Estimate completion in 2 nd half of 2013 22 Gershman, Brickner & Bratton, Inc. 11
Fulcrum BioEnergy 23 Targeted Fuel Extraction (TFE) process cost effectively transforms MSW: Dirty MRF separates, processes organic and hydrocarbon fractions Converts organic fraction into cellulosic biofuel through hydrolysis, fermentation, and anaerobic digestion Converts hydrocarbon fraction into plant energy and electricity Utilizes byproducts for beneficial sale or energy production Cellulosic pulp can produce 90 gallons of ethanol per ton End-to-end process operates on a 100% MSW input System has been tested at scale Dirty MRF Hydrolysis, Fermentation, Distillation Bio-ethanol 24 Gershman, Brickner & Bratton, Inc. 12
Ethanol fermentation Feedstock- MSW Fiberight High-Solids Pulping Plants: Pilot plant in Lawrenceville, VAreceived a key approval from the U.S. EPA and is now working on a $20 million expansion Blairstown, IA- 6 mill gal/year, expected to be fully operational in the first half of 2013. TMO Blairstown, Iowa Layout Has site control for first commercial-scale biofuel plant in Elkridge, MD 25 Plasma gasification technology (Westinghouse Plasma Corp.) Produces syngas from a wide variety of feedstocks: auto shredder, plastics, biomass, wood Generates a syngas for power generation or further conversion to ethanol 80% of energy input converted to syngas 48 ton per day commercial demonstration facility in Madison, PA Commercially installed in facilities in Japan, Canada, India, and the U.S. AlterNRG gasifier 26 Gershman, Brickner & Bratton, Inc. 13
Shreds/processes MSW prior to conversion chamber Produces syngas (for electrical generation), recyclable slag, water, and recovered metals through gasification Uses plasma torches to refine the syngas produced 94 ton-per-day capacity, 4MW commercial-scale Trail Road facility in Ottawa, Canada Selected by the Salinas Valley Solid Waste Authority (CA) as a viable technology for planned Resource Management Park, Environmental Impact Study currently underway Shortlisted in Santa Barbara, CA Plasco Trail Road 27 28 Gershman, Brickner & Bratton, Inc. 14
BlueFire Ethanol Concentrated Acid Hydrolysis Technology Process converts cellulosic waste materials to ethanol, and other viable alternatives to petroleum derived fuels Have demonstrated production of ethanol and other petroleum displacing fuels from post-recycled MSW, rice and wheat straws, wood waste and other agricultural residues 29 BlueFire Ethanol Plants: Lancaster, CA 3.7 million gallon per year facility will use postsorted MSW from landfills around the Los Angeles area. Anticipated start time is TBD Mecca, CA 17 million gallon per year facility will use postsorted MSW and wood waste from all over southern California. Anticipated start time is TBD Fulton, MS 19 million gallon per year facility will use woody biomass and mill wastes from Cooper Marine & Timberlands. BlueFire has received $88 million in DOE funding and has secured 15-year offtake agreements for products. Fulton, MS site prepared for construction, June 2011 30 Gershman, Brickner & Bratton, Inc. 15
Taylor Biomass Town of Montgomery, NY Converts organic biomass portion of mixed solid waste to electric power, through gasification; 20 MW power 1,050 tpd C&D, Wood Waste and MSW Construction started in January 2011, completion expected by end of 2013 145 million construction cost -financed by $100 million in U.S. DOE grants, $20 million in private investment, and tax credits 31 Summary and Trends 32 Gershman, Brickner & Bratton, Inc. 16
Technologies and Risk Alternative Risks/Liability Risk Summary Mass Burn/WaterWall Proven commercial technology Very Low Mass Burn/Modular Proven commercial technology Low RDF/ Dedicated Boiler Proven commercial technology Low RDF/Fluid Bed Anaerobic Digestion Mixed-Waste Composting Pyrolysis Proven technology; limited U.S. commercial experience Proven technology; limited U.S. commercial experience Previous large failures; No large-scale commercially viable plants in operation; subject to scale-up issues Previous failures at scale, uncertain commercial potential; no operating experience with large - scale operations Moderate to Low Moderate to Low Moderate to high High Gasification Chemical Decomposition/ Depolymerization Limited operating experience at only small scale; subject to scale-up issues Technology under development; not a commercial option at this time High High 33 Issues in Technology Development Performance history and size Scaling uncertainties Environmental impacts Siting and permitting needs Cost uncertainties and their $ coverage Product market uncertainties Process guarantees Financial resources of developer Community acceptance 34 Gershman, Brickner & Bratton, Inc. 17
Future Trends Continued interest in conversion technologies Projects will advance 3-5 years for the new technologies to prove technical and economic feasibility Continuation of public sector taking Low Risk attitude until proven More mixed waste processing systems 35 Thank you! John Carlton jcarlton@gbbinc.com 908-319-5992 cell 703-573-5800 office 800-573-5801 office 703-698-1306 fax www.gbbinc.com 36 Gershman, Brickner & Bratton, Inc. 18