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2005 OBP Bi-Annual Peer Review

2005 OBP Bi-Annual Peer Review . Fran Ferraro Merrick & Company Sealaska Corporation Southeast Alaska Ethanol Project Integrated Biorefinery Session November 16, 2005. Overview. Time Line Proj. Start: 6/03 Proj. End: 12/06 55% Complete. Barriers Contaminated Feed Mat’l Scale-up

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2005 OBP Bi-Annual Peer Review

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  1. 2005 OBP Bi-Annual Peer Review Fran Ferraro Merrick & Company Sealaska Corporation Southeast Alaska Ethanol Project Integrated Biorefinery Session November 16, 2005

  2. Overview Time Line • Proj. Start: 6/03 • Proj. End: 12/06 • 55% Complete Barriers • Contaminated Feed Mat’l • Scale-up • Integration • Yield/Costs Stage • Stage 3 • Development • Pilot Testing Budget • Total Proj. Start: $5,350,021 • Project End: $5,350,021 • 58% Complete Partners • Sealaska Corporation • Merrick & Company • USDOE • USDA

  3. Project Goals and Objectives Project Goals and Objectives • Select and demonstrate suitable technologies to convert SE Alaska wood residues to Ethanol for the Alaska market. Previous – established project concepts and economics. • Select gasification (steam reforming) technology • Select ethanol conversion technology • Confirm suitable gas cleanup technologies • Pilot test technologies on contaminated wood residue • Design commercial scale facility • Construct and operate wood residue conversion to ethanol

  4. Project Strategic Fit Relevance to Platform and Pathway Objectives and Barriers • Thermochemical Platform – Feed and Thermochemical Processing, Gas Clean-up • Products – Fuels, Chemicals, CHP • Integrated Biorefineries – Ag Residues, Energy Crops, Pulp & Paper, and Forest Products Mill Improvement Pathways

  5. Technology Fit and Demo Vision Technology Fit for Sealaska/Merrick • Regional timber and lumber processing • Residues environmental control • Alaska ethanol market • Multiple Biomass-to-Ethanol projects Demo Phase Vision by 2008 • Design Basis and Costs – early 2006 • Financing and Design – 2006 to 2007 • Construction – 2007 to 2008 • Ready

  6. Project Approach & Design Technical Barriers • Feed • Preparation • Contaminants • Gasification (Steam Reforming) • Gas Composition – yield • Gas Cleanliness • Conversion • Yield vs. Costs • Fermentation – limitations? • Catalytic • Process Efficiency • Waste Energy Utilization • Tail Gas • Process Integration Project Design • Practical Syngas Quality and Quantity • Practical Conversion – Integrated • Practical Energy Utilization – Integrated • Later – Improve all 3

  7. Technical Feasibility • Feed • Preparation • Contaminants • Gasification (Steam Reforming) • Syngas Composition • Syngas Cleanliness • Conversion • Alcohol Yield(s) • Heat Utilization • Tail Gas

  8. Project Tasks • Select Technologies • Basis – yield 70 gal per Dry Ton • Compatible with feed and product • Risks – readiness, suitability for feed, yield, cost • Pilot Demos – Integrated Process • Commercial Scale Design Basis and Cost Estimate • Design, Build, Run Demo – 2006 – 2008 • Adjust designs for other project feedstocks, locations, etc • Commercial Operating Plants

  9. Competitive Advantages • Suitable for numerous feedstocks with proper preparation • Superior yield vs. costs • Integrated heat/energy and potential export Potential Show-Stoppers: • Scale-up • Demo 200 – 250 DTPD • Integration with reasonable costs • Initial Projected Economics • Future Projected Economics

  10. Commercial Scale Design Basis Commercial Scale Design Basis and Cost Estimate • Basis – 6 mm gal/year AK facility on salt water contaminated wood residue • Risks: cost, business • Milestones – cost $30 - $40 mm, business/technology useful elsewhere • Go/No-Go – Economic Return on net Equity Investment • Accomplishments – underway • Future Plans – more feedstocks and locations, heat and power integrated

  11. Project Collaboration Project Collaboration • Sealaska Corporation with Merrick & Company • USDA, USDOE, NREL • Technologies – Enerkem Technologies, Inc.; ThermoChem, Inc.; Bioengineering Resources, Inc.; BioConversion Technology, LLC • Industry – other similar projects – RDF, Pet Coke, Ag Residues • Alaska – AIDEA, AEA, Ketchikan Gateway Borough

  12. Market & Customers Market & Customers • Ethanol Product – fuel blending • Heat and Power – users Costs • Ethanol @ $0.90/gal. depends on scale and other aspects • Current/Future Market Shifts

  13. Competitive Advantage Competitive Advantage • Window – next few years • Competing Technology – gasification and fermentation or other catalytic conversions • Ready for commercial demo, yield • Market Change – fuel and octane blending value; min. costs from other producers • Economic/Investments – multiple interested project developers with suitable economics

  14. Project Stage Stage 3 – Development Pilot Testing and Commercial Scale Design Basis

  15. Progress and Accomplishments Progress and Accomplishments • Pilot Testing – Integrated • Platform – Integrated Thermochemical Platform Conversion to Ethanol • Project – Technologies and business compatible

  16. Future Work Future Work • Final Integrated Pilot runs on AK feed material • Commercial Plant Design Basis and Cost Estimate • Design, Build Demo Milestones: Pilot Runs – 12/05 Design Basis – 2/06 Cost Estimate – 3/06 Design Underway - 2006

  17. Contact Information Contact Information Francis (Fran) Ferraro Senior Technical Specialist Merrick & Company 2450 S. Peoria Street Aurora, CO 80014-5472 Phone: (303) 751-0741 Fax: (303) 368-1299 Email: fran.ferraro@merrick.com

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