Transcript Slide 1

Dry Mill Ethanol Plants
Environmental Impacts
and Future Growth
Presented to Governor’s Coalition
February 10, 2006
by Bill Roddy
110 MGY
Dry Mill Industry Evolution
Plants in operation during each decade:
● 1980’s -175 Plants (20K to 7M gallons)
● 1990’s - 33 Plants (1.5M to 30M gallons)
● 2000’s - 91 Plants (30M to 110M gallons)
● ICM has 37 Plants in operation today
ranging from 5 M to 110 M gallons
ICM Process Guarantees
• Ethanol-2.80 denatured (@ 5%) gallons per
bushel
• Natural Gas-34,000 BTU per denatured
gallon of ethanol with DDGS (22,000 wet
cake only)
• Electrical - 0.75 Kw per denatured gallon per
hour
• Emissions compliance – Written guarantee
"Potential to Emit" Preliminary Estimate:
100% DDGS Capability
Bushmills Ethanol: 49 MMgpy (permitted), 500,000 tons/yr grain (17,857,144 bu/yr), 162,218 tpy DDGS
ICM Plants Under Construction
Agri-Farms, LLC
Hawkeye Renewables Expansion
Hawkeye Renewables – Fairbank
Lincolnway Energy
US Bioenergy
Western Wisconsin Ethanol
Heron Lake Ethanol
Superior Corn Products
Red Trail Ethanol
Front Range Energy
Suncor
Commercial Alcohol
Trenton Agri Energy Expansion
Commonwealth Agri Energy Expansion
Prairie Horizon Agri-Energy
The Andersons Albion Ethanol
Illinois River Energy LLC
Heartland Grain Fuels LP Expansion
Iroquois BioEnergy Co. LLC
GLE Redfield
Aventine Renewable Energy Inc
Ethanol Grain Processors
Anderson’s Grain – Clymers
Demeter Bloomingburg
Platte Valley Ethanol Expansion
Big River Resources Expansion
Blue Flint Ethanol
Siouxland Ethanol
Necedah, WI
Iowa Falls, IA
Fairbank, IA
Nevada, IA
Albert City, IA
Boyceville, WI
Heron Lake, MN
Lake Odessa, MI
Richardton, ND
Windsor, CO
Sarnia, ONT
Varennes, QUE
Trenton, NE
Hopkinsville, KY
Phillipsburg, KS
Albion, MI
Rochelle, IL
Huron, SD
Rensselear, IN
Redfield, SD
Pekin, IL
Washington, KS
Clymers, IN
Bloomingburg, OH
Central City, NE
West Burlington, IA
Underwood, ND
Jackson, NE
50 MMGPY
from 40 to 80 MMGPY
100 MMGPY
50 MMGPY
100 MMGPY
40 MMGPY
50 MMGPY
40 MMGPY
50 MMGPY
40 MMGPY
50 MMGPY
30 MMGPY
from 30 to 40 MMGPY
from 20 to 33 MMGPY
30 MMGPY
55 MMGPY
50 MMGPY
from 14 to 30 MMGPY
40 MMGPY
40 MMGPY
60 MMGPY
30 MMGPY
110 MMGPY
100 MMGPY
from 40 to 80 MMGPY
from 40 to 80 MMGPY
50 MMGPY
50 MMGPY
Environmental Approvals
● Air Permit
● Non Contact Water Discharge (irrigation, POTW, or
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surface water)
Storm water NOI & SWP2
Above Ground Storage Tanks
Water Allocation Permit (supply)
Endangered Species
Historical and Archaeological
Environmental Assessment (e.g., MN)
Note: ICM Plants are CESQGs
Energy Balance
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All Studies (with exception of Professor David Pimental of
Cornell) cite a net energy gain of 34% for dry mill fuel ethanol
manufacture.
Ethanol: 84,000 Btu/gal & octane 130 (compares to gasoline
at 125,000 Btu/gal)
Driving forces include; improved farming efficiencies (e.g., no
till), better chemicals for weed and insect control for fewer
trips in field, improved manufacturing efficiencies.
Impact of EPA’s Consent Decrees
Required Equipment:
● Dryer Emissions: Thermal Oxidizer
● Product Loadout: Flare
● Fermentation: Improved Scrubbers
● Fugitive VOCs: Leak Detection and Repair
● Road Dust: Street Sweeping
● Process Dust: Baghouses
● Cost:
$1.5 - $2.0 Million per plant (equipment)
$30,000 - $50,000 per plant (fines)
Thermal Oxidizer/Heat Recovery Steam Generator
Steam Out To Process
Exhaust
Stack
Steam Drum
Steam Generator
Approximately
1500 F
Water In
Combustion
Section
Exhaust
Thermal
Oxidizer
Rotary Drum
Dryer
Combustion Air & Natural Gas
(Final temp
determined
in compliance test)
ICM Thermal Oxidization System
ICM Fermentation Scrubber
Key Emission Standards
● NOx, CO, VOCs (scaled), PM/PM10, SO2 are
guaranteed by ICM to be less than 100 tpy each for
the following:
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Gas Fired Steam Generation (by TO or Boilers): 100
Mgpy
Coal Fired (ICM’s Clean Coal Technology; Bubbling
Fluid Bed with limestone/lime & ammonia injection &
baghouse): 50 Mgpy
● HAPs are guaranteed to be less than 10/25 tpy for
Gas and Coal Configurations
Example Water Discharge*
● Source: Cooling Tower, Multi Media Filter, RO &
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Softener (all non contact water)
Volume: 100 gpm
Total Dissolved Solids: 3,000 mg/l (controlled by
cooling tower cycles)
Chlorides: 40 mg/l
Conductivity: 5000 μmhos/centimeter
pH: 6.5 – 9.0
Temperature: < 90° F
*State Dependent, Water Source Dependent
Nuisance Odor
ICM recommends development of an “Odor
Action Plan” as follows: (not a regulatory
requirement)
● A single odor complaint will be immediately
investigated and “validated.”
● The source of odor will be corrected or shut
down and repaired.
● The plant shut will shut down if necessary to
correct the source of nuisance odor.
● In case of TO failure, the plant automatically
shuts down.
Nuisance Odor?
Brantford, Ontario, March
10, 2003 - The tour bus
was stopped directly
downwind of the ethanol
plant in Monroe,
Wisconsin and many got
out to sniff the air. “I was
very impressed with the
fact that there was hardly
any odor at all from the
plant”, said Edith Davis,
wife of Roger Davis of
Davis Petroleum. “One of
the reasons I came along
on this tour was to make
sure that the proposed
ethanol plant would be a
good neighbor to our
community, and I am now
more convinced than ever
that it will be.”
Environmental Impacts
● Plants are engineered to have insignificant impact
on the surrounding environment.
● Water Discharge quality is engineered to meet state
standards (irrigation, surface water or POTW).
● When using groundwater, test wells are installed and
groundwater is monitored prior to construction to
insure the water table can handle 500 gpm (typical
50 Mgy plant) without impacting the water table or
nearby wells.
Environmental Impacts (cont.)
● Erosion and sedimentation during construction
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are minimized with a stormwater pollution
prevention plan.
Surface runoff is controlled by stormwater pond
and released after inspection.
Process waste water is returned to the process
after treating in an anaerobic digester called the
biomentanator.
The biomethanator gas (methane) displaces
natural gas in the DDGS Dryer.
Tanks are sited in an impervious secondary
containment area.
Environmental Impacts (cont.)
● Stationary source air emissions qualify the source
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as a “synthetic” minor source.
Noise levels will not exceed 80 dB off property.
Potential for nuisance odor is minimized with the
Best Available Control Technology and Odor Action
Plan.
ICM’s plants typically assure that no adverse impact
on nearby natural resources will occur.
Wetlands are typically avoided.
Bad Batch (Due to Infection)
● Continue to process wet cake or DDG
● Blend it back in
● Truck to municipal waste plant
Goals:
● Avoiding
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NOT:
Land application
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Land filling
ICM’s Future
● ICM’s backlog:
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Nearly 100 US plants in planning stages
6 foreign plants in planning stages
1 Canadian plant under construction (50 MGY)
● Predicted sizes:
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50 to 110 MGY range
200 MGY under discussion
● Demand for coal energy increasing
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ICM’s first coal plant is operational (50 MGY)
Coal guarantee currently limited to PRB coal (0.25%
sulfur)
Questions?