Sunflower Integrated Bioenergy Center SIBC. Kansas Bioscience Authority NISTAC (National Institute for Strategic Technology Acquisition and Commercialization)

Sunflower Integrated

Bioenergy Center

SIBC

Kansas Bioscience AuthorityNISTAC

(National Institute for Strategic Technology Acquisition and

Commercialization)

A Touchstone Energy Cooperative

Sunflower Electric Power Corporation

NISTAC Founded in 1994 as a nonprofit under the

auspices of Kansas State University and the Kansas Technology Enterprise Corporation (KTEC)

Commercialization of intellectual property from:– Kansas State University– Corporate patent portfolio

Promote business development in Kansas and around the nation through the use of technology

SIBC

Kansas Bioscience Authority

Created in April 2004 under the Kansas Economic Growth Act

Independent entity of the state with the authority to invest $580 million in bioscience activities

Mission to make Kansas a national leader in bioscience development and commercialization

SIBC

Sunflower Electric Nonprofit corporation formed in 1957 by six

rural electric distribution cooperatives

Services 34 western Kansas counties with over 61,000 meter points

Actively engaged in rural development activities throughout western Kansas for many years

SIBC

Holcomb Station 2013

Artist’s Rendering

Holcomb Expansion Project

Total installed cost of the three plants is expected to be $3.6 billion

Over a 35-year period will exceed $8 billion

Construction Impact (6 year period) 3,600 jobs created (direct and induced) in Kansas Annual payroll of more than $116 million

Continuing Impact (35-year study period) More than 400 full-time jobs (direct and induced) created in Kansas Annual payroll of more than $24 million

Studies completed by Dr. Ralph Gamble, a noted Fort Hays State University Economics professor

Sunflower Integrated Bioenergy Center

Goal is to develop a bioenergy project that will integrate a number of commercial or near commercial renewable energy technologies with the coal-based power plant located at Holcomb Station

SIBC

Global Energy MarketsComparative Historic Prices of Fuel Alternatives

Historic Prices of Crude Oil

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olla

rs p

er b

bl.

Historic Prices of Gasoline

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Historic Prices of Natural Gas

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7.00

8.00

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bic

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ot

Historic Prices of Diesel

020406080

100120140160180200

1994

1996

1998

2000

2002

2004

Years

Pri

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in U

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olla

rs p

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Gal

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SIBC

Dairy

Anaerobic Digester

Sunflower Holcomb

Power Plant

Biodiesel Plant

Ethanol Plant

Algae Reactor

Ethanol BiodieselElectricityMethane

Reduced Waste Streams = CO2, NOx, SOx, Nutrient Load (Nitrogen & Phosphorus), Heat, & Waste Water

Energy Products

Biogas

Nutrients (Nitrogen &

Phosphorus) & Water

Electricity

Flue GasWater

Algae Solids

Algae Oil

Biodiesel

Ethanol

Wet Distillers’ Grain

Waste Water

Corn/Grain Sorghum

Tallow

Livestock Processing

Manure

Other Oils (Soybean

etc)

Thin Stillage

Ammonia

Methanol (Converted from

Methane)

Glycerol

Extracted Corn Oil

CO2


SIBCPatent Pending

Anaerobic Digester

Biodiesel Plant

Ethanol Plant

MethaneEnergy Products

Biogas

Waste Water

Tallow


CO2

Livestock Processing Subsystem

Processor waste water and manure are converted to methane in the anaerobic digester.

Beef tallow is used as an oil source for the biodiesel plant.

CO2 from the ethanol plant can be converted to dry ice for refrigeration purposes.

SIBC

Dairy

Anaerobic Digester

Ethanol Plant

Algae Reactor


Biogas

Algae Solids


Manure

Dairy Subsystem

Dairy manure and waste water are converted to methane in the anaerobic digester.

Wet distillers grain from the ethanol process and algae solids (protein residue) are used for cattle feed.

SIBC

Dairy

Anaerobic Digester

Sunflower Holcomb

Power Plant

Ethanol Plant

Algae Reactor


Biogas


Phosphorus) & Water

Waste Water


Manure

Thin Stillage

Ammonia

Glycerol

Anaerobic Digester Subsystem

Biodiesel Plant

Digester processes waste water and manure from the livestock facilities and potentially glycerol from the biodiesel plant.

Bacteria in the digester produces methane which can be used by the ethanol and power plant.

Digester ammonia, nutrients (nitrogen and phosphorus), and water are used in the algae reactor and power plant.

SIBC

MethaneMethane Digester Market and Process Data

Historic Prices of Natural Gas

0.001.002.003.004.005.006.007.008.00

1922

1931

1940

1949

1958

1967

1976

1985

1994

2003

Years

Pri

ces

in U

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olla

rs p

er

Cu

bic

Fo

ot

Simplified Model of Inputs and Outputs in Methane Production

0

20

40

60

80

100

120

Input Output

We

igh

t in

Po

un

ds Solid

Waste100 lb.

CO232 lbs

CH458 lbs

(1298cuft)

Biomass 10 lbs

Estimated Cost of Inputs in Methane Production

$(100.00)

$-

$100.00

$200.00

$300.00

$400.00

$500.00

$600.00

$700.00

Th

inS

till

ag

e

Liv

es

toc

kW

ate

rW

as

te

Dai

ryW

as

te

Gly

ce

rol

Co

st/T

on

$660

$12 -$13 -$1

Digester Btu's Produced from Various Waste Streams

05,000

10,00015,00020,00025,00030,00035,00040,00045,000

Dairy Ethanolthin stillage

Biodieselglycerol

Beefprocesswater

BT

U/g

allo

n o

f w

ast

e

135 Btu

SIBC

Anaerobic Digester

Sunflower Holcomb

Power Plant

Algae Reactor

ElectricityMethaneEnergy Products

Biogas Electricity

Flue GasWater

Ammonia

Coal-based Power Plant Subsystem Flue gas emissions from the power plant are

stripped as they flow through the algae reactor creating algae oil and solids.

Ammonia from the anaerobic digester can be used for the SCR in power plant and excess methane can replace some demand for natural gas.

Excess water from algae reactor can be cleaned for electricity production.

SIBC

Dairy

Anaerobic Digester

Sunflower Holcomb

Power Plant

Biodiesel Plant

Ethanol Plant

Algae Reactor

BiodieselEnergy Products


Phosphorus) & Water

Flue GasWater

Algae Solids

Algae Oil

Biodiesel

Algae SubsystemConverts C02 emissions into renewable

fuels

A significant portion of the Algae is harvested from the reactor daily and is separated into Algae oil, solids, and water.

Flue gas is introduced to the bioreactor, where algae utilize CO2, NOx and suspended nutrients from the anaerobic digester to optimize the growth.

Algae solids are used as animal feed, starch for the ethanol plant, or burned directly in the coal unit.

Algae oils are a feedstock for the biodiesel plant.

SIBC

Algae ReactorConverts C02 emissions into renewable

fuels Microalgae is the most primitive plant form - typically one or two cells.

This simple structure allows algae to be very efficient at converting sunlight, CO2, and nutrients into oil (for biodiesel) and starch (for ethanol).

The algae reactor is capable of utilizing the waste CO2 and NOx in flue gas and the nutrients from livestock/processing waste to create valuable energy products.

Algae systems have been research for decades including work by the National Renewable Energy Laboratory. Production was found to be viable but most work was done when fuel prices were half of what they are today.

No large scale algae reactor is in operation today but significant investment has been made recently in conjunction with higher global energy costs.

SIBC

AlgaeAlgae Market and Process Data

U.S. Vegetable Oil and Fat Prices

010203040506070

1996

/97

1997

/98

1998

/99

1999

/00

2000

/01

2001

/02

2002

/03

2003

/04

2004

/05

2005

/06

2006

/07

High

2006

/07

Low

U.S

. Cen

ts p

er P

ou

nd

Soybean oil Cottonseed oilSunflower oil Peanuts oilCorn oil LardEdible tallow

Simplified Model of Inputs and Outputs in Algae Oil Production

0

500

1000

1500

2000

2500

Input Output

We

igh

t in

Po

un

ds CO2

1 ton

O21050 lbs

Oil 350 lbs (45 gal)

Nitrogen & nutrients 100 lbs

Starch 350 lbs

Protein/Fiber 350 lbs

Resources Required to Supply Oil to a 30 MGY Biodiesel Plant

0

200,000

400,000

600,000

800,000

1,000,000

1,200,000

1,400,000

Algae Canola Soybean Beef cattle

Oil source

Acr

es

Head of cattle(tallow)

3000 acres

Algae Yield Comparison to Other Oilseed Crops

0

2000

4000

6000

8000

10000

12000

Algae Canola Sunflow er Soybean

Gal

lon

s o

f oi

l pe

r ac

re

130 100 50

SIBC

Dairy

Anaerobic Digester

Biodiesel Plant

Ethanol Plant

Algae Reactor

EthanolMethaneEnergy Products

Algae Solids

Ethanol

Wet Distillers’ Grain Corn/Grain SorghumLivestock

Processing

Thin Stillage

Glycerol

Extracted Corn Oil

CO2

Ethanol Subsystem

Ethanol plant will consume methane gas, grain, glycerol, and algae solids.

Ethanol plant will produce ethanol, distillers grains used by the dairy, thin stillage for the anaerobic digester and extracted corn oil that will be used in the biodiesel plant.

SIBC

Ethanol

SIBC

Ethanol Market and Process Data

Historic and Future Forcasted U.S. Fuel Ethanol Production

0

1,000

2,000

3,000

4,000

5,000

6,000

7,000

8,000

1980

1984

1988

1992

1996

2000

2004

2008

2012

Years

Mill

ion

s o

f Gal

lons

Historic Forecast

Historic Prices of Fuel Ethanol (Terminal Market Price)

0

0.5

1

1.5

2

2.5

3

Years

Pri

ces

in U

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olla

rs p

er

Gal

lon

Simplified Model of Inputs and Outputs in Ethanol Production

0

20

40

60

80

100

120

Input Output

Wei

ght

in P

oun

ds Corn/

Sorghum(100 lb.)

Ethanol (33.3 lb.)

CO2(33.3 lb.)

DDGS(33.3

U.S. Corn and Sorghum Prices

$-$1.00$2.00$3.00$4.00$5.00$6.00

1980

1984

1988

1992

1996

2000

2004

Pri

ce

in U

.S. D

oll

ars

Corn ($/bu)

Sorghum ($/ctw )

Anaerobic Digester

Biodiesel Plant

Ethanol Plant

Algae Reactor

BiodieselEnergy Products

Algae Oil

Biodiesel

Ethanol

Tallow


Other Oils (Soybean

etc)


Methane)

Glycerol

Extracted Corn Oil

Biodiesel Subsystem The biodiesel plant can utilize a

number of oil sources including algae oil, tallow, recovered corn oil, and other vegetable oils such as soybean.

The biodiesel plant will produce Glycerol as a by-product which can be sold (ingredient in soap and cosmetics) or processed in the anaerobic digester.

SIBC

BiodieselBiodiesel Market and Process Data

U.S. Biodiesel Production

0.0

50.0

100.0

150.0

200.0

250.0

1999

2000

2001

2002

2003

2004

2005

2006

Years

Mill

ion

s o

f Gal

lon

s

Historic Prices of Diesel

020406080

100120140160180200

199

4

199

5

199

6

199

7

199

8

199

9

200

0

200

1

200

2

200

3

200

4

200

5

Years

Pri

ces

in U

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olla

rs p

er G

allo

n

Simplified Model of Inputs and Outputs in Biodiesel Production

0

20

40

60

80

100

120

Inputs Outputs

Wei

ght

in P

oun

ds

Vegetable Oil or

Animal Fat(100 lb.)

Biodiesel(100 lb.)

Methanol (10 lb.) Glycerine (10 lb.)

In the presence of catalyst

U.S. Vegetable Oil and Fat Prices

010203040506070

1996

/97

1998

/99

2000

/01

2002

/03

2004

/05

2006

/07

High

U.S

. C

en

ts p

er

Po

un

d

Soybean oil Cottonseed oilSunflower oil Peanuts oilCorn oil LardEdible tallow

SIBC

Expected Benefits Efficiencies of integration

– Improved economics over stand-alone system– Water re-use– Value from waste streams– Flue gas utilization

New job creation Additional regional economic activity Shared human resources

SIBC

Current Status Formation of founding partners company

Final technology and financial partner selection

Enhanced subsystem feasibility studies– Economic– Engineering for integration– Environmental / water

Ethanol plant construction 2007

SIBC

Dairy

Anaerobic Digester

Sunflower Holcomb

Power Plant

Biodiesel Plant

Ethanol Plant

Algae Reactor

Ethanol BiodieselElectricityMethane

Reduced Waste Streams = CO2, NOx, SOx, Nutrient Load (Nitrogen & Phosphorus), Heat, & Waste Water

Energy Products

Biogas


Phosphorus) & Water

Electricity

Flue GasWater

Algae Solids

Algae Oil

Biodiesel

Ethanol


Waste Water

Corn/Grain Sorghum

Tallow


Manure

Other Oils (Soybean

etc)

Thin Stillage

Ammonia


Methane)

Glycerol

Extracted Corn Oil

CO2


SIBCPatent Pending

Documents

Sunflower Integrated Bioenergy Center SIBC. Kansas Bioscience Authority NISTAC (National Institute for Strategic Technology Acquisition and Commercialization)