ICM Development Technologies Related to

FractionationDouglas B. Rivers, Ph.D.

October 27, 2010

ICM History•

Founded in 1995; History dating to the 1970’s•

Based in Colwich, KS with ~ 300 Employees•

Design, Construction, Manufacturing, and Support of Ethanol Plants•

R&D, Engineering, Energy, Controls, and Environmental

Research. Engineer. Construct. Support.•

Research›

Technology Integration›

Process Development›

Product Development›

Troubleshooting•

Engineer›

Process Design›

Process Guarantees›

DCS Configuration & Programming

›

Air & Water Permitting›

Waste Water Engineering›

Integration•

Build•

Support›

Comprehensive support program›

One-stop service provider

Our plant support services include:•Environmental permitting and compliance software

•Water treatment

•Insurance and safety programs

•Training and start up services

•Computerized maintenance management system and plant asset preservation

•Scheduled shut down assistance

•1000-point inspections

•DCS service contracts

•Emergency contract and assistance

•Plant expansion services

•Plant equipment manufacturing and repair

Current ICM Developments Related to Fractionation

•

Combined Food-Grade Protein Recovery•

Integrated Grain and Cellulose to Ethanol

Corn Components

Line of Sight

Food AND FuelFood AND Fuel™™

through TKOthrough TKO(Total Kernel Optimization)(Total Kernel Optimization)

Bridge to Cellulosic Ethanol

Add Value through Dry Fractionation

•

TKO –›

Dry Fractionation

›

Oil Extraction›

Germ Protein

›

Single Cell Protein›

Gasification

›

Fiber-to-Ethanol

HydrationCleaning

Tempering

Bran Removal

Sifting

AspirationHydration

Germ Removal

Sifting

Germ Flattening

Separation

Reduction

Dry Fractionation is added to the process producing three new product streams:1.Germ (protein + oil)2.Endosperm (starch)3.Bran/Fiber (cellulose)

High protein DDG from germ stream

Combustor to produce thermal energy from renewable resources

Improved Efficiencies & Costs

Phase II

Protein is processed creating new Food Grade Protein product.

Germ Protein

›

Germ Protein–

Functional proteins = Desirable physical properties

»

Foam, gel, oil-protein emulsion and dispersion

–

High nutritional value

›

Other benefits -–

Color -

White

–

Tasteless –

Easily Incorporated into Product Ingredients

–

Market Size –

World needs more nutritional protein

Germ Protein Benefits

●

A 130 MGY ethanol plant produces about 94,000 lb of germ protein per day. ●

48,000 lbs / day of protein or ●

73,800 lbs / day of 65% protein concentrate

Value of Germ Protein

Defatted Germ Production & Value Estimates

Bushels (100 MGY) 37,600,000

Protein Extraction Efficiency 43%

Lbs Protein Concentrate/Bushel 0.7

Protein Concentrate Value @ $1.50 $39,358,837.95

Protein Concentrate Value @ $3.00 $78,717,675.89

Corn Fiber is pretreated and broken down to sugars with enzymes and fermented to ethanol similarly as to what is done today with starch.

Fiber (Cellulose) to Ethanol Goals

•

To capture more value from corn fiber (cellulose / hemi-cellulose) than can be captured as thermal energy.

•

To capture starch lost in dry frac separation process.

•

To increase the quantity of both ethanol and SCP by converting cellulose and hemicellulose

sugars.

Implementation Stages of Fiber Cellulose to Ethanol

Ethanol SCPHigh Protein

DDG

Stage A 5.8 mgy 40,000 tpy 24,000 tpy

Stage B 4 mgy

Stage C 4 mgy (14,000 tpy)

TOTAL 13.8 mgy 26,000 tpy 24,000 tpy

Cellulose to Ethanol Potential

•

What is the potential?›

Theoretical is up to 140-150 gallons/ton

›

Practical limit is closer to 100 gallons/ton›

First plants will be around 50-70 gallons/ton

•

Grain based today is ~96 gallons/ton›

~ 60 billion gallons ethanol potential in US from biomass

What are the challenges?•

Production costs are high›

Capital is 3 to 6 times starch plant

›

Operational costs significantly higher•

Technology is not proven

•

No commercial plants today

Corn

StarchCorn

StoverAnnual Ethanol (MMGal) 50 50

Ethanol Prod. Cost ($/gal) 0.96 1.45

Total Prod. Costs (MM$/yr) 47.8 72.0

Co-product Credit ($/gal) 0.26 0.13

Feedstock costs ($/gal) 0.793 0.51

Capital Invest. (MM$) 48.0 193.7

USDA, March 2005

Cost Comparisons

Keys to Success•

Integration of Starch and Cellulose Systems to Gain Process Synergies

•

Infrastructure for Cost-Effective Biomass Handling›

Collection

›

Storage›

Transportation

•

Pretreatment Strategy•

Conversion Strategy›

Scalable

›

Cost Effective

How Do We Get There?•

Build on Success of Grain Ethanol Industry

•

Leverage Existing Grain Operations•

Develop Highly Integrated and Efficient Process

Value Chain of Cellulosic Ethanol

Ethanol from Energy Crops

•

Experimental plots = 10 tons per acre

•

1200-lb. bale = 48 gallons of

ethanol @ 80 gallons per ton

•

Goal — 100 gallons per ton of biomass = ethanol yield of 1000 gallons per acre

Feedstock Production

Value Chain of Cellulosic Ethanol

DOE Integrated Biorefinery

ICM’s Cellulosic Pilot Plant

•

10 Ton/Day Feedstock›

Corn Fiber, Switchgrass, Energy Sorghum

•

NEPA Documentation›

Categorical Exclusion Granted

•

Construction›

August 2010 Start

•

Operations›

Pretreatment –

January 2011

›

Integrated Operations –

July 2011

Value Chain of Cellulosic Ethanol

Thank you!

Contact:Douglas B. Rivers, Ph.D.Director, Research & Development

310 N. First StreetColwich, KS 67030 Phone: (316) 977-6785E-mail: douglas.rivers@icminc.com