PowerPoint Presentation
Catawba CountyRegional EcoComplex and Resource Recovery
FacilityUsing Existing Landfill Gas Project to Produce Additional
Renewable EnergyJeff Ramsdell, Ph.D., P.E.Appalachian State
University
Barry B. Edwards, P.E.Director of Utilities and
EngineeringCatawba County1
The EcoComplex Catawba County, NC
WHERE: Catawba County- located near Hickory NC in WNC, 1 hour
northwest of Charlotte.Population 150,0008 incorporated
municipalities
2Catawba County EcoComplex & Resource Recovery
FacilityEcological-industrial parkSynergetic waste and resource
management, renewable energy production, and local economic
development Public Private Partnerships 805 acres around Blackburn
Landfill 452 tons/day of municipal and 88 tons of construction
waste daily. 3MW grid-tied LFGTE - GE-Jenbacher engines.
WHAT: Eco-Industrial Park
31990 NC Waste Reduction Mandate1990 baseline 1.51
tons/capita10% by 2000 (1.36 tons/capita)15% by 2005 (1.28
tons/capita)20% by 2010 (1.21 tons/capita)25% by 2015 (1.13
tons/capita)34% by 2020 (1 ton/capita)
WHY: 1990 Waste Reduction Mandate165,000 TONS/YEAR
4
FY 2008-09 at 1.10 tons/capita
STRATEGY:INDUSTRIAL ECOLOGY
HOW: Industrial Ecology6Site Plan
Landfill Gas to Energy
Anchor tenants
Testing site established in 1999LFG flow 1,000 scfmFrom 452
municipal solid wasteNo purification/filtration of gas, top end
rebuilds and maintenance in stead8
Average output: 2.3MW +8.1 MMBtus Waste Heat
1MW capacity eachOver 15M BTUs/hr recoverable heat9Blackburn
Landfill, Catawba County, NCFacility began producing electricity in
November 1999Facility has operations at a 94% up-timeTo date,
facility has produced 168,000 MW electrical+ Electrical Sales of
$5,698,595+$257,258.00 in REPI+$279,041.00 in RECFacility has
provided electricity to approximately 600 average homes
annually10Current and Future Uses of Waste Heat from Electricity
Production
Biodiesel Research & Production Facility
Algae Growth and Research for Mitigating CO2
Biosolids Management Facility
Solid Waste Digester11Heat energy employed in various
capacities. I will touch on each of these in the next few
slidesPrivate Industrial Partners
Pallet One
Gregory Wood Products
Public Private Partnerships:Gregory Wood Products: 65,000 BF/hr
capacityPallet One: largest new pallet manufacturer in the US (17
facilities in 11 states- 4 in NC)12
1.9MW, + 6.7MM Btus Heat
Wood Waste Gasification15,000-20,000 dry tons of clean wood
fuel/year1.9MWWaste heat to provide process heat for Kiln 13
Multi-Feed Anaerobic DigesterAg & Food WastesAlgaeAnimal
ManuresMixed PaperWastewater sludge
Organic Waste Anaerobic Digester Facility - The Organic (Sewage,
Animal and Food Waste) Anaerobic Digester Facility will consist of
two newly constructed anaerobic digesters. One digester will be
used to process sewage (wastewater sludge) from wastewater plants
and the other digester will process animal and food wastes. Biogas
from both digesters will be used to produce electricity and heat
through the operation of GE-Jenbacher Generator sets.14Oilseed
Feedstock Crops & Processing
15
200 acres on EcoComplex buffer area for row cropsDouble crop
potential of rapeseed/sunflower in NC: 3.5-5 tons/acre and 220 gal
oil/acre/year.(7.7-11.2 tons/Ha/yr and 2,000 Liters
Oil/Ha/yr)Sunflower: 2-3 tons/acre 100galoil/AcCanola: 1.5-2
tons/Ac 120gal oil/AcAfter two years, follow double crop with
soy/rapeseed or soy/winter wheat.
Feedstock Processing StationCapacity: 100,000 gal oil/year
(~400,000 liters oil/year)Crop area (with double cropping): 450 Ac
(180 Ha)Material handling: 1900 tons seed/year, 1300 tons of
meal
15Oilseed Feedstock CropsDouble crop potential of
rapeseed/sunflower in NC: 3.5-5 tons/acre = 220 gal
oil/acre/year.(7.7-11.2 tons/Ha/yr = 2,000 Liters Oil/Ha/yr)
Sunflower: 2-3 tons/acre 100galoil/AcCanola: 1.5-2 tons/Ac
120gal oil/AcAfter two years, follow double crop with soy/rapeseed
or soy/winter wheat.
16EcoComplex Feedstock Processing StationCapacity: 100,000 gal
oil/year (~400,000 liters oil/year)Crop area (with double
cropping): 450 Ac (180 Ha)Material handling: 1900 tons seed/year,
1300 tons of meal
Capacity: 100,000 gal oil/year (~400,000 liters oil/year)Crop
area (with double cropping): 450 Ac (180 Ha)Material handling: 1900
tons seed/year, 1300 tons of meal17Cellulosic Ethanol/ Algae
Alternative Cap
200 acres of landfill cap, Cellulosic ethanol yield from
switchgrass = 400 gal/acre18Gen-Set Heat employment:Injecting CO2
into Algae ponds to facilitate growthBlending Algae with oilseed
meal to enhance livestock feedAlgae used as soil amendment in
Greenhouse Possible gasification in Bio-Energy FacilityAlgae for
Mitigating CO2Algae will be grown in greenhouse setting primarily
for mitigating CO2
Too costly to extract oil for biofuel production. However, we
will be getting energy from algae in some fashion (gasification,
digestion, livestock feed-to-livestock waste). 19
BIOMASS ENERGY POTENTIAL
FeedstockProcessEnergy TypeNet Energy (MW)Net Heat
(MMBtus)Annual Energy (MWh)Annual CO2 Reduction (metric
tons)MSWAnaerobic DigestionLandfill
Gas2.38.0919710.011826.0TriglyceridesTranesterifi-cationMethyl
Esters100,000 gal/yearN/A3516.02109.6Wood fuelGasificationSyn
Gas1.96.6814979.68987.8Biosolids/algaeAnaerobic
DigestionMethane1.03.527884.04730.4Perennial Grass/energy
cropsCellulosic EthanolEthanol80,000
gal/yearN/A1758.01054.8TOTALS5.218.347847.628708.5
Appalachian Biofuels Research and Testing Facility A Vision
GOLD LEED CERTIFIED22Biodiesel Production Chain at Catawba
County EcoComplex23
ProcessesAnalyticsNIR-spec ProbeGC-MSQA/QC -Reduced Spec ASTM
D6751Free & Total GlycerinFlash pointSulfated AshAcid
NumberPhosphorousWater & sedimentCold Flow
Process HeatingCatalystsReactant mixingMethanol recovery Fuel
washingGlycerol separation & refiningCo-product
developmentProcess Efficiency (Energy Balance)Modular
TestingCatalyst: acid/baseReactant mixing: pump mix, shear mix,
cavitation mixGlycerol refining w/ KOHMethanol recovery: vacuum,
energy intensity, Clean-up: Water, magnesium silicate, ion
exchange- hybrid washing systemsBy-products- recovered fuel from
wash water w/ acidulation24Appalachian Biofuels Research and
Testing Facility A Reality
Appalachian Biofuels Research and Testing Facility A Reality
Oil Extraction and Refinement Research and Outreach
Biofuels Emissions Analysis The Need
Source: NREL/TP-580-30004Biofuels Emissions Analysis A
Vision
Biofuels Emissions Analysis A Reality
Returns Emissions in g/km, g/kg fuel, g/s, or g/bhp-hr: CO2, CO,
SOx, NOx, THC, Particulate Matter
Visit the EcoComplex
Barry B. Edwards, P.E.Director of Utilities and EngineeringPhone
[email protected]
Jeremy FerrellBiodiesel Operations & Outreach
ManagerAppalachian Energy [email protected]
Utilities and Engineering site:
www.catawbacountync.gov/depts/u&e31