ICM Development Technologies Related to Fractionation. Douglas B. Rivers, Ph.D. October 27, 2010

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1 ICM Development Technologies Related to Fractionation Douglas B. Rivers, Ph.D. October 27, 2010

2 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

3 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

4 Current ICM Developments Related to Fractionation Combined Food-Grade Protein Recovery Integrated Grain and Cellulose to Ethanol

5 Corn Components

6 Line of Sight

7 Bridge to Cellulosic Ethanol Food AND Fuel through TKO (Total Kernel Optimization)

8 Add Value through Dry Fractionation TKO Dry Fractionation Oil Extraction Germ Protein Single Cell Protein Hydration Cleaning Tempering Germ Removal Sifting Gasification Fiber-to-Ethanol Bran Removal Germ Flattening Sifting Separation Aspiration Reduction Hydration

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

11 High protein DDG from germ stream Combustor to produce thermal energy from renewable resources

12 Improved Efficiencies & Costs

13 Phase II Protein is processed creating new Food Grade Protein product.

14 Germ Protein

15 Germ Protein Benefits 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

16 Value of Germ Protein 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 Defatted Germ Production & Value Estimates Bushels (100 MGY) 37,600,000 Protein Extraction Efficiency 43% Lbs Protein Concentrate/Bushel 0.7 Protein Concentrate $1.50 $39,358, Protein Concentrate $3.00 $78,717,675.89

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

18 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.

19 Implementation Stages of Fiber Cellulose to Ethanol Ethanol SCP High 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

20 Cellulose to Ethanol Potential What is the potential? Theoretical is up to gallons/ton Practical limit is closer to 100 gallons/ton First plants will be around gallons/ton Grain based today is ~96 gallons/ton ~ 60 billion gallons ethanol potential in US from biomass

21 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

22 Cost Comparisons Corn Starch Corn Stover Annual Ethanol (MMGal) Ethanol Prod. Cost ($/gal) Total Prod. Costs (MM$/yr) Co-product Credit ($/gal) Feedstock costs ($/gal) Capital Invest. (MM$) USDA, March 2005

23 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

24 How Do We Get There? Build on Success of Grain Ethanol Industry Leverage Existing Grain Operations Develop Highly Integrated and Efficient Process

25 Value Chain of Cellulosic Ethanol

26 Ethanol from Energy Crops Experimental plots = 10 tons per acre 1200-lb. bale = 48 gallons of 80 gallons per ton Goal 100 gallons per ton of biomass = ethanol yield of 1000 gallons per acre

27 Feedstock Production

28 Value Chain of Cellulosic Ethanol

29 DOE Integrated Biorefinery

30 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

31 Value Chain of Cellulosic Ethanol

32 Thank you! Contact: Douglas B. Rivers, Ph.D. Director, Research & Development 310 N. First Street Colwich, KS Phone: (316)