Renewable Carbon Management, LLC
Choosing your Containerized Organics Management Solution A step by step guide www.renewablecarbon.com RCM@composter.com 44 28th Ave N Suite J Saint Cloud, MN 56303 320-253-5076 Fax 253-4976
Why Choose Containerized Composting?
1. Learn from experience – perceived lowest cost for “waste disposal” often leads to new and greater problems 2. Prevent odors, stop or prevent complaints 3. Protect investment in land and permits – keep operating 4. Prevent surface water run-off 5. Meet new air quality, ozone, smog and greenhouse gas rules 6. Transition technologies, i.e. buildings, bags, covers have high operating and maintenance costs 7. Ready for reliable, utility grade technology with predictable performance – Best Management Practices 8. Reduce pathogens and ensure product liability safety 9. Value-added soil product marketing opportunity 10. Ready for sustainable community – integrated bio-systems approach to corporate or community stewardship planning
The Ten Step Organics Learning Curve Welcome to Levels 8-10
1. Let piles sit 2. Grind everything, later source separation 3. Turn piles with front-end loader 4. Turn piles with windrow turner 5. Hard surface, stormwater containment 6. Pathogen destruction and reduction of vectors 7. Stormwater protection; buildings, bags, covers 8. Aeration and temperature control – biofiltration - Air is less expensive than turning – turning is not necessary 9. Containerization – lower operating cost 10. Integrated biosystems, sustainable communities
How Containerized Composting Meets Your Goals
1. Waste disposal 2. Volume reduction 3. Pathogen destruction 4. Odor prevention 5. Air and water pollution prevention 6. Value-added soils production 7. Cost reduction – stable, predictable cost over time 8. Profitability
Previous buyers expressed the following reasons to purchase a containerized system:
1. Locate near feedstock 2. More capacity per acre/hectare - up to 100 TPD per acre 3. Compliance with current & future air & water regulations 4. Odor control – process control and biofiltration 5. Capable of handling difficult, raw, or wet feedstock 6. Liability reduction – certain pathogen and vector control 7. Consistent soil product – higher soil revenue 8. Lower operating costs – move 40 tons per cycle vs. 4 tons 9. Lower maintenance costs – fewer moving parts “air is cheap” 10. Intermodal container efficiency and transportation 11. Epoxy coated Cor-ten corrosion resistant steel 12. Replaceable insulation wear liner – long life of asset
Select Your Management Strategy
Containerized Composting has Six Management Options
1. Stationary Containers 20’ or 40’ 2. Mobile 20’ containers moved and tipped 3. Mobile 40’ containers moved and tipped 4. Double, or even triple stacking for space optimization 5. Local initial processing and transport to remote area by train, ship or truck 6. Integrate with sustainable community and integrated biosystems
Stationary Composting
20’ or 40’ containers rest on concrete footings Load and unload with front-end loader Load with conveyor Load with mobile spreader box Mix with loader or with box scale
Advantage – lower initial capital cost Disadvantage – higher labor and operating cost
Mobile 20’ Container System
Best for projects under 80 Tons Per Day Move containers from mixer to aeration grid Raise angle of container from 45o to 90o Fill with conveyor without open lid Dump container – either fixed point or mobile Common roll-off truck compatibility Intermodal container handling equipment Advantage - Lower operating cost
Mobile 40’ Container System
Best for projects 80 Tons Per Day and Larger Economy of Scale at 600-800 TPD Lowest capital cost per TPD Lowest operating cost per TPD Most processing capacity per acre/hectare
Material Handling Process Flow
Grind Wood
Mix Ingredients
Aerate
To Stockpile for Sale
Containerized Composting Process Material Collected & Delivered
Batch Management
Value-added Enhancement
Wood Grinding
Containerized Composting
Screening
Mixing
Aeration Odor Control
Storing/Marketing
Customizing Your Containerized System
Every containerized site from 5TPD to 600 TPD has these preliminary costs: Site preparation, grading and hard surfacing Utilities, water, electricity Tipping and mixing area with concrete and push walls Engineering, Training, Zoning, Construction Management Front-end Loader Mixer Screen
Facilities over 20 tons per day Permitting Container Mover/Tipper Mixing and screening area cover
Front-End Loader Selection
Cycle time is related to bucket-load tonnage
The Front-end Loader 1. Fills mixer 2. Feeds screener 3. Loads trucks
Under 10 TPD – skid-steer 1 ton $40K 10-30 TPD - 2 ton loader $90K 30-80 TPD – 4 ton loader $200K Add one 4 ton loader per 100 TPD Costs are estimates – Select light material bucket option Ensure that the loader can reach all of the necessary heights
Bobcat 330 or equivalent 1 ton capacity - light material bucket
New Holland TV-140 2 ton hydrostatic tractor loader
Cat 930, 950, 966 wheel loaders or equivalent
Mixers Mixer Containerized Composting is referred to as “In-vessel composting” but it is actually “enclosed aerated static pile” technology. Air dependent systems require more precision mixing than windrows. On a commercial scale over 5 TPD, a batch mixer is mandatory with a scale for precision mixing.
Under 5 TPD – loader scale $5K 5-30 TPD – Ag batch mixing system $40-80K 30-80 TPD – Twin screw batch mixer $130K
Loader Mixing – Under 5 TPD
Ag Batch Mixers – Auger style with Weigh Feed System Under 30 TPD
Twin Screw Mixers
Forage Box for Filling Composter -add Load Cells and Scale for Box to Serve Dual Function as Mixer
Stellar Hook Lift Roll-off System
53 degrees dump vs. 47 degrees Versatile hook system Rated up to 65,000 lbs vs. 60,000 “Spider” ISO Intermodal connector Eliminate roll-off sub-chassis weight & $$ Additional opportunities in container moving North America distribution network Other roll-offs require special sub-chassis
Stellar Hook Lift System
Stellar ISO “Spider” Adapter Eliminates Roll-off Sub-Chassis
ISO Container Handler
Tow style economical container mover Double stacking option Dump option or take to fixed dump point Economical cable and winch system Self propelled 78HP option Automated spreader option 20’ or 40’ versatility
40’ and 20’ double stacker with spreader
Stationary Tip Point
Dish Screen – Under 60 TPD Could be fed with batch mixer
Trommel Screen 60 TPD and up
Cover-all Fabric Building for unloading, mixing and screening
80’ x 80’ Building can be built on top of four 40’ biofilter containers, raising height and optimizing space
Other Options and Integrated Bio-systems
Dewatering mesh inserts – gravity filters Greenhouse and building heat exchange Bio-fertilizer production joint ventures Lease financing for qualified project Custom conveyors and loader buckets Service contracts, regulatory compliance Compost marketing services Biogas pre-processing options Wood chip and biomass drying
Removable Dewatering Filter Insert Thicken solids to 20% or more, remove insert and use container as digester
60 TPD Project Cash Flow
$30 per ton Tipping Fee $1,800 per day - Starting Day 1 $657,000 per year Operating Cost - Labor, Utilities, Maintenance $6-17 per ton Average $10 - $600 per day - $219,000 per year $50-100 per ton for Compost Sales 40 TPD $4,000 per day $1,460,000 year - Starting 45+ days after opening
Tipping fee and Compost sales - $2,117,000 per year Operating cost - $438,000 – Net $1,679,000
Kyoto Carbon Credits RCM process is certified Actual credits site specific
Fugitive Methane prevention – up to $15 per ton Carbon Sequestration - up to $4 per ton Smog and NOX credits – up to $4 per ton Other misc. credits – up to $4 per ton
Total up to $30 per ton
12’
C44 C46 C48 C50 C52 C54 C56 C58 C60 C62 C64 C66 C68 C70 C72 C74 C76 C78 C80 C82 C84
D3
D5
D7
D9
D11
D13
D15
D17
D19
D21
D23
D25
D27
D29
D31
D33
D35
D37
D39
D41
D2
D4
D6
D8
0 D1
D12
D14
D16
D18
D20
D22
D24
D26
D28
D30
D32
D34
D36
D38
D40
D42
C42
Phase 2-Curing Bins 16-45 days
C41
C21
C23
C25
C27
C29
C31
C33
C35
C37
C20
C22
C24
C26
C28
C30
C32
C34
C36
C38
C40
C19
C18
C39
C17
C5
C7
C9
C11
C13
C4
C6
C8
C10
C12
C14
C16
C3
C2
C15
C1 Pre-warmed Intake Air
D1
Phase 1-Active Compost Digesters-0-15 days
One example of a 60 TPD Layout
Phase 3-Curing Bins 0-15 days
C43 C45 C47 C49 C51 C53 C55 C57 C59 C61 C63 C65 C67 C69 C71 C73 C75 C77 C79 C81
C83
10’
Typical Small Scale Site Layout Composting Containers
110 ft.
Mixed Pile or Conveyor Fill Digester Area
Mixer
Process Control, Office & Laboratory Container
Biofilter
Screen Curing Piles 20-120 Days
4 ft. Retaining Walls
Amendments
Compostables
Cured Compost
160 ft.
300 TPD Project Cash Flow
$30 per ton Tipping Fee $9,000 per day - Starting Day 1 $3,285,000 per year Operating Cost - Labor, Utilities, Maintenance $6 per ton $1,800 per day - $657,000 per year $50-100 per ton for Compost Sales 200 TPD $10,000 per day $3,650,000 year - Starting 45+ days after opening
Tipping fee and Compost sales - $6,935,000 per year Operating cost - $657,000 – Net $6,278,000
Financing Options
Funding for North American Projects with Dry anaerobic digestion over 100 TPD Equipment leasing for qualified projects in US RCM equity options for certain projects
RCM Patents Awarded – US and International
#6,281,001 In-vessel Composting and Bioremediation, August 2001 #6,524,848 Improvements in Composting System September 2003 #6,627,434 Biofertilizer “Air recirculation Methodology” February 2003
Pending
Stand Alone Containerized Biofiltration - Air and Water Filed 1997, Misplaced in Patent Office, Renewed February 2007 Dual Function Intermodal Bio-container - Filed April, 2007 Stationary Composting Bunker – Filed April, 2007
Summary
Patented, improved environmental technology Low cost processing containers Low operating costs Environmentally compliant Proven technology and experienced support team Portable modules with low fixed capital outlay Regulatorily exempt in some cases Positive operating cash flow after start up Choose your own capital vs. operating cost formula