choosing a composting system

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Renewable Carbon Renewable Carbon Management, LLC Management, LLC Choosing your Containerized Organics Choosing your Containerized Organics Management Solution Management Solution A step by step guide A step by step guide www.renewablecarbon.com www.renewablecarbon.com [email protected] [email protected] 44 28 44 28 th th Ave N Ave N Suite J Suite J Saint Cloud, MN 56303 Saint Cloud, MN 56303 320 320 - - 253 253 - - 5076 Fax 253 5076 Fax 253 - - 4976 4976

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General guides to choosing a system.

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Page 1: Choosing a Composting System

Renewable Carbon Renewable Carbon Management, LLCManagement, LLC

Choosing your Containerized Organics Choosing your Containerized Organics Management SolutionManagement Solution

A step by step guideA step by step guide

www.renewablecarbon.comwww.renewablecarbon.com

[email protected]@composter.com

44 2844 28thth Ave NAve NSuite JSuite JSaint Cloud, MN 56303Saint Cloud, MN 56303320320--253253--5076 Fax 2535076 Fax 253--49764976

Page 2: Choosing a Composting System

Why Choose Containerized Composting?Why Choose Containerized Composting?1. Learn from experience 1. Learn from experience –– perceived lowest cost for perceived lowest cost for ““waste waste disposaldisposal”” often leads to new and greater problemsoften leads to new and greater problems2. Prevent odors, stop or prevent complaints2. Prevent odors, stop or prevent complaints3. Protect investment in land and permits 3. Protect investment in land and permits –– keep operatingkeep operating4. Prevent surface water run4. Prevent surface water run--offoff5. Meet new air quality, ozone, smog and greenhouse gas rules5. Meet new air quality, ozone, smog and greenhouse gas rules6. Transition technologies, i.e. buildings, bags, covers have 6. Transition technologies, i.e. buildings, bags, covers have high operating and maintenance costshigh operating and maintenance costs7. Ready for reliable, utility grade technology with predictable7. Ready for reliable, utility grade technology with predictableperformance performance –– Best Management PracticesBest Management Practices8. Reduce pathogens and ensure product liability safety8. Reduce pathogens and ensure product liability safety9. Value9. Value--added soil product marketing opportunityadded soil product marketing opportunity10. Ready for sustainable community 10. Ready for sustainable community –– integrated biointegrated bio--systems systems approach to corporate or community stewardship planningapproach to corporate or community stewardship planning

Page 3: Choosing a Composting System

The Ten Step Organics Learning CurveThe Ten Step Organics Learning CurveWelcome to Levels 8Welcome to Levels 8--1010

1. Let piles sit1. Let piles sit2. Grind everything, later source separation 2. Grind everything, later source separation 3. Turn piles with front3. Turn piles with front--end loaderend loader4. Turn piles with windrow turner4. Turn piles with windrow turner5. Hard surface, stormwater containment5. Hard surface, stormwater containment6. Pathogen destruction and reduction of vectors6. Pathogen destruction and reduction of vectors7. Stormwater protection; buildings, bags, covers7. Stormwater protection; buildings, bags, covers8. Aeration and temperature control 8. Aeration and temperature control –– biofiltration biofiltration -- Air is less Air is less expensive than turning expensive than turning –– turning is not necessaryturning is not necessary9. Containerization 9. Containerization –– lower operating costlower operating cost10. Integrated biosystems, sustainable communities10. Integrated biosystems, sustainable communities

Page 4: Choosing a Composting System

How Containerized How Containerized Composting Meets Your GoalsComposting Meets Your Goals1. Waste disposal 1. Waste disposal 2. Volume reduction2. Volume reduction3. Pathogen destruction3. Pathogen destruction4. Odor prevention4. Odor prevention5. Air and water pollution prevention5. Air and water pollution prevention6. Value6. Value--added soils productionadded soils production7. Cost reduction 7. Cost reduction –– stable, predictable cost over timestable, predictable cost over time8. Profitability8. Profitability

Page 5: Choosing a Composting System

Previous buyers expressed the following Previous buyers expressed the following reasons to purchase a containerized system:reasons to purchase a containerized system:

1. Locate near feedstock1. Locate near feedstock2. More capacity per acre/hectare 2. More capacity per acre/hectare -- up to 100 TPD per acreup to 100 TPD per acre3. Compliance with current & future air & water regulations 3. Compliance with current & future air & water regulations 4. Odor control 4. Odor control –– process control and biofiltrationprocess control and biofiltration5. Capable of handling difficult, raw, or wet feedstock5. Capable of handling difficult, raw, or wet feedstock6. Liability reduction 6. Liability reduction –– certain pathogen and vector controlcertain pathogen and vector control7. Consistent soil product 7. Consistent soil product –– higher soil revenuehigher soil revenue8. Lower operating costs 8. Lower operating costs –– move 40 tons per cycle vs. 4 tonsmove 40 tons per cycle vs. 4 tons9. Lower maintenance costs 9. Lower maintenance costs –– fewer moving parts fewer moving parts ““air is cheapair is cheap””10. Intermodal container efficiency and transportation10. Intermodal container efficiency and transportation11. Epoxy coated Cor11. Epoxy coated Cor--ten corrosion resistant steelten corrosion resistant steel12. Replaceable insulation wear liner 12. Replaceable insulation wear liner –– long life of assetlong life of asset

Page 6: Choosing a Composting System

Select Your Management Select Your Management StrategyStrategy

Containerized Composting has Six Management Containerized Composting has Six Management OptionsOptions

1. Stationary Containers 201. Stationary Containers 20’’ or 40or 40’’2. Mobile 202. Mobile 20’’ containers moved and tippedcontainers moved and tipped3. Mobile 403. Mobile 40’’ containers moved and tippedcontainers moved and tipped4. Double, or even triple stacking for space optimization4. Double, or even triple stacking for space optimization5. Local initial processing and transport to remote area by 5. Local initial processing and transport to remote area by train, ship or trucktrain, ship or truck6. Integrate with sustainable community and integrated bio6. Integrate with sustainable community and integrated bio--systems systems

Page 7: Choosing a Composting System

Stationary CompostingStationary Composting2020’’ or 40or 40’’ containers rest on concrete footingscontainers rest on concrete footingsLoad and unload with frontLoad and unload with front--end loaderend loaderLoad with conveyorLoad with conveyorLoad with mobile spreader boxLoad with mobile spreader boxMix with loader or with box scaleMix with loader or with box scale

Advantage Advantage –– lower initial capital costlower initial capital costDisadvantage Disadvantage –– higher labor and operating costhigher labor and operating cost

Page 8: Choosing a Composting System

Mobile 20Mobile 20’’ Container SystemContainer SystemBest for projects under 80 Tons Per DayBest for projects under 80 Tons Per DayMove containers from mixer to aeration gridMove containers from mixer to aeration gridRaise angle of container from 45Raise angle of container from 45oo to 90to 90oo

Fill with conveyor without open lidFill with conveyor without open lidDump container Dump container –– either fixed point or mobileeither fixed point or mobileCommon rollCommon roll--off truck compatibilityoff truck compatibilityIntermodal container handling equipmentIntermodal container handling equipmentAdvantage Advantage -- Lower operating costLower operating cost

Page 9: Choosing a Composting System

Mobile 40Mobile 40’’ Container SystemContainer System

Best for projects 80 Tons Per Day and LargerBest for projects 80 Tons Per Day and LargerEconomy of Scale at 600Economy of Scale at 600--800 TPD800 TPDLowest capital cost per TPDLowest capital cost per TPDLowest operating cost per TPDLowest operating cost per TPDMost processing capacity per acre/hectareMost processing capacity per acre/hectare

Page 10: Choosing a Composting System

Material Handling Process FlowMaterial Handling Process Flow

Grind Wood

AerateMix Ingredients

To Stockpile for Sale

Page 11: Choosing a Composting System

Material Collected &Delivered

ContainerizedComposting

WoodGrinding

Mixing

Aeration Odor Control

Value-addedEnhancement

Screening Storing/Marketing

Batch Management

Containerized Composting Containerized Composting ProcessProcess

Page 12: Choosing a Composting System

Customizing Your Containerized SystemCustomizing Your Containerized System

Every containerized site from 5TPD to 600 TPD has these preliminEvery containerized site from 5TPD to 600 TPD has these preliminary costs:ary costs:

Site preparation, grading and hard surfacingSite preparation, grading and hard surfacingUtilities, water, electricityUtilities, water, electricityTipping and mixing area with concrete and push wallsTipping and mixing area with concrete and push wallsEngineering, Training, Zoning, Construction ManagementEngineering, Training, Zoning, Construction ManagementFrontFront--end Loaderend LoaderMixer Mixer ScreenScreen

Facilities over 20 tons per day Facilities over 20 tons per day PermittingPermittingContainer Mover/TipperContainer Mover/TipperMixing and screening area coverMixing and screening area cover

Page 13: Choosing a Composting System

FrontFront--End Loader SelectionEnd Loader SelectionCycle time is related to bucketCycle time is related to bucket--load tonnageload tonnage

The FrontThe Front--end Loader end Loader 1. Fills mixer1. Fills mixer2. Feeds screener2. Feeds screener3. Loads trucks3. Loads trucks

Under 10 TPD Under 10 TPD –– skidskid--steer 1 ton $40Ksteer 1 ton $40K1010--30 TPD 30 TPD -- 2 ton loader $90K2 ton loader $90K3030--80 TPD 80 TPD –– 4 ton loader $200K4 ton loader $200KAdd one 4 ton loader per 100 TPDAdd one 4 ton loader per 100 TPD

Costs are estimates Costs are estimates –– Select light material bucket optionSelect light material bucket optionEnsure that the loader can reach all of the necessary heightsEnsure that the loader can reach all of the necessary heights

Page 14: Choosing a Composting System

Bobcat 330 or equivalentBobcat 330 or equivalent1 ton capacity 1 ton capacity -- light material bucketlight material bucket

Page 15: Choosing a Composting System

New Holland TVNew Holland TV--1401402 ton hydrostatic tractor loader2 ton hydrostatic tractor loader

Page 16: Choosing a Composting System

Cat 930, 950, 966 Cat 930, 950, 966 wheel loaders or equivalentwheel loaders or equivalent

Page 17: Choosing a Composting System

MixersMixerMixerContainerized Composting is referred to as Containerized Composting is referred to as ““InIn--vessel vessel

compostingcomposting”” but it is actually but it is actually ““enclosed aerated static enclosed aerated static pilepile”” technology. Air dependent systems require technology. Air dependent systems require more precision mixing than windrows. On a more precision mixing than windrows. On a commercial scale over 5 TPD, a batch mixer is commercial scale over 5 TPD, a batch mixer is mandatory with a scale for precision mixing.mandatory with a scale for precision mixing.

Under 5 TPD Under 5 TPD –– loader scale $5Kloader scale $5K55--30 TPD 30 TPD –– Ag batch mixing system $40Ag batch mixing system $40--80K80K3030--80 TPD 80 TPD –– Twin screw batch mixer $130KTwin screw batch mixer $130K

Page 18: Choosing a Composting System

Loader Mixing Loader Mixing –– Under 5 TPDUnder 5 TPD

Page 19: Choosing a Composting System

Ag Batch Mixers Ag Batch Mixers –– Auger style Auger style with Weigh Feed System with Weigh Feed System

Under 30 TPDUnder 30 TPD

Page 20: Choosing a Composting System

Twin Screw MixersTwin Screw Mixers

Page 21: Choosing a Composting System

Forage Box for Filling ComposterForage Box for Filling Composter--add Load Cells and Scale for Box to add Load Cells and Scale for Box to

Serve Dual Function as MixerServe Dual Function as Mixer

Page 22: Choosing a Composting System

Stellar Hook LiftStellar Hook LiftRollRoll--off Systemoff System

53 degrees dump vs. 47 degrees53 degrees dump vs. 47 degreesVersatile hook systemVersatile hook systemRated up to 65,000 lbs vs. 60,000Rated up to 65,000 lbs vs. 60,000““SpiderSpider”” ISO Intermodal connectorISO Intermodal connectorEliminate rollEliminate roll--off suboff sub--chassis weight & $$chassis weight & $$Additional opportunities in container movingAdditional opportunities in container movingNorth America distribution networkNorth America distribution networkOther rollOther roll--offs require special suboffs require special sub--chassischassis

Page 23: Choosing a Composting System

Stellar Hook Lift SystemStellar Hook Lift System

Page 24: Choosing a Composting System

Stellar ISO Stellar ISO ““SpiderSpider”” AdapterAdapterEliminates RollEliminates Roll--off Suboff Sub--ChassisChassis

Page 25: Choosing a Composting System

ISO Container HandlerISO Container Handler

Tow style economical container moverTow style economical container moverDouble stacking optionDouble stacking optionDump option or take to fixed dump pointDump option or take to fixed dump pointEconomical cable and winch systemEconomical cable and winch systemSelf propelled 78HP optionSelf propelled 78HP optionAutomated spreader optionAutomated spreader option2020’’ or 40or 40’’ versatilityversatility

Page 26: Choosing a Composting System

4040’’ and 20and 20’’ double stacker double stacker with spreaderwith spreader

Page 27: Choosing a Composting System

Stationary Tip PointStationary Tip Point

Page 28: Choosing a Composting System

Dish Screen Dish Screen –– Under 60 TPDUnder 60 TPDCould be fed with batch mixerCould be fed with batch mixer

Page 29: Choosing a Composting System

Trommel ScreenTrommel Screen60 TPD and up60 TPD and up

Page 30: Choosing a Composting System

CoverCover--all Fabric Building for all Fabric Building for unloading, mixing and screeningunloading, mixing and screening

80’ x 80’ Building can be built on top of four 40’ biofilter containers, raising height and optimizing space

Page 31: Choosing a Composting System
Page 32: Choosing a Composting System

Other Options and Integrated Other Options and Integrated BioBio--systemssystems

Dewatering mesh inserts Dewatering mesh inserts –– gravity filtersgravity filtersGreenhouse and building heat exchangeGreenhouse and building heat exchangeBioBio--fertilizer production joint venturesfertilizer production joint venturesLease financing for qualified projectLease financing for qualified projectCustom conveyors and loader bucketsCustom conveyors and loader bucketsService contracts, regulatory complianceService contracts, regulatory complianceCompost marketing servicesCompost marketing servicesBiogas preBiogas pre--processing optionsprocessing optionsWood chip and biomass dryingWood chip and biomass drying

Page 33: Choosing a Composting System

Removable Dewatering Filter Removable Dewatering Filter InsertInsert

Thicken solids to 20% or more, remove insert and use Thicken solids to 20% or more, remove insert and use container as digestercontainer as digester

Page 34: Choosing a Composting System

60 TPD Project Cash Flow60 TPD Project Cash Flow$30 per ton Tipping Fee $1,800 per day $30 per ton Tipping Fee $1,800 per day -- Starting Day 1Starting Day 1$657,000 per year$657,000 per year

Operating Cost Operating Cost -- Labor, Utilities, Maintenance $6Labor, Utilities, Maintenance $6--17 per ton17 per tonAverage $10 Average $10 -- $600 per day $600 per day -- $219,000 per year$219,000 per year

$50$50--100 per ton for Compost Sales 40 TPD $4,000 per day100 per ton for Compost Sales 40 TPD $4,000 per day$1,460,000 year $1,460,000 year -- Starting 45+ days after openingStarting 45+ days after opening

Tipping fee and Compost sales Tipping fee and Compost sales -- $2,117,000 per year $2,117,000 per year Operating cost Operating cost -- $438,000 $438,000 –– Net $1,679,000Net $1,679,000

Page 35: Choosing a Composting System

Kyoto Carbon CreditsKyoto Carbon CreditsRCM process is certified RCM process is certified

Actual credits site specificActual credits site specificFugitive Methane prevention Fugitive Methane prevention –– up to $15 per tonup to $15 per tonCarbon Sequestration Carbon Sequestration -- up to $4 per tonup to $4 per tonSmog and NOX credits Smog and NOX credits –– up to $4 per tonup to $4 per tonOther misc. credits Other misc. credits –– up to $4 per tonup to $4 per ton

Total up to $30 per tonTotal up to $30 per ton

Page 36: Choosing a Composting System

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Pr e -wa rm

ed I n ta k e Ai r

P ha se 2 - Cu rin g B in s 1 6 -4 5 d a ys

P ha se 3 - Cu rin g B in s 0 - 1 5 d ay s

P ha se 1 -Act iv e C

o mp os t D

ig e ste rs -0 -1 5 d a ys

12’

10’

One example of a 60 TPD Layout

Page 37: Choosing a Composting System

110

ft.

CompostablesAmendments

Mixer

Mixed Pileor

Conveyor FillDigester Area

Screen

Cured Compost

160 ft.

Composting Containers

ProcessControl, Office & LaboratoryContainer

4 ft. Retaining Walls

Biofilter

Curing Piles 20-120 Days

Typical Small Scale Site Layout

Page 38: Choosing a Composting System

300 TPD Project Cash Flow300 TPD Project Cash Flow$30 per ton Tipping Fee $9,000 per day $30 per ton Tipping Fee $9,000 per day -- Starting Day 1Starting Day 1$3,285,000 per year$3,285,000 per year

Operating Cost Operating Cost -- Labor, Utilities, Maintenance $6 per tonLabor, Utilities, Maintenance $6 per ton$1,800 per day $1,800 per day -- $657,000 per year$657,000 per year

$50$50--100 per ton for Compost Sales 200 TPD $10,000 per day100 per ton for Compost Sales 200 TPD $10,000 per day$3,650,000 year $3,650,000 year -- Starting 45+ days after openingStarting 45+ days after opening

Tipping fee and Compost sales Tipping fee and Compost sales -- $6,935,000 per year $6,935,000 per year Operating cost Operating cost -- $657,000 $657,000 –– Net $6,278,000Net $6,278,000

Page 39: Choosing a Composting System

Financing OptionsFinancing Options

Funding for North American Projects with Dry Funding for North American Projects with Dry anaerobic digestion over 100 TPDanaerobic digestion over 100 TPDEquipment leasing for qualified projects in USEquipment leasing for qualified projects in USRCM equity options for certain projectsRCM equity options for certain projects

Page 40: Choosing a Composting System

RCM PatentsRCM 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 WaterFiled 1997, Misplaced in Patent Office, Renewed February 2007Dual Function Intermodal Bio-container - Filed April, 2007Stationary Composting Bunker – Filed April, 2007

Page 41: Choosing a Composting System

SummarySummaryPatented, improved environmental technologyPatented, improved environmental technologyLow cost processing containersLow cost processing containersLow operating costsLow operating costsEnvironmentally compliantEnvironmentally compliantProven technology and experienced support teamProven technology and experienced support teamPortable modules with low fixed capital outlayPortable modules with low fixed capital outlayRegulatorily exempt in some casesRegulatorily exempt in some casesPositive operating cash flow after start upPositive operating cash flow after start upChoose your own capital Choose your own capital vs.vs. operating cost formulaoperating cost formula