choosing a composting system
DESCRIPTION
General guides to choosing a system.TRANSCRIPT
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
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
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
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
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
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
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
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
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
Material Handling Process FlowMaterial Handling Process Flow
Grind Wood
AerateMix Ingredients
To Stockpile for Sale
Material Collected &Delivered
ContainerizedComposting
WoodGrinding
Mixing
Aeration Odor Control
Value-addedEnhancement
Screening Storing/Marketing
Batch Management
Containerized Composting Containerized Composting ProcessProcess
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
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
Bobcat 330 or equivalentBobcat 330 or equivalent1 ton capacity 1 ton capacity -- light material bucketlight material bucket
New Holland TVNew Holland TV--1401402 ton hydrostatic tractor loader2 ton hydrostatic tractor loader
Cat 930, 950, 966 Cat 930, 950, 966 wheel loaders or equivalentwheel loaders or equivalent
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
Loader Mixing Loader Mixing –– Under 5 TPDUnder 5 TPD
Ag Batch Mixers Ag Batch Mixers –– Auger style Auger style with Weigh Feed System with Weigh Feed System
Under 30 TPDUnder 30 TPD
Twin Screw MixersTwin Screw Mixers
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
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
Stellar Hook Lift SystemStellar Hook Lift System
Stellar ISO Stellar ISO ““SpiderSpider”” AdapterAdapterEliminates RollEliminates Roll--off Suboff Sub--ChassisChassis
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
4040’’ and 20and 20’’ double stacker double stacker with spreaderwith spreader
Stationary Tip PointStationary Tip Point
Dish Screen Dish Screen –– Under 60 TPDUnder 60 TPDCould be fed with batch mixerCould be fed with batch mixer
Trommel ScreenTrommel Screen60 TPD and up60 TPD and up
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
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
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
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
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
D42
D40
D38
D36
D34
D32
D30
D28
D26
D24
D22
D20
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D16
D14
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D8D6
D4
D2
D1 D3
D5
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D15
D17
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D21
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D25
D27
D29
D31
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D39
D41
C2 C4 C6 C8
C10
C12
C14
C16
C18
C20
C22
C24
C26
C28
C30
C32
C34
C36
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C42
C81
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C65
C63
C61
C59
C57
C55
C53
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C49
C47
C45
C43
C83
C3 C5 C7 C9
C11
C13
C15
C17
C19
C21
C23
C25
C27
C29
C31
C33
C35
C37
C39
C41
C1C84C82
C80
C78
C76
C74
C72
C70
C68
C66
C64
C62
C60
C58
C56
C54
C52
C50
C48
C46
C44
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
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
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
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
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
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