ECM
Ethanol Capital
Management LLC
Special Report
The Food Vs. Fuel Controversy Is Over:
New Ethanol Technology Now
Produces Food
October 2008Special Report
The Food Vs. Fuel Controversy Is Over:
New Ethanol Technology Now Produces Food.
EXECUTIVE SUMMARY
ECM’s top executives recently met with a company whose leaders and
scientists have developed and have in the production pipeline stunning
technological advances for the ethanol industry. These advances will end
the controversy about food vs. fuel, enhance revenue and reduce operating
costs for ethanol biorefineries, The new technology will have the ability to
provide significant investment opportunities with potentially higher rates of
return.
ICM, Inc., the leading ethanol technology provider in North America, is
responsible for these advances. ICM’s proven track record of excellence has
allowed it to become the leading process-design engineering firm for ethanol
production in the US,
ECM executives spent two days at ICM’s new state-of-the-art scientific and
engineering facilities, meeting with ICM founder and CEO David Vander
Griend, scientists, PhDs, and other technology experts from his staff. ‘The
focus of the meeting was the dramatic new technology developed by ICM
that processes corn into food products for human consumption and greater
amounts of ethanol.Summary Conclusions of the Special Report
New manufacturing technology ends the debate on food versus fuel by
simultaneously producing, from a single kernel of corn, food for
human consumption and ethanol to fuel cars and trucks.
ICM’s new technology will produce corn oil, food grade protein for
human consumption, feed protein from syrup, high protein distiller
grains and raw material for cellulosic production, and result in more
than a 20% inerease in ethanol production.
The buildings and equipment necessary to implement this new
technology can be integrated with existing biorefineries. Investors
will have new opportunities to profit from this innovation,
Fully implemented, ICM projects a 2 year payback of the roughly
$200 million investment, which would provide a 70% annual return
on investment when the project is fully implemented.
Ethanol biorefineries adopting the new technology are projected to
experience increased earnings and improved cash flows, which could
translate into higher investment valuations and greater potential
returns for investors.New Technology Creates Both Food and Fuel
ICM’s new technology incorporates a series of processes that provide
additional revenue from food, ethanol and feed products. Each process
creates additional revenue streams, increases operational efficiency and
reduces operating costs, thereby increasing carnings. The first phase of the
process is dry fractionation.
Dry Fractionation
Dry fractionation is the process of breaking the cor apart into its component
parts.
« The first component, the endosperm, is a combination of highly
fermentable starch used to produce ethanol and a high protein feed
product.
* The second component, the pericarp (bran), is processed into an
animal feed product, used for combustion to reduce energy costs, or
used as a feedstock for cellulosic ethanol.
* The third component, the germ, is processed into com oi
‘The endosperm accounts for about 82% of the kemel’s dry weight and is the
source of energy (starch) and protein for the germinating seed. Starch is the
‘most widely used part of the Ketel and is used in food, fuel and other
products.
“The pericarp (bran) is the outer covering that protects the kernel and
preserves the nutrient value inside. Bran may be used for food products or as
‘an alternative to natural gas as a fuel for running the ethanol plant.
‘The germis the only living past of the com kernel. About 25% of the germ
is com oil—the most valuable part ofthe Kernel. Com oil may be used to
produce food-grade oil, animal feed and bi
‘The tip cap is the attachment point ofthe kernel tothe cob, through
which water and nutrients flow—and is the only area of the kemel not
covered by the pericarp.Increased Ethanol Capacity
Dry fractionation increases ethanol production by 20% because the process
separates the endosperm from the other components of the kernel, and only
the endosperm, which contains the highly fermentable starch, is used to
produce ethanol. Through dry fractionation, bran and germ are separated
from the starchy endosperm and not passed through the production process
for ethanol. Instead, the bran and germ are turned into food for human
consumption.
In contrast to dry fractionation, today’s biorefineries process the entire com
kernel into ethanol and inexpensive distiller grains for livestock and poultry.
Natural Gas Reduction
The new ICM process may also lower natural gas costs for the ethanol
biorefinery by burning the bran to replace some of the natural gas used in the
plant. There is an 68% potential reduction in the cost of natural gas if the
bran and other by-products are burned to provide energy for the biorefinery.
To achieve this reduction in the cost of natural gas, biorefineries may add a
solid fuel combustor, which can burn a wide variety of waste products to
create the heat necessary for ethanol production, This will allow
biorefineries to choose from a wide variety of fuels, including biomass
and/or production co-products, depending on pricing and availability. Low-
cost combustible biomass might also include low-priced materials such as
wood chips, com stalks, corn cobs, and municipal solid waste. As a result,
biorefineries will have energy options that will help mitigate high natural gas
prices.
According to ICM, the combination of dry fractionation and a solid fuel
combustor will reduce the amount of natural gas used from 32,000 BTU per
gallon of ethanol produced to 10,000 BTU, with an estimated $23 million
annual reduction in the cost of natural gas.
Corn oil extraction
As a result of corn fractionation, com oil can be produced from a component
of the corn, Corn oil is marketed to companies that have corn oil-refiningsystems to further process this oil as food for human consumption. The corn
oil may also be used as nutritious animal feed supplement or for biodiesel
production.
As compared to a traditional corn oil-extraction process, ICM’s processing
technology retains the protein value of the corn, and therefore the corn oil is
sold for a higher price.
Many ethanol plants are adding just the corn oil extraction part of the
process to existing facilities. Some plants in which ECM is invested are
adding @ corn oil extractor, and others are now planning or considering
doing so. The corn oil extraction process alone is projected to increase a
biorefinery’s profit by about 14% per year.
Human Food-Grade Protein
Human food-grade protein is a high-value co-product recovered in the com
oil production process. It sells for twice as much as an unprocessed corn
component protein. Human food-grade protein has nutritional aspects
comparable to an egg white.
Fiber is a by-product of creating human food-grade protein from the germ,
and can be used for animal feed or in ICM’s fiber-to-ethanol process.
Cellulosic Ethanol from Corn Fiber
The final phase of ICM’s technology implementation enables the biorefinery
to produce cellulosic ethanol in addition to corn-based ethanol. This phase
will convert fiber, a lower value component of corn, into much higher-value
ethanol through a cellulosic process rather than through traditional corn
starch fermentation.
The corn fiber-to-cellulosic ethanol technology is expected to increase the
profitability of an ethanol biorefinery by approximately 12% per year.
Deploying the New Technology
‘The new dry fractionation process is already in operation at a facility that
has been successfully producing ethanol and food for human consumption
since November 2007.The technology is built in phases that can be implemented separately or all
together to maximize additional earnings, For existing biorefineries, ICM
guarantees that all phases will be completed and in full production by 2012
if construction begins in early 2009.
ICM expects that its new technology will significantly improve a
biorefinery’s earnings and provide an outstanding return on investment,
ICM has estimated that the additional profit generated through its new
technology will pay for the investment in less than 2 years if all parts of the
process are fully implemented and provide an estimated 70% annual return
on investment if the investment is fully funded through equity. The return
would be higher if it is leveraged with debt.
The equipment to implement the technology and the buildings to house the
equipment are projected to cost $200 million. The proforma earnings for
cach phase are as follows:
= Germ Production and Bran $34 million
= Corn Oil 19 million
= Food-grade Protein 42 million
= Feed-grade Protein 16 million
* Cellulosic Ethanol 29 million
$140 million
Other Benefits
From a risk management perspective, corn oil provides a hedge against the
cost of corn, because the price at which corn oil and other corn-derived
products are sold will rise or fall with increases or decreases in the cost of
corn. Therefore, in an environment of high corn prices, corn oil will
mitigate the negative impact that high corn prices would have on
profitability.
By combining the food outputs and additional ethanol production that result
from implementation of the new technology, an ethanol plant may be
profitable even if ethanol prices fall and corn continues to remain high, For
example, an ethanol biorefinery that adopts the full dry fractionation process
will remain profitable even if the price for ethanol were to drop to $1.80 per