CONVERTING BIOMASS AND SOLID WASTE INTO ENERGY

MODULAR & SCALABLE FLEX PLANTS TO MAKE RENEWABLE LIQUID FUELS, GAS & ELECTRICITY

HOME

ABOUT US

TECHNOLOGY

CONTACT US

Since 2012, we have dedicated ourselves to reducing greenhouse gases (GHGs) by producing energy from renewable resources; in particular "waste" and locally grown fuel crops.

Combining only market-proven, pre-engineered modular technology keeps our capital costs low and speeds deployment and construction.

Combined, our partner suppliers have over 150 working installations of their equipment. We configure their equipment under our roofs to optimize our production and internal rate of return, making it an attractive option for investors.

Our simplified approach to developing and building our FLEX facilities means we can deploy them almost anywhere, keeping them closer to the customer and closer to the raw materials.

FLEX Plants reduce waste, create local jobs, cut GHGs, and improve energy security at unit costs competitive with traditional fossil fuels.

Our People

Our technical team includes dozens of engineers and technologists each expert in their specific discipline. They are backed up by hundreds more in engineering firms and fabrication shops around the US and offshore.

Our business team includes experts from some of the largest Fortune 500 companies. Our combined goal is to build as many plants as possible ... as quickly as possible. The best way to do this is to partner with others.

Our growing base of partners is developing projects in over 50 countries. Each project is based on our platform and unique business model. They will transform the way energy is produced around the world and enhance the quality of life in their communities while reducing global GHG emissions.

The more FLEX plants we can build together, the better it is for our planet!

Rob Redfearn

Founder/CEO

Rob@TerraStarEnergy.com

CONVERSION: SOLID WASTE & BIOMASS TO ENERGY

Biomass

Waste

• Construction/Demolition Waste
  

• Locally Grown Fuel Crops
  

• Commercial Waste
  

• Sustainable Forest Trimmings
  

• Industrial Waste
  

• Yard Trimmings
  

• Agricultural Waste
  

Gases

Soil Amendments

• Biogas
  

• Digestate
  

Liquid Fuels

Electricity

• Syngas
  

• Biochar
  

• Renewable Diesel (RD)
  

• Internal Use
  

• Renewable NG
  

• Organic Fertilizers
  

• Jet Fuel (SAF)
  

• Grid Available
  

• Hydrogen
  

• Naptha
  

Basic components are combined to produce the greatest volume of finished product from the available resources, at the lowest possible cost.

Feedstock Receiving and Sorting

INcoming Feedstock SORTING (EXPANDABLE)

Gasifier/ Pyrolysis Line

Anaerobic DIgestion Line

Digestate Out

BioChar Out

Digesters & gas storage (expandable)

Biogas

Synthesis Gas

Biogas conditioning

Fischer-Tropsch Process Line

gasifier/PYROLYSIS arrayS (EXPANDABLE)

Fischer-Tropsch process Equipment (EXPANDABLE)

Naptha

D975 Renewable Diesel

Sustainable Aviation Fuel

Although we can generate electricity, and create renewable Natural Gas (RNG), we have identified that producing renewable diesel (RD) is a better business model; it is easier to sell, and in increasingly high demand in many more places around the world.

Globally, the transportation sector is dependent on diesel and in our opinion will be for a long time. Therefore we believe replacing fossil diesel with renewable diesel will have a bigger effect on GHG emissions in the coming decades.

The technologies we employ are not new, but we and our partners have scaled down the size of our plants, compared to our competition. We can build many small facilities (closer to the feedstock and closer to the customers) vs a single large facility. This keeps the capex more realistic, the speed of deployment faster, and our finished cost per barrel of diesel low.

It also spreads around the investment and job creation, creating opportunities in regions that might not otherwise have any.

Instead of centralizing our ownership and management, we are building a network of local operating partners to assist in the initial local development process and manage the ongoing operations. They can "earn out" their equity position over time with their share of profits.

Making the case for renewable diesel

• The USA consumes 4.02 million barrels per day.(169 million gallons per day = 60 billion gallons per year). Mostly in the transportation sector.
  

• Global consumption of diesel is 100 million barrels per day . 4.2 billion gallons per day = 1.5 trillion gallons per year
  

• 22.38 pounds of CO2 is emitted from every gallon of diesel burned. Globally, diesel pumps 17 trillion tons of CO2 into the atmosphere every year.
  

• Diesel made from renewable resources (plants, trees, waste, etc) has a negative carbon footprint. That is, the carbon taken from the air by the trees and plants is less than is returned to the air via our processes and products when they are used.
  

• Every gallon of renewable diesel that is used, eliminates the carbon from a gallon of traditional diesel while also diminishing the total amount of carbon in the atmosphere. The more RD we make and use, the more we will reduce global concentrations of CO2 in the atmosphere.
  

• Our use of modular components allows us to scale each plant according to the available feedstock and keeps production local, creating jobs and new economic opportunities. Capital costs are reduced and the return on investment is high.
  

BOTTOM LINE: There will be a high demand for diesel far into the future and replacing fossil diesel with renewable diesel will curb CO2 emissions and help to stabilize the effects of climate change. We can do it quickly, affordably, and profitably.

ESG: Environmental, Social, Governance

More than just buzzwords!

TerraStar places a high emphasis on our ESG responsibilities. It is important for investors, customers, employees, and the Earth itself.

We are impacting globally while working locally.

ENVIRONMENTAL PRIORITIES

• Reducing waste, pollution and global carbon emissions with our products and systems is our entire reason for being.
  

• Our own facilities have net zero carbon footprints.
• We have no hazardous emissions and minimize landfill waste.
  

• We work directly with communities and other companies to reduce their own environmental impacts.
  

SOCIAL PRIORITIES

• We are deploying local facilities to create local opportunities around the world.
  

• Our goal is to help reduce the social injustice of legacy energy companies.
  

• We extend our corporate presence into many countries and many socio-economic situations without prejudice or preference.
  

• An emphasis on clean operations and responsible management at all times.
  

• Our goal is to create good jobs, with family-friendly scheduling, and numerous employee advancement programs.
  

GOVERNANCE PRIORITIES

• A culturally diverse board of directors at the corporate level.
  

• An emphasis on building local teams with local market understanding.
  

• Transparent management policies and interactive communication at all levels.
  

• Concentration on data protection and systems security at all levels.
  

FEEDSTOCK

• Feedstock is received into the facility
• Feedstock may require sorting either by hand or via automated lines
• "Soft and Wet" material is sent to digester lines
• Manure
  
• Green waste
• Septic waste
• Food waste
• Dedicated Fuel Crops
• "Hard and Dry" material is sent to gasifier and pyrolysis lines
• Wood
  
• Paper
• Cardstock
• Plastics
• Dedicated Fuel Crops
  

Preprocessing of certain feedstock types, including drying and pelletizing, can streamline production, and improve feed rates and gas consistency.

MSW SORTING LINE

NEWLY INSTALLED SORTING LINE: USA

ROBOTIC PICKERS: USA

Agricultural waste from animals can be intercepted before it releases methane into the atmosphere

Anaerobic digesters

• DIgesters use bacteria to consume solid organic material
• Bacteria "eat" the organics and "exhale" methane (CH4, natural gas) which is collected
• Digesters are heated to maximize gas production
• Digesters can be above-ground or in-ground
• The solid material is shredded and blended into a slurry which is pumped into the digester reactors
• Contents of the reactor are stirred constantly and kept at 100F to maximize gas production.
• The feedstock is fed into reactors on a continuous basis
• Digested material (digestate) is removed on a continuous basis
• Biogas (a blend of CO2 and CH4) can be used to generate electricity to supplement the facility's energy needs and also be converted to liquid fuels
• The volume of biogas is dependent on the feedstock.
• 100 tons of hog manure = 2000 cubic meters
  
• 100 tons of vegetable waste = 5700 cubic meters
• 100 tons of wheat grain = 58,000 cubic meters
• Feedstock can be blended to maximize gas yields
  
• Digestate is a carbon-rich soil additive that can also be enhanced with NPK to boost the fertilizer value.

DIGESTER ARRAY: China

3D MODELING OF DIGESTER FACILITY

OUR TEST DIGESTER FACILITY IN SOUTH AFRICA

gasifiers

• Gasifiers convert hard and dry materials to syngas, a blend of volatile gases CO, CH4, and H2.
• Material is fed into the gasifier retort and heated to a high temperature, in the absence of oxygen.
• The feedstock may be dried and pelletized or briquetted to be more uniform
• In the retort, molecular bonds are broken and constituent elements (gases) are released and collected.
• Syngas can be used to generate electricity or can be converted to liquid fuel.
• Our modules can process 50 -100 tons of feedstock per day /each (2-3 tph)
• To process more material, we add more gasifier modules.
• Syngas constituent proportions vary with feedstock
• Liquid fuel production is based on the quality of the syngas
• Solid carbon (biochar) is a residual co-product that is left over after the volatile gases are extracted.
• The biochar quality is dependent on the original feedstock. Biochar is an excellent soil additive.
• Sequestering biochar in the ground enhances the soil quality and also keeps it out of the atmosphere.

single gasifier module with gas clean-up and generators in place

An ARRAY OF 5 GASIFIERS WITH 10 CHP GENSETS PLUS FILTERS AND COOLERS: BURUNDI

A 2MW GASIFIER INSTALLED: GREECE

PYROLYSIS

• Similar in many respects to gasification, except with zero ambient air infiltration to the process.
• Higher concentrations of useable gases than gasification produces, for energy production in successive stages.
• Excellent process for conversion of various biomass including municipal solid waste, plastics, tires, etc.
• Modular units process 2 tons/hour (+/-) of feedstock
• Pyrolysis modules can be ganged together to meet feedstock input quantities.
• Separate modules can be designated to specific feedstock types to improve the value proposition of carbon/biochar production.
• The components of our pyrolysis machine are made of the highest quality steel to be resilient against most types of feedstock and high operating temperatures.
• High quality biochar is available from this process.

FISCHER - TROPSCH

Our pyrolysis equipment has been operating since 2012.

• Established technology that converts synthesis gas into liquid fuels and solvents: diesel, jet fuel, and naphtha.

• Using proprietary metal catalysts syngas is condensed into liquid fuel and refined to produce high-quality fuels.

• The process takes place at 150-300 degrees C at pressures of up to 10 ATM.

• F-T technology has been in use since 1925 but has gotten more attention recently as a means to convert gas from biomass into diesel to replace fossil fuels.

• The largest F-T fuel plant in operation was started in 1952 in South Africa,. It produces 165,000 barrels (7 million gallons) per day

• Our system is unique because it is scaled down to achieve economies of scale at significantly less volume. This has opened the door to many opportunities that would be too small to consider with traditional equipment.

• Our smaller scale makes it feasible to put fuel plants almost anywhere there is access to feedstock.

• Smaller fuel plants kept closer to the feedstock and closer to the customers make sense. Large plants are dependent on huge volumes of feedstock being delivered on time and without interruption at a cost that can be high due to the distances it is hauled.

SCALED DOWN F-T PROCESS EQUIPMENT

mODULAR f-t = 20,000 gallons per day

LARGE f-t = MILLIONS OF GALLONS PER DAY

BIOMASS FARMING AND PRODUCTION

Biomass is an excellent fuel for energy production. Many communities are capable of producing enough biomass to generate all their own energy needs.

Biomass from farming operations can include farm waste as well as crops grown expressly for energy.

Depending on the type of biomass, which can be optimized according to local climates and soils, it can be either anaerobically digested or gasified for energy.

Some commonly grown biomass for energy include:

• Grass
• Yard waste
• Forest trimmings
• Eucalyptus
• Peat
• Soybeans
• Corn
  

• Rice hulls
• Wood chips
• Bamboo
• Miscanthus Grass
• Jerusalem Artichoke
• Cotton Stalks
• Corn Stover
  

Fuel crops absorb CO2 from the air, creating biomass for energy .

Local farmers can earn income from the sale of crops to the local power plant. Fuel crop value is equal to or greater than many other crops.

Fuel crops can augment other feedstock streams expanding opportunities for fuel production, creating more jobs, and expanding local economies.

MSW COLLECTIONS AS FEEDSTOCK

Municipal Solid Waste (MSW) is a problem for many communities as well as for our oceans and streams. By using it for fuel to make energy we give it value, which encourages its capture and use. TerraStar will work with local authorities to arrange for the collection, sorting, and processing of waste into energy.

• Waste is collected from transfer stations and city sites via containers and trucks. These containers are transported to our sorting facility where recyclables are removed and the balance moves onward to be processed.

• Paper, plastic, textiles, wood, and rubber are all materials that can be gasified and pyrolyzed. Both technologies convert solid material into syngas (a combustible gas comprised of CO, CH4, and H2) which can be used to generate electricity, in gensets and boilers and/or converted to liquid fuels.
  

• Food waste, septic waste, and other biomass can be anaerobically digested to produce biogas (a combustible gas comprised of CH4 and CO2) which can be used similarly to syngas to generate electricity and/or liquid fuels.
  

An integral part of TerraStar Energy's business and growth plan is to attract and engage working partners to develop and manage projects in their own communities.

Our modular and scalable plant designs enable us to match a system to almost any circumstance, take advantage of available feedstock, and to make energy products (gas, electricity, and/or liquid fuels).

We have several ways to work with partners, including finders fees, commissions, joint ventures, and equity opportunities.

We provide:

• Development Support
  
• Feasibility Studies
• Equipment Packages
• Environmental Assessments
• Site Selection Assistance
• Offtake Agreements (in certain locations)
• Offtake Assistance
• Investor Summaries
• Investor Contacts
• Installation Crews
• Engineering/Procurement/Construction
• Construction Management
• Turnkey Packages
• Individual equipment modules

Project Development Map:

Getting Started:

• Identify your potential opportunity
  
• Feedstock type & availability
  
• Offtake availability
• Preferred product (electricity, fuel, etc)
• Identify site availability.
  
• Email us to initiate discussions.
• Our initial consultations are free of charge and are without obligation.
• We can provide some high-level cost and profit projections at this stage, providing an estimate of the return on investment.
• Later development costs are staged in increments based on project specifics.