Sunnyside Biogas

Sun Prairie, Wisconsin 

Phase 1: 2011 | Phase 2: 2013 

Phase 3: 2012 | Phase 4: 2013-2017

Dynamic provided the engineering and construction management services for the Sunny Side Digester project. This system processes the manure from a 1,200-cow dairy and utilizes off-farm substrates to power a 633 kW Combined Heat and Power unit to produce renewable electricity.  It also includes a solids separation system to create a bedding product for the dairy, the solids separation system consisted of a slope screen and modified screw press with an air-conveyance blower system to provide supplemental moisture reduction.  Services provided for the project include: 

Phase 1: Initial Project Development

The following scope of services was included as a part of Phase I of the project development:

  • Preliminary evaluation of substrate sources

Dynamic researched substrate providers and did an analysis on lab sampling and nutrient of materials for possible long-term supply agreements to obtain Sunnyside Biogas nutrient management goals.

  • Manure Analysis

Dynamic did lab sampling and nutrient analysis of materials and mass balance of feedstocks

 

  • Research Permit and Zoning Requirements

Dynamic evaluated and deciphered various local codes and restrictions to determine what permits apply to the specific project. A comprehensive list of the required permits from the varying regulatory agencies was provided as well as a schedule of approval durations.

  • Initial Interconnect Application

Dynamic assembled all required information including the drafting of a preliminary one-line schematic, transfer trip schematic, grounding, and submittal of the application to the utility. Dynamic worked with the utility company to define the scope and provide an estimate for the utility to conduct a grid analysis engineering study which ultimately determined the scope of any required infrastructure upgrade costs for interconnection.

  • Purchase Power Agreement

Dynamic identified candidates for biogas or electricity based on proposed plant location, size. Met with candidates to explore interest in long-term off-take agreements. Outlined interconnection process, interconnection costs, and range of timelines for each alternative.

  • Financial Modeling

Dynamic Provided a detailed 15 Year financial proforma including capital costs, revenue projections, operation, and maintenance cost, Internal rate of return on investment, net present value, and payback period.

  • Technology Review of the “Backside” or digester effluent

Dynamic research nutrient recovery technology solutions that are available, or others that the customer has the knowledge to determine if they can be integrated into the project and enhance project returns.

 

  • Initial Local Township Contact

Dynamic contacted the Local Township and presented the basics of the technology, project description followed by a Q&A session.  It was important to engage local officials early and often to establish a sound educational background and understanding of the project as this type of facility was unique to avoid misconceptions.

 

At the conclusion of Phase I of the development process the customer provided a detailed summary of our findings regarding the above subjects, a proposal from the utility to conduct their grid analysis engineering study, and a comprehensive list of all required permits.

Phase 2: Due Diligence of Documentation 

The due diligence and documentation phase commenced a detailed project-specific design scope of work.  The scope of this phase was focused on doing the work required to satisfy all project permit applications to keep the costs down. Consequently, Phase 2 of the development process completed enough of the pertinent items allowing owners to make the investments required by the U.S. government 1603 Treasury Grant before the end of the 2011 calendar year. Phase II of the development process included the following services:

 

  • Permit Assembly and Filing

Dynamic acquired the following permits:  Air Pollution Control Permits, Manure Storage Permits, Erosion and Stormwater Control Permits, Discharge Permits, Discharge Permits, Discharge Permits, Local & State NOI’s & Construction Permits, Zoning Permits.  Dynamic also included assistance in writing stormwater management plans, site emergency response plans, project narratives, facility-specific nutrient management plans.

 

  • Preliminary Facility Engineering

This included a detailed site layout, preliminary site Process Flow Diagrams, complete civil and stormwater management design, complete structural foundation design of all buildings, tank slabs, equipment pads, lagoons, pits, and manholes, detail of all underground process piping and sewer work, well system design and location. The preliminary engineering was delivered in the form of the first draft of basic construction drawings and included a first draft of the construction specification book, documenting the required construction practices and procedures.

 

  • Technical Support

Dynamic attended local town meetings and any required public hearings to assist with technical questions about the project and worked with the customer to assist with the negotiating of the town operating agreement details.

 

During Phase 2 of the project development, there was frequent interaction with the customer to discuss and agree on the site location, layout, and logistics. During this time, decisions on specific building floor plans, optional buildings such as a shop, or solids processing building, effluent storage, technology inclusions, etc.… were made so that final stormwater and structural engineering were completed to ensure a comprehensive plan was submitted for permit approval.

Phase 3:  Construction

Dynamic assisted in selecting a general contractor firm.  Dynamic also provided on-site construction management, being responsible for setting and keeping schedules, monitoring finances, and making certain that everybody is doing what they should, every day.

 

Services Provided:

  • Operator training

  • Facility commissioning

  • Detailed financial analysis 

  • Total project cost estimate

  • Digester equipment furnishing

  • Total system design and engineering

  • Substrate agreements for off-farm wastes 

  • Currently providing operational consulting services

  • Interconnection agreement and power purchase with Alliant Energy

  • Led engineering, procurement, and construction management of the project

  • Obtained all necessary permit and zoning requirements for placement, construction, and operation of the project

Phase 4: Operations and Management

  • Oversaw the day to day operations

  • Monthly budget management vs actual cost 

  • Hired and managed a full staff of employees 

  • Created vendor payments and managed accounts

  • Responsible for facility maintenance and upkeep of the property

Facility Service Provided:

  • Inventory management

  • Total day to day operations

  • Permit reporting and compliance

  • Biological AD system management

  • Project business plan development

  • Substrate waste procurement and management

  • Preventative and corrective maintenance programs