indirect gasification of municipal solid waste

1

Indirect Gasification of Municipal Solid Waste

Team BravoEleftheriosAvtzis

David GarciaBryan Isles

Zack LabaschinAlena Nguyen

Mentor Dan Rusinak

Che 397 - Team Bravo

2

Overview

• Design Basis and Goals• RDF Processing• Taylor Biomass Energy Process• Block Flow Diagrams• Economics• Plant Layout• Recommendations

Che 397 - Team BravoChe 397 - Team Bravo

3

Problem: Municipal Solid Waste


4

Solution: Indirect Gasification

• Project Design Goals• Indirect Gasification of Refuse-Derived Fuel

using TBE Process• Providing High Quality Synthesis Gas to Team

Alpha’s Specifications• Location: Newton County Landfill in Brooke, IN• Environmentally Friendly Process• Economic and Energy Efficient


5

Design Benefits


• Turns Garbage into Useful Products• Reduces or Eliminates the Landfill

Problem• Provides a Feedstock for Liquid

Transportation Fuels• No Air Separation Unit Required• Internally Generated Steam• Environmentally Friendly Process

6

Design Basis

• Commercial Scale Production• 13,000 tons per day MSW

• 6,000+ tons per day Syngas

• Ideal Max. Output 7,100 tons per day

• Scale-up Available


7

Engineering Specifications

Team Alpha Syngas SpecificationPressure 725 psi

Temperature 518°FMin. tons/day 6,000H2/CO Ratio 2


Team Bravo Syngas Syngas (tons/day)

Max. tons/day from 11,025 tons/day RDF 7,105

8

RDF Processing


9

Trommel Screen


• Cylinder with screen on the outside

• Sorts shredded MSW by size

• Rotates to drive the MSW through from one side to the other

10

Eddy-Current Separator


• Basic Schematic of Eddy-Current Separator

• Non-Ferrous Metals are Ejected

11

Magnetic Separator


• For Removal of Ferrous Metals

• Uses Magnets to Hold Metals to Roller

• Releases Metals into Separate Bin for Return to Landfill

12

Block Flow Diagram


MSW Processing

TBE Gasification

Cooling & Cleaning

Electricity Steam Generation

CO2 Removal

Team Alpha Gasoline

Production

MSW RDF

Ash toLandfill

Raw SynGas

SulfurHalogens

HazardousMaterials

Steam

ElectricalGrid

CleanSynGas

Captured CO2

SynGas at Spec. Water Gas Shift

Methane Reforming

Return toLandfill

Steam Steam

CleanSynGas

CleanSynGas

BoilerFeedWater

ExcessSynGas

13

TBE Gasification


Raw SynGas

CirculatingFluidized

BedGasification

Unit

Gas-Conditioning

Unit

CombustionUnit

Steam

RDF

Effluent

HotOlivine

Olivine and Char

Air

Raw SynGas

Dirty Flue

Hot Olivine Effluent

14

Block Flow Diagram


MSW Processing

TBE Gasification Cooling &

Cleaning

Electricity Steam Generation

CO2 Removal

Team Alpha Gasoline

Production

MSW RDF

Ash toLandfill

Raw SynGas

SulfurHalogens

HazardousMaterials

SteamElectrical

Grid

CleanSynGas

CapturedCO2

SynGas at Spec. Water Gas Shift

Methane Reforming

1

5, 11,14

19

27,36

28

51

42

20

71, A3, A4

52

53

57

64

Return toLandfill

A2

65

68

Streams Reflect PFD


Steam SteamBoiler Feed Water

CleanSynGas

CleanSynGasExcess

SynGas

15

Block Flow Diagram


MSW Processing

TBE Gasification

MSW

Return toLandfill

RDF

Ash toLandfill

Raw SynGas

Steam

1

5,11,14

19

27, 36

28

20

964,512 Ib/hr 918,583 Ib/hr

365,600 Ib/hr

72 lb/hr Olivine21,954 Ib/hr Ash

8,301 Ib/hr NH3

740,221 Ib/hr CO2

259,924 Ib/hr CO 7,395 Ib/hr C2H6

39,095 Ib/hr C2H4 55,206 Ib/hr H2

1,616 Ib/hr HCl 3,020 Ib/hr H2S 55,448 Ib/hr CH4

71,381 Ib/hr H2O

Streams Reflect PFD


16

Block Flow Diagram


Streams Reflect PFD


Cooling & Cleaning

Raw SynGas 28

51

42 71,381 lb/hr H2O740,221 lb/hr CO2

259,924 lb/hr CO 55,448 lb/hr CH4

55,206 lb/hr H2

39,095 lb/hr C2H4

7,395 lb/hr C2H6

3,020 lb/hr H2S 1,616 lb/hr HCl 8,301 lb/hr NH3

475,288 lb/hr CO2

252,477 lb/hr CO 51,619 lb/hr CH4

55,098 lb/hr H2

25,815 lb/hr C2H4 3,330 lb/hr C2H6

2,071,381 Ib/hr H2O 264,933 Ib/hr CO2

2,866 Ib/hr H2S 355 Ib/hr SelexolTM

Clean SynGas

Sour Gas

17

Block Flow Diagram


Clean SynGas Methane Reforming

51

A2

Water Gas Shift x3x3

52 53

99,212 Ib/hr H2O

475,288 Ib/hr CO2

252,477 Ib/hr CO 51,619 Ib/hr CH4

55,098 Ib/hr H2

25,815 Ib/hr C2H4

3,330 Ib/hr C2H6

44,970 Ib/hr CO2

673,870 Ib/hr CO 62,887 Ib/hr H2

181,112 Ib/hr H2O

289,758 Ib/hr CO2

518,095 Ib/hr CO 74,014 Ib/hr H2

80,972 Ib/hr H2O

Streams Reflect PFD


Steam

18

Block Flow Diagram


Streams Reflect PFD


CO2 RemovalTeam Alpha

Gasoline Production

57

54 64289,758 Ib/hr CO2

518,095 Ib/hr CO74,014 Ib/hr H2

80,972 Ib/hr H2O

289,758 Ib/hr CO2

2,000,000 Ib/hr H2O 355 lb/hr SelexolTM

437,500 Ib/hr CO 62,500 Ib/hr H2

65

80,595 Ib/hr CO11,514 Ib/hr H2

CapturedCO2

Raw SynGas SynGas at Spec.

Excess SynGas

19Che 397 - Team Bravo

This table displays the selective economics for year zero, one, five, seven, fifteen, and twenty. The net present value and internal rate of return are also displayed.

Economics

IRR = 27.96%


This table displays the cost for selected processes and units required for Team Bravo’s indirect gasification of municipal solid waste. The capital cost as well as the operations, utilities, salaries, and annual cost in total are also listed.

Economics


This table displays the revenue for Team Bravo’s indirect gasification of municipal solid waste. Major products and electricity are shown. About 90 kW of electricity are available for consumption outside the facility.

Economics


Economics

This graph displays the ideal estimated profit from operating years one through twenty. The breakeven period is just over six years.


Newton County

Current MSW Active Site

711 ft

Prevailing Wind

This figure represents the one square mile area that Newton County Landfill owns and occupies. The current active landfill covers a quarter mile space, allowing for Team Bravo to build their process on available Newton County land.

Team Alpha Team Bravo

Flare

24Che 397 - Team Bravo 328 ft Flare

Active Landfill

TBEProcess

Claus

Utility

Tank and Storage

Office

To Alpha

CO2

Power Generation

Syngas Treatment

RDF Processing

Prevailing Wind

S 300 E

County Rd 400 S

Plot Area

This figure shows the basic plot area of Team Bravo’s process and supporting facilities. Blocks were chosen in order to best take advantage each process


Plant Plot

This figure represents the plant plot area of both the TBE process and most of the syngas treatment facilities. Placement was based on need of access. The compressors are situated next to a plant maintenance road.


Recommendations

Move forward with the Indirect Gasification of Municipal Solid Waste Design Project

• Environmental Benefits• Lower Landfill Methane Emissions, CO2 Treatment and Little Thermal Pollution

• Excellent Location• Newton County Landfill Provides Plenty of Feedstock and Space

• High Economic Sensitivity• Increase Annual Expenses and Capital Investment $100MM – IRR = 15.56%

• Increase Capital Investment More by $100MM – IRR = 13.04%

27

References

• Municipal Solid Waste (MSW) to Liquid Fuels Synthesis, Volume 1: Availability of Feedstock and Technology (PNNL-18144)

• Municipal Solid Waste (MSW) to Liquid Fuels Synthesis, Volume 2: A Techno-economic Evaluation of the Production of Mixed Alcohols (PNNL-18482)

• www.taylorbiomassenergy.com - TBE • www.rentechinc.com – Rentech• Engineering Toolbox• Heats of formation: http://cccbdb.nist.gov/hf0k.asp• Municipal Solid waste Generation, Recycling, and Disposal in the United States:

Facts and Figures for 2008 – EPA• Higman, Christopher and van derBurgt, Maarten. Gasification 2nd Edition. Gulf

Professional Publishing. Oxford, 2008.• Paisley, Mark A., Corley, Ralph N. and Dayton, David C. Advanced Biomass

Gasification for the Economical Production of Biopower, Fuels, and Hydrogen. Taylor Biomass Energy


28

Aspen Acid Removal


29

Furnace-Boiler Schematic


30

Ash Material Balance

PET organicwood

(treated)wood

(untreated)wood

(demo)leather Totals

wt % 0.0286 0.8678 0.6878 0.00552 0.3859 0.4137 1.000

ash (tons/day)

3.1614 95.66 75.82 0.6090 42.54 45.61 263.41



Sample Calculation

Gasification SizingCalculation


Sample Calculation


35

Sample Calculation


Absorber


36

Sample Calculation


Absorber



Conceptual Control Scheme

The TBE Process



Conceptual Control Scheme

Acid Cleanup


Composition of Syngas

Compound PercentH2 45 – 48%

CO 15 – 20%

CH4 10 – 13%

C2H4 1 – 3%

CO2 18 –20%

C2H6 0 – 1%

N2 Trace

40

Dioxins


• At 800-900°C, dioxins thermally decomposes

• SynGas temp. through gas conditioning unit is raised to 1000°C

• No copper: which promotes dioxin formation

• Dioxins tend to adsorb on char and breakdown in the combustion reactor

41

Carbon Footprint


Carbon IN (kmole/day)

Carbon OUT (kmole/day)

Ratio of OUT/IN

393,142.7 238,659.6 0.607

Environmentally friendly process by removing carbon waste from the environment.

Total Carbon Dioxide OUT

6,801 tons/day

42

Design Basis

• River Bend Prairie Landfill– 88 Acres– 20 Acres of expansion– Access to MSW of

Chicago– Rail and River access– Residential– Limited Expansion


43

Design Basis

• Newton County Landfill– 265 Acres– Room for expansion– Access to MSW of South

Chicago– Transportation– No river access


44

Design Basis

• Environmental ReviewPositives

• Removal of MSW from local landfill (75% of 12000 tonnes per day estimated value enter gasification processing)

• Gasification by-products are captured and properly stored (no venting into atmospheres)

– Negatives• 400 million lbs of hazardous waste per year (mostly ash)• 100,000 lbs will need relocation (cannot be further utilized)


45

Design Basis

Industrial Standard Review• Clean Syngas produced in 2.4-3.0 ratio H2/CO for use by

chemical production

Clear Statement of Feedstock• MSW from landfills• Return to landfill includes: glass, appliances, paints or

oils• Metal will be recycled


46

Methane Emissions in U.S.Top 5 Sources


Source Category 2008 (Tg of CO2Equi.) %Total

Enteric Fermentation 140.8 24.81

Landfills 126.3 22.26

Natural Gas Systems 96.4 16.99

Coal Mining 67.6 11.91

Manure Management 45.0 7.93

Total for US 567.4 100.00

47

Municipal Solid Waste

• EPA 2008 report on MSW generation– Approximately 250 million tons of MSW

generated by Americans in 2008• ~33.2% is recycled and composited (83 million tons)

– Approximately 4.5 pounds of MSW generated per person per day

• 1.5 pounds of the 4.5 is recycled and composited.


48

Why MSW?

• Renewable Energy Source• Helps the Environment (CH4 emissions)

• Cost effective• Transportation Reduction• Located near cities and existing

infrastructure


49

Disadvantages of MSW

• Preparation of feedstock• A lower heating value than conventional

feedstocks • Higher Ash content than conventional

feedstocks


50

MSW to RDF

• MSW – municipal solid waste in• Sorting – removal of recycle metals and

other rejects• Screening procedures• Shredding and drying • RDF – Refuse Derived Fuel out


51

Current Processes


• Batelle• Silva Gas• Montgomery Project

52

Disadvantages of Other Processes

• High pressure/Energy intensive• Lower quality raw syngas• Air or oxygen requirements• Poor scale up• Unproven technology


53

Advantages of TBE Process

• Low pressure• Relatively low temperature• Efficient ash removal• Indirect gasification• Residence time less than one second


54

Backup Slide: Rough Mass Balance

• 2500 TPD Basis• 625 TPD rejected material

– 306 TPD Ash (considered rejected material)

• 361.8 TPD CO2

• 219.6 TPD CH4


55

Backup Slide: Reactor Compositions – Carbon

• 2500 TPD Basis• Gasifier composition

– Carbon• 188767.6 lb-mol per day

• Combustion Reactor Carbon– Carbon

• TBD


56

Gasification Reactions

• C is a carbon containing compound

• Char reacts with CO2 and steam (gasifier)C + H2O CO + H2 + 131 MJ/kmol

C + CO2 CO + 172 MJ/kmol

• Combustion reactor heats sand (olivine)C + ½ O2 CO - 111 MJ/kmol CO + ½ O2 CO2 - 238 MJ/kmol

H2 + ½ O2 H2O - 242 MJ/kmol Che 397 - Team Bravo

57

Water-Gas Shift and Methane Rxns

CO + H2O CO2 + H2 - 41 MJ/kmol

• Slightly exothermic, in Gas-Conditioning Unit• Required to achieve Syn Gas ratio of 2.05• Methane reforming of raw syngas

• CH4 + H2O CO + 3H2 + 206 MJ/kmolChe 397 - Team Bravo

58

TBE Gasification Process


59

TBE Process


Gasifi

er

RDF

Steam

Gas C

ondi

tioni

ng

Reac

tor

SynGasTars

SynGas

Olivine

Com

busti

on

Reac

tor

Olivine(Hot)

Air

Flue Gas

Char, Ash & Olivine(Cool)

Ash Removal

60

Gasifier: Material Balance


RDF

Steam Olivine

SynGasTars

CharOlivine

IN tons/day OUT tons/day

C 5,205.1 CO 3,933.7

H 681.1 CO2 4,250.5

O 3,443.8 CH4 1,077.9

N 125.4 H2 546.0

S 22.0 C2H4 510.5

Cl 11.5 Char C 1,114.3

H2O in RDF 1,534.1 Char H 0.63

H2O Supplied 2,853.1 Char N 0.22

Char S 0.00026

H2O 2,254.9

H2S 23.4

HCl 11.8

NH3 152.2

Total 13,876.1 Total 13,876.1

61

Gasifier: Energy Balance


RDF

Steam Olivine

SynGasTars

CharOlivine

Component BTU/lbmolRDFCO 21,460.07CO2 -8,286.88CH4 -1,527.77C2H4 -260.37C2H6 -H2S -14.66NH3 -50.52HCl -16.47

Char -Total 11,303.4

ReactionsC + H2O CO + H2 + 56,376 BTU/lbmol

CO + ½O2 CO2 -1.2 E5 BTU/lbmol

62

Combustion Reactor: Material Balance


Air

Char, Ash & Olivine

(Cool)

Olivine(Hot)

Flue Gas

Ash Removal


Char C 1,114.3 CO2 4,084.4

Char H 0.63 H2O 5.63

Char N 0.22 NO2 0.72

Char S 0.00026 SO2 0.00052

O2 2,979.1 O2 0

N2 9,811.1 N2 9,814.6

Total 13,905.4 Total 13,905.4

63

Combustion Reactor: Energy Balance


Air

Char, Ash & Olivine

(Cool)

Olivine(Hot)

Flue Gas

Ash Removal

Reactions C + O2 CO2 -1.7 E5 BTU/lbmol

Component BTU/lbmolRDF

CO -

CO2 -

CH4 -

C2H4 -

C2H6 -

H2S -

NH3 -

HCl -

Char -11,171.50

Total -11,171.50

64

Gas Conditioning Reactor:Material Balance


SynGasTars

Olivine

SynGas

Olivine


CO 3,933.7 CO 2,917.4

CO2 4,250.4 CO2 5,295.1

CH4 1,077.9 CH4 1,171.6

H2 546.1 H2 519.5

C2H4 510.5 C2H4 436.5

C2H6 0 C2H6 180.0

H2O 2,254.9 H2O 2,053.4

H2S 23.4 H2S 23.4

HCl 11.8 HCl 11.8

NH3 152.2 NH3 152.2

Total 12,760.9 Total 12,760.9

65

Gas Conditioning Reactor:Energy Balance


SynGasTars

Olivine

SynGas

Olivine

Component BTU/lbmolRDF

CO -451.03

CO2 -

CH4 -

C2H4 -

C2H6 -

H2S -

NH3 -

HCl -

Char -

Total -451.03

Water Gas Shift reaction reaches thermal equilibrium.

66

Gas Clean Up: ScrubberMaterial Balance


RawSynGas

SulfurHalogens

HazardousMaterials

RawSynGas


H2S 23.429 H2S 23.429

HCl 11.847 HCl 11.847

NH3 152.184 NH3 152.184

Total 187.46 Total 187.46

Basically all incoming volatiles will be treated (place holder).

67

Gas Clean Up: ReformerMaterial Balance


CO 2,917.4 CO 4,711.5

CO2 5,295.1 CO2 7,586.9

CH4 1,171.6 CH4 0

H2 519.5 H2 1,251.9

C2H4 436.6 C2H4 0

C2H6 180.0 C2H6 0

H2O 2,053.4 H2O 0

H2O Supplied

2,092.0H2O

Supplied1,115.3

Total 14,665.6 Total 14665.6


SynGas

RawSynGas

Steam

68

Reverse Water Gas Shift: Material Balance

ReactionsCO2 + H2 CO + H2O +17,644 BTU/lbmol


SynGas SynGasAt spec.


CO 4,711.5 CO 7,368.8

H2 1,251.9 H2 1,060.7

CO2 7,586.9 CO2 3,411.7

H2O 1,115.3 H2O 2,824.3

Total 14,665.6 Total 14,665.6

69

TBE: Total Energy Balance

Gasifier G.C.R. C.R.

BTU/lbmolRDF BTU/lbmolRDF BTU/lbmolRDF

CO 21,460.07 -451.03 -

CO2 -8,286.88 - -

CH4 -1,527.77 - -

C2H4 -260.37 - -

C2H6 - - -

H2S -14.66 - -

NH3 -50.52 - -

HCl -16.47 - -

Char - - -11,171.50 TOTAL

Total 11,303.4 -451.03 -11,171.50 -319.13Che 397 - Team Bravo

70

Investment Trend


~ 595 tons/hour --> ~335 millions $

71

TIC RDF Processing

2011 Dollars at 5% interest

Processing Unit Lower Upper AvgNon-Ferrous Material Removal -- -- $465,390.00

Gravity Separation $142,719.60 $465,390.00 $304,054.80Size Reduction $1,213,116.60 $2,606,184.00 $3,819,300.60Thermal Drying $2,295,924.00 $5,832,888.00 $4,064,406.00Total TIC

-- -- $8,653,151.40


Total Installed Cost of Some RDF Processing Equipment

72

Costs


Total Installed Cost Equipment Cost

Heat Exchangers $ 2,970,000 $ 1,230,000

Compressor $ 95,000,000 $ 91,700,000

Absorbers $ 949,000 $ 417,000

Strippers $ 695,000 $ 198,000

TBE Process $ 347,000,000 $ 182,000,000

Total $ 447,000,000 $ 276,000,000


73

Capital Costs

Year 2008Million $ (+/- 45%)

% of Total (+/- 45%)

RDF Processing $58 - $153 13% - 35%

Feedstock $22 - $58 5% - 15%

Gasification, Tar Reforming, Scrubbing $36 - $98 9% - 23%

SynGas Conditioning $90 - $238 21% - 57%

Steam System and Power Generation $18 - $50 6% - 16%

Total Capital Investment $224 - $597 Million


74

TIC Assumptions

• TIC breakdown– Purchased Equipment– Installation – Instrumentation and Controls – Piping – Electrical Systems – Buildings (including services)– Yard Improvements


• Indirect Costs – Engineering – Construction – Legal and Contractors

Fees – Project Contingency

75

Operating Costs

Operating Costs $/operating unitRaw materials

Feedstock 0.00Catalysts & Chemicals 0.10

By-product creditsScrap Aluminum -0.86Scrap Iron -0.58Electricity sold to grid -0.17

Waste treatment or DisposalGasifier ash 0.00MSW rejects 0.00Spent carbon 0.0001Waste water treatment 0.026


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