indirect gasification of municipal solid waste
DESCRIPTION
Indirect Gasification of Municipal Solid Waste. Team Bravo EleftheriosAvtzis David Garcia Bryan Isles Zack Labaschin Alena Nguyen Mentor Dan Rusinak. Process Review. Indirect gasification of RDF using TBE process Providing Syngas to Team Alpha - PowerPoint PPT PresentationTRANSCRIPT
Indirect Gasification of Municipal Solid Waste
Team BravoEleftheriosAvtzis
David Garcia
Bryan Isles
Zack Labaschin
Alena Nguyen
Mentor Dan Rusinak
Che 397 - Team Bravo
Process Review
• Indirect gasification of RDF using TBE process
• Providing Syngas to Team Alpha• Location: Newton County Landfill
in Brooke, IN• Environment, Economy and
Energy
Che 397 - Team Bravo
Indirect Gasification
• The TBE process is a three unit, indirect gasification process
• The oxidizing agent is steam, therefore no air or ASU is required
• Olivine is cycled between the three units: gasification, combustion and gas conditioning
Che 397 - Team Bravo
Engineering Specifications
Team Alpha Syngas Specification
Pressure 725 psi
Temperature 518°F
Syngas tons/day 6,000
H2/CO Ratio 2
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Team Bravo SyngasSyngas
(tons/day)
Max. tons/day from 11,000 tons/day RDF
7,000
Location
• Newton County Landfill– 265 Acres– Room for expansion– Access to MSW of South
Chicago– Transportation– No river access
The Three E’s
• Eco-friendly: low NOx, no dioxins and landfill cleanup lowers methane
• Economical: great IRR, get paid to remove trash, provides electricity and steam
• Energy: synthesis gas sent to Team Alpha becomes gasoline
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PFD - Main
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PFD - Main
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PFD - Main
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PFD – TBE
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PFD – TBE
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PFD – Reformers
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PFD – Reformers
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Sinks and Loads
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Energy out of Turbine
Assump. COP=1/5
Btu/hr kW-h/hr kW-h/year $0.07/kW-hr $0.11/kW-h
(4,184,916,609) (1,226,180) (9,774,621,003) $(684,223,470) $(1,075,208,310)
Capital Investment Overview
Che 397 - Team Bravo
Total Installed Cost Equipment Cost
Heat Exchangers $ 2,970,000 $ 495,000
Compressors $ 95,000,000 $ 19,000,000
Absorbers $ 949,000 $ 417,000
Strippers $ 695,000 $ 198,000
TBE Process $ 350,000,000 $ 50,000,000
RDF Processing $ 88,600,000 $ 12,660,000
Other$ 100,400,000 $ 16,730,000
Total $ 638,600,000 $ 99,500,000
Salaries and Fringes
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Single Shift Basis
Personnel Amnt/Shift Salary $ Benefits $ Total/Shift $
Process Manager 2 120,000 20,000 280,000
Chemical Engineer 5 70,000 20,000 450,000
Maintenance Operator 10 35,000 20,000 550,000
Day Basis
Personnel Amount Salary $ Benefits $ Total $
Process Manager 6 120,000 20,000 840,000
Chemical Engineer 15 70,000 20,000 1,350,000
Maintenance Operator 30 35,000 20,000 1,650,000
Chemists 2 40,000 20,000 120,000
Total $ 3,960,000
Rough NPV- Annual/Rev. Costs
Che 397 - Team Bravo
Annual Costs Cost Revenues Cost
Operating Costs $101,000,000 Syngas $498,225,000
Maintenance Costs $19,158,000 Others $107,000,000
Utilities $88,400,000 Total $605,225,000
Raw Materials $10,000,000
Salaries and Fringes $3,960,000
Total $222,518,000
Rough NPV- One Time Costs
Che 397 - Team Bravo
One Time Costs (CI) Cost Intrest
Aspen CI $93,000,000 8.00%
TBE $350,000,000 P/A
RDF Processing $88,600,000 9.818
Others $107,000,000 Tax
Total $638,600,000 40%
Rough NPV
$1,871,290,396
Economic Overview
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Year 0 1 5 8 15 20Capital Cost -$638,600,000 Revenues
6000 tons/day at $250/ton $498,225,000 $539,294,763 $572,303,917 $657,397,307 $725,819,746
Others $107,000,000 $120,429,443 $131,596,504 $161,847,101 $187,625,148Expenses Utilities
Loan Expense $38,316,000 $33,759,385 $29,572,949 $16,426,634 $3,151,475Total Annual Cost $88,400,000 $99,494,979 $108,720,850 $133,712,932 $155,009,935
Operating Costs $101,000,000 $113,676,390 $124,217,260 $152,771,562 $177,104,111
Depreciation $9,274,140 $9,274,140 $9,274,140 $9,274,140 $9,274,140Salaries and Fringes $3,960,000 $4,457,015 $4,870,301 $5,989,855 $6,943,884
Maintenance 3% of cap cost $19,158,000 $20,737,235 $22,006,520 $25,278,574 $27,909,588Raw Materials $10,000,000 $10,824,322 $11,486,857 $13,194,788 $14,568,112
Total Expenses $270,108,140 $292,223,465 $310,148,877 $356,648,485 $393,961,246
Income before Taxes $335,116,860 $367,500,740 $393,751,544 $462,595,922 $519,483,649Taxes, 40% $134,046,744 $147,000,296 $157,500,617 $185,038,369 $207,793,459
Income After Taxes $201,070,116 $220,500,444 $236,250,926 $277,557,553 $311,690,189Add Back Depreciation $9,274,140 $9,274,140 $9,274,140 $9,274,140 $9,274,140
Cash Flow From
Operations -$638,600,000 $210,344,256 $229,774,584 $245,525,066 $286,831,693 $320,964,329
Cumulative Cash Flow $210,344,256 $1,099,764,185 $1,820,351,781 $3,700,345,024 $5,235,181,714 Payback of 8 yrs
NPV $1,659,988,954IRR 35.05
Interest 8.00%
Economic Sensitivity Analysis
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Report Outline
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•Executive Summary - Done•Discussion - IP•Recommendations - IP•Appendices - IP
•Design Basis - Done•Block Flow Diagram - Done•Process Flow Diagram - IP•Material and Energy Balance - Done•Calculations - Done•Annotated Equipment List - IP•Economic Evaluation - IP•Utilities - IP•Conceptual Control Scheme - IP•General Layout of Major Equipment - IP•Distribution and End-Use Issue Review - IP•Constraints Review - IP•Applicable Standards - IP•Project Communications File - IP•Information Sources and References - IP
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
Back up: 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
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Backup: Economic Sens. Analysis
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Aspen Flowsheet
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Aspen Flowsheet
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Aspen Flowsheet
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