Indirect Gasification of Municipal Solid Waste Team Bravo Eleftherios Avtzis David Garcia Bryan Isles Zack Labaschin Alena Nguyen Mentor Dan Rusinak Che 397 - Team Bravo Overview • • • • • • • Design Basis Economics Block Flow Diagram Sample Calculations Conceptual Control Scheme Plant Plot Recommendations Che 397 - Team Bravo Design Basis • 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 Che 397 - Team Bravo 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 Engineering Specifications Team Bravo Syngas Syngas (tons/day) Max. tons/day from 11,025 tons/day RDF 7,105 Team Alpha Syngas Specification Pressure 725 psi Temperature 518°F Min. tons/day 6,000 H2/CO Ratio 2 Che 397 - Team Bravo Economics This table displays the selective economics for year zero, one, five, eight, fifteen, and twenty. The project life is projected for twenty years. The net present value and internal rate of return are also displayed. IRR = 32.23% Che 397 - Team Bravo Economics 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. 332 Days in Op. Process Stage Acid Cleanup ZnO and Pot Still SMR and WGS Comp., HX and Misc. TBE Process RDF Processing Single Cost TIC $25,730,610 $9,326,704 $101,575,592 $100,965,603 $300,000,000 $112,665,824 CO2 Removal Olivine Disposal Raw Materials $25,730,610 N/A N/A N/A Capital Cost Total Op. Total Utilities Salaries Total Annual Costs $675,994,943 N/A N/A N/A N/A Che 397 - Team Bravo Annual Costs Utilities Op. Costs $726,218 $3,230,000 $32,438 $927,545 $36,406 $870,919 $88,400,000 $101,000,000 In Above In Above In Above In Above $726,218 N/A N/A N/A 3230000 $1,412,137 $3,205,769 $1,912,137 N/A $113,876,370.18 $89,921,280.80 $3,960,000 $207,757,650.98 Block Flow Diagram Streams Reflect PFD Return to landfill 5, 11,14 1 MSW MSW Processing Ash to landfill RDF Sulfur Halogens Hazardous materials 27,36 Gasifier 19 Raw SynGas 28 10 Cooling & Cleaning 42 51 Steam Electrical grid Electricity 71, A3, A4 Steam Generation 68,70 57 52 CO2 Team Alpha Gasoline Production SynGas at spec. 64 CO2 Removal 65 Che 397 - Team Bravo Methane Reforming 53 Clean SynGas Water Gas Shift A2 Block Flow Diagram Streams Reflect PFD 27, 36 Ash to landfill 1 MSW 964,512 Ib/Hr MSW Processing RDF 19 918,583 Ib/Hr 72 lb/Hr Olivine 21,954 Ib/Hr Ash TBE Gasification 20 5,11,14 Steam Return to landfill 365,600 Ib/Hr Che 397 - Team Bravo Raw SynGas 28 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 Block Flow Diagram Streams Reflect PFD Raw SynGas 28 71,381 lb/Hr H2O 740,221 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 Cooling & Cleaning 51 2,071,381 Ib/Hr H2O 264,933 Ib/Hr CO2 2,866 Ib/Hr H2S 71,000 Ib/Hr MDEA 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 Che 397 - Team Bravo 42 Block Flow Diagram Streams Reflect PFD Clean SynGas 475,288 252,477 51,619 55,098 25,815 3,330 Ib/Hr CO2 Ib/Hr CO Ib/Hr CH4 Ib/Hr H2 Ib/Hr C2H4 Ib/Hr C2H6 51 Methane Reforming A2 52 x3 44,970 673,870 62,887 181,112 Ib/Hr CO2 Ib/Hr CO Ib/Hr H2 Ib/Hr H2O 99,212 Ib/Hr H2O Che 397 - Team Bravo Water Gas Shift 53 x3 289,758 518,095 74,014 80,972 Ib/Hr CO2 Ib/Hr CO Ib/Hr H2 Ib/Hr H2O Block Flow Diagram Streams Reflect PFD 57 54 289,758 518,095 74,014 80,972 Ib/Hr CO2 Ib/Hr CO Ib/Hr H2 Ib/Hr H2O 289,758 Ib/Hr CO2 2,000,000 Ib/Hr H2O CO2 Removal 64 437,500 62,500 65 80,595 11,514 Ib/Hr CO Ib/Hr H2 Che 397 - Team Bravo Ib/Hr CO Ib/Hr H2 Team Alpha Gasoline Production Sample Calculation Gasification Sizing Calculation CO CO2 CH4 H2 C2H4 C2H5 H20 Σ Kmol/Day 127,404 87,616.9 60,950.9 245,726 16,507.5 0 113,551 651,756.3 Sizing of Gasification Unit Inputs MW (Kg/Kmol) WT Frac MW x WT Frac (Kg/Kmol) 28 0.195477972 5.473383226 44 0.134431996 5.915007803 16 0.09351793 1.496286879 2 0.377021288 0.754042577 28 0.025327718 0.709176114 17 0 0 18 0.174223095 3.136015716 153 1 17.48391232 Table 5-1: Calculation of synthesis gas molecular weight for ideal gas density equation. Che 397 - Team Bravo Sample Calculation PV = NRT Gasification Sizing Calculation P= n RT V P !MW = ! RT ! syn = P MWsyn RT g g mol ! syn = = 374.4 3 m3 ² 5 Bar!m 8.314 !10 1123K mol!K 2Bar !17.48 Che 397 - Team Bravo Sample Calculation Gasification Sizing Calculation kmol kg kg w = 651, 756.3 !17.48 = 11, 392, 700.124 day kmol day m3 day hour m3 q = 30, 429, 220.42 ! ! = 352.2 day 24!hour 3600sec sec Assume superficial gas velocity of 7.5 m/s Che 397 - Team Bravo Sample Calculation Gasification Sizing Calculation m3 352.2 q sec = 46.96m 2 A= = m v 7.5 sec d= 4A ! = Che 397 - Team Bravo 4 !46.96m 2 ! = 7.73m Sample Calculation Absorber If !t = 0.6m H » 1.1(0.6m)(35stages) = 23.1m = 75.79 ft lb hr = 63.23 lb = 1012.85 kg rL = 3 ft 3 m3 4 ft 7.32 ×10 hr lb 8.65×10 5 hr = 4.23×10 -2 lb = 0.678 kg rV = 3 ft 3 m3 7 ft 2.04 ×10 0.5 é hr kg ù ê (1012.85 - 0.678) m3 ú 2 m ûv = -0.171( 0.6m) + 0.27× ( 0.6m) - 0.047 ê = 2.06 ú kg s ê ú 0.678 3 ë û m 6.63×10 6 ( ) Che 397 - Team Bravo Sample Calculation Absorber æ lb öæ kg öæ hr ö 4 ç8.65×10 5 ÷ç 0.4536 ÷ç ÷ è ø è ø è hr lb 3600s ø Dc = æ kg öæ mö p ç 0.678 3 ÷ç 2.06 ÷ è m øè sø Dc = 9.95m = 32.7 ft Che 397 - Team Bravo Conceptual Control Scheme The TBE Process Che 397 - Team Bravo Conceptual Control Scheme Acid Cleanup Che 397 - Team Bravo Newton County 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 Bravo Current MSW Active Site 711 ft Che 397 - Team Bravo Plot Area County Rd 400 S Office Prevailing Wind CO2 Claus Tank and Storage To Alpha Utility RDF Processing Active Landfill TBE Process Power Generation Flare Che 397 - Team Bravo 328 ft S 300 E Syngas Treatment 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. Che 397 - Team Bravo 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 = 19.02% •Increase Capital Investment More by $100MM IRR = 16.15% Che 397 - Team Bravo 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 Technoeconomic 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 Aspen Acid Removal Furnace-Boiler Schematic Ash Material Balance wood wood wood leather (treated) (untreated) (demo) PET organic 0.0286 0.8678 0.6878 0.00552 0.3859 0.4137 1.000 ash 3.1614 (tons/day) 95.66 75.82 0.6090 42.54 45.61 263.41 wt % Che 397 - Team Bravo Totals Composition of Syngas Compound H2 CO CH4 C2H4 CO2 C2H6 N2 Percent 45 – 48% 15 – 20% 10 – 13% 1 – 3% 18 –20% 0 – 1% Trace Che 397 - Team Bravo 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 Che 397 - Team Bravo 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 Che 397 - Team Bravo Design Basis • River Bend Prairie Landfill – 88 Acres – 20 Acres of expansion – Access to MSW of Chicago – Rail and River access – Residential – Limited Expansion Design Basis • Newton County Landfill – 265 Acres – Room for expansion – Access to MSW of South Chicago – Transportation – No river access Design Basis • Environmental Review Positives • 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) 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 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 Che 397 - Team Bravo 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. Che 397 - Team Bravo Municipal Solid Waste Che 397 - Team Bravo Why MSW? • • • • • Renewable Energy Source Helps the Environment (CH4 emissions) Cost effective Transportation Reduction Located near cities and existing infrastructure Che 397 - Team Bravo Disadvantages of MSW • Preparation of feedstock • A lower heating value than conventional feedstocks • Higher Ash content than conventional feedstocks Che 397 - Team Bravo 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 Current Processes • Batelle • Silva Gas • Montgomery Project Che 397 - Team Bravo Disadvantages of Other Processes • • • • • High pressure/Energy intensive Lower quality raw syngas Air or oxygen requirements Poor scale up Unproven technology Advantages of TBE Process • • • • • Low pressure Relatively low temperature Efficient ash removal Indirect gasification Residence time less than one second RDF Processing Shredder • Hammers running at high speeds to chop and shred waste Trommel Screen • Rotating, tubular vessels for sorting waste by size Mill • Shred material into fie particles Eddy-Current Separator • Ejects non-ferrous metals for recycle Magnetic Separator • Removes ferrous metals for recycle Che 397 - Team Bravo 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 Che 397 - Team Bravo Eddy-Current Separator •Basic schematic of Eddy-Current Separator •Non-Ferrous metals are ejected •This is prior to removal of ferrous metals Che 397 - Team Bravo Magnetic Separator •For removal of Ferrous metals •Uses magnets to hold iron containing metals to the roller •Releases them into separate bin for return to landfill Che 397 - Team Bravo 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 Che 397 - Team Bravo Backup Slide: Reactor Compositions – Carbon • 2500 TPD Basis • Gasifier composition – Carbon • 188767.6 lb-mol per day • Combustion Reactor Carbon – Carbon • TBD Che 397 - Team Bravo 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 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/kmol Che 397 - Team Bravo TBE Gasification Process TBE Process Steam Gasifier RDF Flue Gas Olivine (Hot) Olivine Combustion Reactor SynGas Tars Gas Conditioning Reactor SynGas Char, Ash & Olivine (Cool) Ash Removal Che 397 - Team Bravo Air Gasifier: Material Balance RDF Steam SynGas Tars Olivine 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 Char Olivine Total Che 397 - Team Bravo 13,876.1 Gasifier: Energy Balance Reactions RDF Steam SynGas Tars C + H2O CO + H2 + 56,376 BTU/lbmol CO + ½O2 CO2 -1.2 E5 BTU/lbmol Olivine Char Olivine Che 397 - Team Bravo Component CO CO2 CH4 C2H4 C2H6 H2S NH3 HCl Char Total BTU/lbmolRDF 21,460.07 -8,286.88 -1,527.77 -260.37 -14.66 -50.52 -16.47 11,303.4 Combustion Reactor: Material Balance Flue Gas Olivine (Hot) Air Char, Ash & Olivine (Cool) IN tons/day OUT tons/day 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 Ash Removal Che 397 - Team Bravo Combustion Reactor: Energy Balance Reactions C + O2 CO2 Flue Gas Olivine (Hot) Air Char, Ash & Olivine (Cool) Ash Removal Che 397 - Team Bravo -1.7 E5 BTU/lbmol Component BTU/lbmolRDF CO - CO2 - CH4 - C2H4 - C2H6 - H2S - NH3 - HCl - Char -11,171.50 Total -11,171.50 Gas Conditioning Reactor: Material Balance SynGas SynGas Tars Olivine Olivine IN tons/day OUT tons/day 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 Che 397 - Team Bravo Gas Conditioning Reactor: Energy Balance Water Gas Shift reaction reaches thermal equilibrium. SynGas SynGas Tars Olivine Olivine Che 397 - Team Bravo Component BTU/lbmolRDF CO -451.03 CO2 - CH4 - C2H4 - C2H6 - H2S - NH3 - HCl - Char - Total -451.03 Gas Clean Up: Scrubber Material Balance Sulfur Halogens Raw SynGas Hazardous Materials Raw SynGas IN tons/day OUT tons/day 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). Che 397 - Team Bravo Gas Clean Up: Reformer Material Balance Raw SynGas SynGas Steam IN tons/day OUT tons/day 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 2,092.0 H2O Supplied 1,115.3 Total 14,665.6 Total 14665.6 Che 397 - Team Bravo Reverse Water Gas Shift: Material Balance Reactions CO2 + H2 CO + H2O SynGas SynGas At spec. +17,644 BTU/lbmol IN tons/day OUT tons/day 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 Che 397 - Team Bravo 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 -11,171.50 -319.13 Che-451.03 397 - Team Bravo Investment Trend ~ 595 tons/hour --> ~335 millions $ Che 397 - Team Bravo TIC RDF Processing Total Installed Cost of Some RDF Processing Equipment Processing Unit Non-Ferrous Material Removal Gravity Separation Size Reduction Thermal Drying Total TIC 2011 Dollars at 5% interest Lower Upper Avg -- -- $465,390.00 $142,719.60 $1,213,116.60 $2,295,924.00 $465,390.00 $2,606,184.00 $5,832,888.00 $304,054.80 $3,819,300.60 $4,064,406.00 -- -- $8,653,151.40 Che 397 - Team Bravo 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 Che 397 - Team Bravo Capital Costs Million $ (+/- 45%) % of Total (+/- 45%) $58 - $153 13% - 35% Feedstock $22 - $58 5% - 15% Gasification, Tar Reforming, Scrubbing $36 - $98 9% - 23% $90 - $238 21% - 57% $18 - $50 6% - 16% Year 2008 RDF Processing SynGas Conditioning Steam System and Power Generation Total Capital Investment Che 397 - Team Bravo $224 - $597 Million 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 Che 397 - Team Bravo Operating Costs Operating Costs Raw materials Feedstock Catalysts & Chemicals By-product credits Scrap Aluminum Scrap Iron Electricity sold to grid Waste treatment or Disposal Gasifier ash MSW rejects Spent carbon Waste water treatment Che 397 - Team Bravo $/operating unit 0.00 0.10 -0.86 -0.58 -0.17 0.00 0.00 0.0001 0.026