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Indirect Gasification of Municipal Solid Waste

Indirect Gasification of Municipal Solid Waste. Team Bravo EleftheriosAvtzis David Garcia Bryan Isles Zack Labaschin Alena Nguyen Mentor Dan Rusinak. Overview. Design Basis and Goals RDF Processing Taylor Biomass Energy Process Block Flow Diagrams Economics Plant Layout

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Indirect Gasification of Municipal Solid Waste

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  1. Indirect Gasification of Municipal Solid Waste Team Bravo EleftheriosAvtzis David Garcia Bryan Isles Zack Labaschin Alena 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 Bravo Che 397 - Team Bravo

  3. Problem: Municipal Solid Waste Che 397 - Team Bravo

  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 Che 397 - Team Bravo Che 397 - Team Bravo

  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 Che 397 - Team Bravo Che 397 - Team Bravo

  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 Che 397 - Team Bravo

  7. Engineering Specifications Che 397 - Team Bravo

  8. RDF Processing Che 397 - Team Bravo

  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 Che 397 - Team Bravo

  10. Eddy-Current Separator • Basic Schematic of Eddy-Current Separator • Non-Ferrous Metals are Ejected Che 397 - Team Bravo

  11. Magnetic Separator • For Removal of Ferrous Metals • Uses Magnets to Hold Metals to Roller • Releases Metals intoSeparate Bin for Return to Landfill Che 397 - Team Bravo

  12. Block Flow Diagram Sulfur Halogens Hazardous Materials Return to Landfill Ash to Landfill MSW Processing TBE Gasification Cooling & Cleaning RDF Raw SynGas MSW Clean SynGas Steam Steam Steam Electrical Grid Electricity Steam Generation Methane Reforming Boiler Feed Water Captured CO2 Clean SynGas Team Alpha Gasoline Production CO2 Removal Water Gas Shift SynGas at Spec. Clean SynGas Excess SynGas Che 397 - Team Bravo Che 397 - Team Bravo

  13. TBE Gasification Raw SynGas Dirty Flue Gas-Conditioning Unit Effluent Effluent Hot Olivine Circulating Fluidized Bed Gasification Unit Combustion Unit Raw SynGas Hot Olivine RDF Olivine and Char Steam Air Che 397 - Team Bravo Che 397 - Team Bravo

  14. Block Flow Diagram Streams Reflect PFD Sulfur Halogens Hazardous Materials Return to Landfill 27,36 Ash to Landfill 5, 11,14 MSW Processing TBE Gasification Cooling & Cleaning 1 RDF Raw SynGas MSW 19 28 42 Clean SynGas 20 51 Steam 68 A2 Electrical Grid Electricity Steam Generation 71, A3, A4 Methane Reforming Steam Steam Boiler Feed Water Captured CO2 Clean SynGas 52 57 Team Alpha Gasoline Production CO2 Removal Water Gas Shift 53 SynGas at Spec. Clean SynGas 64 Excess SynGas 65 Che 397 - Team Bravo Che 397 - Team Bravo

  15. Block Flow Diagram Streams Reflect PFD 27, 36 Ash to Landfill 72 lb/hr Olivine 21,954 Ib/hr Ash MSW Processing TBE Gasification 1 19 28 Raw SynGas RDF MSW 20 5,11,14 Steam Return to Landfill 964,512 Ib/hr 918,583 Ib/hr 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 365,600 Ib/hr Che 397 - Team Bravo Che 397 - Team Bravo

  16. Block Flow Diagram Streams Reflect PFD 2,071,381 Ib/hr H2O 264,933 Ib/hr CO2 2,866 Ib/hr H2S 355 Ib/hr SelexolTM Cooling & Cleaning 28 Raw SynGas 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 42 Sour Gas 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 51 Clean SynGas Che 397 - Team Bravo Che 397 - Team Bravo

  17. Block Flow Diagram Streams Reflect PFD 53 52 475,288 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 x3 44,970 Ib/hr CO2 673,870 Ib/hr CO 62,887 Ib/hr H2 181,112 Ib/hr H2O x3 289,758 Ib/hr CO2 518,095 Ib/hr CO 74,014 Ib/hr H2 80,972 Ib/hr H2O Water Gas Shift Clean SynGas Methane Reforming 51 Steam 99,212 Ib/hr H2O A2 Che 397 - Team Bravo Che 397 - Team Bravo

  18. Block Flow Diagram Streams Reflect PFD Captured CO2 289,758 Ib/hr CO2 2,000,000 Ib/hr H2O 355 lb/hr SelexolTM SynGas at Spec. Raw SynGas 437,500 Ib/hr CO 62,500 Ib/hr H2 289,758 Ib/hr CO2 518,095 Ib/hr CO 74,014 Ib/hr H2 80,972 Ib/hr H2O Excess SynGas 57 65 80,595 Ib/hr CO 11,514 Ib/hr H2 CO2 Removal Team Alpha Gasoline Production 54 64 Che 397 - Team Bravo Che 397 - Team Bravo

  19. Economics IRR = 27.96% 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. Che 397 - Team Bravo

  20. 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. Che 397 - Team Bravo

  21. 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. Che 397 - Team Bravo

  22. Economics This graph displays the ideal estimated profit from operating years one through twenty. The breakeven period is just over six years. Che 397 - Team Bravo

  23. Newton County Prevailing Wind Team Alpha Team Bravo 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. Current MSW Active Site Flare 711 ft Che 397 - Team Bravo

  24. Plot Area County Rd 400 S Office CO2 Prevailing Wind Claus Syngas Treatment Tank and Storage S 300 E 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 To Alpha TBE Process Utility Power Generation RDF Processing Active Landfill Flare 328 ft Che 397 - Team Bravo

  25. 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

  26. 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% Che 397 - Team Bravo

  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 Che 397 - Team Bravo

  28. Aspen Acid Removal Che 397 - Team Bravo

  29. Furnace-Boiler Schematic Che 397 - Team Bravo

  30. Ash Material Balance Che 397 - Team Bravo

  31. Sample Calculation Gasification Sizing Calculation Che 397 - Team Bravo

  32. Sample Calculation Gasification Sizing Calculation Che 397 - Team Bravo

  33. Sample Calculation Gasification Sizing Calculation Che 397 - Team Bravo

  34. Sample Calculation Gasification Sizing Calculation Che 397 - Team Bravo

  35. Sample Calculation Absorber Che 397 - Team Bravo Che 397 - Team Bravo

  36. Sample Calculation Absorber Che 397 - Team Bravo Che 397 - Team Bravo

  37. Conceptual Control Scheme The TBE Process Che 397 - Team Bravo Che 397 - Team Bravo

  38. Conceptual Control Scheme Acid Cleanup Che 397 - Team Bravo

  39. Composition of Syngas Che 397 - Team Bravo

  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 Che 397 - Team Bravo

  41. Carbon Footprint Environmentally friendly process by removing carbon waste from the environment. Che 397 - Team Bravo

  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 Che 397 - Team Bravo

  43. Design Basis Newton County Landfill 265 Acres Room for expansion Access to MSW of South Chicago Transportation No river access Che 397 - Team Bravo

  44. 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) Che 397 - Team Bravo

  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 Che 397 - Team Bravo

  46. Methane Emissions in U.S.Top 5 Sources Che 397 - Team Bravo

  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. Che 397 - Team Bravo

  48. Why MSW? • Renewable Energy Source • Helps the Environment (CH4 emissions) • Cost effective • Transportation Reduction • Located near cities and existing infrastructure Che 397 - Team Bravo

  49. Disadvantages of MSW • Preparation of feedstock • A lower heating value than conventional feedstocks • Higher Ash content than conventional feedstocks Che 397 - Team Bravo

  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 Che 397 - Team Bravo

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