“Garbage to Gas” Team Bravo EleftheriosAvtzis David Garcia Bryan Isles Zack Labaschin Alena Nguyen Mentor Dan Rusinak Che 397 - Team Bravo

“Garbage to Gas”

Team BravoEleftheriosAvtzis

David Garcia

Bryan Isles

Zack Labaschin

Alena Nguyen

Mentor Dan Rusinak

Che 397 - Team Bravo

Design Basis

•Commercial Scale Production•12,000-14,000 tonnes per day MSW• 3,000+ tonnes per day Syngas•Ideal max. capacity 8,000+ tonnes per day•Scale-up available

•Landfill choice confirmation•Location•Proximity to City•Water Sources•Size and expansion

Engineering Specifications

Team Alpha Syngas Specification

Pressure 725 psi

Temperature 518°F

Min. tons/day 3,310

H2/CO Ratio 2


Team Bravo SyngasSyngas

(tons/day)

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

8,430

Design Basis

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

Chicago– Transportation– No river access

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

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

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

Block Flow Diagram


MSW Processing

MSW Processing GasifierGasifier

Cooling & Cleaning Cooling & Cleaning

Methane ReformingMethane

Reforming

ElectricityElectricity Steam Generation

Steam Generation

CO2 Removal

CO2 Removal

Team Alpha Gasoline

Production

Team Alpha Gasoline

Production

MSW

Recycledmetals

Return tolandfill

RDF

Ash tolandfill

Raw SynGas

SulfurHalogens

Hazardousmaterials

Steam

Electricalgrid

CleanSynGasCO2

SynGas at spec. Reverse Water-Gas

Shift

Reverse Water-Gas

Shift

RDF Processing


Shredding: Hammer Mill


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

Eddy-Current Separator


•Basic schematic of Eddy-Current Separator

•Non-Ferrous metals are ejected

•This is prior to removal of ferrous metals

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

TBE Process


RDF

Steam

SynGasTars

SynGasTars

SynGasSynGas

OlivineOlivine

Olivine(Hot)

Air

Flue Gas

Char, Ash & Olivine(Cool)

Ash Removal

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

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

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

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

Gas Conditioning Reactor:Material Balance


SynGasTarsSynGasTars

OlivineOlivine

SynGasSynGas

OlivineOlivine


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

Gas Conditioning Reactor:Energy Balance


SynGasTarsSynGasTars

OlivineOlivine

SynGasSynGas

OlivineOlivine

Component BTU/lbmolRDF

CO -451.03

CO2 -

CH4 -

C2H4 -

C2H6 -

H2S -

NH3 -

HCl -

Char -

Total -451.03

Water Gas Shift reaction reaches thermal equilibrium.

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

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).

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

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

Investment Trend


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

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


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

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

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


Documents

“Garbage to Gas” Team Bravo EleftheriosAvtzis David Garcia Bryan Isles Zack Labaschin Alena Nguyen Mentor Dan Rusinak Che 397 - Team Bravo