“Garbage to Gas” Team Bravo EleftheriosAvtzis David Garcia Bryan Isles Zack Labaschin Alena Nguyen Mentor Dan Rusinak Che 397 - Team Bravo
Jan 03, 2016
“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
Che 397 - Team Bravo
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
Che 397 - Team Bravo
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
Che 397 - Team Bravo
• 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
Che 397 - Team Bravo
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
Che 397 - Team Bravo
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
Che 397 - Team Bravo
Shredding: Hammer Mill
Che 397 - Team Bravo
Trommel Screen
Che 397 - Team Bravo
•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
Che 397 - Team Bravo
•Basic schematic of Eddy-Current Separator
•Non-Ferrous metals are ejected
•This is prior to removal of ferrous metals
Magnetic Separator
Che 397 - Team Bravo
•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
Che 397 - Team Bravo
RDF
Steam
SynGasTars
SynGasTars
SynGasSynGas
OlivineOlivine
Olivine(Hot)
Air
Flue Gas
Char, Ash & Olivine(Cool)
Ash Removal
Gasifier: Material Balance
Che 397 - Team Bravo
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
Che 397 - Team Bravo
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
Che 397 - Team Bravo
Air
Char, Ash & Olivine
(Cool)
Olivine(Hot)
Flue Gas
Ash Removal
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
Combustion Reactor: Energy Balance
Che 397 - Team Bravo
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
Che 397 - Team Bravo
SynGasTarsSynGasTars
OlivineOlivine
SynGasSynGas
OlivineOlivine
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
Gas Conditioning Reactor:Energy Balance
Che 397 - Team Bravo
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
Che 397 - Team Bravo
RawSynGas
SulfurHalogens
HazardousMaterials
RawSynGas
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).
Gas Clean Up: ReformerMaterial Balance
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
2,092.0H2O
Supplied1,115.3
Total 14,665.6 Total 14665.6
Che 397 - Team Bravo
SynGas
RawSynGas
Steam
Reverse Water Gas Shift: Material Balance
ReactionsCO2 + H2 CO + H2O +17,644 BTU/lbmol
Che 397 - Team Bravo
SynGas SynGasAt spec.
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
Investment Trend
Che 397 - Team Bravo
~ 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
Che 397 - Team Bravo
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
Che 397 - Team Bravo
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
Che 397 - Team Bravo
• 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
Che 397 - Team Bravo