Activated carbon by co-pyrolysis and steam activation from particle board and melamine formaldehyde resin: techno-economic evaluation

drs. Ing. Kenny Vanreppelen (MSc)

Promoters prof. dr. Robert Carleer prof. dr. Jan Yperman dr. Sonja Schreurs

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1. Introduction: Activated Carbon

2. Objective

3. Cost-benefit analysis

Methodology

Process design

Results

4. Conclusion

Table of content

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Activated carbons large number of applications water treatment

chemical and pharmaceutical processing

air and gas purification

…

1.2 Mt/Year by 2012

Average growth 5.2%/year

Standard AC 2,25 – 3,30 kEUR/t (2008)

Introduction

3

Specialty AC 3,3 – 6,0 kEUR/t (2008)

Activated carbons Normal low N (~0.5%)

N key parameter for

adsorbents, catalytical activity and catalyst supports

T.J. Bandosz, Surface Chemistry of Carbon Materials, in: P. Serp, J.L. Figueiredo (Eds.), Carbon

Materials for catalysis, John Wiley & Sons Inc., New Jersey, 2009, pp. 45–92.

Introduction

4

N introduction treatment with N-reagents

Raw material

Particle board (MUF) waste

Melamine formaldehyde waste

Introduction

Waste processing company

In situ nitrogen incorporation

Gate fee

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N: 5,9 wt%

N: 54,1 wt%

T.J. Bandosz, Surface Chemistry of Carbon Materials, in: P. Serp, J.L. Figueiredo (Eds.), Carbon

Materials for catalysis, John Wiley & Sons Inc., New Jersey, 2009, pp. 45–92.

1. Introduction: Activated Carbon

2. Objective

3. Cost-benefit analysis

Methodology

Process design

Results

4. Conclusion

Table of content

6

Investigation of the feasibility for the

production of nitrogenised activated carbon

from PB and MF waste streams.

in function of processing rate and mixing

ratio

Objective

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1. Introduction: Activated Carbon

2. Objective

3. Cost-benefit analysis

Methodology

Process design

Results

4. Conclusion

Table of content

8

Cost-benefit analysis: methodology

Proces Design

Economical Model

– Total capital investment

– Total Expenditure

– Total Revenue

Monte Carlo sensitivity analysis

– Define uncertain variables

• Simulation (10 000 runs)

Net Present Value

– Minimal selling price

– Selling price to guarantee 95 % chance positive NPV

Net Present Value

– Minimal selling price

9 Vanreppelen, K., Kuppens, T., Thewys, T., Carleer, R., Yperman, J., and Schreurs, S., Activated

carbon from co-pyrolysis of particle board and melamine (urea) formaldehyde resin: A techno-

economic evaluation Chem Eng J, Vol. 172, No. 2-3: p. 835-846, 2011

Based on a rather pessimistic scenario:

• Low average operating time (7 000 h)

• No gate fee for MF waste (now a MF factory pays

220EUR/t)

• First plant cost

Vanreppelen, K., Kuppens, T., Thewys, T., Carleer, R., Yperman, J., and Schreurs, S., Activated

carbon from co-pyrolysis of particle board and melamine (urea) formaldehyde resin: A techno-

economic evaluation Chem Eng J, Vol. 172, No. 2-3: p. 835-846, 2011

1. Introduction: Activated Carbon

2. Objective

3. Cost-benefit analysis

Methodology

Process design

Results

4. Conclusion

Table of content

10

Cost-benefit analysis: Results

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PB – MF

(5/0)

PB – MF

(4/1)

PB – MF

(3/2)

PB – MF

(2/3)

PB – MF

(1/4)

AC Yield (wt%) 22 21 19 15 11

Ultimate analysis

(%) (dry and ash free)

C 91 ± 1 85 ± 4 86 ± 2 83 ± 2 83.4 ± 0.7

N 2.24 ± 0.04 4.3 ± 0.2 7.35 ± 0.07 9.6 ± 0.3 14 ± 1

AC from PB N: 1,5 – 2 wt% 2,0 kEUR/t (Girods et al. 2009)

We expect 2,0 kEUR/t – 2,5 kEUR/t

Cost-benefit analysis: Results

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-15

-10

-5

0

5

10

15

20

25

30

1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5

NPV

(MEUR)

Price of active carbon

(kEUR/ton; feed 1 ton/h )

Ratio PB - MF (5/0)

Ratio PB - MF (4/1)

Ratio PB - MF (3/2)

Ratio PB - MF (2/3)

Ratio PB - MF (1/4)

Minimal selling price (NPV > 0)

1,6 kEUR/t 1,8 kEUR/t 2,0 kEUR/t 2,6 kEUR/t 3,9 kEUR/t

Are the obtained results valid??

only in case of 100% certainty of the base variables

some variables are uncertain by definition, others might change the NPV strongly if its value changes slightly

Monte Carlo sensitivity simulation

Cost-benefit analysis: Results

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Monte Carlo simulation

Total Capital Investment; Electricity Cost; Water Cost; Delivered feed cost; Discount

rate; Liquid nitrogen cost; Char output; AC output; Staff cost / shift;

Annual working hours facility

Triangulair distribution

Calculation of numerous NPVs (10 000 runs)

Cost-benefit analysis: Results

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ML MIN

(-10%)

MAX

(+10%)

Chance

Cost-benefit analysis: Results

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Minimal selling price (min 95% chance on NPV > 0)

2,0 kEUR/t 2,2 kEUR/t 2,5 kEUR/t 3,1 kEUR/t 4,5 kEUR/t

-15

-5

5

15

25

35

1 1,5 2 2,5 3 3,5 4 4,5

NPV

(MEUR)

Price of active carbon

(kEUR/ton; feed 1 ton/h)

PB - MF (5/0)

PB - MF (4/1)

PB - MF (3/2)

PB - MF (2/3)

PB - MF (1/4)

1. Introduction: Activated Carbon

2. Objective

3. Cost-benefit analysis

Methodology

Process design

Results

4. Conclusion

Table of content

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Really encouraging results are obtained for a profitable production of nitrogenised AC !

Even as the current assumptions start from a rather pessimistic scenario

In situ incorporation of N

Ability to reuse 2 waste streams

The feasibility depends largely on the

AC yield

the product quality

Conclusion

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Future research

Activated carbon by co-pyrolysis and steam activation from particle board and melamine formaldehyde resin: techno-economic evaluation

kenny.vanreppelen@xios.be

Promoters prof. dr. Robert Carleer prof. dr. Jan Yperman dr. Sonja Schreurs

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