“garbage to gas”

30
“Garbage to Gas” Team Bravo EleftheriosAvtzis David Garcia Bryan Isles Zack Labaschin Alena Nguyen Mentor Dan Rusinak Che 397 - Team Bravo

Upload: phaedra-calliope

Post on 03-Jan-2016

27 views

Category:

Documents


0 download

DESCRIPTION

“Garbage to Gas”. Team Bravo EleftheriosAvtzis David Garcia Bryan Isles Zack Labaschin Alena Nguyen Mentor Dan Rusinak. 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 - PowerPoint PPT Presentation

TRANSCRIPT

Page 1: “Garbage to Gas”

“Garbage to Gas”

Team BravoEleftheriosAvtzis

David Garcia

Bryan Isles

Zack Labaschin

Alena Nguyen

Mentor Dan Rusinak

Che 397 - Team Bravo

Page 2: “Garbage to Gas”

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

Page 3: “Garbage to Gas”

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

Page 4: “Garbage to Gas”

Design Basis

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

Chicago– Transportation– No river access

Page 5: “Garbage to Gas”

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

Page 6: “Garbage to Gas”

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

Page 7: “Garbage to Gas”

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

Page 8: “Garbage to Gas”

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

Page 9: “Garbage to Gas”

RDF Processing

Che 397 - Team Bravo

Page 10: “Garbage to Gas”

Shredding: Hammer Mill

Che 397 - Team Bravo

Page 11: “Garbage to Gas”

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

Page 12: “Garbage to Gas”

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

Page 13: “Garbage to Gas”

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

Page 14: “Garbage to Gas”

TBE Process

Che 397 - Team Bravo

RDF

Steam

SynGasTars

SynGasTars

SynGasSynGas

OlivineOlivine

Olivine(Hot)

Air

Flue Gas

Char, Ash & Olivine(Cool)

Ash Removal

Page 15: “Garbage to Gas”

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

Page 16: “Garbage to Gas”

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

Page 17: “Garbage to Gas”

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

Page 18: “Garbage to Gas”

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

Page 19: “Garbage to Gas”

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

Page 20: “Garbage to Gas”

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.

Page 21: “Garbage to Gas”

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

Page 22: “Garbage to Gas”

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).

Page 23: “Garbage to Gas”

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

Page 24: “Garbage to Gas”

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

Page 25: “Garbage to Gas”

Investment Trend

Che 397 - Team Bravo

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

Page 26: “Garbage to Gas”

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

Page 27: “Garbage to Gas”

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

Page 28: “Garbage to Gas”

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

Page 29: “Garbage to Gas”

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

Page 30: “Garbage to Gas”

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