Carpet Waste Gasification: Technical, Economic, Environmental Assessment for Carpet Mills An Interim Presentation ENCH 4300—Capstone UT Chattanooga Jordan Buecker April 12, 2017 Christopher Burns Advisor: Dr. Jim Henry Katharine Davis Hemali Dholakia Kevin O’Brien

Outline Problem Statement Principle of Gasification Methodology Proposed Systems Syngas Uses Environmental Analysis Economics Conclusions

Problem Statement 250 tons per day of post-consumer carpet (PCC) Currently pay disposal fees Reclaim a portion of the chemical energy from the PCC

Problem Statement PCC has lower heating value of 8,800 Btu/lb Bituminous coal LHV = 11,000 Btu/lb Natural gas LHV = 20,000 Btu/lb Gasification Processes PCC considered Produce syngas Syngas LHV = 8,000-12,000 Btu/lb

Principle of Gasification  

Percentage of Carpet (wt%) Percentage removed pre-gasification (wt%) Methodology 250 tons/day of post consumer carpet Carpet composition (wt%) Component Percentage of Carpet (wt%) Percentage removed pre-gasification (wt%) Polypropylene (PP) 17 Calcium Carbonate (CaCO3) 35 80 Polyethylene Terephtalate (PET) 6 Nylon 6 (N 6) 100 Nylon 6,6 (N 6,6) 14 Styrene Butadiene Rubber (SBR) 11

Methodology PP -18600 1700 -32 CaCO3 800 700 0.6 PET -9500 630 -6 SBR Material Heat of Combustion (BTU/lb) Flowrate (lb/hr) MMBTU/hr PP -18600 1700 -32 CaCO3 800 700 0.6 PET -9500 630 -6 SBR -18900 1100 -21 N66 -13800 1400 -19 Total 79 MM BTU/hr

Methodology Employed ChemCad modeling software Material balance Energy balance

Proposed Systems Air Gasifier

Proposed Systems Air Gasifier N2 presence reduces heating value Produces NOx

Proposed Systems O2 Gasifier

Proposed Systems O2 Gasifier Capital increase due to N2 separation Capital decrease due to volumetric flow from the gasifier

Proposed Systems Steam Gasifier

Proposed Systems Steam Gasifier Lower Temperature Produces CH4 (higher heating value syngas)

Current Syngas Use Current Syngas Use Boiler Exhaust Steam Air Syngas Plant Use

Potential Syngas Use Exhaust High Pressure Steam Air Boiler Syngas Steam Turbine Condensate Low Pressure Steam Condenser

Potential Syngas Use Low Temp Exhaust High Pressure Steam Boiler Hot Exhaust Steam Turbine Work Gas Turbine Air Work Syngas

Energy Recovery Gasifier MM BTU/h BTU/lb PCCW Air 58 5800 O2 Steam 35 3500

Pollutants Air 14000 240 13% 300 -14% O2 negligible Steam 11000 310 Gasifier lb/h CO2 lb CO2/MM BTU Coal compare lb/h NOx Air 14000 240 13% 300 -14% O2 negligible Steam 11000 310 48%

Interim Conclusions Technologically and Environmentally Feasible Economic Analysis will be performed

Questions We Have What were the strong points? What can be improved upon? What can be omitted?