Indirect Gasification of Municipal Solid Waste Team Bravo EleftheriosAvtzis David Garcia Bryan Isles Zack Labaschin Alena Nguyen Mentor Dan Rusinak Che Team Bravo

Process Review Indirect gasification of RDF using TBE process Providing Syngas to Team Alpha Location: Newton County Landfill in Brooke, IN Environment, Economy and Energy Che Team Bravo

Indirect Gasification The TBE process is a three unit, indirect gasification process The oxidizing agent is steam, therefore no air or ASU is required Olivine is cycled between the three units: gasification, combustion and gas conditioning Che Team Bravo

Engineering Specifications Team Alpha SyngasSpecification Pressure725 psi Temperature518°F Syngas tons/day6,000 H 2 /CO Ratio2 Che Team Bravo Team Bravo Syngas Syngas (tons/day) Max. tons/day from 11,000 tons/day RDF 7,000

Location Newton County Landfill – 265 Acres – Room for expansion – Access to MSW of South Chicago – Transportation – No river access

The Three E’s Eco-friendly: low NO x, no dioxins and landfill cleanup lowers methane Economical: great IRR, get paid to remove trash, provides electricity and steam Energy: synthesis gas sent to Team Alpha becomes gasoline Che Team Bravo

PFD - Main Che Team Bravo

PFD - Main Che Team Bravo

PFD - Main Che Team Bravo

PFD – TBE Che Team Bravo

PFD – TBE Che Team Bravo

PFD – Reformers Che Team Bravo

PFD – Reformers Che Team Bravo

Block Flow Diagram Che Team Bravo MSW Processing Gasifier Cooling & Cleaning Methane Reforming Electricity Steam Generation CO 2 Removal Team Alpha Gasoline Production MSW Recycled metals Return to landfill RDF Ash to landfill Raw SynGas Sulfur Halogens Hazardous materials Steam Electrical grid Clean SynGas CO 2 SynGas at spec. Water-Gas Shift

TBE: Total Energy Balance GasifierG.C.R.C.R. BTU/lbmolRDF CO21, CO 2 -8, CH 4 -1, C2H4C2H C2H6C2H6 --- H2SH2S NH HCl Char---11,171.50TOTAL Total11, , Che Team Bravo

Equipment Sizing Che Team Bravo

Sinks and Loads Che Team Bravo Steam Cooling WaterBtu/hrkW-h/hrkW-h/year 1 4,531,000,000 1,327,58310,582,960, ,470,000, ,710 5,769,126, ,069,435 33, ,429, ,173,587 83, ,073, ,173,587 83, ,073, ,069,435 33, ,429, ,173,587 83, ,073, ,173,587 83, ,073,901 Total 8,369,833,218 2,452,361 19,549,242,006 Energy out of Turbine Assump. COP=1/5 Btu/hr kW-h/hr kW-h/year $0.07/kW-hr$0.11/kW-h (4,184,916,609) (1,226,180) (9,774,621,003) $(684,223,470) $(1,075,208,310)

Capital Investment Overview Che Team Bravo Total Installed CostEquipment Cost Heat Exchangers$ 2,970,000$ 495,000 Compressors$ 95,000,000$ 19,000,000 Absorbers$ 949,000$ 417,000 Strippers$ 695,000$ 198,000 TBE Process$ 350,000,000$ 50,000,000 RDF Processing$ 88,600,000$ 12,660,000 Other$ 100,400,000$ 16,730,000 Total$ 638,600,000 $ 99,500,000

Salaries and Fringes Che Team Bravo Single Shift Basis PersonnelAmnt/ShiftSalary $Benefits $Total/Shift $ Process Manager2120,00020,000280,000 Chemical Engineer570,00020,000450,000 Maintenance Operator1035,00020,000550,000 Day Basis PersonnelAmountSalary $Benefits $Total $ Process Manager6120,00020,000840,000 Chemical Engineer1570,00020,0001,350,000 Maintenance Operator3035,00020,0001,650,000 Chemists240,00020,000120,000 Total $ 3,960,000

Rough NPV- Annual/Rev. Costs Che Team Bravo Annual CostsCostRevenuesCost Operating Costs$101,000,000Syngas$498,225,000 Maintenance Costs$19,158,000Others$107,000,000 Utilities$88,400,000Total$605,225,000 Raw Materials$10,000,000 Salaries and Fringes$3,960,000 Total$222,518,000

Rough NPV- One Time Costs Che Team Bravo One Time Costs (CI)CostIntrest Aspen CI$93,000, % TBE$350,000,000P/A RDF Processing$88,600, Others$107,000,000Tax Total$638,600,00040% Rough NPV $1,871,290,396

Economic Overview Che Team Bravo Year Capital Cost-$638,600,000 Revenues 6000 tons/day at $250/ton $498,225,000$539,294,763$572,303,917$657,397,307$725,819,746 Others $107,000,000$120,429,443$131,596,504$161,847,101$187,625,148 Expenses Utilities Loan Expense $38,316,000$33,759,385$29,572,949$16,426,634$3,151,475 Total Annual Cost $88,400,000$99,494,979$108,720,850$133,712,932$155,009,935 Operating Costs $101,000,000$113,676,390$124,217,260$152,771,562$177,104,111 Depreciation $9,274,140 Salaries and Fringes $3,960,000$4,457,015$4,870,301$5,989,855$6,943,884 Maintenance 3% of cap cost $19,158,000$20,737,235$22,006,520$25,278,574$27,909,588 Raw Materials $10,000,000$10,824,322$11,486,857$13,194,788$14,568,112 Total Expenses $270,108,140$292,223,465$310,148,877$356,648,485$393,961,246 Income before Taxes $335,116,860$367,500,740$393,751,544$462,595,922$519,483,649 Taxes, 40% $134,046,744$147,000,296$157,500,617$185,038,369$207,793,459 Income After Taxes $201,070,116$220,500,444$236,250,926$277,557,553$311,690,189 Add Back Depreciation $9,274,140 Cash Flow From Operations-$638,600,000$210,344,256$229,774,584$245,525,066$286,831,693$320,964,329 Cumulative Cash Flow $210,344,256$1,099,764,185$1,820,351,781$3,700,345,024$5,235,181,714 Payback of 8 yrs NPV$1,659,988,954 IRR35.05 Interest8.00%

Economic Sensitivity Analysis Che Team Bravo

Report Outline Che Team Bravo Executive Summary - Done Discussion - IP Recommendations - IP Appendices - IP Design Basis - Done Block Flow Diagram - Done Process Flow Diagram - IP Material and Energy Balance - Done Calculations - Done Annotated Equipment List - IP Economic Evaluation - IP Utilities - IP Conceptual Control Scheme - IP General Layout of Major Equipment - IP Distribution and End-Use Issue Review - IP Constraints Review - IP Applicable Standards - IP Project Communications File - IP Information Sources and References - IP

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) - TBE – Rentech Engineering Toolbox Heats of formation: Municipal Solid waste Generation, Recycling, and Disposal in the United States: Facts and Figures for 2008 – EPA Higman, Christopher and van derBurgt, Maarten. Gasification 2 nd Edition. Gulf Professional Publishing. Oxford, 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 PETorganic wood (treated) wood (untreated) wood (demo) leatherTotals wt % ash (tons/day) Che Team Bravo

Backup: Economic Sens. Analysis Che Team Bravo

Aspen Flowsheet Che Team Bravo

Aspen Flowsheet Che Team Bravo

Aspen Flowsheet Che Team Bravo