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

2. 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

3. Engineering Specifications
Team Bravo Syngas
Syngas (tons/day)
Max. tons/day from
11,025 tons/day RDF
8,430
Team Alpha Syngas
Specification
Pressure
725 psi
Temperature
518°F
Min. tons/day
3,310
H2/CO Ratio 2
Che Team Bravo

4. Design Basis Newton County Landfill 265 Acres Room for expansion
Access to MSW of South Chicago
Transportation
No river access

5. Methane Emissions in U.S. Top 5 Sources
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
Che Team Bravo

6. Dioxins 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
Che Team Bravo

7. Carbon OUT (kmole/day) Total Carbon Dioxide OUT
Carbon Footprint
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
Che Team Bravo

8. Block Flow Diagram MSW Processing Gasifier Cooling & Cleaning
Methane Reforming
Electricity
Steam Generation
CO2 Removal
Team Alpha Gasoline Production
MSW
Recycled
metals
Return to
landfill
RDF
Ash to
Raw SynGas
Sulfur
Halogens
Hazardous
materials
Steam
Electrical
grid
Clean
SynGas
CO2
SynGas at spec.
Reverse Water-Gas Shift
Che Team Bravo

9. RDF Processing Shredder
Hammers running at high speeds to chop and shred waste
Trommel Screen
Rotating, tubular vessels for sorting waste by size
Eddy-Current Separator
Ejects non-ferrous metals for recycle
Magnetic Separator
Removes ferrous metals for recycle
Mill
Shred material into fie particles
Che Team Bravo

10. Shredding: Hammer Mill
Che Team Bravo

11. Trommel Screen Cylinder with screen on the outside
Sorts shredded MSW by size
Rotates to drive the MSW through from one side to the other
Che Team Bravo

12. Eddy-Current Separator
Basic schematic of Eddy-Current Separator
Non-Ferrous metals are ejected
This is prior to removal of ferrous metals
Che Team Bravo

13. Magnetic Separator For removal of Ferrous metals
Uses magnets to hold iron containing metals to the roller
Releases them into separate bin for return to landfill
Che Team Bravo

14. Gas Conditioning Reactor
TBE Process
Gasifier
RDF
Steam
Gas Conditioning Reactor
SynGas
Tars
Olivine
Combustion
Reactor
(Hot)
Air
Flue Gas
Char, Ash
& Olivine
(Cool)
Ash Removal
Che Team Bravo

15. Gasifier: Material BalanceIN
tons/day
OUT 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
H2O
2,254.9
H2S
23.4
HCl
11.8
NH3
152.2
Total
13,876.1
SynGas
Tars
Char
Olivine
RDF
Steam
Olivine
Che Team Bravo

16. Gasifier: Energy Balance
Reactions
C + H2O  CO + H ,376 BTU/lbmol
CO + ½O2 CO E5 BTU/lbmol
SynGas
Tars
Char
Olivine
RDF
Steam
Olivine
Component
BTU/lbmolRDF CO
21,460.07
CO2
-8,286.88
CH4
-1,527.77
C2H4
C2H6 -
H2S
-14.66
NH3
-50.52
HCl
-16.47
Char
Total
11,303.4
Che Team Bravo

17. Combustion Reactor: Material BalanceIN
tons/day
OUT
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
SO2 O2
2,979.1 N2
9,811.1
9,814.6
Total
13,905.4
Olivine
(Hot)
Flue Gas
Ash Removal
Air
Char, Ash
& Olivine
(Cool)
Che Team Bravo

18. Combustion Reactor: Energy Balance
Reactions
C + O2 CO E5 BTU/lbmol
Olivine
(Hot)
Flue Gas
Ash Removal
Component
BTU/lbmolRDF CO -
CO2
CH4
C2H4
C2H6
H2S
NH3
HCl
Char
-11,171.50
Total
Air
Char, Ash
& Olivine
(Cool)
Che Team Bravo

19. Gas Conditioning Reactor: Material Balance
tons/day
OUT CO
3,933.7
2,917.4
CO2
4,250.4
5,295.1
CH4
1,077.9
1,171.6 H2
546.1
519.5
C2H4
510.5
436.5
C2H6
180.0
H2O
2,254.9
2,053.4
H2S
23.4
HCl
11.8
NH3
152.2
Total
12,760.9
SynGas
Olivine
SynGas
Tars
Olivine
Che Team Bravo

20. Gas Conditioning Reactor: Energy Balance
Water Gas Shift reaction reaches thermal equilibrium.
SynGas
Olivine
Component
BTU/lbmolRDF CO
CO2 -
CH4
C2H4
C2H6
H2S
NH3
HCl
Char
Total
SynGas
Tars
Olivine
Che Team Bravo

21. TBE: Total Energy Balance
Gasifier
G.C.R.
C.R.
BTU/lbmolRDF CO
21,460.07 -
CO2
-8,286.88
CH4
-1,527.77
C2H4
C2H6
H2S
-14.66
NH3
-50.52
HCl
-16.47
Char
-11,171.50
TOTAL
Total
11,303.4
Che Team Bravo

22. Gas Clean Up: Scrubber Material Balance
Sulfur
Halogens
Hazardous
Materials
Raw
SynGas IN
tons/day
OUT
H2S
23.429
HCl
11.847
NH3
Total
187.46
Raw
SynGas
Basically all incoming volatiles will be treated (place holder).
Che Team Bravo

23. Gas Clean Up: Reformer Material BalanceIN
tons/day
OUT CO
2,917.4
4,711.5
CO2
5,295.1
7,586.9
CH4
1,171.6 H2
519.5
1,251.9
C2H4
436.6
C2H6
180.0
H2O
2,053.4
H2O Supplied
2,092.0
1,115.3
Total
14,665.6
SynGas
Raw
Steam
Che Team Bravo

24. Reverse Water Gas Shift: Material Balance
Reactions
CO2 + H2 CO + H2O ,644 BTU/lbmol IN
tons/day
OUT CO
4,711.5
7,368.8 H2
1,251.9
1,060.7
CO2
7,586.9
3,411.7
H2O
1,115.3
2,824.3
Total
14,665.6
SynGas
At spec.
Che Team Bravo

25. Investment Trend ~ 595 tons/hour --> ~335 millions $
Che Team Bravo

26. Capital Costs $58 - $153 13% - 35% $22 - $58 5% - 15% $36 - $98
Year 2008
Million $
(+/- 45%)
% of Total
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 Team Bravo

27. TIC RDF Processing
Total Installed Cost of Some RDF Processing Equipment
2011 Dollars at 5% interest
Processing Unit
Lower
Upper
Avg
Non-Ferrous Material Removal --
$465,390.00
Gravity Separation
$142,719.60
$304,054.80
Size Reduction
$1,213,116.60
$2,606,184.00
$3,819,300.60
Thermal Drying
$2,295,924.00
$5,832,888.00
$4,064,406.00
Total TIC
$8,653,151.40
Che Team Bravo

28. TIC Assumptions TIC breakdown Purchased Equipment Installation
Instrumentation and Controls
Piping
Electrical Systems
Buildings (including services)
Yard Improvements
Indirect Costs
Engineering
Construction
Legal and Contractors Fees
Project Contingency
Che Team Bravo

29. 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 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

30. Back up: Ash Material Balance
PET
organic
wood (treated)
wood (untreated)
wood (demo)
leather
Totals
wt %
0.0286
0.8678
0.6878
0.3859
0.4137
1.000
ash (tons/day)
3.1614
95.66
75.82
0.6090
42.54
45.61
263.41
Che Team Bravo