1. Indirect Gasification of Municipal Solid Waste Team Bravo EleftheriosAvtzis David Garcia Bryan Isles Zack Labaschin Alena Nguyen Mentor Dan Rusinak Che 397 - Team Bravo1

2. Overview Design Basis and Goals RDF Processing Taylor Biomass Energy Process Block Flow Diagrams Economics Plant Layout Recommendations Che 397 - Team Bravo 2

3. Problem: Municipal Solid Waste Che 397 - Team Bravo3

4. Solution: Indirect Gasification Project Design Goals Indirect Gasification of Refuse-Derived Fuel using TBE Process Providing High Quality Synthesis Gas to Team Alpha’s Specifications Location: Newton County Landfill in Brooke, IN Environmentally Friendly Process Economic and Energy Efficient Che 397 - Team Bravo 4

5. Design Benefits Che 397 - Team Bravo 5 Turns Garbage into Useful Products Reduces or Eliminates the Landfill Problem Provides a Feedstock for Liquid Transportation Fuels No Air Separation Unit Required Internally Generated Steam Environmentally Friendly Process

6. Design Basis Commercial Scale Production 13,000 tons per day MSW 6,000+ tons per day Syngas Ideal Max. Output 7,100 tons per day Scale-up Available Che 397 - Team Bravo6

7. Engineering Specifications Team Alpha SyngasSpecification Pressure725 psi Temperature518°F Min. tons/day6,000 H 2 /CO Ratio2 Che 397 - Team Bravo Team Bravo Syngas Syngas (tons/day) Max. tons/day from 11,025 tons/day RDF 7,105 7

8. 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 fine particles Che 397 - Team Bravo8

9. 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 9

10. Eddy-Current Separator Che 397 - Team Bravo Basic Schematic of Eddy-Current Separator Non-Ferrous Metals are Ejected 10

11. Magnetic Separator Che 397 - Team Bravo For Removal of Ferrous Metals Uses Magnets to Hold Metals to Roller Releases Metals into Separate Bin for Return to Landfill 11

12. Block Flow Diagram Che 397 - Team Bravo 12 MSW Processing TBE Gasification Cooling & Cleaning Electricity Steam Generation CO 2 Removal Team Alpha Gasoline Production MSW RDF Ash to Landfill Raw SynGas Sulfur Halogens Hazardous Materials Steam Electrical Gri d Clean SynGas Captured CO 2 SynGas at Spec. Water Gas Shift Methane Reforming Return to Landfill Steam Clean SynGas Clean SynGas Boiler Feed Water Excess SynGas

13. TBE Gasification Che 397 - Team Bravo 13 Raw SynGas Circulating Fluidized Bed Gasification Unit Circulating Fluidized Bed Gasification Unit Gas- Conditioning Unit Gas- Conditioning Unit Combustion Unit Combustion Unit Steam RDF Effluent Hot Olivine Olivine and Char Air Raw SynGas Dirty Flue Hot Olivine Effluent

14. Block Flow Diagram Che 397 - Team Bravo MSW Processing TBE Gasificatio n Cooling & Cleaning Electricity Steam Generation CO 2 Removal Team Alpha Gasoline Production MSW RDF Ash to Landfill Raw SynGas Sulfur Halogens Hazardous Materials Steam Electrical Grid Clean SynGas Captured CO 2 SynGas at Spec. Water Gas Shift Methane Reforming 1 5, 11,14 19 27,36 28 51 42 20 71, A3, A4 52 53 57 64 Return to Landfill A2 65 68 Streams Reflect PFD Che 397 - Team Bravo14 Steam Boiler Feed Water Clean SynGas Clean SynGas Excess SynGas

15. Block Flow Diagram Che 397 - Team Bravo MSW Processing TBE Gasification MSW Return to Landfill RDF Ash to Landfill Raw SynGas Steam 1 5,11,14 19 27, 36 28 20 964,512 Ib/hr918,583 Ib/hr 365,600 Ib/hr 72 lb/hr Olivine 21,954 Ib/hr Ash 8,301 Ib/hr NH 3 740,221 Ib/hr CO 2 259,924 Ib/hr CO 7,395 Ib/hr C 2 H 6 39,095 Ib/hr C 2 H 4 55,206 Ib/hr H 2 1,616 Ib/hr HCl 3,020 Ib/hr H 2 S 55,448 Ib/hr CH 4 71,381 Ib/hr H 2 O Streams Reflect PFD Che 397 - Team Bravo15

16. Block Flow Diagram Che 397 - Team Bravo Streams Reflect PFD Che 397 - Team Bravo16 Cooling & Cleaning Raw SynGas 28 51 42 71,381 lb/hr H 2 O 740,221 lb/hr CO 2 259,924 lb/hr CO 55,448 lb/hr CH 4 55,206 lb/hr H 2 39,095 lb/hr C 2 H 4 7,395 lb/hr C 2 H 6 3,020 lb/hr H 2 S 1,616 lb/hr HCl 8,301 lb/hr NH 3 475,288 lb/hr CO 2 252,477 lb/hr CO 51,619 lb/hr CH 4 55,098 lb/hr H 2 25,815 lb/hr C 2 H 4 3,330 lb/hr C 2 H 6 2,071,381 Ib/hr H 2 O 264,933 Ib/hr CO 2 2,866 Ib/hr H 2 S 355 Ib/hr Selexol TM Clean SynGas Sour Gas

17. Block Flow Diagram Che 397 - Team Bravo Clean SynGas Methane Reforming 51 A2 Water Gas Shift x3 52 53 99,212 Ib/hr H 2 O 475,288 Ib/hr CO 2 252,477 Ib/hr CO 51,619 Ib/hr CH 4 55,098 Ib/hr H 2 25,815 Ib/hr C 2 H 4 3,330 Ib/hr C 2 H 6 44,970 Ib/hr CO 2 673,870 Ib/hr CO 62,887 Ib/hr H 2 181,112 Ib/hr H 2 O 289,758 Ib/hr CO 2 518,095 Ib/hr CO 74,014 Ib/hr H 2 80,972 Ib/hr H 2 O Streams Reflect PFD Che 397 - Team Bravo17 Steam

18. Block Flow Diagram Che 397 - Team Bravo Streams Reflect PFD Che 397 - Team Bravo18 CO 2 Removal Team Alpha Gasoline Production 57 54 64 289,758 Ib/hr CO 2 518,095 Ib/hr CO 74,014 Ib/hr H 2 80,972 Ib/hr H 2 O 289,758 Ib/hr CO 2 2,000,000 Ib/hr H 2 O 355 lb/hr Selexol TM 437,500 Ib/hr CO 62,500 Ib/hr H 2 65 80,595 Ib/hr CO 11,514 Ib/hr H 2 Captured CO 2 Raw SynGas SynGas at Spec. Excess SynGas

19. Che 397 - Team Bravo This table displays the selective economics for year zero, one, five, seven, fifteen, and twenty. The net present value and internal rate of return are also displayed. Economics 19 IRR = 27.96%

20. Che 397 - Team Bravo This table displays the cost for selected processes and units required for Team Bravo’s indirect gasification of municipal solid waste. The capital cost as well as the operations, utilities, salaries, and annual cost in total are also listed. Economics 20

21. Che 397 - Team Bravo This table displays the revenue for Team Bravo’s indirect gasification of municipal solid waste. Major products and electricity are shown. About 90 kW of electricity are available for consumption outside the facility. Economics 21

22. Che 397 - Team Bravo Economics 22 This graph displays the ideal estimated profit from operating years one through twenty. The breakeven period is just over six years.

23. Che 397 - Team Bravo Newton County Current MSW Active Site 711 ft Prevailing Wind This figure represents the one square mile area that Newton County Landfill owns and occupies. The current active landfill covers a quarter mile space, allowing for Team Bravo to build their process on available Newton County land. 23 Team Alpha Team Bravo Flare

24. Che 397 - Team Bravo 328 ft Flare Active Landfill TBE Process Claus Utility Tank and Storage Office To Alpha CO2 Power Generation Syngas Treatment RDF Processing Prevailing Wind S 300 E County Rd 400 S Plot Area This figure shows the basic plot area of Team Bravo’s process and supporting facilities. Blocks were chosen in order to best take advantage each process 24

25. Che 397 - Team Bravo Plant Plot This figure represents the plant plot area of both the TBE process and most of the syngas treatment facilities. Placement was based on need of access. The compressors are situated next to a plant maintenance road. 25

26. Che 397 - Team Bravo Recommendations Move forward with the Indirect Gasification of Municipal Solid Waste Design Project Environmental Benefits Lower Landfill Methane Emissions, CO 2 Treatment and Little Thermal Pollution Excellent Location Newton County Landfill Provides Plenty of Feedstock and Space High Economic Sensitivity Increase Annual Expenses and Capital Investment $100MM – IRR = 15.56% Increase Capital Investment More by $100MM – IRR = 13.04% 26

27. 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 2 nd 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 Che 397 - Team Bravo27

28. Aspen Acid Removal Che 397 - Team Bravo28

29. Furnace-Boiler Schematic Che 397 - Team Bravo29

30. Ash Material Balance PETorganic wood (treated) wood (untreated) wood (demo) leatherTotals wt %0.02860.86780.68780.005520.38590.41371.000 ash (tons/day) 3.161495.6675.820.609042.5445.61263.41 Che 397 - Team Bravo30

31. Che 397 - Team Bravo Sample Calculation Gasification Sizing Calculation 31

32. Che 397 - Team Bravo Sample Calculation Gasification Sizing Calculation 32

33. Che 397 - Team Bravo Sample Calculation Gasification Sizing Calculation 33

34. Che 397 - Team Bravo Sample Calculation Gasification Sizing Calculation 34

35. Sample Calculation Che 397 - Team Bravo Absorber Che 397 - Team Bravo35

36. Sample Calculation Che 397 - Team Bravo Absorber Che 397 - Team Bravo36

37. Che 397 - Team Bravo Conceptual Control Scheme The TBE Process Che 397 - Team Bravo37

38. Che 397 - Team Bravo Conceptual Control Scheme Acid Cleanup 38

39. Che 397 - Team Bravo Composition of Syngas CompoundPercent H2H2 45 – 48% CO15 – 20% CH 4 10 – 13% C2H4C2H4 1 – 3% CO 2 18 –20% C2H6C2H6 0 – 1% N2N2 Trace 39

40. 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 40

41. Carbon Footprint Che 397 - Team Bravo Carbon IN (kmole/day) Carbon OUT (kmole/day) Ratio of OUT/IN 393,142.7238,659.60.607 Environmentally friendly process by removing carbon waste from the environment. Total Carbon Dioxide OUT 6,801 tons/day 41

42. Design Basis River Bend Prairie Landfill – 88 Acres – 20 Acres of expansion – Access to MSW of Chicago – Rail and River access – Residential – Limited Expansion Che 397 - Team Bravo42

43. Design Basis Newton County Landfill – 265 Acres – Room for expansion – Access to MSW of South Chicago – Transportation – No river access Che 397 - Team Bravo43

44. Design Basis Environmental Review Positives Removal of MSW from local landfill (75% of 12000 tonnes per day estimated value enter gasification processing) Gasification by-products are captured and properly stored (no venting into atmospheres) – Negatives 400 million lbs of hazardous waste per year (mostly ash) 100,000 lbs will need relocation (cannot be further utilized) Che 397 - Team Bravo44

45. Design Basis Industrial Standard Review Clean Syngas produced in 2.4-3.0 ratio H 2 /CO for use by chemical production Clear Statement of Feedstock MSW from landfills Return to landfill includes: glass, appliances, paints or oils Metal will be recycled Che 397 - Team Bravo45

46. Methane Emissions in U.S. Top 5 Sources Che 397 - Team Bravo Source Category2008 (Tg of CO 2 Equi.)%Total Enteric Fermentation140.824.81 Landfills126.322.26 Natural Gas Systems96.416.99 Coal Mining67.611.91 Manure Management45.07.93 Total for US567.4100.00 46

47. Municipal Solid Waste EPA 2008 report on MSW generation – Approximately 250 million tons of MSW generated by Americans in 2008 ~33.2% is recycled and composited (83 million tons) – Approximately 4.5 pounds of MSW generated per person per day 1.5 pounds of the 4.5 is recycled and composited. Che 397 - Team Bravo47

48. Why MSW? Renewable Energy Source Helps the Environment (CH 4 emissions) Cost effective Transportation Reduction Located near cities and existing infrastructure Che 397 - Team Bravo48

49. Disadvantages of MSW Preparation of feedstock A lower heating value than conventional feedstocks Higher Ash content than conventional feedstocks Che 397 - Team Bravo49

50. MSW to RDF MSW – municipal solid waste in Sorting – removal of recycle metals and other rejects Screening procedures Shredding and drying RDF – Refuse Derived Fuel out Che 397 - Team Bravo50

51. Current Processes Che 397 - Team Bravo Batelle Silva Gas Montgomery Project 51

52. Disadvantages of Other Processes High pressure/Energy intensive Lower quality raw syngas Air or oxygen requirements Poor scale up Unproven technology Che 397 - Team Bravo52

53. Advantages of TBE Process Low pressure Relatively low temperature Efficient ash removal Indirect gasification Residence time less than one second Che 397 - Team Bravo53

54. Backup Slide: Rough Mass Balance 2500 TPD Basis 625 TPD rejected material – 306 TPD Ash (considered rejected material) 361.8 TPD CO 2 219.6 TPD CH 4 Che 397 - Team Bravo54

55. Backup Slide: Reactor Compositions – Carbon 2500 TPD Basis Gasifier composition – Carbon 188767.6 lb-mol per day Combustion Reactor Carbon – Carbon TBD Che 397 - Team Bravo55

56. Gasification Reactions C is a carbon containing compound Char reacts with CO 2 and steam (gasifier) C + H 2 O  CO + H 2 + 131 MJ/kmol C + CO 2  CO + 172 MJ/kmol Combustion reactor heats sand (olivine) C + ½ O 2  CO - 111 MJ/kmol CO + ½ O 2  CO 2 - 238 MJ/kmol H 2 + ½ O 2  H 2 O - 242 MJ/kmol Che 397 - Team Bravo56

57. Water-Gas Shift and Methane Rxns CO + H 2 O  CO 2 + H 2 - 41 MJ/kmol Slightly exothermic, in Gas-Conditioning Unit Required to achieve Syn Gas ratio of 2.05 Methane reforming of raw syngas CH 4 + H 2 O  CO + 3H 2 + 206 MJ/kmol Che 397 - Team Bravo57

58. TBE Gasification Process Che 397 - Team Bravo58

59. TBE Process Che 397 - Team Bravo Gasifier RDF Steam Gas Conditioning Reactor SynGas Tars SynGas Tars SynGas Olivine Combustion Reactor Combustion Reactor Olivine (Hot) Air Flue Gas Char, Ash & Olivine (Cool) Ash Removal 59

60. Gasifier: Material Balance Che 397 - Team Bravo RDF Steam Olivine SynGas Tars Char Olivine INtons/dayOUTtons/day C5,205.1 CO3,933.7 H681.1CO 2 4,250.5 O3,443.8CH 4 1,077.9 N125.4H2H2 546.0 S22.0C2H4C2H4 510.5 Cl11.5Char C1,114.3 H2O in RDF1,534.1Char H0.63 H2O Supplied2,853.1Char N0.22 Char S0.00026 H2OH2O2,254.9 H2SH2S23.4 HCl11.8 NH 3 152.2 Total13,876.1Total13,876.1 60

61. Gasifier: Energy Balance Che 397 - Team Bravo RDF Steam Olivine SynGas Tars Char Olivine ComponentBTU/lbmolRDF CO21,460.07 CO 2 -8,286.88 CH 4 -1,527.77 C2H4C2H4 -260.37 C2H6C2H6 - H2SH2S-14.66 NH 3 -50.52 HCl-16.47 Char- Total11,303.4 Reactions C + H 2 O  CO + H 2 + 56,376 BTU/lbmol CO + ½O 2  CO 2 -1.2 E5 BTU/lbmol 61

62. Combustion Reactor: Material Balance Che 397 - Team Bravo Air Char, Ash & Olivine (Cool) Olivine (Hot) Flue Gas Ash Removal INtons/dayOUTtons/day Char C1,114.3CO 2 4,084.4 Char H0.63H2OH2O5.63 Char N0.22NO 2 0.72 Char S0.00026SO 2 0.00052 O2O2 2,979.1O2O2 0 N2N2 9,811.1N2N2 9,814.6 Total13,905.4Total13,905.4 62

63. Combustion Reactor: Energy Balance Che 397 - Team Bravo Air Char, Ash & Olivine (Cool) Olivine (Hot) Flue Gas Ash Removal Reactions C + O 2  CO 2 -1.7 E5 BTU/lbmol Component BTU/lbmolRDF CO- CO 2 - CH 4 - C2H4C2H4 - C2H6C2H6 - H2SH2S- NH 3 - HCl- Char-11,171.50 Total-11,171.50 63

64. Gas Conditioning Reactor: Material Balance Che 397 - Team Bravo SynGas Tars SynGas Tars Olivine SynGas Olivine INtons/dayOUTtons/day CO3,933.7CO2,917.4 CO24,250.4CO25,295.1 CH41,077.9CH41,171.6 H2546.1H2519.5 C2H4510.5C2H4436.5 C2H60 180.0 H2O2,254.9H2O2,053.4 H2S23.4H2S23.4 HCl11.8HCl11.8 NH3152.2NH3152.2 Total12,760.9Total12,760.9 64

65. Gas Conditioning Reactor: Energy Balance Che 397 - Team Bravo SynGas Tars SynGas Tars Olivine SynGas Olivine Component BTU/lbmolRDF CO-451.03 CO 2 - CH 4 - C2H4C2H4 - C2H6C2H6 - H2SH2S- NH 3 - HCl- Char- Total-451.03 Water Gas Shift reaction reaches thermal equilibrium. 65

66. Gas Clean Up: Scrubber Material Balance Che 397 - Team Bravo Raw SynGas Sulfur Halogens Hazardous Materials Raw SynGas INtons/dayOUTtons/day H2SH2S23.429H2SH2S HCl11.847HCl11.847 NH 3 152.184NH 3 152.184 Total187.46Total187.46 Basically all incoming volatiles will be treated (place holder). 66

67. Gas Clean Up: Reformer Material Balance INtons/dayOUTtons/day CO2,917.4CO4,711.5 CO 2 5,295.1CO 2 7,586.9 CH 4 1,171.6CH 4 0 H2H2 519.5H2H2 1,251.9 C2H4C2H4 436.6C2H4C2H4 0 C2H6C2H6 180.0C2H6C2H6 0 H2OH2O2,053.4H2OH2O0 H 2 O Supplied 2,092.0 H 2 O Supplied 1,115.3 Total14,665.6Total14665.6 Che 397 - Team Bravo SynGas Raw SynGas Steam 67

68. Reverse Water Gas Shift: Material Balance Reactions CO 2 + H 2  CO + H 2 O +17,644 BTU/lbmol Che 397 - Team Bravo SynGas At spec. INtons/dayOUTtons/day CO4,711.5CO7,368.8 H2H2 1,251.9H2H2 1,060.7 CO 2 7,586.9CO 2 3,411.7 H2OH2O1,115.3H2OH2O2,824.3 Total14,665.6Total14,665.6 68

69. TBE: Total Energy Balance GasifierG.C.R.C.R. BTU/lbmolRDF CO21,460.07-451.03- CO 2 -8,286.88-- CH 4 -1,527.77-- C2H4C2H4 -260.37-- C2H6C2H6 --- H2SH2S-14.66-- NH 3 -50.52-- HCl-16.47-- Char---11,171.50TOTAL Total11,303.4-451.03-11,171.50-319.13 Che 397 - Team Bravo69

70. Investment Trend Che 397 - Team Bravo ~ 595 tons/hour --> ~335 millions $ 70

71. TIC RDF Processing 2011 Dollars at 5% interest Processing UnitLowerUpperAvg Non-Ferrous Material Removal -- $465,390.00 Gravity Separation $142,719.60$465,390.00$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 397 - Team Bravo Total Installed Cost of Some RDF Processing Equipment 71

72. Costs Che 397 - Team Bravo 72

73. Capital Costs Year 2008 Million $ (+/- 45%) % of Total (+/- 45%) RDF Processing $58 - $15313% - 35% Feedstock $22 - $585% - 15% Gasification, Tar Reforming, Scrubbing $36 - $989% - 23% SynGas Conditioning $90 - $23821% - 57% Steam System and Power Generation $18 - $506% - 16% Total Capital Investment$224 - $597 Million Che 397 - Team Bravo73

74. 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 74

75. Operating Costs $/operating unit Raw materials Feedstock0.00 Catalysts & Chemicals0.10 By-product credits Scrap Aluminum-0.86 Scrap Iron-0.58 Electricity sold to grid-0.17 Waste treatment or Disposal Gasifier ash0.00 MSW rejects0.00 Spent carbon0.0001 Waste water treatment0.026 Che 397 - Team Bravo75