Gasification of Solid Waste: Is this the recipe for trash to treasure? Northwest CERT Darren D. Schmidt, P.E. April 27, 2006
Waste to Energy (WTE) Technologies Incineration Gasification Pyrolysis Proven, viable option Permitting challenges Cost challanges Plasma Conversion Not proven in US High cost Waste typically segregated Not incineration Anaerobic Digestion Less proven than gasification Potential to produce liquids, fuels Scale up issues Thermal Depolymerization Proven, in Japan Westinghouse plasma corporation Higher cost than WTE, incineration Good environmental performance Relatively inexpensive Typical for processing sewage/manure Landfill gas applications Relatively proven Turkey offal plant Con Agra Foods Carthage, Missouri Produce fuels / fertilizer
Incineration 150 WTE plants 1970 1990 $10 - $40 million No new plants since 1993, decline to 98 8 suppliers 13% of all MSW in US incinerated
Plasma Conversion Hitachi Metals Ltd. Pilot to full scale development Yoshii, Japan Commissioned 1999 Pilot 24 tons/day Full scale 2002 170 tpd MSW & ASR 1.8 MW / 8 MW
What is Gasification? Air, Heat, Steam, Oxygen Fuel Thermal Conversion Gas Conditioning Product Gas Utilization Residues Charcoal Condensate Boiler/Heat/ Engine/ Generator Typical Product Gas: CO & H2 (15% - 30%) each Combustibles CH4 (2% - 10%) Diluents CO2 & N2 (over 50%) Contaminants Particulate, Organics
Biomass Gasification History Early History 1788 - Robert Gardner obtained the first patent with regard to gasification 1840 - First commercially used gasifier was built in France. 1878 - Gasifiers were successfully used with engines for power generation 1900 - First 600 hp gasifier was exhibited in Paris 1930 - Nazi Germany accelerated effort to convert existing vehicles to producer gas drive as part of plan for national security and and independence from imported oil. 1939 - About 250,000 vehicles were registered in the Sweden. Out of them, 90 % were converted to producer gas drive. Almost all of the 20,000 tractors were operated on producer gas. 40 % of the fuel used was wood and remainder charcoal 1945 After end of second world war, with plentiful gasoline and diesel available at cheap cost, gasification technology lost glory and importance
Coal Gasification Large scale, high volume production of products and power. Relatively mature commercial technology. Capital intensive, steam, & oxygen inputs. Potential future of coal fired power development due to low emissions and potential CO2 recovery.
Coal Gasification Developments (from National Energy Technology Laboratory, C. Taylor) 1842 Baltimore Electric Town Gas 1887 Lurgi Gasification Patent 1910 Coal Gasification Common in U.S. / Europe for Town Gas 1940 Gasification of Nature Gas for Hydrogen in the Chemical Industry (Ammonia) 1950 Gasification of Coal for Fischer-Tropsch (F-T) Liquids (Sasol-Sasolburg) 1960 Coal Tested as Fuel for Gas Turbines (Direct Firing) 1970 s IGCC Studies by U.S. DOE 1970 Gasification of Oil for Hydrogen in the Refining Industry 1983 Gasification of Coal to Chemicals Plant (Eastman Chemical) 1984 First Coal IGCC Demonstration (Coolwater Plant) 1990 s First Non-Recourse Project Financed Oil IGCC Projects (Italy) 1993 First Natural Gas Gasification F-T Project (Shell Bintulu) 1994 NUON/Demkolec s 253 MWe Buggenum Plant Begins Operation 1995 PSI Wabash, Indiana Coal IGCC Begins Operation (DOE CCT IV) 1996 Tampa Electric Polk Coal IGCC Begins Operation (DOE CCT III) 1997 First Oil Hydrogen/IGCC Plant Begin Operations (Shell Pernis) 1998 ELCOGAS 298 MWe Puertollano Plant 2003 WMPI IGCC Polygeneration Projected Selected (CCPI I)
Cumulative Worldwide Gasification Capacity and Growth
Recent U.S. Biomass Gasification Work DOE related projects 1990 2000, tended to focus on large scale processes; Vermont, Hawaii, Minnesota IGCC Shift to small modular program Shift to Biorefinery Many related projects 1970-1990, but few commercial successes. Primary success for thermal applications.
EERC s Approach for Power Generation
Keys to Success Economic Objectives Low Capital Simplified Operation Automation Robustness Market Driven
Downdraft Gasification Fuel Feed Combustion Zone Reduction Zone Drying Zone Pyrolysis Zone Air Inlet Product Gas Char -Ash
Other Types of Gasification Up draft Cross draft Down draft
Process Fuel Feed BX M-10 80 II DI 80 F-80 HV-80 HV-90 SF-90 PF-10 DO DO M-20 90 DO M-11 C-20 Air Inlet HX-210 DI TT 30 M-33 FE 32 32 LT 31 G-30 TT 31 M-30 30 KC 30 GV-31 GV-32 M-31 M-32 LT 30 TT 32 31 DO DO DI TT 35 VS-35 HV-40 40 CF-40 T-165 HV-60 FE TT 71 71 71 HV-50 FFP-60 HV-51 FFA-50 M-50 KC 50 60 50 70 HV-70 B-70 M-70 CT-100 TE TK 100 100 M-101 M-100 PF-10 Platform Feeder C-20 Conveyor G-30 Gasifier VS-35 Venturi Scrubber CF-40 Coarse Filter FFA-50 Fine Filter Active FFP-60 Fine Filter Passive B-70 Blower FL-80 Flare SF-90 Safety Filter CT-100 Cooling Tower FT 110, 120, 130 Flex-Microturbines A-140 Auger A-150 Auger T-160 Holding Tank T-165 Holding Tank P-170 Gasifier Pump P-180 Scrubber Pump F-190 Filter Coarse F-200 Filter Fine HX-210 Air Fin Heat Exchanger JT 130 JR 130 JQ 130 Exhaust Check Valve Gate Valve Float Valve Butterfly Valve Ball Valve FT-110, 120, 130 Turbine Air Signal to Computer AO Analog Input Analog Output 110 TT 110 XV-130 DI DO FE 120 120 Discrete Input Discrete Output II 140 DI M-140 M-150 HV-140 HV-150 Screen A-140 Instrument Letter Code First Letter Second Letter B - Burner C - Control F - Flow E - Element H - Hand I - Indicator I - Current K - Control Station J - Power Q - Totalizer K - Time R - Recorder L - Level T - Transmitter P - Pressure X - Igniter T - Temperature Screen A-150 II 150 DI TT 160 FI 170 HV-171 HV-170 Overflow / Sewer Vent T-160 FV-160 HV-160 M-170 M-180 P-170 P-180 II 170 DI II 180 DI Make up Water FI 180 HV-181 HV-180 HV-190 HV-200 HV-195 HV-191 F-190 HV-201 F-200
Experience
Waste Utilization Operational Savings - Electricity & Heat - Residue handling/disposal Lower Emissions No Boiler License Requirement Renewable Energy - Grants - RECs - Public Relations Typical 2 8 year payback Benefits