Inclined Rotary Gasifier (IRG)ROTARY GASIFICATION SYSTEM AND USE AS A RECYCLE ALTERNATIVE
FOR PLASTICS AND TIRES
INCLINED ROTARY GASIFIER (IRG) – GRANT HISTORY
• STRATEGIC ENVIRONMENTAL RESEARCH AND DEVELOPMENT PROGRAM (SERDP) • SERDP IS DOD’S ENVIRONMENTAL SCIENCE AND TECHNOLOGY PROGRAM
• PLANNED AND EXECUTED IN PARTNERSHIP WITH • DEPARTMENT OF ENERGY (DOE)
• ENVIRONMENTAL PROTECTION AGENCY (EPA)
• ESTABLISHED IN 1995
Reference: https://www.serdp-estcp.org/
• IT IS NOT a Combustion/Incineration Process • Inclined Rotary Gasifier
• Drives out inherent gases and oils out of waste • Uses heat created by chemical reactions • Waste is converts directly to
• a synthetic fuel gas (syngas) • biosynthetic crude oil
• Synthetic fuel used to fuel electrical generator • Only Air Emission is Engine Exhaust
UNDERLYING MAGIC (COMPETITIVE ADVANTAGE)
Unprocessed Waste Compression Dried <50%
Moisture passes as superheated steam
Tars & Pyrolytic Oil: Recycled and Cracked into gaseous BTEX Enriching syngas (BTU 2-5x )
Syngas fuels generator to produce electricity
Waste heat recycled to gasifier shell
Patents: US (15/305,985) Canada (2,946,729) International patent application (PCT/US2015/026854)
- Waste Pushed on a Rotating Bed (2.2k deg F) - Instantly converts to synthetic
gas (Syngas)
ADVANTAGES OF IRG TECHNOLOGY (PAGE 1 OF 2)
• Reduces Air Emissions • Biosynthetic Crude Oil • Re-gasifying oil increases the energy • Normal Air • Starts/Stops quickly • Soiled waste Ok • Recover Scrap Metals • Waste > 50% moisture content
ADVANTAGES OF IRG TECHNOLOGY (PAGE 2 OF 2)
• Safe Operation • Tumbling Action • Heterogenous Feedstock • System Power from Waste • No Mechanical Seals • No Refractory • Hydraulic Power • Accept / Provide Waste Heat • Automated – Part-Time Operator
GC/MASS SPEC ANALYSIS - ENGINE AND EXHAUST
Engine Exhaust Comparisons
Engine Feed Comparisons
Reference: GC/Mass Spec analysis performed by NYS Health Dept Wadsworth Labs
Standard Mix
+50% Plastic
+50% Food
Road Diesel
Standard Mix
+50% Plastic
+50% Food
Road Diesel
NOX EMISSIONS
• less N2 into engine • Cooler combustion
temperatures
IRG Prototype Trailer Mounted with Cleanup Equipment,Genset and Load Center
Site Ariel: IRG Prototype Site at SUNY Cobleskill
WP185127: Rotary Waste to Energy Converter for Overseas Contingency Operations Performers: • Project Lead Agency: State University NY at Cobleskill - Research Foundation • Gov’t Contributors: USMA West Point, US Army Corps of Engineers • Commercial Partners: Mainstream Engineering, Synstainable Energy Systems, LLC Technology Focus • Demonstrate a Rotary Gasification System to produce electricity using solid waste
generated at a domestic or Forward Operating Base (FOB) Demonstration Site • US Army Military Academy, West Point Demonstration Objectives • Reduce the amount of liquid fuel required for electrical power generation at the
generator by at least 50%. • Consumption of all fluids, non-hazardous ash, meeting of required federal and
state emissions requirements and military performance requirements Project Progress and Results • Original Prototype Gasifier, retrofitted with proposed modifications to address
issues, has been tested and performed beyond expectations Implementation Outlook • Proposed modifications for a continuous feed system being constructed and
tested. 10
Laboratory (CERL)
• Implement improvements over SERDP • Address cold weather issues • Auto-feed (Hopper, conveyor, opt shredder) • Fully automate
• Demonstrate safe operation by indigenous troop • Obtain Performance Data
• Feedstock type and usage • Reduced Liquid Fuel Consumption • All fluids consumed • Environmental impact / emissions
• Demonstrate portable/modular design
Container #1 – Feedstock storage, reclaim, conveyors, shredder, power distribution, motor control center, hydraulic power pack, and operator SCADA console
Container #2 - Ram feeder, rotary gasifier, quencher, blower, scrubber, polisher, and generator (all equipment hydraulically driven or 24 VDC) – all sides open for ventilation
Containers positioned in close proximity suited for rough terrain
NYS LANDFILL PROJECT (PROPOSED) • Two phases
• 100 kw System • Supplemental Electricity for the MRF
• 500 kw System • Additional fuel for Landfill Gas
Generator • Favor either of 2 products – Market Pref
• Fuel/co-fuel electrical generator • Use on site or place back on grid
• Production of synthetic crude • Sell to refinery or for use in asphalt
production
• Intent • establish the operating techniques and
procedures for the larger 500 kW unit • May or may not operate at a net profit
• Answer Unknowns associated with project: • Feedstock availability • Feedstock preparation • Ag Plastics • Permitting • Operations • Emissions • Economics
MIX PROFILE – BY % WEIGHT (DRY BASIS)
Tire Ag Soiled Waste Inert & Mix Rubber Plastics Paper/CB Wood Food Textiles Soils Total
Type Description Wt % Wt % Wt % Wt % Wt % Wt % Wt % Wt % Mix A 47% Tire / 35% Ag Plastic 47% 35% 15% 0% 0% 0% 3% 100% Mix B 20% Tire / 35% Ag Plastic 20% 35% 15% 25% 0% 2% 3% 100% Mix C 5% Tire / 35% Ag Plastic 5% 35% 20% 37% 0% 0% 3% 100% Mix D 0% Tire / 35% Ag Plastic 0% 35% 15% 25% 20% 2% 3% 100%
• Primary Requirement: Total Plastics content <= 35% by weight (avg over a 2- hour period)
• If the > 35%, the viscosity properties of the BSC oil dramatically increases, making the oil too viscous to handle.
• Four theoretical mixes (A, B, C, and D) vary the tire rubber content from 47%, 20%, 5%, and 0% by supplementing with other commonly available waste components
TEST MIXES AND PROXIMATE ANALYSIS Total Total Total Est. Total Est.
Volatiles Fixed C Ash Moisture HHV Oil Yield Type Description Wt % Wt % Wt % Wt % WB BTU/lb % Mix A 47% Tire / 35% Ag Plastic 77% 13% 10% 2.4% 12948 62% Mix B 20% Tire / 35% Ag Plastic 81% 11% 8% 10.1% 12229 50% Mix C 5% Tire / 35% Ag Plastic 84% 10% 6% 14.0% 11177 38% Mix D 0% Tire / 35% Ag Plastic 84% 10% 6% 27.1% 11288 32%
• Waste mixes target fixed carbon contents of 10% to 12% • Mixes < 10% provide insufficient heat to sustain devolatilization • Fixed carbon > 12% will - slow accumulation of a red hot fixed
carbon bed
NYS LANDFILL PROJECT – CALCULATION ASSUMPTIONS
• ELECTRICAL GENERATION • AVERAGE COST OF ELECTRICITY AT $0.14 PER KWH OF ENERGY
(DELIVERED)
• NET METERING OR OTHER UTILITY CONTRACT
• OIL PRODUCTION • RATES BASED ON 1 POUND OIL = 18,000 BTU’S OF ENERGY
• VOLUME (GAL) IS BASED ON SPECIFIC GRAVITY = 0.83
• STORED IN 210 BARREL (9240 GALLON) TRACTOR TRAILERS
• TRUCKING COSTS: 6$ PER MILE, 600 MILE ROUND TRIP
• OIL VALUE = $50 / 42 GALLON BARREL (30% < THE CURRENT MARKET)
100 kW Gasifier - Economic Analysis - Maximum Electrical Power Generation Operate 24 hours per day for 7 days per week at 90% availability = 7862 hours/yr
Value Mix A Mix B Mix C Mix D Parameter $/unit unit Value Value Value Value Tire Rubber $125 ton $26,560 $11,302 $2,826 $0 Soiled Plastics $0 ton $0 $0 $0 $0 Soiled Paper and Cardboard $93 ton $7,007 $7,007 $9,343 $6,093 Wood $35 ton $0 $5,651 $8,364 $4,914 Food Waste $93 ton $0 $0 $0 $48,747 Textiles $93 ton $0 $934 $0 $812 Inerts (soil, stones, glass, metals, etc.) $93 ton $1,802 $1,802 $1,802 $1,567 Electricity Sold to Grid $0.140 kWh $80,043 $74,685 $66,556 $56,036 Biosynthetic Crude Oil $50 BBL $0 $0 $0 $0 Trucking Costs for Biosynthetic Crude Oil -$3,600 Trip $0 $0 $0 $0 Thermal Energy $0 MBTU $0 $0 $0 $0 Total = $115,413 $101,382 $88,890 $118,169
100 kW Gasifier - Economic Analysis - Maximum Oil Production Operate 24 hours per day for 7 days per week at 90% availability = 7862 hours/yr
Value Mix A Mix B Mix C Mix D Parameter $/unit unit Value Value Value Value Tire Rubber $125 ton $26,560 $11,302 $2,826 $0 Soiled Plastics $0 ton $0 $0 $0 $0 Soiled Paper and Cardboard $93 ton $7,007 $7,007 $9,343 $6,093 Wood $35 ton $0 $5,651 $8,364 $4,914 Food Waste $93 ton $0 $0 $0 $48,747 Textiles $93 ton $0 $934 $0 $812 Inerts (soil, stones, glass, metals, etc.) $93 ton $1,802 $1,802 $1,802 $1,567 Electricity Sold to Grid $0.140 kWh $18,010 $27,436 $33,735 $31,764 Biosynthetic Crude Oil $50 BBL $47,366 $36,078 $25,060 $18,533 Trucking Costs for Biosynthetic Crude Oil -$3,600 Trip -$16,240 -$12,369 -$8,592 -$6,354 Thermal Energy $0 MBTU $0 $0 $0 $0 Total = $84,506 $77,841 $72,538 $106,077
500 kW Gasifier - Economic Analysis - Maximum Electrical Power Generation Operate 8 hours per day (peak) for 5 days per week at 90% availability = 1872 hours / yr
Value Mix A Mix B Mix C Mix D Parameter $/unit unit Value Value Value Value Tire Rubber $125 ton $41,792 $17,784 $4,446 $0 Soiled Plastics $0 ton $0 $0 $0 $0 Soiled Paper and Cardboard $93 ton $11,026 $11,026 $14,701 $9,285 Wood $35 ton $0 $8,892 $13,160 $7,488 Food Waste $93 ton $0 $0 $0 $74,281 Textiles $93 ton $0 $1,470 $0 $1,238 Inerts (soil, stones, glass, metals, etc.) $93 ton $2,835 $2,835 $2,835 $2,388 Electricity Sold to Grid $0.040 kWh $37,469 $35,389 $31,463 $25,773 Biosynthetic Crude Oil $50 BBL $0 $0 $0 $0 Thermal Energy $8 MBTU $76,026 $71,804 $65,627 $55,814 Total = $169,149 $149,200 $132,233 $176,266
500 kW Gasifier - Economic Analysis - Maximum Oil Generation Operate 8 hours per day (peak) for 5 days per week at 90% availability = 1872 hours / yr
Value Mix A Mix B Mix C Mix D Parameter $/unit unit Value Value Value Value Tire Rubber $125 ton $41,792 $17,784 $4,446 $0 Soiled Plastics $0 ton $0 $0 $0 $0 Soiled Paper and Cardboard $93 ton $11,026 $11,026 $14,701 $9,285 Wood $35 ton $0 $8,892 $13,160 $7,488 Food Waste $93 ton $0 $0 $0 $74,281 Textiles $93 ton $0 $1,470 $0 $1,238 Inerts (soil, stones, glass, metals, etc.) $93 ton $2,835 $2,835 $2,835 $2,388 Electricity Sold to Grid $0.040 kWh $10,139 $14,572 $17,003 $15,417 Biosynthetic Crude Oil $50 BBL $74,531 $56,768 $39,432 $28,241 Thermal Energy $8 MBTU $28,890 $35,902 $40,689 $37,953 Total = $169,213 $149,249 $132,267 $176,291
CONCLUSIONS
• MINIMAL EMISSIONS
• POTENTIAL INCOME FROM WASTE STREAM
CONTACT
518-255-5384 (office)
Demonstration Project for a Portable Waste to Energy Rotary Gasification System and Use as a Recycle Alternative for Plastics and Tires
Inclined Rotary Gasifier (IRG) – Grant History
What is the Process IRG Technology
Underlying Magic (Competitive Advantage)
GC/Mass Spec Analysis - Engine and Exhaust
NOX emissions
Slide Number 10
ESTCP – Proposed Container Layout
NYS Landfill Project (proposed)
Phase I – 100 kw
Test Mixes and Proximate Analysis
NYS Landfill Project – Calculation Assumptions
Slide Number 18
Slide Number 19
Slide Number 20
Slide Number 21