Activated carbon by co-pyrolysis and steam activation from particle board and melamine formaldehyde resin: techno-economic evaluation
drs. Ing. Kenny Vanreppelen (MSc)
Promoters prof. dr. Robert Carleer prof. dr. Jan Yperman dr. Sonja Schreurs
1
1. Introduction: Activated Carbon
2. Objective
3. Cost-benefit analysis
Methodology
Process design
Results
4. Conclusion
Table of content
2
Activated carbons large number of applications water treatment
chemical and pharmaceutical processing
air and gas purification
…
1.2 Mt/Year by 2012
Average growth 5.2%/year
Standard AC 2,25 – 3,30 kEUR/t (2008)
Introduction
3
Specialty AC 3,3 – 6,0 kEUR/t (2008)
Activated carbons Normal low N (~0.5%)
N key parameter for
adsorbents, catalytical activity and catalyst supports
T.J. Bandosz, Surface Chemistry of Carbon Materials, in: P. Serp, J.L. Figueiredo (Eds.), Carbon
Materials for catalysis, John Wiley & Sons Inc., New Jersey, 2009, pp. 45–92.
Introduction
4
N introduction treatment with N-reagents
Raw material
Particle board (MUF) waste
Melamine formaldehyde waste
Introduction
Waste processing company
In situ nitrogen incorporation
Gate fee
5
N: 5,9 wt%
N: 54,1 wt%
T.J. Bandosz, Surface Chemistry of Carbon Materials, in: P. Serp, J.L. Figueiredo (Eds.), Carbon
Materials for catalysis, John Wiley & Sons Inc., New Jersey, 2009, pp. 45–92.
1. Introduction: Activated Carbon
2. Objective
3. Cost-benefit analysis
Methodology
Process design
Results
4. Conclusion
Table of content
6
Investigation of the feasibility for the
production of nitrogenised activated carbon
from PB and MF waste streams.
in function of processing rate and mixing
ratio
Objective
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1. Introduction: Activated Carbon
2. Objective
3. Cost-benefit analysis
Methodology
Process design
Results
4. Conclusion
Table of content
8
Cost-benefit analysis: methodology
Proces Design
Economical Model
– Total capital investment
– Total Expenditure
– Total Revenue
Monte Carlo sensitivity analysis
– Define uncertain variables
• Simulation (10 000 runs)
Net Present Value
– Minimal selling price
– Selling price to guarantee 95 % chance positive NPV
Net Present Value
– Minimal selling price
9 Vanreppelen, K., Kuppens, T., Thewys, T., Carleer, R., Yperman, J., and Schreurs, S., Activated
carbon from co-pyrolysis of particle board and melamine (urea) formaldehyde resin: A techno-
economic evaluation Chem Eng J, Vol. 172, No. 2-3: p. 835-846, 2011
Based on a rather pessimistic scenario:
• Low average operating time (7 000 h)
• No gate fee for MF waste (now a MF factory pays
220EUR/t)
• First plant cost
Vanreppelen, K., Kuppens, T., Thewys, T., Carleer, R., Yperman, J., and Schreurs, S., Activated
carbon from co-pyrolysis of particle board and melamine (urea) formaldehyde resin: A techno-
economic evaluation Chem Eng J, Vol. 172, No. 2-3: p. 835-846, 2011
1. Introduction: Activated Carbon
2. Objective
3. Cost-benefit analysis
Methodology
Process design
Results
4. Conclusion
Table of content
10
Cost-benefit analysis: Results
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PB – MF
(5/0)
PB – MF
(4/1)
PB – MF
(3/2)
PB – MF
(2/3)
PB – MF
(1/4)
AC Yield (wt%) 22 21 19 15 11
Ultimate analysis
(%) (dry and ash free)
C 91 ± 1 85 ± 4 86 ± 2 83 ± 2 83.4 ± 0.7
N 2.24 ± 0.04 4.3 ± 0.2 7.35 ± 0.07 9.6 ± 0.3 14 ± 1
AC from PB N: 1,5 – 2 wt% 2,0 kEUR/t (Girods et al. 2009)
We expect 2,0 kEUR/t – 2,5 kEUR/t
Cost-benefit analysis: Results
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-15
-10
-5
0
5
10
15
20
25
30
1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5
NPV
(MEUR)
Price of active carbon
(kEUR/ton; feed 1 ton/h )
Ratio PB - MF (5/0)
Ratio PB - MF (4/1)
Ratio PB - MF (3/2)
Ratio PB - MF (2/3)
Ratio PB - MF (1/4)
Minimal selling price (NPV > 0)
1,6 kEUR/t 1,8 kEUR/t 2,0 kEUR/t 2,6 kEUR/t 3,9 kEUR/t
Are the obtained results valid??
only in case of 100% certainty of the base variables
some variables are uncertain by definition, others might change the NPV strongly if its value changes slightly
Monte Carlo sensitivity simulation
Cost-benefit analysis: Results
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Monte Carlo simulation
Total Capital Investment; Electricity Cost; Water Cost; Delivered feed cost; Discount
rate; Liquid nitrogen cost; Char output; AC output; Staff cost / shift;
Annual working hours facility
Triangulair distribution
Calculation of numerous NPVs (10 000 runs)
Cost-benefit analysis: Results
15
ML MIN
(-10%)
MAX
(+10%)
Chance
Cost-benefit analysis: Results
16
Minimal selling price (min 95% chance on NPV > 0)
2,0 kEUR/t 2,2 kEUR/t 2,5 kEUR/t 3,1 kEUR/t 4,5 kEUR/t
-15
-5
5
15
25
35
1 1,5 2 2,5 3 3,5 4 4,5
NPV
(MEUR)
Price of active carbon
(kEUR/ton; feed 1 ton/h)
PB - MF (5/0)
PB - MF (4/1)
PB - MF (3/2)
PB - MF (2/3)
PB - MF (1/4)
1. Introduction: Activated Carbon
2. Objective
3. Cost-benefit analysis
Methodology
Process design
Results
4. Conclusion
Table of content
17
Really encouraging results are obtained for a profitable production of nitrogenised AC !
Even as the current assumptions start from a rather pessimistic scenario
In situ incorporation of N
Ability to reuse 2 waste streams
The feasibility depends largely on the
AC yield
the product quality
Conclusion
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Future research
Activated carbon by co-pyrolysis and steam activation from particle board and melamine formaldehyde resin: techno-economic evaluation
Promoters prof. dr. Robert Carleer prof. dr. Jan Yperman dr. Sonja Schreurs
19