Beruflich Dokumente
Kultur Dokumente
by
Celerick Stephens
A Thesis Submitted to the Graduate
Faculty of Rensselaer Polytechnic Institute
in Partial Fulfillment of the
Requirements for the degrees of
MASTER OF ENGINEERING SCIENCE AND
MASTERS OF SCIENCE IN MANAGEMENT
Approved:
_________________________________________
Dr. Ernesto Gutierrez-Miravete, Thesis Advisor
Rensselaer Polytechnic Institute
Hartford, Connecticut
April 2014
CONTENTS
CONTENTS ............................................................................................................................. i
LIST OF DEFINITIONS .......................................................................................................iv
LIST OF SYMBOLS .............................................................................................................vi
LIST OF TABLES ................................................................................................................vii
LIST OF FIGURES .............................................................................................................viii
ACKNOWLEDGMENT ....................................................................................................... xi
ABSTRACT .......................................................................................................................... xii
1. Introduction ....................................................................................................................... 1
1.1
1.2
1.3
1.4
Matter reuse............................................................................................................. 7
1.5
2.2
3.2
Syngas conditioning.............................................................................................. 39
3.4
3.5
Ancillary systems.................................................................................................. 49
4.2
5. Conclusions ..................................................................................................................... 61
5.1
Viability ................................................................................................................. 61
5.2
6. References ....................................................................................................................... 63
7. Appendices ...................................................................................................................... 68
7.1
7.2
7.3
7.4
7.5
7.6
7.7
iii
LIST OF DEFINITIONS
Adsorption chemical process by which a chemical compound adheres to another
substance, allowing other compounds to pass without obstruction
Distributed power - generation of power on a where-needed and, often when-needed,
basis
Desulfidation process by which sulfur is removed from a substance (fluid)
Cathodic crucible a negative electrode shaped in a manner that allows for solid matter
to be contained within the electrode
Fuel Cell a device that coverts a fluid fuel to electricity by a chemical process which
separates hydrogen molecules, reforming it with oxygen and producing also heat
and water
Gasification - a process by which a hydrocarbon-based substance undergoes a thermochemical conversion from a solid to a gas
Globalization - the fundamental changes in the spatial and temporal contours of social
existence, according to which the significance of space or territory undergoes
shifts in the face of a no less dramatic acceleration in the temporal structure of
crucial forms of human activity (1)
Landfill(ing) - gathering wastes in aggregate and allowing generally natural processing
to decompose the matter over time (landfilling is the process thereby)
Leachate typically hazardous liquid composed primarily of water and contaminated
salts, present due to the transmission of water through waste
Middle class a segment of the population determined on the basis of an income (between $6,000 US and $30,000 US) that, on the worldwide aggregate year 2007
purchasing-power parity, provides household disposable income (2)
Municipal solid waste (MSW) Refuse or discard from a local populace that is in nature
composed of consumable, non-biologically generated matter
Organization for Economic Cooperation and Development (OECD) - an international
group of 50 generally affluent nations with the mission to promote international
and local policies to improve the socioeconomic situation of the worlds population
Plasma - a state of matter comprised of a charged fluid which is characterized by having
nearly equal concentrations of electrons and positively charged ions
iv
LIST OF SYMBOLS
In order of appearance
Q Higher heating value of refuse derived fuel, in kJ/kg
G Gibbs free energy, or the standard free energy change of a species , kJ/mol
R Ideal gas constant, in J/mol-K
T Temperature, in K
K0 Chemical equilibrium constant for the stabilized reaction
K Equilibrium constant as related by the concentrations of the compounds
H Standard enthalpy change, kJ/mol
S Standard entropy change, kJ/mol
Partial change in the quantity the preceding symbol modifies
Partial derivative
p Pressure in N/m2
cp Specific heat given constant pressure, in J/mol-K
A, B, C, D, and E Coefficients of regression, used primarily for tabular reference
Hf Standard heat of formation of a chemical compound, subscripted, in kJ/kmol
nx Coefficient of a solute in the global gasification equation, in kmol
P Power, in kW
PH Conveyor power required to progress material (load), in kW
PN Conveyor power required to drive the conveyor (rotational), in kW
PST Conveyor power required to drive the conveyor (static), in kW
IM Media mass flow rate of the conveyor, in tonnes/hr
L Conveyor length, in m
Conveyor coefficient of friction
D Conveyor diameter, in m
vi
LIST OF TABLES
Table 3-1: Proximate analysis of the typical OECD municipal solid waste stream,
showing also the typical moisture content of constituents (10). *The water weight
of the waste presented is calculated from the data presented and is not present in
the original source. ................................................................................................... 26
Table 3-2: Water-gas shift reaction as experimentally demonstrated by Byun, et al (42).
The calculated production ratio is used for hydrogen reformation in the
distributed gasification analysis presented here. .................................................... 40
Table 4-1: Average composition of synthesis gas from the multivariate plasma
gasification analysis. ................................................................................................ 57
Table 4-2: Summary of the distributed plasma arc gasification system sizing based upon
power requirements and consumption, showing positive net power production . 60
Table 7-1: The growth of the world middle class compared to the growth of the world
population: a compilation of data from the Goldman Sachs* (2) and the U.S.
Census Bureau** (53). ............................................................................................. 69
Table 7-2: Elemental contents of a typical municipal solid waste stream (26)Categories
highlighted are represented constituents of the waste stream in this analysis.
**Mixed textiles are not found in Tchobanoglous text, but is averaged here for
simplification of the waste stream analysis. ........................................................... 79
Table 7-3: Heat capacities of elements and compounds of gasification reaction model as
compiled from the Chemical Properties Handbook (22) ....................................... 97
Table 7-4: Standard Gibbs Free Energy of Molecular Compounds Presented in the
Plasma Gasification Reaction (22) .......................................................................... 97
Table 7-5: Standard Heats of formation of molecular compounds presented in the plasma
gasification reaction (22) ......................................................................................... 98
vii
LIST OF FIGURES
Figure 1-1: Growth of the worldwide middle class from 1960 to 2010, with projections
to 2030. The total world middle class population is read on the left axis, while
the percentage is read to the right. Sources: US Census Beaureau (3), Wilson (2).
..................................................................................................................................... 3
Figure 1-2: Worldwide middle class electrical energy consumption, with data from 1960
to 2008 and projections to 2030. Compilation of sources: Goldman Sachs (2),
U.S. EIA (4), The World Bank (6) ............................................................................ 4
Figure 1-3: Worldwide middle class waste generation per year showing, with a
conservative projection that refuse generation rates are constant that more than
2.0 billion metric tons [2.2 billion tons US] of waste may be generated by the
middle class people of the world. The methodology and rationale for this
projection is detailed in Appendix 7.1. ..................................................................... 5
Figure 1-4: Waste stream processing showing the reduction of landfill waste from the
point of generation. Source: U.S. EPA (7)............................................................... 6
Figure 3-1: Plasma gasification process showing waste consumption and power
production cycle. The waste is first community generated, and proceeds through
a recycling stream prior to being converted into a refuse derived fuel. The RDF
is then converted to heat and waste gas in the plasma gasifier. The waste gas is
finally converted into electrical energy to sustain the plasma process and
supplement power for the community. In this figure are symbols describing the
constituents of the waste stream and waste gas that will be discussed in detail in
Sections 3.2 and 3.3.................................................................................................. 16
Figure 3-2: The waste stream constituents of waste generated in the United States in
2006 as determined from Chang (25). The category listed as 3% is other wastes
that are undetermined in Changs analysis. ............................................................ 23
Figure 3-3: Trends in the constituents of the municipal solid waste stream of the United
States from 1960 to 2006 as given by Chang (25), but simplified as shown more
directly in Figure 3-4................................................................................................ 24
Figure 3-4: Waste Stream Breakdown of the United States in 2006 as simplified from
Chang (25). Organics contains food and yard wastes. The category Textiles
includes rubber.......................................................................................................... 25
viii
Figure 3-5: Hydrogen reformation process from syngas, showing the system inputs to
providing for the water-gas shift reactions and the pressure-swing adsorption
system........................................................................................................................ 42
Figure 3-6: Plasma arc gasification system as concepted for small scale gasification. The
process runs only until the RDF is completely consumed, allowing for small
amounts of waste to be processed discontiguously and efficiently....................... 44
Figure 3-7: Block diagram detailing the concept of mass -based waste induction for the
distributed gasification of municipal solid waste. .................................................. 47
Figure 3-8: Grid-based electrical power storage technologies depicted by discharge
potential relative to system capacity. This information is presented from the
United States Department of Energy Sandia National Laboratories (48). ............ 48
Figure 4-1: Trends of electrical consumption (left) and hydrogen production (right) for
varying molar air ratios ............................................................................................ 51
Figure 4-2: The trend of electrical consumption (normalized) and hydrogen production
(inverted) to show optimum molar air ratio for a given waste stream. ................. 52
Figure 4-3: Hydrogen content of the syngas from the plasma gasification furnace as
related to the gasification temperature for a large sample of randomly diverted
waste stream constituents......................................................................................... 54
Figure 4-4: Plasma arc power requirements as a function of gasification temperature for
a large sample of randomly diverted waste stream constituents ........................... 55
Figure 4-5: Trends of the concentration of various waste stream constituents on
hydrogen gas production for a large sample of randomly diverted waste stream
constituents ............................................................................................................... 56
Figure 4-6: The waste generation rate and the plasma arc power requirements to yield
2.6 grams/second of hydrogen in the resulting syngas when three unique waste
streams are subjected to plasma gasification.......................................................... 58
Figure 4-7: Feed rate versus power consumption (upper diagram) and hydrogen
generation rate following gasification cycle and water gas shift (lower diagram)
showing the linear relationship among the three paramaters. The waste stream
has a contamination content of glass and metals due to imperfect separation. The
hydrogen flow rate is that leaving the syngas reforming system. ......................... 59
ix
Figure 7-1: Excerpt from Goldman Sachs report on the expanding middle clas s showing
a pareto of the per capita income in 2007 and comparing it to the world
projection in 2050. The chart on the right shows a swell of middle class income,
particularly in the nations known as the BRICs.................................................... 69
Figure 7-2: World population growth showing the growth of the middle class. Data
sources: Goldman Sachs* (2)and the United States Census Bureau** (53)......... 70
Figure 7-3: World electrical energy consumption on the basis of the world population.
This chart shows correlation to Figure 6.2, where the increase in the world wide
middle class correlates to the growth of the world projections of energy
consumption.............................................................................................................. 71
Figure 7-4: The projected world electricity consumption against the projected middle
class population growth showing close linear correlation between the global
middle class and power consumption...................................................................... 71
Figure 7-5: IPCC unrecycled waste generation data showing minimum annual rates of
carbon storage in landfills from 1971 to 2002. (8) Units of the ordinate axis are
teragrams (Tg) of carbon.......................................................................................... 73
Figure 7-6: PCC graphical representation of post-consumer waste generation between
1971 and 2002 (8). The units of the scales are in teragrams [Tg] ......................... 74
Figure 7-7: OECD waste generation in kg/capita/year for the period between 1980 and
2005. As all OECD countries are represented in the legend, only several are
listed. (9) ................................................................................................................... 75
Figure 7-8: U.S. EPA data showing municipal solid waste generation of the United
States between 1960 and 2008 (in million tons). (12)............................................ 76
Figure 7-9: U.S. EPA data showing municipal solid waste recycling (in million tons).
(12) ............................................................................................................................ 76
Figure 7-10: United States waste generation as determined independently by the United
States EPA (11)and the OECD (9). ......................................................................... 77
Figure 7-11: Waste generation as a function of the population of the world wide middle
class. This figure is analytically generated based upon data and p rojections from
the U.S. EPA (12), the OECD (9), and Goldman Sachs (2).See also Figure 1-3. 78
ACKNOWLEDGMENT
It is appropriate that the day of my final adjustments to this paper is on Easter Sunday. It is termed resurrection Sunday by many disciples of Christ. I look forward to the
completion of this study, and the completion of my degree, to be a resurrection of my
professional career. To Jesus Christ, my savior and Lord, and my Father God who sent
him and the Holy Spirit who dwells in me, I give all praise.
My wife Kimberly, whom I love dearly, has encouraged me more than significantly
in this endeavor. Her patience, understanding, attention, and love towards me are
unmatched in this world. I am ecstatic to have her as my wife.
To Dr. Antonios Mountouris, who provided me the details of the model which is the
backbone of this thesis, I give great gratitude.
I also thank Dr. Ernesto Gutierrez-Miravete, who has undoubtedly poured hours into
critically reviewing my work. He has been an excellent professor, coach, and mentor in
the completion of my Masters degrees. I feel that what he exuded as his personal
responsibility towards my degree completion inspired me to put in my best effort and not
let him down.
xi
ABSTRACT
The growth of a worldwide middle class and the electrification of mobility are factors stressing the current standards in electrical power generation. In developed
countries, electrical power is produced in mass at central locations and delivered over
large distances to communities. Growing electrical demand, coupled with inherent grid
losses, will ultimately require additional points of generation, further promoting the
consumption of valuable resources in power plant construction and operation.
Further, as middle-class communities continue to grow, the amount of waste generated also increases, promoting the problems associated with waste disposal. The
proliferation of inexpensive consumer electronics also ensures that a significant percentage of the generated waste stream becomes inorganic and biologically harmful, and the
innocuous disposal and treatment of post-consumer waste is a growing concern.
The research presented in this thesis addresses both of these concerns by investigating a means of converting waste into energy. Though waste-to-energy conversion is a
mundane technology, the peculiar benefit being proposed by this work is that energy
may be produced by the reduction of the waste stream on a local basis to advance
sustainable communities. The research and analysis presented develops a case for using
plasma gasification of municipal solid wastea clean method of converting waste into
useful synthesis gasto generate distributed power for individual communities. The
analysis conducted uses the principles of thermodynamic and economic systems analysis
to determine the benefit and feasibility of a distributed power plasma arc municipal solid
waste gasification system.
This thesis incorporates developed and vetted chemical modeling to simulate the
gasification of waste using plasma and sizes a scaled system that is capable of decrea sing electrical demand of a small community, while eliminating and neutralizing waste.
The results show that a community of fewer than 300 homes can fully support the
gasification process while producing enough power to offset the electrical demand of 10
homes. The distributed production of energy on a community basis is feasible, and it
could significantly and simultaneously reduce electrical delivery losses and waste
equating to an overall net energy savings.
xii
1. Introduction
Sustainability is an area of research targeted at reducing the ecological impact of
processes by reducing consumption and producing valuable inputs to itself or other
processes. The concept is made ever more important due to the growth the world
population and the finite resources by which to support it. However there is a global
phenomenon outstripping the resource pressures caused by population growth: it is the
growth of the worldwide middle class . The worldwide middle class currently is a
minority, but a person of this minority group consumes resources and produces wastes
many times that of the average person of the worlds population. Globalization 1 is a
factor supporting that growth. Globalization allows for larger pool of human resources
that can provide goods and services to distant regions conveniently (with little loss in
time) and, due to economic disparity in the costs of those rendered goods and services,
attractively on a global scale. In turn, the compensation for those rendered goods and
services provide for previously impoverished people to afford not only wealth to meet
their needs, but also wealth to satisfy their desires. Also, as the definition of globalization implies, this growing middle class is technologically driven; meaning that a greater
and growing percentage of the population enjoys the benefits of technology, especially
electrification. This places upon the established methodologies of energy delivery and
production stresses previously unmatched. Scientists and engineers are attacking the
issue by pursuing renewable power generation, giving life to new technologies in solar,
wind, biofuel, and tidal energy technologies. Conservationists are also pushing for more
efficient means of utilizing energy by pursuing advances that reduce power consumption, while preserving the comforts that electrical consumption afford.
A major sector of the environmental movement that has the potential to significantly
influence both energy production and energy (and resource) conservation is not as
1
It is this definition offered by Scheuerman (1) that demonstrates globalization and the
significance it has upon the world middle class population growth. This definition
highlights that the globalization is directly fueled by technology, which decreases the
significance of distance by decreasing the time by which physical and/or intellectual
goods or services subtend that distance.
1
popularly discussed: waste generation. Along with the growth of the world middle class
is an increase in world resource consumption. The waste generated by this increased
consumption middle class is also increasing: the space in which to dispose of the waste
is not. The generated waste must be disposed of, and that process requires the expend iture of energythe waste is generally transported to a destination and repeatedly
agitated or treated to accelerate its decomposition, as evidenced in landfilling operations.
Reductions in the energy required to dispose of waste is conventionally realized through
recycling, but this constitutes a fraction of the overall waste stream. The remainder (the
majority) of the waste is deposited in a landfill, with a small percentage used to generate
heating and electrical power. Because of environmental concerns however, waste-toenergy conversion is used primarily where land is a constraint.
The global middle class is also stressing the systems that deliver electrical power.
Even with the most advanced utility systems, significant losses are incurred in the
transmission of electrical power from the point of generation to the point of use. This
loss of electrical power through resistance and power transformation is compounded
with the distance over which that electrical power must travel. Again, referring to
Scheuermans definition of globalization, it is easy to see that the speed at which tec hnology enables the flow of ideas and materials effectively promotes the dispersal of
people, because the time-based perception of distance is decreased. The points of
electrical consumption are thus more widely distributed. The energy lost in transmission
is thus increased.
This thesis addresses waste disposal and its associated resource consumption, electrical power generation, and electrical power transmission with one unifying technology.
The unifying technology utilizes the process of plasma gasification to convert municipal
solid waste into energy. This technology is ecologically responsible in that it reduces
concentrations of both immediately hazardous and potentially hazardous waste products,
and is also sustainable as it requires a renewable resource, waste, as its fuel. The
purpose of this work is to explore plasma conversion technology as a means of reducing
the human waste stream and producing distributed electrical power to promote sustainable communities in an ecologically benign manner.
2
Figure 1-1: Growth of the worldwide middle class from 1960 to 2010, with projections to 2030. The
total world middle class population is read on the left axis, while the percentage is read to the right.
Sources: US Census Beaureau (3), Wilson (2).
people in the year 2030 consuming electrical power at levels in excess of projected
capacity 3 (4) (as shown in Figure 1-2). Such an electrification growth rate is nearly the
Middle class percentage statistics are compiled from worldwide population statistics
from the United States Census Bureau (3) and the Goldman Sachs Economics Research
Group (2), respectively
3
This analysis was conducted based upon worldwide energy consumption data (6)
(4)and the projections of the middle class growth rate (2).
3
quintupling, in less than twenty years, the current electrical power generation rate of the
United States (5).
Figure 1-2: Worldwide middle class electrical energy consumption, with data from 1960 to 2008 and
projections to 2030. Compilation of sources: Goldman Sachs (2), U.S. EIA (4), The World Bank (6)
The growth of the worldwide middle class also influences waste production. In
2007, Americans alone produced 230 million metric tons [254 million tons US] of trash
at a rate of about 2.0 kg [4.5 lbs] per individual per day (7). The effect of this is noted
by research by the Intergovernmental Panel on Climate Change (IPCC) which directly
relates the rate of municipal solid waste generation to prosperity and population (8).
Assuming that the growing worldwide middle class may be represented by the consortium of primarily majority middle class nations known as the Organization for Economic
Cooperation and Development (OECD), the worlds middle class may generate municipal waste at a rate of 1.5 kg [3.4 lbs] per day (9). Though this waste generation rate is
substantially lower than that of the United States, projecting this over the growth of the
worlds middle class indicates that 2.0 billion metric tons [2.2 billion tons US] of refuse
may be discarded per annum in the year 2030, as shown in Figure 1-3. The amount of
4
waste generated in one year in 2030, based upon this potentially conservative projection,
would be enough to bury New York City in nearly 6 meters [20 feet] of trash 4.
Governmentally imposed regulation, and a shift in awareness in OECD countries ,
has led to the significant reduction in disposed waste because of waste source reduction,
recycling efforts, and conventional waste to energyincinerationtechnologies. Still
by the process described in Figure 1-4, 54% of the waste generated in the predominantly
Figure 1-3: Worldwide middle class waste generation per year showing, with a conservative projection that refuse generation rates are constant that more than 2.0 billion metric tons [2.2 billion tons
US] of waste may be generated by the middle class people of the world. The methodology and
rationale for this projection is detailed in Appendix 7.1.
middle class OECD nations is deposited in open waste decomposition sites called
landfills (7). These decaying landfills cause further environmental damage due to the
release of carbon dioxide, methane, and ground water pollution. Because of the dangers
of open waste decomposition, many nations have implemented regulations to allow for
sanitary landfills only. In these designed areas of open waste decomposition, hazardous
materials emission is limited by the implementation of hyd rological and geological
technology (10).
Figure 1-4: Waste stream processing showing the reduction of landfill waste from the point o f
generation. Source: U.S. EPA (7)
The emissions from landfills (both toxic and environmental) are significant. However, the process of disposing waste in a landfill is arguably more damaging. Municipal
waste vehicles travel to more than 79 million American homes, a 40,200 km [25,000mile] journey each year for the average was te collection vehicle. With 136,000 waste
collection vehicles in operation in the United States alone, the consumption on a fuel
basis exceeds 4.5 billion liters [1.2 billion gallons] of fuel each year (11)5.
The solution for ensuring sufficient resources exist to support the world demands is
multifaceted. Conservation, recycling, and the use of renewable resources for power
generation (wind, solar, and wave energy) are all important improvements in our energy
dependent society, but recycling is the predominate technology assisting in waste
reduction. The definition of sustainability should be augmented to not only address
power consumption and conservation but also waste generation and waste reduction.
Establishing waste and energy sustainable communities could significantly reduce
harmful emissions and improve resource conservation.
Municipal waste collection vehicles consume on average one liter of fuel for every 1.3
km [one gallon of fuel for every 3 miles] traveled due to the repetitive acceleration cycle
on waste collection routes (21)
6
In 2005, the average American single family detached home consumes electricity at the
rate of 13,162 kW-hrs. (4).
7
ism, however, more byproduct is produced than what is readily recyclable by natural
means. Because of this disproportionate cycle, humans are faced with the interesting
quandary of how to dispose of waste.
Though recycling and waste to energy methods have been used to reduce the waste
footprint of the developed world, the dominant means of waste disposal is landfilling.
Simply, the process of landfilling gathers wastes in aggregate and allows generally
natural processing to decompose the matter over time. Landfills in actuality are much
more complicated, and require a significant energy input. Firstly, the landfill must be
created. With environmental regulations to control the flow rate of biologically damaging leachates from landfills, wastes can no longer be openly discarded. Instead, landfills
are ecologically and geologically designed and constructed in a process known as
sanitary landfilling. Once the landfill is operational, the waste must be collected from
the points of generation and delivered to the site of disposal. To speed the process of
decomposition, increasing the useful life of the landfill, waste agitation is put into effect.
This process of using earthmovers to churn the wastes periodically results in yet more
fuel consumption. Upon attaining the limit capacity of a sanitary landfill, the landfill is
capped, a process by which organic materials (soils, grasses, other forms of vegetation,
and man-made inorganic materials) are placed on top of the landfill to render the site less
harmful.
Recycling in its various forms has a lower ecological impact and because of this fact
has been promoted worldwide. Today, up to thirty-three percent of the wastes that
would be bound for a sanitary landfill are recovered or immediately reused as otherwise
useful materials (11). Typically for the products that are in high demand, the reclamation of these materials is even more economical and environmentally friendly than
extracting the materials from the earth. Increased emphasis is being placed upon composting as well. In composting, organic materials are combined in such a way that the
natural decomposition of the materials is relatively fast. The byproducts are also nutrient rich, allowing for an environmentally friendly soil generation method. Though
recycling and composting currently make up a significant percentage of the recoverable
waste, vigilance and education are still required to ensure that the appropriate materials
are placed in the recycling and composting waste streams.
8
2.1.1 Plasma
The generally accepted scientific definition of plasma is a charged fluid, which is
characterized by having nearly equal concentrations of electrons and positively charged
ions. The physical characteristics of this matter is generally complex and not readily
described by the solid, liquid, or gaseous states of matterplasmas have also been
termed the fourth state of matter for this reason. Although the discovery of plasma is
recent, it is considered the most abundant state of matter in the universe, as it is the very
material composing our sun and countless other stars and celestial bodies in the universe.
On earth, we typically see plasma in the mundane forms of lightning and open flames,
and confined within fluorescent bulbs.
High-temperature plasmas that are formed by gases in electric arcs have also found
industrial uses. By passing high velocity gases in a highly charged electric arc, streams
of high-energy electrons and ions emit intense amounts of heat at temperatures exceeding 6,300 K [11,000F] (14). Devices that perform this function are plasma torches, and
at the exit conditions of a plasma torch, materials undergo rapid pyrolysis in the case of
organic materials or, in the case of inorganic materials, rapid melting , vaporization, and
10
even decomposition. It is this useful function of high temperature plasma that is the
basis of the technology described in this body of work.
2.1.2 Gasification
The other side of the technology presented is gasification. Gasification is a process
by which a hydrocarbon-based substance undergoes a thermochemical conversion from
a solid to a gas. This conversion allows for energy in a typically solid form to be tran sformed into a more useful form (either for transport, energy density, or utility).
Described as an ancient art by Higman and Van der Burgt due to its roo ts in woodfueled fires (15), the gasification typically described in engineering processes employs
pyrolysis, the heated and near-anaerobic conversion of a hydrocarbon to a useful,
combustible gas. The more modern development of gasification was employed in the
early 1800s as a means of turning coal into a form of gas. This town gas was widely
distributed for various uses ranging from industrial power and heat generation, to public
and private lighting, heating and cooking, in much the same way that natu ral gas is
currently delivered and utilized.
Because of the town gas origins of gasification and because of the widespread availability of the fuel source, coal gasification continues to be the most widespread
application of the technology. However, the quest for clean and renewable sources of
fuel spurred along with the discovery of liquid fuel processing using the Fischer-Tropsch
method of converting gas into liquid fuel (easing its transport and increasing its energydensity) has led to the gasification processing of other hydrocarbon feed stocks such as
biomass, including human wastes.
torches to gasify refuse) has recently made the transition from the laboratory and controlled environments to industry implementation. The former and the latter reveal that
plasma thermal processing of human refuse is sufficient for the gasification of waste into
a useful, energy rich gas (synthesis gas) with about one-half the heating value of methane.
The combination of plasma and gasification differs significantly from waste incineration. Incineration processes are low-temperature thermal processes. Though the flue
gases generated by combustion often have sufficient free carbon (soot), hydrocarbons,
and carbon oxides (particularly carbon monoxide) to be combustible, the main product
of interest from incineration is heat. It is the heat from the combustion process that
provides steam to generate electrical power through steam turbine generators and
process or municipal heating. Further, incineration is typically an environmentally toxic
process. As wastes are destroyed at low temperature and in typically atmospheric
conditions, fly-ash, containing harmful substances, often escapes the process due to their
buoyancy and difficulty of processing. Further, the low-temperature recombination of
products of partial combustion results in the production of polychlorinated dibenzo-pdioxins, human carcinogens (16), and colloquially termed dioxins. To limit the production of toxic byproducts, incineration facilities employ extensive waste filtering and
recycling to remove potentially toxic products from the incoming waste stream and
extensive environmental monitoring and flue gas and ash processing to remove harmful
impurities from the exhaust.
Conversely, plasma gasification is regarded in industry as a clean process for the
thermal conversion of waste to fuel. Because of the extremely high temperatures
involved and the oxygen starved environment under which the process takes place,
municipal solid wastes can be nearly instantly converted into a combustible and useful
fuel with significantly fewer potentially harmful agents being generated (17). Further,
conventional gas scrubbing technology may be used to process clean the synthesis gas
while reprocessing the syngas contaminants through the plasma gasifier. The resulting
synthesis gas with a heating value about half that of natural gas is immediately useful for
the clean production of steam for steam power generation, directly in a Brayton cycle, or
as a fuel source in a fuel cell. There is only one other form of waste product from
12
plasma gasification. The inorganic materials, which would generally become fly ash in
an incineration process, become molten materials due to the high process temperature.
These molten materials are vitrified, encapsulating even potentially harmful substances
in an inert silica or alumina glass, while other hazardous materials at these process
temperatures form harmless oxides, which are also vitrified (18). This innocuous glasslike material is useful in construction materials, without any subsequent treatment.
The use of plasma gasification presented here may be considered of three purposes.
The primary area of focus is sustainable power production. The secondary focus also
builds upon the premises of the first, the elimination of waste at the source of the waste.
Finally, by generating the power at the place of necessity, significant reductions in
power transmission can be realized, and by consuming waste locally to generate power
locally, significant reductions in waste energy expenditures are also attainable.
14
Figure 3-1: Plasma gasification process showing waste consumption and power production
cycle. The waste is first community generated, and proceeds through a recycling stream prior
to being converted into a refuse derived fuel. The RDF is then converted to heat and waste gas
in the plasma gasifier. The waste gas is finally converted into electrical energy to sustain the
plasma process and supplement power for the community. In this figure are symbols describing the constituents of the waste stream and waste gas that will be discussed in detail in
Sections 3.2 and 3.3
The refuse-derived fuel is then passed into the plasma convertor. In the plasma
convertor, the waste fuel is thermally converted at extremely high temperatures resulting
in a gas which, when controlled in its cooling, produces a combustible fuel. Another
byproduct of the plasma converter is a molten slag which is process cooled in a controlled manner to ensure vitrification, the result of which is an inert solid that needs no
further processing. Finally, due to the heat input into the waste stream by the plasma
torch and the energy rejection from the synthesis gas and vitrification processes, a
significant amount of residual heat is generated. This byproduct can be fluid transferred
16
for use in waste conditioning (reducing moisture content) and community heating (for
heated water, process heat, or for air-conditioned living spaces). It is the primary
byproduct, synthesis gas, which is of significant interest as it becomes the main source
of energy for the plasma process.
The synthesis gas, or syngas, can be combusted or directed to a fuel cell (as is done
in this analysis) for the generation of electrical power. The electrical power created from
the syngas is at least sufficient for creating the plasma arc, but it is also possible that
enough syngas is produced to power the equipment used to create the RDF and treat the
syngas while providing supplemental power for the community. In this way, not only is
the ultimate amount of refuse reduced, but power is also generated to realize the benefits
of waste reduction and distributed power production.
The calculations are based upon the American average fuel economy of 0.14 L/km
[17.2 mpg] and the American average yearly commuter vehicle mileage of 19,000 km
[11,900 miles]. (58)
17
the United States were converted to natural gas, the savings could amount to an oil usage
reduction of 14.3 million barrels of oil each year (21).
Regardless of the potential savings in reducing the oil consumption of refuse veh icles, the collection and transportation of waste perpetuates the waste of resources for the
sole purpose of disposing of waste. Another solution to the problem is to diminish the
need for the collection and transportation of waste. By consuming the waste locally, at
or very near the point of generation, significant reductions in overall fuel consumption
may be realized. For a typical waste stream in the United States, more than 58% of the
waste by mass9 is plastic, paper, and organic non-food wastes (wood, leather, textiles,
and rubber). Local plasma gasification could remove these wastes from the waste
stream, resulting in a highly recyclable mix of glass and metals. Accordingly, the energy
consumption associated with waste transportation and collection of the remainder of the
waste stream is more than halved. This opportunity is addressed in the distributed power
aspect of plasma waste gasification explored in this research, as most of the waste
generated could be locally consumed in a small, local plasma gasification facility.
A mass basis is considered due to the assumption that compaction reduces the volume
of trash collected.
10
Source reduction as it pertains to waste-to-energy methods such as plasma gasification
is addressed in the Appendix in Section 7.6.
18
This research shows that a tailored waste stream creates a more energy rich synth esis gas. Elementarily, one can come to this conclusion by considering the constituents of
a gas with a high recoverable energy. On the basis of the higher heating value of a fuel,
hydrogen is the most energy rich, with a heating value of 142,000 kJ/kg [61,100 BTU/lb]
(22). A more abundant natural gas, methane, is a hydrocarbon with a chemical compos ition of CH4 and has a heating value of 55,600 [23,900BTU/lb] (22). When organically
derived components of the waste stream are subjected to plasma conversion the result is
the generation of hydrogen and low heating value hydrocarbon gases, while the inorganic portions of the waste stream only debits the net energy generation of the process. In
fact, the most energy productive plasma waste processing would completely recycle out
all metals and non-organic wastes in favor of dry hydrocarbonssuch as paper, plastics,
rubber, textiles, and wood. It should be noted in the previous statement that dry hydrocarbons are preferred: the process of converting water into its gaseous form in plasma
gasification only consumes energy with no significant benefitwater effectively only
changes its form without releasing valuable byproducts by the plasma process. For th is
reason wet organic wastes such as food wastes only subtract from the net valuable
energy of plasma gasification of waste. Since one of the goals of plasma gasification is
the production of the highest energy synthesis gas for the production of electricity,
recycling on a plasma waste conversion basis simplifies the waste stream into the simple
categories of food waste, metals , glass, and everything else.
It is this simplification of the recyclable waste stream that continues to promote
plasma gasification. To reduce the costs of recycling collection, and to promote recycling collection from the private and corporate sectors, many municipalities have
transitioned to single-stream recycling. In single-stream recycling, all post-consumer
content is aggregated at the time of collection. The public remains uneducated about
what is acceptable as recyclable materials, and this method has resulted in more contaminated recycling streams, as inappropriately separated materials degrade the quality of
recycled input leading to material losses. For example, in multi-stream recycling there is
no differentiation in paper products, so all articles from copier paper to milk cartons are
bundled together at the single-stream recycling centers (or material recovery facilities)
and then sold to pulp and paper mills. Though this is in theory beneficial, large amounts
19
Plastics recycling initiatives result in significant wastes due to contamination. Because the public remains unaware of the necessity to empty thoroughly the plastic
containers to be recycled, quantities of food wastes, oils, cleaning fluids and medications
pollute the potentially recyclable plastics stream.
12
Source reduction is an important consideration in waste management and is discussed
in the Appendix Section 7.6.
20
the container and the residual contents while vitrifying constituents that do not gasify. It
is possible that paper and plastic wastes with high moisture contents (as in a con tainer of
water being introduced in the plasma convertor) increase the energy required for gasification, but the only consequence in such a scenario is the net loss in power; no waste is
created. In fact, due to the ultimate compounds present, more useful hydrogen gas may
be produced. This also holds true for other recycling and non-recycling content that may
be introduced into the waste stream.
Metals and glass13, are considered undesirable as the power for melting and vaporization during the plasma gasification process produces no useful synthesis gas. Multistream recycling in this scenario is then reduced to two streams of low contamination
rates (or conversely high recovery rates). All other forms of waste provide for the
creation of a useful syngas of moderate heating value in the plasma gasification reaction.
The robust nature of this recycling scheme precludes public education and accidental
recycling stream contamination, and for this reason plasma waste conversion of post consumer waste products may be viewed as enhanced recyclinga recycling method
that generates the ultimate starting state of the matter being consumed: energy. For its
benefits to recycling, plasma gasification of waste might be considered plasma enhanced
recycling.
tion in the formation of carbon, soot or char. The analysis of this process is of prime
importance in the plasma gasification of waste because it generates the synthesis gas that
makes this process ecologically and economically feasible.
The plasma furnace (also referred to as the plasma convertor, as it changes waste into useful byproducts) is the fundamental component in the high-temperature pyrolysis of
the waste stream. The process for determining the value of the plasma gasification
process is based upon a chemical ultimate analysis. The products of the ultimate analysis
are the gases that are used to then generate electrical power, which is in turn used to
power the plasma gasification system. The residual electrical power is then used to
supplement the power requirements of the community. The residual heat from the
plasma torch may be used to dry the input waste (reducing the moisture content and
increasing the net energy output) and can be used for hot water production for process or
community usage.
Section 7.1.3 details waste and recycling statistics used in the determination of the
waste and recycling habits of the worldwide middle class.
22
piece of the waste stream (due in large part to products, packaging, and electronics).
Paper has recently remained unchanged or is on a slight decline as a percentage of the
overall waste stream. The importance of this trend is that plastics and paper provide the
highest calorific benefit in the plasma conversion of waste. As a part of the optimization, it may also be determined that the presence of plastics provides for the higher
production of synthesis gas.
A simplification from Changs work is made in the use of the data presented , noted
in Figure 3-4. As, textiles and rubber and leather are of similar percentages, and noting
that the presence of metals, rubber, plastics, and inorganics are also present in todays
Figure 3-2: The waste stream constituents of waste generated in the United States in 2006 as
determined from Chang (25). The category listed as 3% is other wastes that are undetermined in
Changs analysis.
textiles, these categories are combined into a single category, textiles, in this analysis.
Similarly, due to the likeness of food wastes and yard wastes, these two waste streams
are combined into a single category termed organics. Thought was given towards
combining other similar categories (wood and paper in particular) but this was not done
due to the significant chemical differences that may exist due to the methods of production treatment and processing for wood wastes (e.g. paints and stains, waxes, and
plastics).
23
Figure 3-3: Trends in the constituents of the municipal solid waste stream of the United States from
1960 to 2006 as given by Chang (25), but simplified as shown more directly in Figure 3-4
Obviously missing from the constituent analysis (or proximate analysis) of the
waste stream is the presence of water. This is accounted for in the typical content of
moisture inherent in the constituents, as helped by the relationship developed by
Tchobanoglous (26) and summarized in Table 3-1. The content of moisture will be
important not only for accounting for the water present in the waste stream, but also for
determining the amount of drying that may help optimize the production of synthesis gas
and in the raising of the temperature of the plasma reaction. The basis for determining
water used in this analysis is simply the product of the constituent mass and the typical
moisture content. Research presented consistently implies that this method is an underestimate of the moisture content of the waste stream. It must be noted that in this
analysis, the presence of externally provided water in the waste stream (from the colle ction of rainwater and waste water) is expected to be minimized, as the waste will be
locally generated and disposed. Water that enters the waste stream from large scale
collection methods can therefore be discounted. As such, the starting input moisture of
the waste stream is nearly 20%, as opposed to the 28% 35% moisture content docu24
Figure 3-4: Waste Stream Breakdown of the United States in 2006 as simplified from Chang (25).
Organics contains food and yard wastes. The category Textiles includes rubber.
mented in the prevailing research. Further, the conditioning of the waste stream (prima rily in the composting or other disposal of organic wastes) will drop the moisture content
of the waste stream to approximately 7%.
This reduction of the moisture content of the waste stream at the point of generation
is a very significant point: the presence of water increases the input energy required to
maintain a given pyrolitic temperature. More energy may be required for electrical torch
operation and waste stream drying. There is a balance involved, however. Water is
required to aid in the formation of hydrogen, methane, and other low-energy gases that
comprise the syngas, which will ultimately be providing electrical power fo r the gasification reaction and for supplemental power generation. This study will determine this
balance.
25
Table 3-1: Proximate analysis of the typical OECD municipal solid waste stream, showing also the
typical moisture content of constituents (10). *The water weight of the waste presented is calculated
from the data presented and is not present in the original source.
Weight
Generated
Material
Paper & Paperboard
Glass
Metals
Plastics
Rubber & Leather
Textiles
Wood
Other Organic Wastes
Other Inorganic
Wastes
77.42
12.15
20.85
30.05
7.41
12.37
16.39
64.69
Percentage
Generation
31%
5%
8%
12%
3%
5%
7%
26%
Typical
Moisture
Content
6%
2%
0%
2%
15%
6%
35%
60%
8.28
3%
0%
(Millions of
Tons)
Water
Weight
of
Waste *
(Millions
of Tons)
4.65
0.24
0
0.60
1.11
0.74
5.74
38.81
0
Finally, because the optimization of power generation from the waste stream is d ependent upon the energy of the input fuel, we need a means of relating the contents of
the waste to the chemical constituents of the waste stream. A chemical elemental
analysis (ultimate analysis) of the waste stream generates this data. As it is beyond the
scope of this research to perform the ultimate analysis in a laboratory environment, again
the research documented by Tchobanoglous for the dry basis of elemental content of
items in the waste stream is used and compared with the works of Boie. Explanation of
this method is further developed in Section 3.2.2. Useful in this analysis is the
Tchobanoglous (26) break down on an elemental basis the predominant contents of a
municipal solid waste stream, shown in Appendix Section 7.2, Table 7-2.
This is further backed by an ultimate analysis that classifies the waste stream in
terms of its heating value, a measure of the potential calorific energy of the refuse
derived fuel. Measuring this requires the use of a bomb calorimeter in a controlled
laboratory environment. Instead, the conditioned waste stream that results from selective recycling will be compared to that presented in research, ensuring the analysis
remains valid over the range of conditions being evaluated. Primarily the Boie methodology is employed to provide this assurance.
26
waste stream that promote hydrogen production while requiring low input energy for
gasification. The accounting for the presence of nitrogen15 (32), oxygen, and potentially
significant amounts of moisture makes the choice of Boie a robust method for this study.
The robustness relative to these constituents is important due to the design of the gasification furnace: the plasma arc operates in a natural air furnace to reduce cost and
complexity of operation.16 Without laboratory testing, the work of Boie allows for the
determination of the heating value of the waste stream, necessary for the equilibrium
reaction that results in the production of synthesis gas .
The accounting for dry ash is also important, as the ash in the process is also vitrified in the slag produced from the plasma process. In this analysis, ash is accounted for
in the proximate analysis of the waste stream as noted in the Appendix, Table 7-2.
The completion of the proximate analysis and the ultimate analysis, as described earlier, is the
starting point for employing the Boie relationship. The Boie formula for the higher-heating value of
the waste stream as a fuel is given by [1]
[1, where C, H, O, N and S are the elements, Carbon Hydrogen, Oxygen Nitrogen,
and Sulfur and the coefficients are the percentages of the constituents of the waste
stream from the ultimate analysis , and Q, the higher heating value of the RDF is given in
kJ/kg.
[1]
In the work presented by Mountouris (34), a bomb calorimeter was used to experimentally determine the heating value of sewage sludge. Several widely accepted
mathematical models were used to approximate the sludge in order to select an analytical
15
Buckley (32) indicates that the presence of nitrogen in the waste is small enough that
it may be discounted. However, the presence of nitrogen in air (for an atmospheric
process as is designed here) may be significant.
16
While an atmospheric environment of the plasma furnace promotes inexpensive
facilities and allows for the simplicity of operation, it is noted that the facility will have
the propensity to generate more ashan effect that can be countered by increasing the
plasma furnace temperatureand require more frequent maintenance. The useful life of
the plasma torch is also reduced due to oxygenated erosion of the electrode.
28
method that could be used to determine the HHV of the specific sludge of his analysis.
The Boie relationship was not referenced among them, but it yields results within 4
percent of the empirical value of the dry, ash-free basis of the Psittalia sludge waste
stream referenced 17. The analyzed sewage-sludge waste stream consisting of 55%
carbon, 8.0% hydrogen, 33% oxygen, 3.8% nitrogen, and negligible sulfur content on a
dry, ash-free basis, gave a higher-heating value of 24,198 kJ/kg, and the Boie relationship for the same waste stream provides a heating-value of 25,100 kJ/kg, an overestimate
consistent with that found in other research (31) (32). The difference in the two methods
is significant and will be discussed in the conclusions (Section 5.2) of this analysis.
To ensure that the Boie method is applicable to the municipal solid waste stream of
this analysis, the ultimate analysis of a recycling-optimized (or conditioned) waste
stream is compared to that of the sewage sludge. It will be shown later that the cond itioned waste stream desires to be free of dry paper (see Section 4.1), glass, and metals,
yielding a fuel that is 52% carbon, 6.7% hydrogen, 33% oxygen, 2.2% nitrogen, and
negligible sulfur content. Each of these elemental constituents is within 2 percent of the
sewage sludge on a dry basis, providing confidence in the application of the Boie
methodology to the determination of the heating value in this analysis.
Mountouris, et al (34) shows the Dulong relationship to have 0.6% error from the
calorimeter results, on a dry, ash-free basis.
18
Credit for the insight and application of the theory discussed in this section is due to
A. Mountouris et al. (27), as the methodology is concisely demonstrated in their study of
gasification and the development of the GasifEq model that is the basis of this analysis.
19
Other multi-phased approaches to plasma gasification (35) are being developed that
will yield higher power outputs by employing separate gasification chambers, but this
also introduces other system complexity and cost.
29
presence of even a small amount of sour-gas cannot be tolerated by the fuel cell. For
this reason, the syngas filtration system includes energy debits for having to remove
H2S, along with CO and CO2 for the longevity of the fuel cell stack.
The plasma gasification process is also made to occur in environmental conditions.
The primary benefit of this is the absence of the need for a controlled atmosphere
(temperature, pressure, and inert gas supply) which significantly reduces the cost and
complexity of the plasma reactor unit. The major detriment is the significantly reduced
life of the plasma torch or electrode. The chemical reaction is established to make use of
the free oxygen and nitrogen in the atmosphere.
The moisture in the waste stream that typically occurs due to distributed waste collection and central gathering, also allowing for the collection of atmospheric
precipitation, is disregarded. Instead, moisture in the waste stream is a result of only the
constituents of the waste stream and is calculated from the conditioned (post-recycled)
trash stream. The presence of atmospheric moisturerelative humidityis also not
accounted for in the moisture content of the waste. The atmospheric temperature is
accounted for in the analysis and is factored into the ambient temperature of the reactor
as an average yearly temperature for the New England region of the United States
(10.7 C).
The gasification reaction proceeds from the proximate analysis (the content of the
waste stream, including moisture and ash content) to the ultimate analysis (the elemental
constituents of the waste stream) and the determination of the heating value of the waste
stream (which is, with the pre-gasification recycling and waste shredding, the refuse
derived fuel) to the thermochemical equilibrium equation. The method of performing
this analysis is embedded in the GasifEq model developed by Mountouris et al. (27)
This method employs the ultimate analysis of the waste stream (
), where ash,
sulfur, metals, and the other trace elements, if present after the gasification reaction, are
assumed to be mostly vitrified in the conversion of waste material into p rimarily gaseous
forms. However, the presence of these trace compounds is important for the environ-
30
mental performance of the reaction and the products of significance are simplistically 20
handled in this study as a treatment of the syngas prior to induction in the fuel cell (as
detailed in Section 3.3). The global gasification reaction is:
[2]
In this equation, the coefficients n x denote the stoichiometric concentrations in kilomoles (kmol) to balance the equation, m is the amount of air per kmol of waste and w is
the moisture content, also in kmol. The amount of air is an important factor, as it
directly controls the oxidant. Another significant oxidant comes from the waste stream
itself. Mountouris et al. (27) noted that the increasing content of oxygen significantly
decreases the production of hydrogen (as more free oxygen is present to promote the
formation of water) (35). Alternately, increasing oxygen lowers the required input
energy, as anticipated due to the oxidant nature of the reaction. For the reasons stated,
the molar concentration of air governing the stoichiometric ratio will be fixed 21 as to
produce the most hydrogen for the least consumed energy, but as stated, the content of
the waste stream will vary the stoichiometric ratio due to the quantity of oxygen proximately present in the waste stream. The addition of energy in [2] is described by the
symbology . The added energy is from the plasma torch used to motivate the
reaction, and is captured in the conservation of energy employed in the heat balance.
The equilibrium assumption is verified from a well-documented application of a system
of independent equations commonly used in the analysis of gasification reactions (36),
20
As noted by Zhang, et al., the detailed pyrolitic process of gasification for such a
complex feedstock as municipal solid waste is not well understood (38). The vitreous
byproducts were thus assumed. In this study, it is recognized that the presence of these
inorganic constituents will serve to increase the required plasma arc energy requirements.
21
The value for m used in this analysis is 0.47 mol/mol of waste in accordance with the
study presented by Mountouris, et al. (27), as it produces the most hydrogen for the least
energy.
31
and is reasonable because of the high temperatures involved . This follows from the
application of the phase rule of chemical equilibrium that relates the number of coexis tent phases and the degrees of freedom (independently variable environmental conditions
controlling the physical state of the components) to the components that comprise those
phases.
The solution of the global gasification reaction will require seven independent equations to solve for the seven unknowns (n 1, n 2, n 3, n 4, n 5, n 6, and n 7). The first three of
these independent equations will be determined from the water-gas shift, the methane
decomposition reaction, and the steam-carbon reaction. The enthalpy balance gives the
fourth equation, and the partial mass balances of the products and reactants provide the
last three.
From the phase rule and an understanding of the compounds of the products and reactants of equilibrium, a subset of gasification reaction equations are determined (27).
These equations are used to establish the reversible composition of methanea process
noted to be favored in gasification modeling in moisture rich environments 22 (given by
[3]) (37), the catalytic water-gas shift (given by [4]), and the endothermic steam-carbon
reaction given by [5].
[3]
[4]
[5]
22
The moisture rich gasification process is also favored in this study for the understan ding of waste streams of significantly wet feedstock as present in a primarily organic
waste stream.
32
[6]
where
is the equilibrium
constant of the reaction equation which is computed from the law of mass action (which
relates the concentrations of the reactants to the rates of reaction) for each of the governing gasification reactions that comprise the overall gasification reaction24. For instance,
in the case of the endothermic steam carbon reaction [5], the equilibrium constant is
given by
[7]
Then, utilizing the definition of Gibbs free energy applied at constant temperature and
pressure (41)
Residence times are reported in the plasma gasification process on the order of 10s of
seconds, and the assumption of molten inorganics in the process provides good indic ation that equilibrium is a valid assumption under these conditions.
24
Details of this determination are standard in chemical engineering and are referenced
here from the Handbook of Environmental Engineering Calculations (22)
33
23
[8]
taken here as the difference between the heats of formation and the heats of reaction of
the compounds in the reaction), the gasification temperature, and the change in entropy
(
which conveniently provides a relation to the energy absorbed from the enviro n-
[9]
Combining the relationships yields a useful formula for the determination of the energy
balance for the overall gasification reaction
[10]
Noting that taking the partial of [8] with respect to temperature in a constant pressure environment yields
)
[11]
and presenting this in a more useful form by performing the differential with respect to
temperature reveals
34
)
]
[12]
and introducing [8] and [11] provides the Gibbs-Helmholtz equation (41)
)
]
[13]
which is central in relating the temperature to equilibrium for a constant pressure env ironmental process. It is this relationship that is used in conjunction with the Gibbs free
energy and at a constant pressure reaction; we have the relationship from a substitution
of [6]
[14]
The equilibrium constant is thus evaluated by the application of the heat capacity
correlation (22)
[15]
35
where the coefficients A, B, C, D, and E are the regression coefficients for the chemical
compounds from the empirical tables. Integrating [15] at constant pressure for the
change in thermal states of the reaction gives
]
[16]
)
[17]
where
change in species coefficients for each of the equilibrium reactions. The values T1 and
T2 are the atmospheric temperatures and the gasification temperatures, respectively.
Using again [5] the endothermic carbon-steam reaction, as an example,
[18]
In addition to the above independent equations used to determine the three independent equilibrium constants (that is the application of Equation [17] to Equations [3],
36
[4], and [5]), four additional equations are required to satisfy the number of unknown
coefficients in the overall gasification reaction. To do this, we employ the enthalpy
balance of the overall gasification reaction (39). Relating the heat of formation of the
products to the heat capacity of the reactants and the interjected energy is the relatio nship provided by [8] and, along with [9],
[19]
[20]
with the products and reactants of the overall gasification reaction, accounting for the
entropic term as energy input from the plasma arc (Q) to motivate the reaction gives the
heat balance for the gasification reaction (27)or our fourth independent equationas
(
)
[21]
It should be noted here that the heats of formation (Section 7.4.3) of the gaseous compounds and water (liquid and vaporous) are the terms ,
(Section 7.4.1) are given by,
of this reference are used due to the analogous nature of the thermal characteristic within
the temperature bounds of the gasification reaction used in this analysis (285 K 1500
K), with the exception of solid carbonthe soot termhaving a maximum applicable
temperature of 1100 K. This ensures the analysis operates within the bounds of the
measured parameters.
To solve the system of simultaneous equations three additional relationships are
needed. These proceed from the partial mass balances of carbon, hydrogen, and oxygen
(the three elements present in the gasification reaction modeled) from the gasification
reaction [2] (27):
the carbon balance,
[22]
[23]
[24]
Using a numerical solver for the seven equations (equations [3], [4], and [5] whose
equilibrium constants form the independent equations as determined by equations [17]
and [18], the enthalpy balance given by equation [21], and the partial mass balances
given by equations [22], [23], and [24]) and seven unknowns (n 1, n 2, n 3, n 4, n 5, n 6, and
n 7, the coefficients of equation [2]) yields the values of the coefficients of the chemical
reaction, from which we determine the molar concentrations of the products, reactants,
and the input energy. The detailed methodology of the calculations is documented in a
routine written in Mathematica that allows for multivariate analysis , determining the
38
significant contributors to the gasification reaction and calculating the energy consumption of the plasma torch. The primary Mathematica routine is documented in the
Appendix Section 7.2.
Commercial grade hydrogen is commonly regarded per SAE J2719. This gas quality
standard has widespread adoption for use in fuel cell vehicles and other commercial
solid oxide fuel cell (SOFC) usages. It is noted that proton exchange membrane (PEM)
fuel cells require higher purity H2 to prevent membrane COx contamination.
26
As noted in Section 3.2.3, the water-gas shift reaction is not the application of a new
technology, but an industry practice that is commonly used in gasification reactions.
Much research has been noted that aims to improve catalyst effectiveness and lower
reaction temperatures, aimed at product aimed at reducing cost and complexity. However, the cycle mimicked in this analysis is industrially proven and of demonstrated
capacity.
39
[4]) for the increased production of hydrogen from carbon monoxide and water. Byun,
et al (42) performed this in two stages for more efficient production of H 2 by allowing
for a high-temperature shift reaction using an iron-chrome catalyst and a lowtemperature shift reactor using a copper-zinc catalyst 27. Between the two stages, the
syngas is cooled and hydrogen sulfide (sour gas) was removed using a fluidized bed
reactor, serving to further purify the syngas, but also to ensure t hat the copper-zinc
catalyst was not polluted by the aggregation of sulfur.
Assuming the water-gas shift reaction occurs at chemical equilibrium, the coefficients of the species in the reaction are scalable. Understanding this, and using the
empirically determined relationship noted by Byun, et al. (42)28, a species production
ratio is determined as the outlet syngas composition relative to the entrance syngas
composition. This production ratio is applied directly to the syngas that is generated
from the process described in Section 3.2.3. The related H2S removal is assumed to
occur similarly.
Table 3-2: Water-gas shift reaction as experimentally demonstrated by Byun, et al (42). The calculated
production ratio is used for hydrogen reformation in the distributed gasification analysis presented h ere.
Syngas Composition
CO
CO2
H2
N2
H2 O
27
Inlet
Average
Outlet
Average
Percentage
Change
Production
Ratio
38.8%
14.5%
36.5%
7.3%
4.0%
0.3%
37.2%
51.2%
7.6%
4.0%
-99.2%
157.4%
40.3%
4.4%
0.0%
0.00773
2.57400
1.40329
1.04396
1.00000
The water-gas shift is exothermic, with the increase in temperature being provided by
the reaction itself as it is motivated by the catalyst. Only sufficient pressure is required
in the operation of this reaction.
28
Noting that the average compositions do not exactly equate to the full composition of
syngas, there are probable errors introduced at this stage, but the errors are estimated to
be within 1-3% of the species by volume, and are acceptable for the gross evaluation
presented in this analysis.
40
Following the water-gas shift, the syngas, rich in hydrogen and carbon dioxide, is
introduced into a pressure swing adsorption (PSA) unit 29. This unit functions by introducing the gas into tank containing a molecular adsorbent that, when under sufficient
pressure, allows carbon-dioxide to embed in the adsorbent. The gas stays contained in
the tank for sufficient residence time, and is then evacuated. In the evacuated process,
the CO2 is released and can be off-gassed or stored for use in the bagged filtration step
where it is used to free particulate matter from the sides of the filter. This process can be
repeated to the maximum efficiency of the adsorbent, and exiting the pressure-swing
adsorption process is a purified hydrogen gas. Hydrogen gas purities have been empirically measured following such a process exceeding that required for commercial grade
usage per SAE J2719 (42). The hydrogen purification process described is depicted in
Figure 3.5.
For the purposes of this analysis, efficiencies of the syngas conditioning cycle are
assumed, as it is beyond the scope of this study to select catalysts and adsorbents for
system optimization for the production of hydrogen from WGS and PSA, though this in
future work could significantly improve the results presented.
Pressure swing adsorption is a process that requires pressure and evacuation, valving,
and computer or mechanical controls, but no significant external energy input.
41
built, tested, and evaluated. For this analysis, the assumed system is a transferred arc
gasification system, depicted in Figure 3-6.
The advantages of the transferred arc units are increased efficiency (between 65%
and 85% of the power consumed by the arc is transferred to the working material, as
opposed to 60%-75% of that of a plasma torch) (43), and improved electrode life. The
detriments include difficulty of maintenance (replacement of the electrodes is more labor
intensive than the replacement of a simple torch assembly) and the increased cooling
requirements as there is no accelerated working fluid (such as steam or air) t o assist in
the preservation of the electrodes, as there is in a torch based system. Some research
suggests additional benefits in torch-based gasification systems that are not accounted
for in a transferred arc configuration. The pressurized gas that is fed through the torch
tip exits at sufficient stagnation pressure as to motivate the waste product as it is being
molten in the plasma furnace (42). In a transferred arc system, the agitation of the waste
product (if necessary) must otherwise be accomplished.
The author believes that there are advantages of a novel arrangement of transferred
arc plasma that will capitalize upon the benefits of efficiency, while allowing for a
Figure 3-5: Hydrogen reformation process from syngas, showing the system inputs to providing for the
water-gas shift reactions and the pressure-swing adsorption system.
42
compact reactor and crucible in the plasma chamber. The basis is to run a series of
plasma arcs through the waste particulate as it rests inside the crucible, similar to methods used in induction furnaces for the large scale smelting of metals. Such a method
may not require cooling 30, but it does require the invention of a cathodic crucible, as the
waste stream is primarily non-conductive. In this arrangement the plasma arcs are
generated from a graphite anode and directly attack the crucible with the introduced
waste being volatilized in the process. Research has revealed similar apparatus used in
laboratory environments (44), though this concept will require some invention .
Because this analysis uses plasma arcs instead of gas or steam torches, transfer efficiencies of the plasma reactor above 80% are assumed (43). To improve durability of
the anode and the crucible in such an arrangement, the working chamber may be evac uated prior to the introduction of power, however system complexity would escalate as an
accelerant would need to be introduced in the chamber to allow stoichiometric equilibrium for the gasification reaction (recall in Section 3.2.3 the system is based as an open
environment with excess air). This study does not introduce these complexities. Instead, the system described in Figure 3-6 is simple. Waste is shredded once a target
input weight of waste is present in the hopper. Conveyors lightly compress the RDF and
introduce it to plasma chamber. The chamber closes and seals, allowing then only for
the air present in the chamber to contribute to the gasification process. In this way,
excess air may be controlled by the waste displacing a known quantity of airin other
words, the plasma chamber would be sized based upon the target input weight to provide
the nominal stoichiometric fuel-air ratio. As the plasma arcs are only energized after
waste is input, the system conserves electrical power, using only that which is required
to gasify the waste.
30
Plasma torches are typically run with steam or an oxidant that serves to lengthen the
life of the electrode (43).
43
It is important here to also revisit the prior assumption that the crucible is free of
slag, as it is purged at the end of each cycle, with the syngas exit tube being valved shut
(the syngas is evacuated at the end of the gasification process), and pumped air being
introduced. The slag is not separated, but allowed to cool into bricks outside the gasification chamber. Because the vitrified solids and metals separate by buoyancy when
molten and because of the solidification rate when heat is removed (45), the cooled brick
can be easily recycled. This system requires timing and sensing logic and is envisioned
Figure 3-6: Plasma arc gasification system as concepted for small scale gasification. The process
runs only until the RDF is completely consumed, allowing for small amounts of waste to be
processed discontiguously and efficiently.
44
to be completely robotic.
Dynamic modeling and experimental verification of a PEM fuel cell shows stabilization of current and voltage within 4 seconds of introduction of sufficiently supplied fuel,
and stabilization of response within 0.1 s econds for a stepped current draw (47).
32
The fuel cell selected is the Ballard FCVelocityHD6 (51).
45
greater than 60%, prior to any form of waste energy (heat) recovery. The benefits of
heat recovery from a solid-oxide fuel cell are also very significant. As the fuel cell stack
may operate at temperatures nearing 1280 kelvin, the thermal efficiency of heat transfer
promotes heat recovery (co-generation) that boosts overall system efficiencies above
80% (46). The high-temperature operation also encourages the development of on-board
reformation of the input fuel, eliminating the need for external facilities for highpurification of the input fuel. They are also resistant to concentrations of sour-gas and
are not influenced by the presence of carbon monoxide. Unfortunately, it is the same
high temperature operation enabling these properties that is the main detractor for solidoxide fuel cells for the distributed gasification process noted here. The high temperature
requires significant complexity in stack cooling and expensive alloys for durability
within the operating environment. Materials also offset the reduced cost of the fuel cell
stack, making SOFC technology expensive for implementation. As SOFC technology
advancements continue to reduce costs (or for significantly larger applications where
costs may be more offset by economies of scale), solid-oxide fuel cells should be considered for distributed power generation resulting from the production of syngas.
Figure 3-7: Block diagram detailing the concept of mass-based waste induction for the distributed
gasification of municipal solid waste.
33
Due to the presence of residual matter and to ensure complete gasification, the cruc ible of the plasma reactor should be preheated. This pre-heating creates a molten slag
prior to the introduction of additional waste, serving to aid in vitrification of inorganics
and complete gasification of organics (60). The electrical power requirement for the
preheating of the slag is not accounted for in this analysis , as it is assumed there is no
residual matter from the prior cycle.
47
consumes some electrical power) is needed. Any excess electrical power could then be
used for community purposes. For this process to work as planned, battery storage is
important.
Figure 3-8: Grid-based electrical power storage technologies depicted by discharge potential relative
to system capacity. This information is presented from the United States Department of Energy
Sandia National Laboratories (48).
Due to the cyclic operating nature of the mass-based induction gasification system,
continuous cyclic performance is required. Power generated and used in the system
48
occurs at relatively rapid rates of charge and discharge. In plasma gasification processes, wastes have been converted to syngas at rates of 50kg/hour (42), the time for the
water-gas shift and pressure-swing adsorption reactions is on the order of a few minutes
for flow rates on the order of a 100 liters per minute of syngas (42), and the operation of
the fuel cell stack is also nearly instantaneous, as described in Section 3.4.2. These
process times require the ability to quickly charge and discharge the electrical storage
system, setting the stage for solid-state battery systems. Lithium-ion batteries are
selected not only due to their ability for rapid charge and discharge 34, but also for their
small packaging characteristics, thermal operating range, partial charge acceptance,
systems simplicity, cyclic endurance, and reasonable cost of implementation 35. Based
upon research conducted by Qian, et al. a controller and inverter couples with a state-ofcharge (SOC) and state-of-health (SOH) battery management system (BMS) for gridbased power storage provides an overall storage efficiency of 92.6% (49). Charging
times were also recorded to be within the range of of an hour to charge a 1kW lithiumion from 30% to 70% SOC.
Though cyclic charging and discharging are tolerable, computer controls should be
implemented to ensure deep-discharging does not occur as dendrite formation is accelerated, promoting storage decay and shorting (49).
35
Uses of lithium-ion batteries in automotive applications challenges the production of
an inexpensive vehicle, but considered on the kilowatt scale for other electrical power
storage options, lithium-ion batteries are cost competitive when rated against similar
capacity electrical storage options (48).
49
systems were chosen for the anticipated electrical capacity. The energy requirements of
computer controls were not accounted for, but are understood to be of fractional contributions to the electrical requirements of the system.
A mechanical solid waste shredder, capable of grinding and shredding organic and
hard inorganic matter (metals, plastics, and glass) was selected. The durability and
capability of this machine is of key importance. Though it is recommended that glass
and metals are completely diverted from the waste-stream feed, it is reasonable to
anticipate waste stream contamination36. The durability and robustness of the system
should be unencumbered by the accidental (or purposeful) introduction of these components in the waste stream. A unit was selected of the appropriate size class (360
kg/hour). Its operation is driven by a 5 Hp electric motor operating at 20 amps at 230
volts (50).
The envisioned system of waste delivery utilizes a horizontal, augur driven, tubed
conveyor. The benefit of such a system is that the particulate waste can be further
compacted and delivered into the plasma furnace in a single process (with the size of the
furnace chamber and crucible of sufficient mass to accommodate the waste input. Most
of the commercially developed tube-conveying systems are sized for thousands of
pounds per hour throughput. These are too large for a community sized application,
however. The power requirements to deliver and compress the waste are therefore
calculated. The details of the calculation are given in the Appendix Section 7.7.
Concluding the significant power requirements of the gasification process, p umps
are needed for the pressurization requirements of the water-gas shift system, pressureswing adsorption, and for pressurization of the fuel cell. The selected automotive-grade
fuel cell (51) requires pressure delivered at 16 bar(g), or 1,600 kPa. At 230 VAC, a 15
Hp high-purity gas pump is selected to deliver flow at rates of up to 7.25 m3/sec for the
fuel cell at a current of 37 amps. This same pumping power is assumed to be duplicated
for operation of the gas cleaning systems .
36
Figure 4-1: Trends of electrical consumption (left) and hydrogen production (right) for varying
molar air ratios
51
in Figure 4-1, increasing molar air ratio decreases power consumption but also decreases
hydrogen production. To find the optimum, the trend of electrical consumption was
Figure 4-2: The trend of electrical consumption (normalized) and hydrogen production (inverted) to show optimum molar air ratio for a given waste stream.
normalized and hydrogen production was inverted. This shows an intercept in the two
trends at 0.44, shown in Figure 4-2. Note, however that the value used in the analysis
presented here is not changed from what was previously assumed. The reason for this is
two-fold, the species ratios of compounds in the waste stream, which vary significantly
in this study, influence the optimum air ratio substantially, and the system desc ribed in
Section 3.4.1 would have a fixed air to fuel ratio by design. It is noted that improved
efficiency can be attained by modifying the air ratio based upon the introduced waste
stream, and further study would be required to ensure the added complexity trades
favorably to generated power.
Appended to the Mathematica code is the Boie estimate for the heating value of
the waste stream. As discussed in Section 3.2.2, the Boie method compares to research
within 4% of the reported heating values of municipal solid waste and similar organic
feeds (34), though it generally overestimates HHV (33). To understand the significance
of 4% on the HHV of the RDF, the Boie estimated HHV was scaled by 0.96. The result
52
was a 14% increase in the power requirements for the plasma torch, with no ch ange (as
expected) on the production of hydrogen. On such a small system as is evaluated here,
such error is significant, however it is noted that the system can still yield supplemental
electrical power for the community with the addition of more RDF. In the practical
application of plasma gasification technology the gasification temperature could be
controlled real-time to minimize power consumption.
The benefits of using Mathematica to model the plasma gasification system are
revealed in the ability to have many multivariate cases processed, aiding in the development of key trends that promote understanding the desired waste stream, arc energy
requirements, and community sizing for the commissioning of distributed plasma arc
gasification systems. For the results presented here, the Mathematica model was
exercised to vary gasification temperature within the bounds of the chemical properties
values that comprise the gasification model (1200 K 1500 K [1700F 2240F]). The
RDF feed was varied by using the typical waste stream proximate analysis provided in
Figure 3-4, but modified to simulate the effect of diverting a percentage of the waste
stream from the gasification process. This was done to mimic a user recycling po rtions of the waste stream prior to introducing it to the gasification process. For each
major category of the waste stream content (e.g. organic matter) the percentage of the
constituent that becomes RDF was randomly varied using a uniform distribution 37.
Limits were placed on the randomized recycling percentages to firstly insure that some
waste content was present in every tested waste stream, and secondly to better mimic
recycling contamination. Finally, the program was allowed to run 100 of the multivariate points per temperature condition to capture significant trends.
Among the first characteristics observed was the significance of gasification te mperature on hydrogen content of the syngas, shown in Figure 4-3. This slightly declining
trend indicates that lower gasification temperatures are desirable, but the temperatures
required to ensure complete vitrification of solids and reductions of exitin g solid particulate (soot) warrants the gasification temperatures be held above 1273 K (27). Doing so
37
i.e., the proximate composition of the typical municipal solid waste stream was fixed
per Figure 3-4, but the recycling percentages were allowed to vary randomly per a
uniform distribution.
53
Figure 4-3: Hydrogen content of the syngas from the plasma gasification furnace as related to the
gasification temperature for a large sample of randomly diverted waste stream constituents
results in 1% less hydrogen content in the syngas (on a volume basis), and a corresponding 14% increase in plasma arc power requirements, as calculated from Figure 4-4.
Understanding the change in hydrogen as a function of the waste stream proximate
content is also useful. When reviewing the data from this perspective, the results may
appear counterintuitive. If so, it is likely due to familiarity with pyrolitic processes in
which optimization is heavily reliant upon calorific performance of the constituents.
This is not the case for the desired creation of hydrogen gas. Figure 4-5 shows the
volume percentage of hydrogen resulting from the concentrations of various constituents
in the waste stream. A steep positive slope of the curve indicates a strong and beneficial
relationship of that constituent to the generation of hydrogen. Similarly a steep negative
slope indicates that the presence of a constituent may detract from the production of
hydrogen.
Textiles provide the greatest hydrogen output. Two things are important in this result: the assumption was made that textiles would include rubber as a means of
54
Figure 4-4: Plasma arc power requirements as a function of gasification temperature for a large
sample of randomly diverted waste stream constituents
simplifying the number of constituents in the waste stream (reference Section 3.2.1), and
the typical content of textiles and rubber is a small percentage of the overall waste
stream. While it is beneficial to have these compounds present, they are not present in
the volumes to produce sufficient syngas alone.
Plastics (as may be expected by reviewing their hydrogen rich chemical co mpounds) have nearly as much influence as textiles. What may not be expected is that
what follows are the organics (food wastes and yard clippings). Food wastes and yard
clippings are high in hydrocarbons, and the high moisture content favors the water-gas
shift portion of the reaction, boosting hydrogen output.
Conversely, wood and paper have negative trends in the production of hydrogen.
Paper is primarily carbon, as is wood, and are relatively dry. Their abundance of carbon
was hypothesized to drive the steam-carbon reaction, equation [5], but their dry nature
does not provide sufficient water to favorably advance the reaction.
55
Figure 4-5: Trends of the concentration of various waste stream constituents on hydrogen gas
production for a large sample of randomly diverted waste stream constituents
In Figure 4-5, it seems that the presence of glass and metals has been neglected
when in fact they have been removed to simplify the graphic. These constituents provided a slightly greater than 0 slope, which indicates the production of hydro gen is not
significantly affected by the presence of glass and metal in the waste stream. The power
requirements of having glass and metals present (even at small percentages) outweigh
their hydrogen performance and should be diverted from the plasma gasification process
(though there is no other detrimental effect with having them present other than the
reduction in net energy generated).
The species present in the synthesis gas as a result of the plasma arc process are also
important. As may be expected from having run the random multivariate analysis over a
range of gasification temperatures and recycling percentages, post-recycling RDF
mixture averaged over all the cases run appears very similar in proximate content to the
typical waste stream. The composition of the syngas is therefore similar to what may be
expected from introducing an unmodified waste stream into the plasma gasification unit.
56
Table 4-1 shows the average syngas composition as given from the global gasification
reaction, equation [2]. There is almost no methane, indicating the weak influence of the
methane decomposition reaction, equation [3], but hydrogen is abundant in the syngas.
Table 4-1: Average composition of synthesis gas from the multivariate plasma gasification analysis.
CO
(%vol)
CO2
(%vol)
H2O
(%vol)
15%
17%
8%
15%
CH4
(%vol)
0.0001%
N2
(%vol)
45%
Understanding the trends discussed, one final relationship is needed to begin the
macroscopic systems analysis: the post-recycling content of the waste stream. Three
cases were evaluated based upon the results. The program was run: with a waste stream
containing only plastics, organics, and textiles (as a perfect case); with a waste stream
that does not divert any waste from the plasma reactor; and a waste stream that impe rfectly diverts glass and metals 38. The results of this case, graphed in Figure 4-6, show
the most beneficial waste stream is the one that recycles only metals and glass. It has the
lowest power requirement and the lowest required waste generation rate to yield a target
amount of hydrogen production.
38
The imperfect diversion of glass and metals is a contamination rate of 5%. See
discussion in Section 3.2.1.
57
Figure 4-6: The waste generation rate and the plasma arc power requirements to yield 2.6
grams/second of hydrogen in the resulting syngas when three unique waste streams are subjected to
plasma gasification.
reading the power requirement from the upper diagram of Figure 4-7, and reading from
that power requirement to the hydrogen generation rate on the lower diagram of Figure
4-7, one finds that one kg of waste per day produces approximately .0007 grams of
hydrogen per second [1 lb/day RDF .0002 lb/s H2] exiting the syngas reforming
system following the plasma gasification cycle.
Figure 4-7: Feed rate versus power consumption (upper diagram) and hydrogen generation rate
following gasification cycle and water gas shift (lower diagram) showing the linear relationship
among the three paramaters. The waste stream has a contamination content of glass and metals due
to imperfect separation. The hydrogen flow rate is that leaving the syngas reforming system.
59
Sizing the system solely for electrical power production and consumption starts with
the aforementioned relationship. Understanding that the selected fuel cell (51) generates
75 kW of rated power given the introduction of hydrogen at the rate of 1.3 g/s [10.3
lbs/hr], the required power for the gasification cycle to deliver enough syngas to meet
the fuel cell flow rate is 15.2 kW, acting on 1857 kg/day [approximately 171 lbs/hr] of
RDF. This is enough power to fuel the plasma arcs, operating at 80% efficiency, consuming 35 kW 39. Table 4-2 summarizes the system sizing on the basis of electrical
power consumption and hydrogen generation.
The sizing of the system proceeded from the discussion in Sections 3.1 through 3.5,
but it also integrates assumptions not previously stated. Because of the size required for
the system to produce the hydrogen requirements of the selected fuel cell, it is unlikely
that the system will operate intermittently. The power consumption and hydrogen
production therefore is all based on a full 24-hr daily cycle. The facility power requirements (Misc. Facility and Computing as listed in Table 4-2) is assumed to require no
more than the electrical power required for a typical US household (12).
The resulting power produced, 19.6 kW, is sufficient to power 24 residences (12).
The number of residences required to produce waste feed rate needed for that power
ranges from approximately 280 300 typical US households (3).
Table 4-2: Summary of the distributed plasma arc gasification system sizing based upon power
requirements and consumption, showing positive net power production
Efficiency
Shredder (RDF Processing)
Conveyor (Waste Tranfer Unit)
Gasification Unit
Plasma Arcs
Syngas Processing
Fuel Cell
Electrical Conversion & Storage
Misc Facility and Computing
Net Production
39
---80%
--92.6%
RDF Feed
(kg/day)
1857
1857
1857
Pow er
(kW)
H2 Output
(g/s)
-4.6
-1.2
-15.2
-3.0
-25.0
75.0
-5.6
-0.8
--0.93
-0.37
-1.3
--
19.6
The remaining energy goes into producing heat, that is recoverable with at least 30%
efficiency, however heat energy recovery is not regarded in this study.
60
5. Conclusions
5.1 Viability
The study proves viability. Though the size of the unit does not scale to self-power
the individual home or the small community, larger communities (high -rise apartments
and condominiums, hospitals, retail and commercial establishments) and neighborhoods
may see significant benefit from the on-site installation of this type of facility. Supplementary benefits of heat, hot-water, and adsorption cooling could all be pursued to make
the unit more economically attractive. Further in the case of hospitals , especially,
expensive services for the sanitary disposal of wastes may be eliminated (subject to the
regulations for hazardous waste retention and processing). The system can also be
combined with methane based fuel cell systems (or co-mingled fuel cell systems) that
would permit completely distributed power for those locations that already have gas
feeds for commercial or residential services. This would provide the benefits of nearly
uninterruptible power.
Critical to the implementation of the solution is economics. As most business cases
are generated showing benefit for a limited control volume, the case that the proliferation of distributed plasma waste gasification units will eliminate electrical line loss (and
the significant costs associated with it) and prevent the use of resources in centralized
waste collection is a difficult one to argue. Though the costs of commissioning and
maintaining distributed plasma arc gasification systems is not determined in this study,
the cost of articles of the system (e.g. the fuel cell, the battery, the gas reforming cat alysts, and the plasma chamber) undoubtedly makes such a system expensive. To
promote the development and installation of these systems, applications that directly
benefit from zero waste generation, uninterruptible power, remote (grid disconnected
operations) should be the focused areas for this technology.
bound (by scaling the value provided by Equation [1]. The difference, as expected, is
present in the computation of the input energy required for gasification. Using identical
inputs, except for the 4% scaled estimate of HHV, provides a 14% difference in input
energy (since the Boie typically overestimates HHV (32) (31), this is a 14% increase in
arc power required). Though this is not enough variation to challenge the fundamental
viability of the system, it is enough variation to warrant the review of HHV prediction
methods with future work possibly employing modifications to Dulong or Boie to
provide more accurate input energy predictions.
Materazzi, et al. (35) have developed in the course of this research a more inclusive
methodology that accounts for the various chemical species that are vitrified in the
plasma reaction of municipal solid waste using a multi-step gasification cycle. This
more comprehensive method may estimate more accurately the energy consumed in the
gasification reaction. Future work on this system would benefit from including M aterazzis thermochemical model, as residual slag heating would be inherently accounted
for, improving the estimate of input energy and quantity of waste to net positive electrical benefit from the system defined in this work. The results of the Matterazzis
research were published only after significant progress on this thesis had been completed.
The research conducted in this study has also revealed significant and growing interest in the topics of distributed power generation, land based fuel cells, battery grid
storage systems, and waste gasification. Efficiencies are ever increasing, and innovative
means of reducing cost and improving durability are continually being discovered. The
coming times may herald the hydrogen and renewable energy economy, based on
distributed power generation. Technologies such as plasma arc waste gasification,
which enable distributed waste elimination and distributed power generation for sustainable community development, have a future in the coming ecological and economic
environment.
62
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Mechanical Engineer. [Online] [Cited: April 19, 2014.]
http://www.mechanicalengineeringblog.com/2620-screw-conveyor-powercalculation-screw-conveyor-capacity-calculation-screw-conveyor-formulae/.
56. Anthony, W. Stanley and Mayfield, William D. Cotton Ginners Handbook.
Washington, DC : United States Department of Agriculture, 1995.
57. Burnley, S. J. The Use of Chemical Composition Data in Wast Management
Planning - A Case Study. Waste Management. May 2, 2006, pp. 327-336.
58. United States Department of Transportation; Research and Innovative
Technology Administration: Bureau of Transportation Statistics. National
Transportation Statistics. Washington, DC : Research and Innovative
Technology Administration (RITA): U.S. Department of Transportation (US
DOT), 2012.
59. Lee, C. C. and Dar Lin, Shun. Handbook of Environmental Engineering
Calculations, Second Edition. New York : McGraw-Hill Education, 2007. ISBN:
9780071475839.
60. From Waste to Electricity through Integrated Plasma Gasification/Fuel Cell
(IPGFC) System. Galeno, G., Minutillo, M. and Perna, A. s.l. : International
Journal of Hydrogen Energy, 2011, International Journal of Hydrogen Energy,
Vol. 36, pp. 1692-1701. ISSN: 0360-3199.
67
7. Appendices
7.1 Unsustainable middle class growth
In determining the need for a waste-to-energy solution, research was conducted
concerning the worlds electrical energy consumption, the worlds waste production, and
the rate of growth presented by each. These were then contrasted with the worlds
capability to produce sufficient energy or sufficiently dispose of waste with the rate of
growth projected.
When comparing the worldwide growth of the middle class population (Figure 7-2)
an interesting trend is visible. Between the years 2004 to 2008, a significant increase is
seen in the growth rate of the worldwide middle class, with no correlating growth rate
increase in the world population projections. The growth rate of the middle class is even
seen to be similar to the growth rate of the world population for the years between 2010
and 2030.
Figure 7-1: Excerpt from Goldman Sachs report on the ex panding middle class showing a pareto of
the per capita income in 2007 and comparing it to the world projection in 2050. The chart on the
right shows a swell of middle class income, particularly in the nations known as the BRICs.
Table 7-1: The growth of the world middle class compared to the growth of the world
population: a compilation of data from the Goldman Sachs* (2) and the U.S. Census Bureau** (53).
Year
1960
1968
1972
1980
1990
2000
2004
2008
2010
2020
2030
World Population**
3,042,445,344
3,562,353,760
3,867,338,018
4,452,942,594
5,289,040,477
6,089,648,784
6,393,741,245
6,700,983,106
6,852,472,823
7,592,888,345
8,248,535,284
World Population at
Middle Class Lev el*
500,000,000
750,000,000
800,000,000
1,000,000,000
1,010,000,000
1,100,000,000
1,350,000,000
1,550,000,000
1,800,000,000
2,750,000,000
3,600,000,000
69
World Population
w ithin Middle Class
Status
16%
21%
21%
22%
19%
18%
21%
23%
26%
36%
44%
Figure 7-2: World population growth showing the growth of the middle class. Data sources:
Goldman Sachs* (2)and the United States Census Bureau** (53).
70
production to the prediction of the worldwide middle class population between the years
2007 to 2030, shown in Figure 7-4.
Figure 7-3: World electrical energy consumption on the basis of the world population. This
chart shows correlation to Figure 6.2, where the increase in the world wide middle class correlates to the growth of the world projections of energy consumption.
Figure 7-4: The projected world electricity consumption against the projected middle class
population growth showing close linear correlation between the global middle class and power
consumption.
71
This analysis is a major tenet to the claim of Figure 1-2 in that it relates the key influencing factor in future electrical demand being a growing global class of people of middle
income. From the same analysis presented in Figure 1-2, it may be argued that there is
no actual correlation to the growth of the middle class and global electrical power
consumption. Refuting this argument is the Wilson and Dragusanu report by Goldman
Sachs indicating that the size and thus purchasing power parity of the global middle
class prior to the year 2004 was such that even large swings in middle class consumption
had a small influence on key global indicators, but the recent and explosive expansion of
this population group is shifting the balance of economic power to the global middle
class. One need only review Table 7-1 to see that by 2010, more than 25% of the
worlds population exists at the middle class level, a trend that grows to 46% only
twenty years later.
The question still remains, can the world support such growing demand for electrical power? Because the natural resources exist to sustain such growth 40, the answer is
largely economic (5). The International Energy Agency (IEA) states that an additional
4,800 gigawatts of electrical power will be needed to support the demand in the year
2030 at the cost of 35 billion dollars per year if capital investments were to have started
in 2008. This is no small investment, and the current rate of infrastructure growth and
improvements worldwide will still leave 1.3 billion people without electrical power in
2030 (12).
The worlds energy resources are adequate to meet the projected demand increase
through to 2030 and well beyond. But these Reference Scenario trends have profound
implications for environmental protection, energy security and economic development.
The continuation of current trends would have dire consequences for climate change.
They would also exacerbate ambient air quality concerns, thus causing se rious public
health and environmental effects, particularly in developing countries. (12)
72
40
Figure 7-5: IPCC unrecycled waste generation data showing minimum annual rates of carbon
storage in landfills from 1971 to 2002. (8) Units of the ordinate axis are teragrams (Tg) of carbon
73
1971
thereafter. This trend appears to roughly relate with the same period as the rise of the
middle class and the previously noted changes in electrical generation. Further illustra ting this trend, Bogner relates the waste generation rates graphically, reproduced in
Figure 7-6. Visually coinciding with the growing middle class is the waste characteristic
in the BRIC nations.
Providing an objective measure to this waste trend is of the most interest in the argument that waste projections increase dependent upon the increase in the middle class
population. To this end, environmental data from the Organization for Economic
Cooperation and Development is employeda convenient relational source of data, as
Wilson and Dragusanu related the OECD nations as the upper bound of the global
middle class (2). The OECD Environmental Data Compendium Report of 2006-2008
provides un-recycled municipal solid waste data for the participating nations from 1980
to 2005 in two useful forms: on a total (aggregate) basis, and on a per capita basis. The
data shows for the period that the rate of waste generation was large in the 1990s, but
tapered significantlyand slightly declinedfrom the year 2000 to the year 2005, as
depicted in Figure 7-7. Understanding that most of the participating countries are co nsidered developed nations with middle-class majorities provides some insight to this
trend.
74
Figure 7-7: OECD waste generation in kg/capita/year for the period between 1980 and 2005. As all
OECD countries are represented in the legend, only several are listed. (9)
41
The offset may be due to a variety of factors as mentioned in the assumptions of waste
generation rates and differences in definitions (11) (9).
75
Figure 7-8: U.S. EPA data showing municipal solid waste generation of the United States
between 1960 and 2008 (in million tons). (12)
Figure 7-9: U.S. EPA data showing municipal solid waste recycling (in million tons). (12)
It is the leveling off of the waste generation rate that forms the basis of an important
assumption in the sustainability analysis for waste production. Based on the trends
noted in both the OECD data and the U.S. EPA data, which the amount of waste produced by predominantly middle class developed nations is curbed by recycling and
government enforced regulation, the assumption is formed that the production of waste
76
Figure 7-10: United States waste generation as determined independently by the United States
EPA (11)and the OECD (9).
42
Assuming that the United States represents the highest extreme of the global middle
class
43
The waste generation rates are assumed to be constant due to factors that contribute to
the leveling seen in the waste generation data. It is noted that regulation in the deve loped countries has helped curb discarded waste and helped establish recycling centers
and programs. If a developing nation were not to institute such regulation or otherwise
encourage conservation and recycling, the rate of waste generation of the global middle
class may mimic the waste generation rates of the developed nations in the years prior to
2000.
44
Estimate based upon the average mass to volume relationship for as -received waste at
a landfill from a waste compactor truck.
77
cubic yards of waste. This amount of waste is sufficient to bury all five boroughs of
New York City 45 in nearly 6 meters [20 feet] of MSW.
Again, the question remains as to whether this amount of waste generation is sustainable. The answer on the basis of available land on a worldwide basis is yes.
However, the definitive answer may be largely economic and political, as the most
preferred method of waste management, landfilling, is expensive and, in every locale,
publicly undesirable.
Figure 7-11: Waste generation as a function of the population of the world wide middle class.
This figure is analytically generated based upon data and projections from the U.S. EPA (12), the
OECD (9), and Goldman Sachs (2).See also Figure 1-3.
45
The land area of New York City is estimated at 780 square kilometers [301 square miles] by the NYC statistics page at http://www.nycgo.com/articles/nyc-statistics-page
(referenced April 2014).
78
Carbon
Sulfur
Ash
73.0
48.0
48.5
59.6
11.5
6.4
6.2
9.4
14.8
37.6
39.5
24.7
0.4
2.6
1.4
1.2
0.1
0.4
0.2
0.2
0.2
5.0
4.2
4.9
Paper Products
Cardboard
Magazines
Newsprint
Paper (mixed)
Waxed cartons
43.0
32.9
49.1
43.4
59.2
5.9
5.0
6.1
5.8
9.3
44.8
38.6
43.0
44.3
30.1
0.3
0.1
<0.1
0.3
0.1
0.2
0.1
0.2
0.2
0.1
5.0
23.3
1.5
6.0
1.2
Plastics
Plastics (mixed)
Polyethylene
Polystyrene
Polyurethane
Polyvinyl chloride
60.0
85.2
87.1
63.3
45.2
7.2
14.2
8.4
6.3
5.6
22.8
-4.0
17.6
1.6
-<0.1
0.2
6.0
0.1
-<0.1
-<0.1
0.1
10.0
0.4
0.3
4.3
2.0
48.0
69.7
60.0
59.2
6.4
8.7
8.0
7.7
40.0
-11.6
25.8
2.2
-10.0
6.1
0.2
1.6
0.4
0.7
3.2
20.0
10.0
11.1
46.0
50.1
49.6
49.5
48.1
6.0
6.4
6.1
6.0
5.8
38.0
42.3
43.2
42.7
45.5
3.4
0.1
0.1
0.2
0.1
0.3
0.1
<0.1
<0.1
<0.1
6.3
1.0
0.9
1.5
0.4
0.5
4.5
0.1
0.6
0.4
4.3
<0.1
<0.1
---
98.9
90.5
Miscellaneous
Office sweepings
Oils, paints
24.3
66.9
3.0
9.6
4.0
5.2
0.5
2.0
0.2
--
68.0
16.3
79
80
Plasma Gasification
Optimization Program for Community/Local Waste Consumption and Energy Production
Purpose:
This module is developed from the synthesis gas model of waste gasification
developed by Dr. A. Mountouris.
Methodology:
Optimization electrical output for the case of zero net thermal energy. Based
upon work by Mountouris indicating that the case of zero net thermal energy
results in higher volume of produced synthesis gas. (Sewage
sludge,Mountouris, 2008)
81
82
=
=
=
=
(n/14)/(c/12);
(o/16)/(c/12);
(h/1)/(c/12);
(c/12)/(c/12);
83
heatCapacity[heatCP_] :=
Module[{heatH2 = 0, heatN2 = 0, heatCO = 0, heatCO2 = 0, heatC = 0,
heatO2 = 0, heatCH4 = 0, heatH2Og = 0},
84
Heat of Formation
The following data is from the Chemical Properties Handbook
The Boie relation is employed to determine the HHV of the waste stream and
subsequently the heat capacity of the waste (as an input fuel)
heatFormation[wasteMB_, wasteStream_, heatForm_] :=
Module[{wMB = wasteMB, carbon = wasteStream[[1, 1]],
hydrogen = wasteStream[[1, 2]], nitrogen = wasteStream[[1, 3]],
oxygen = wasteStream[[1, 4]]},
heatForm = Table[0, {1}, {10}];
heatForm[[1,
heatForm[[1,
H2Ol *)
heatForm[[1,
heatForm[[1,
heatForm[[1,
heatForm[[1,
=
=
=
=
0.; (* O2 *)
0.;
0.; (* H2 *)
-110500; (* CO *)
85
86
Equilibrium Balance
This routine performs the chemical equilibrium balance and is the h eart of
the GasifEq system
eQuil[wasteStream_, wasteMB_, ashAW_, molarFraction_, heatForm_, heatCP_,
massO2_, dafMB_, tempSynG_, tempAmb_, tempDry_, solution_] :=
Module[{mc = 0, water = 0, nEquil = 0, balC = 0, balH = 0, balO = 0,
heatBalance = 0,
x, y, z, nrg, cpMethane, cpWaterg, gibbs, k1 = 0, k2 = 0,
lnklnk0 = 0,
lnk0 = 0, lnk = 0},
Clear[nrg, x, y, z]; (* nrg = electricity, x = nH2, y= nCO, z=nCO2 *)
Clear[cpMethane, cpWaterg, gibbs];
(* Gibbs Free Energy in this order: H2 O2 N2 CO CO2 CH4 H2O(g) H2O(l)*)
gibbs = {0, 0, 0, -137.28, -394.38, -50.84, -228.6};
(*Equilibrium Reactions*)
(* CH4 + H2O = CO +
3H2 -- Methane Decomposition*)
cpMethane =
Table[heatCP[[3, i]] + 3*heatCP[[5, i]] - heatCP[[2, i]] heatCP[[6, i]], {i, 1, 5}];
(*Print["cpMethane: ",cpMethane];*)
lnklnk0 = ((cpMethane[[1]]/8.314)*
Log[
tempSynG/298.15]) + ((cpMethane[[2]]/(2*8.314))*(tempSynG - 298.15)) +
((cpMethane[[3]]/(6*8.314))*((tempSynG ^2) - (298.15^2))) +
((cpMethane[[4]]/(12*8.314))*((tempSynG^3) - (298.15^3))) +
((cpMethane[[5]]/(20*8.314))*((tempSynG^4) - (298.15^4))) ((((heatForm[[1, 7]] + 3*heatForm[[1, 6]] - heatForm[[1, 9]] heatForm[[1, 2]])/(8.314)) (1/
8.314)*(cpMethane[[
1]]*298.15 + (cpMethane[[2]]/2)*(298.15^2) + (cpMethane[[3]]/
3)*(298.15^3) +
(cpMethane[[4]]/4)*(298.15^4) + (cpMethane[[5]]/
5)*(298.15^5)))*((1/tempSynG) - (1/298.15)));
lnk0 = -(gibbs[[4]] + 3*gibbs[[1]] - gibbs[[6]] gibbs[[7]])/(8.314*298.15/
1000);
k1 = Exp[lnklnk0 + lnk0];
(* CH4 + H2O = CO + 3H2 -- Water Gas Shift*)
cpWaterg =
Table[heatCP[[4, i]] + heatCP[[5, i]] - heatCP[[3, i]] -
87
88
89
Print[NMinimize[{heatBalance,
{nrg,{x,0,3},y,z}]];
*)
(*
Print["Carbon Balance: ", balC];
Print["Hydrogen Balance: ", balH];
Print["Oxygen Balance: ", balO];
90
91
Main Program
1) Recycling (waste stream conditioning)
2) Proximate Analysis (breakdown of waste stream by waste type)
3) Executes all previous modules to determine synthesis gas production and
energy consumption
4) Outputs data to screen or Excel for additional results manipulation
(* This is the waste stream objective function --- the order of constituents
\
are:
Carbon,
Hydrogen,
Nitrogen,
Oxygen in percent of waste stream and
Ash,
Moisture (added to 100%) and
feedrate (kg/d)
*)
(*Clear[counter,results];
Clear[tempSynGHigh,tempSynGLow, tempStep];
tempSynGHigh=1500;tempSynGLow=1500;tempStep=100;
moistHigh=80;moistLow=20;moistStep=10;
solutionSize= \
(((moistHigh-moistLow)/moistStep)+1)*(((tempSynGHightempSynGLow)/tempStep)+1);
counter=0; results=Table[0,{solutionSize},{3}];
*)
(*Literature indicates plasma gasification temperatures of 2200F.
This is outside of the range of the equations selected for the study from the
Chemical Properties Handbook. Such a high temperature ensures the absence of
solide carbon(soot) *)
arraySize = 10000;
iterates,
estream *)
92
ClearAll[solutionSet];
ClearAll[inputSet];
ClearAll[wasteinput];
solutionSet = Table[0, {arraySize}];
inputSet = Table[0, {arraySize}];
tempAmb =
273 + 10.7; (* Ambient temperature based on average daily New England
temperature for full year operation (K ) *)
tempDry = 373; (* Drying temperature - this will also later be a variable
(K)*)
wasteinput = 10; (* kg/day*)
tempSynG = 1500; (* Temperature of the syntheis gas (K) *)
Do[
(* wasteStream= Carbon, Hydrogen, Nitrogen, Oxygen, Ash *)
(* m = moisture \
content, fr = Feed Rate, t = temperature *)
ClearAll[heatCP, heatForm];
ClearAll[wasteMB, dafMB , daf, ashAW, ashMass, molarFraction, massO2];
ClearAll[solution];
ClearAll[wasteStream];
ClearAll[trashStream];
ClearAll["*'Recycling"];
93
*)
(*
These are the values used for the optimization to allow for the ran domly \
generated waste streams
*)
organicsRecycling =
RandomReal[
1]; (* If[organicsRecycling<.5, organicsRecycling=.05,organicsRecycling=1]; *)
paperRecycling =
RandomReal[
1]; (* If[paperRecycling<.5, paperRecycling=.05 ,paperRecycling=1]; *)
plasticsRecycling =
RandomReal[
1]; (* If[plasticsRecycling<.5, \
plasticsRecycling=.05,plasticsRecycling=1]; *)
textilesRecycling =
RandomReal[
1]; (* If[textilesRecycling<.5, \
textilesRecycling=.05,textilesRecycling=1]; *)
woodRecycling =
RandomReal[
1]; (* If[woodRecycling<.5, woodRecycling=.05,woodRecycling=1]; *)
glassRecycling =
RandomReal[
1]; (* If[glassRecycling<.5, glassRecycling=.05,glassRecycling=1]; *)
metalsRecycling =
RandomReal[
1]; (* If[metalsRecycling<.5, metalsRecycling=.05,metalsRecycling=1]; *)
94
}};
trash[trashStream,
wasteStream];
waste[wasteStream, wasteMB,
molarFraction];
(* Call waste function *)
heatCapacity[
heatCP];
\
95
(* This print routine was also initially used to observe the inputs as the \
program operated
Print["Trash Stream"];
Print[trashStream[[1,1]],"
Print[trashStream[[1,2]],"
Print[trashStream[[1,3]],"
Print[trashStream[[1,4]],"
Print[trashStream[[1,5]],"
Print[trashStream[[1,6]],"
Print[trashStream[[1,7]],"
Print[""];
Organics (kg/day)"];
Paper (kg/day)"];
Plastics (kg/day)"];
Textiles (kg/day)"];
Wood (kg/day)"];
Glass (kg/day)"];
Metals (kg/day)"];
Print["Waste Stream"];
Print[wasteStream[[1,1]],"
Print[wasteStream[[1,2]],"
Print[wasteStream[[1,3]],"
Print[wasteStream[[1,4]],"
Print[wasteStream[[1,5]],"
Print[wasteStream[[1,6]],"
Print[wasteStream[[1,7]],"
Print[""];
Carbon (%)"];
Hydrogen (%)"];
Nitrogen (%)"];
Oxygen (%)"];
Ash (%)"];
Moisture (%)"];
Feed rate (kg/day)"];
Print[MatrixForm[solution]];
Print["nH2, nCO, nCO2, nH2O, nCH4, nN2, Energy Input"];
Print[""];
*)
"END"
96
O2
N2
CO
T regime
250-1500K
50-1500K
50-1500K
60-1500K
2.5399E+01
2.9526E+01
2.9342E+01
2.9556E+01
2.0178E-02
-8.8999E-03
-3.5395E-03
-6.5807E-03
-3.8549E05
3.1880E-08
-8.7585E12
3.8083E-05
1.0076E-05
2.0130E-05
-3.2629E-08
8.8607E-12
-4.3116E-09
2.5935E-13
-1.2227E-08
2.2617E-12
D
E
T regime
CO2
CH4
H2O (g)
50-5000K
50-1500K
250-1500K
200-1100K
2.7437E+01
3.4942E+01
3.3933E+01
-8.3200E-01
4.2315E-02
-3.9957E-02
-8.4186E-03
3.4846E-02
-1.9555E05
3.9968E-09
-2.9872E13
1.9184E-04
2.9906E-05
-1.3233E-05
-1.5303E-07
3.9321E-11
-1.7825E-08
3.6934E-12
D
E
CO2
CH4
H2O (g)
T regime
60-1500K
50-5000K
50-1500K
250-1500K
Gf,298.15 (KJ/mol)
-137.28
-394.38
-50.84
-228.6
97
CO2
CH4
H2O (g)
H2O (l)
T regime
60-1500
50-5000
50-1500
250-1500
250-1500
f,298.15
(KJ/mol)
-110.5
-393.5
-74.85
-241.800
-285.8304
98
Hv apor
44.0304
46
significant, but do not provide enough detriment to negate the feasibility of a plasma
waste gasification system on an operational or economical basis.
100
ments from a commercially available electric motor48. Equations for sizing the conveyor
(55) were then employed based upon the waste feed rate requirements to provide sufficient hydrogen to fuel the gasification process. The equation used is (55):
[25]
where power P, is given in kW and PH is the power for progressing the material, PN is
the driving power of the screw conveyor, and PST is the power required due to the
incline of the conveyor. As this conveyor is horizontal, PST is zero. PH is (55)
[26]
in which IM is the mass flow rate of media in metric tons per hour, L is the length of the
conveyor, and is the friction coefficient resulting from the conveyed media. The mass
flow rate of waste is was directly determined from the gasification program, the length
was determined by sizing the diameter of the conveyor to be 0.6 m [2 ft], which is
reasonably sized based on dimensions of the waste shredder (50). Knowing that municipal solid waste when compacted occupies approximately 297 kg/m3 [500 lb/yd 3] (10)and
the waste introduction rated based upon the results of the gasification system for selfsufficient power is 0.16 metric tons/hr [320 lb/hr or 4 tons US/day], the length of the
conveyor was determined to be 1.68 m [5.5 ft]49. The friction term typically ranges
between 2 and 4 (55), but the conveyed media in the lower portion of this range is rock.
MSW is expected be to much less than this . Instead
48
is used
. Finally
Sized from a MicroMax motor operating at 230V, 3.2 amp, 1 HP electric motor from
Marathon Electric: www.automationdirect.com/motors . Volume 14. p. E15-32.
49
Note that this is a conveyor feeding from both sides so as to slightly compact the
waste in the middle prior to introduction into the plasma gasification chamber.
101
[27]
where D is the diameter of the conveyor. Proceeding through these calculations given in
equations [25], [26], and [27] shows that the conveyor may consume 1.2 kW of power.
102