Carpet Waste Gasification:Carpet Waste Gasification:Technical, Economic,

Environmental Assessment for Carpet

MillsAn Interim Presentation

OutlineOutline• Problem Statement• Principle of Gasification• Methodology• Proposed Systems• Syngas Uses• Environmental Analysis• Economics• Conclusions

Problem StatementProblem Statement

• 250 tons per day of post-consumer carpet (PCC)

• Currently pay disposal fees

• Reclaim a portion of the chemical energy from the PCC

Problem StatementProblem Statement

• PCC has lower heating value of 8,800 Btu/lbo Bituminous coal LHV = 11,000 Btu/lbo Natural gas LHV = 20,000 Btu/lb

• Gasification Processes PCC consideredo Produce syngas

• Syngas LHV = 8,000-12,000 Btu/lb

Principle of Principle of GasificationGasification

MethodologyMethodology• 250 tons/day of post consumer

carpet• Carpet composition (wt%)Component Percentage of

Carpet (wt%)Percentage

removed pre-gasification (wt%)

Polypropylene (PP) 17

Calcium Carbonate (CaCO3)

35 80

Polyethylene Terephtalate (PET)

6

Nylon 6 (N 6) 17 100

Nylon 6,6 (N 6,6) 14

Styrene Butadiene Rubber (SBR)

11

MethodologyMethodologyMaterial Heat of

Combustion (BTU/lb)

Flowrate (lb/hr)

MMBTU/hr

PP -18600 1700 -32CaCO3 800 700 0.6PET -9500 630 -6SBR -18900 1100 -21N66 -13800 1400 -19

Total 79 MM BTU/hr

MethodologyMethodology

• Employed ChemCad modeling

software

• Material balance

• Energy balance

Proposed SystemsProposed SystemsAir GasifierAir Gasifier

Proposed SystemsProposed SystemsAir GasifierAir Gasifier

•N2 presence reduces heating value

•Produces NOx

Proposed SystemsProposed SystemsOO22 Gasifier Gasifier

Proposed SystemsProposed SystemsOO22 Gasifier Gasifier

• Capital increase due to N2 separation

• Capital decrease due to volumetric flow from the gasifier

Proposed SystemsProposed SystemsSteam GasifierSteam Gasifier

Proposed SystemsProposed SystemsSteam GasifierSteam Gasifier

• Lower Temperature

• Produces CH4 (higher heating value syngas)

Current Syngas UseCurrent Syngas Use

BoilerSyngas

Air

Steam

Exhaust

Plant Use

Current Syngas UseCurrent Syngas Use

Potential Syngas UsePotential Syngas Use

BoilerSynga

s

AirHigh Pressure Steam

Low Pressure Steam

Condensate

Exhaust

Condenser

Potential Syngas UsePotential Syngas Use

Gas Turbine

Boiler

Syngas

AirWork

Hot Exhaust

Low Temp Exhaust

High Pressure Steam

Work

Energy RecoveryEnergy Recovery

GasifierMM

BTU/hBTU/lb PCCW

Air 58 5800O2 58 5800

Steam 35 3500

PollutantsPollutants

Gasifier lb/h CO2

lb CO2/MM

BTUCoal

compare lb/h NOxCoal

compare

Air 14000 240 13% 300 -14%O2 14000 240 13% negligible

Steam 11000 310 48% negligible

Interim ConclusionsInterim Conclusions• Technologically and

Environmentally Feasible

• Economic Analysis will be performed

Questions We HaveQuestions We Have

• What were the strong points?

• What can be improved upon?

• What can be omitted?