Small-scale Waste to Energy

Small-scale Waste to Energy
Joint Deployable Waste to Energy (JDW2E)
Industry Day opening session
11 Sept 2013
Leigh Knowlton
Combat Feeding Directorate,
Expeditionary Basing & Collective
Protection Directorate
US Army Natick Soldier RD&E Center
8 SEP 2013
UNCLASSIFIED
The State of the Art in
Small-scale Waste to Energy
17 JUN 2013
UNCLASSIFIED
2
In Pursuit of a Solution…
Community Power Corporation
Onsite Field-feeding Waste to Energy Converter
NSRDEC Involvement
Various inter-related efforts have been
developing technology for battalion-scale
waste to energy conversion
OFWEC
Initial demo
OFWEC
SBIR
Phase I
OFWEC SBIR Phase II
GLGT
SBIR
Phase I
GLGT SBIR Phase II
MEWEPS
DARPA MISER
Phase 1
Green Liquid & Gas Technologies
Indirectly Heated Gasifier
28 SEP 2011
MEWEPS
demo
Prototype
demo
CPC & NextEnergy
Military Encampment Waste to Electrical Power System
Phase 1A
demo
TGER STTR
Phase II
’07
Celltech Power
Liquid Anode Fuel Cell
GEM ESTCP
Edwards
demo
ST150
for CVF
QinetiQ PWDS FCT
Ft Irwin
demo
TGER REF
Phase III
TGER
demo
’06
Ft Irwin
demo
DARPA MISER Phase 1A
QinetiQ IBSS
ST150 on
HMS Ocean
’05
Hickam
demo
OFWEC III
IST GEM (ECBC STTR, TACOM SBIR, ARL SBIR)
TGER
STTR
Phase I
General Atomics
Supercritical Water Gasification
HEDWEC
TGER
OA
’08
’09
’10
’11
Defense Life Sciences
Tactical Garbage to Energy Refinery
UNCLASSIFIED
’12
InfoSciTex
Green Energy Machine
QinetiQ
Pyrolysis Waste Destruction System
3
OFWEC III
OFWEC III
Onsite Field-feeding Waste to Energy
Converter—Phase III
OFWEC III is a 3rd-generation prototype system that demonstrates technology that
can be used to convert solid waste into useful energy. It has two logistical
priorities: reduce the need for waste disposal, and reduce the need to transport
fuel.
The core of the system is Community Power Corporation’s BioMax® gasifier,
which converts carbonaceous feedstock into a clean producer gas that is burned in
a 60 kW Tactical Quiet Generator’s internal combustion engine.
The system is packaged into two 20-foot
Air/Gas
containers for transportability. It automatically
Mixer
processes up to 1200 lb/day dry field waste and
Particulate
Filter
can export electricity worth over 250 gallons of
Gasifier
diesel or JP-8 each week.
Gas Production
Module
Loading
Chute
OFWEC III System Technology
Demonstration at Fort Irwin, March 2011
28 SEP 2011
Shredder
Briquetter
UNCLASSIFIED
Feedstock Conditioning
Module
4
OFWEC III Demonstration
Net Zero Plus JCTD, Fort Irwin
Two-Week Technology Demonstration at Net Zero Plus JCTD
– Connected to EPCC microgrid
• Supplied 50 kW power to Special Operations Task Force site
– Processed RUBA and field waste from the 1st Brigade Combat
Team, 1st Cavalry Division (Iron Horse HBCT)
• Plus garrison waste and wood pallets
Microgrid
Connection
– Preliminary performance data:
•
•
•
•
41.3 lb/h processing rate (average)
98% volume reduction and 93% weight reduction of feedstock
1.4 gal/h net fuel savings after 8.4 kW parasitic power requirement
Throughput limited by briquetter with moist feedstock
Solid Waste from
Deployed Forces
BG Greene Visit
Sorting Tent
60 kW TQG
OFWEC III Demo Site
28 SEP 2011
OFWEC System
UNCLASSIFIED
5
OFWEC III
Predicted Energy Balance
Field Waste
Relatively dry
paper and plastic
packaging and
service items
~55 lb/h
~16% moisture
Losses
WEC Simplified
Energy Balance
FIELD
WASTE
Gasifier handles
46 lb/h very dry
feedstock,
~10000 BTU/lb
135 kWth
Producer Gas
53 kWth
Clean, low-tar, lowBTU flammable
gas; diluted with air
and CO2; ~70% eff.
Parasitics
Average electrical
power required for
startup, shredding,
blowers, augers,
etc.
22 OCT 2010
JP-8
FUEL
UNRECOVERABLE
ENERGY LOSSES
EXHAUST
OFWEC III
SYSTEM
(INCLUDING
GASIFIER,
SHREDDER,
AND
BRIQUETTER)
53 kWth
15 kWth
Heat
PRODUCER
GAS
EXHAUST &
COOLANT
95 kWth
PARASITIC
10 kWe
60 kW
TQG
80 kWth
(@50 kWe)
NET
OUTPUT
40 kWe
16% conversion efficiency of trash to electricity
(subtracting the 18 kW contribution of the JP-8)
Using diesel generator, 1.5 gal/h fuel is invested to export electricity worth 3.3 gal/h (2.2x ROI)
Efficiency
Other Performance Metrics
This trash to electricity
efficiency subtracts the value
of the pilot fuel, assuming it
otherwise would have been
used to generate electricity at
full efficiency
Fuel ROI:
220% (2.2:1 payback)
Fuel used per ton:
54 gal (gross)
Waste eliminated:
up to 1125 lb/day
UNCLASSIFIED
Char residuals,
evaporation, heat
losses
Exhaust heat may
be useful for drying
feedstock, space
and/or water
heating
Generator
TQG derated to
50 kWe max when
running on
producer gas
mixture; assuming
33% efficiency
Fuel
JP-8 required as
pilot fuel for TQG;
this analysis
assumes 64%
diversion
Values based on 2009 testing at Camp Grayling
6
HEDWEC
(ARL / NSRDEC Effort)
HEDWEC
High Energy Density
Waste to Energy Converter
Gas
Cleanup
The HEDWEC effort is an FY08 Alternative Energy Research Increase
managed by ARL and NSRDEC. The objective is to develop and
demonstrate a battalion-scale system that converts trash into electricity
and meets the CASCOM objective of processing 2 tons/day mixed waste
as expressed in the Force Provider draft CPD.
HEDWEC incorporates a brand new 24”-diameter BioMax® gasifier that
can process up to 200 lbs/hour. Wet food is added separately and
dehydrated before being fed to the gasifier. Power is generated with a
custom 120 kW gas generator system or multiple Army diesel gensets.
Gas
Production
Power
Generation
Feedstock
Conditioning
Controls
The prototype will be delivered in FY12 for government testing.
28 SEP 2011∙
UNCLASSIFIED
7
MSW Power GEM Technology
GEM
Green Energy
Machine
GEM technology was developed by Infoscitex Energy (now MSW
Power) as a product of the results of three Army SBIR and STTR
contracts, private investment, and ESTCP funding for demonstration
at Edwards AFB in FY12.
The latest GEM is designed for up to 3 TPD bulk mixed waste,
including paper, wood, plastic, food and agricultural waste. The
system uses a shredder, dryer, and pelletizing preprocessor to fuel
a downdraft gasifier. After filtration, the producer gas is used to
power a diesel generator or generate hot water. The ESTCP
version was packaged in a 48-foot high cube container plus a 20foot container for power generation and distribution.
GEM Configured
with Ground
Level Conveyor
GEM (ESTCP version)
Current Maturity
Tech Demo
Edwards AFB (FY12)
Feedstock
Unsorted Mixed (<40% moisture)
Size
Capacity
Generator
48-foot high cube
2-3 ton/day
135 kW diesel (1x 20-foot ISO)
Cold Gas Efficiency
70-80%
Electrical Efficiency
~12% (net)
Fuel Savings
28 SEP 2011∙
TRL 6
UNCLASSIFIED
400-800 gal/week
8
“Green Energy Machine”
3 TPD Waste to Energy Converter
ESTCP Technology Demonstration
at Edwards AFB
Downdraft
gasifier
NSRDEC 4th generation “BWEC” to be based on Infoscitex GEM
Raw bagged waste
(mixed non-hazardous)
non-hazardous)
09 NOV 2012
Shredded, dried, and
pelletized feedstock
UNCLASSIFIED
Automatic control,
minimal manpower
9
Tactical Garbage to Energy Refinery (TGER)
20 NOV 2012
UNCLASSIFIED
10
17 JUN 2013
UNCLASSIFIED
11
COTS Small Incinerators
NDCEE Project
Inciner8 A850
National Defense Center for
Environmental Excellence (NDCEE)
testing of small incinerators
for ARCENT and PM FSS
Therm-Tec CG-8
•Reduced weight of MSW by 86–90%
•Consumed 1 gal JP8 for 13–17 lbs solid waste
− 40–54% weight in fuel per weight in trash, or
about 5 lb fuel for 10 lb trash
− Small incinerators are optimized for wastes like
animal carcasses, not efficient remediation of
MSW or field waste
•Exceeded US and EU regulations for CO, HCl,
particulate, dioxins and furans, and lead
17 JUN 2013
UNCLASSIFIED
12
QinetiQ PWDS
PWDS
Pyrolysis Waste
Destruction System
PWDS is based on QinetiQ’s Pyrolysis Total Energy Convertor
system deployed on the amphibious assault ship, HMS Ocean.
Under the Foreign Comparative Test program, PM Force Sustainment
Systems is evaluating PWDS for use with Force Provider. The
reconfigured and containerized prototype will undergo operational
assessment at Fort Irwin and Aberdeen Test Center.
The pyrolysis system is packaged into two ISO containers, with a third
container housing energy recovery subsystems including an Organic
Rankine Cycle generator and hot water loop.
ORC Generator
Hot Water Loop
Air Blast Cooler
Heat
Recovery
Unit
The system processes mixed waste, with food
and sludge loaded separated from dry waste.
An auger pulls feedstock through the system
without pre-processing. Waste oil can also be
processed.
Exhaust
Stack
Maximum throughput is 220-250 lbs/hr, 2-3
TPD.
The system is more destructor than energy
converter, but may be able to export more power
than it consumes (dedicated 60 kW generator).
5 APR 2011
Gasifier
Char/Ash
Collector
Oxidizer
UNCLASSIFIED
Pyrolyzer
Food Waste Solid Waste
Hopper
Hopper
Control
Panel
13
SWRS Phase I Approaches
IST
IST // MSW
MSW Power
Power
Rotary
Rotary pyrolysis
pyrolysis and
and
downdraft
downdraft gasification
gasification
Fabrico
Fabrico
Magnetic
Magnetic induction
induction
heated
heated pyrolysis
pyrolysis
Mainstream
Mainstream
Fast
Fast pyrolysis
pyrolysis with
with
bio-oil
recovery
bio-oil recovery
Altex
Altex
Ward
Ward furnace
furnace selfselfpowered
combustion
powered combustion
17 JUN 2013
UNCLASSIFIED
14
Backup
8 SEP 2013
UNCLASSIFIED
15
SWRS Genesis and Overview
• Current solid waste handling has negative impacts on mission
−Logistics, environment, health, safety, energy, etc.
Technical
• Deployed forces produce enormous amounts of solid waste
Problem
−3–4 lbs/person/day of field-feeding waste alone
−Planning factor for small bases is 10 lbs/person/day
Technical
Barrier
• Small incinerators consume a lot of fuel (up to 50% by weight of the waste)
−Not optimized for efficiency
• Current small scale WTE is too large, expensive, and has feedstock limitations
Capability • Practical and efficient technology to eliminate or reduce solid waste for very small
Sought
contingency bases (50-150 PAX)
• Demonstration of waste remediation capability for very small bases
−Provide a viable alternative to burn pits and fuel-hungry small incinerators
Result /
−Reduce logistics and improve safety while protecting the environment
Product
• Objective of 90% reduction of organic waste with minimal energy requirement
−Reduce or eliminate the use of burn pits
• Capabilities Production Document (CPD) for Force Provider currently in staffing
Requirement
within TRADOC
−Contains performance goals as objective requirements
Acquisition • PM Force Sustainment Systems
Program −Force Provider procured and fielded against OCO requirements
17 JUN 2013
UNCLASSIFIED
16
Performance Barriers
Small-scale Waste Remediation
• Waste to Energy technologies are being demonstrated feasible, but are
better suited to small or medium bases—several performance barriers
remain
–
–
–
–
Too expensive, large, and heavy for very small bases
Feedstock limitations, presorting requirements
Too inefficient (poor ROI)
Low TRL, difficult to maintain
• Commercial-off-the-shelf incineration technologies are not an ideal
solution
– Too labor intensive
– High fuel usage
– Difficult to permit and may exceed emissions regulations
• No major breakthroughs are expected without Government investment
– Comparatively little demand in the commercial sector
– ROI highest where the fully burdened cost of fuel or waste is high
• Successfully addressing these challenges should result in systems
suitable for widespread deployment
18 JUN 2013
UNCLASSIFIED
17
Performance Barriers
Conveyor
to Gasifier
Gas
Filters
Feedstock Conditioning
Briquette
Press
Although these technologies
are being demonstrated
feasible, several barriers to
fielding WEC systems have
been identified by NSRDEC,
RDECOM, and PM-FSS
Rotary
Dryer
Large/Heavy
Shredder
Gas
Production
Centrifugal
Dryer
Inefficient
Gasifier
Expensive
Air/Gas
Mixer
Particulate
Filter
Gasifier
ORC Generator
Hot Water Loop
Air Blast Cooler
Feedstock
sensitive
Heat
Recovery
Unit
Exhaust
Stack
Successfully addressing
these challenges should
result in a system more
suitable for widespread
acquisition and
deployment in theater
Loading
Chute
Shredder
Oxidizer
Pyrolyzer
Briquetter
2 MAR 2011
Gasifier
Char/Ash
Collector
UNCLASSIFIED
Food Waste
Hopper
Solid Waste
Hopper
Control
Panel
18