The CWT Thermal Conversion Process. Terry N. Adams, Ph. D. Changing World Technologies, Inc. West Hempstead NY April 2005

Transcription

1 The WT Thermal onversion Process Terry N. Adams, Ph. D. hanging World Technologies, Inc. West empstead NY April 2005

2 WT-Thermal Thermal onversion Process 3-stage process Emphasis on intermediate separation Two thermal stages Separation stage between thermal stages Tested at Philadelphia research facility Operating at arthage MO plant

3 WT-TP TP Two thermal processes Both well established Medium temp hydrothermal treatment ~50 years Delayed coking ~ 50 years Neither process stretched to get final result ydrothermal T ~ 250 Separation Thermal cracking T ~ 500

4 Thermal onversion Process Feedstock Prep 1 st Stage Reactor 2 nd Stage Reactor Product oil storage Pressurizing and eating Flash Tank Oil Separation

5 arthage TP Plant

6 arthage TP Feedstock

7 arthage TP Intermediates Macerated feedstock Intermediate product

8 TP Products arbon Minerals Gasoline Splits Diesel Split 1 st stage oil Raw Feed

9 TP Products From Turkey Offal Nitrogen Fertilizer Aqueous solution of amino acids and glycerol igh BTU Fuel-Gas TP-40 Oil Mineral Matrix igh Purity Fixed arbon

10 TP-40 Oil API 40, similar to gas/diesel blend

11 WT Thermal onversion Process Turkey Offal/Grease Plant 2SO4 (dry) 3.6 TPD 2nd Stage Split ondenser Fuel-gas Oil 7.5 TPD 69.8 TPD 1st Stage with flash and TOTAL FEED 210 TPD steam condenser Water TPD arbon 6.7 TPD Organics 92.9 TPD Minerals 8.2 TPD Ammonia 1.0 TPD entrifuge Evaporator Distilled 79.7 TPD water Water + Glycerol + (N4)2SO TPD entrifuge Mineral Drier Water vapor 8.2 TPD Dry minerals 8.2 TPD

12 TP Energy Efficiency ~ 85% WT-TP Turkey Offal/Grease Plant Electric 3.6 power Natural gas 0.0 1st Stage Fuel-gas 1.4 TOTAL FEED 210 TPD with flash and TDP-40 oil 99.5 Water steam condenser Organics MMBtu/hr Minerals arbon 6.4 Ammonia Separator 2nd Stage Split ondenser Evaporator Distilled water Water + Glycerol + (N4)2SO4 Separator Mineral Drier Water vapor Dry minerals

13 Energy Efficiency 1 st stage is hydrothermal treatment 200 to 250, > 30 atmos Pressure is let down in three steps About 35% of water is flashed off Flash steam used to heat incoming feed ountercurrent heat exchange Liquid water separated from organic oil entrifuge or settling tower Minimizes energy use in 1 st stage

14 TP 1 st Stage Energy Efficiency ountercurrent heat exchange Liquid water in, liquid water out Wet feed Liquid water Pre- heaters Final heater Flash steam Reactor Flash tanks Liquid water Organic to 2 nd stage Mineral

15 2 nd Stage TP Thermal racking Organic oil heated to ~ 500 Similar to delayed coking Only dry organic oil heated to final temp eat transfer to oil is rapid, isothermal Decarboxylation is main reaction Deamination + some thermal cracking Fuel-gas has high calorific value About 75% of natural gas heating value About 10% of organic oil becomes fuel-gas Used as fuel in fired-heater for 2 nd stage

16 Food omposition Fat arbos Protein

17 Fats Are Triglycerides Fats Are Triglycerides O O O O O O A glycerol backbone with three fatty acids A glycerol backbone with three fatty acids

18 Fats Split ( Fats Split (ydrolyze ydrolyze) in 1 ) in 1 st st Stage of TP Stage of TP O O O O O O O O

19 Fatty Acids Fatty Acids rack rack to to s in the 2 s in the 2 nd nd Stage Stage etane etane Palmitic Acid Palmitic Acid arboxylic group, -OO O O

20 Proteins Proteins are compounds made up of many amino acids Proteins are linked by peptide (N) bonds and sulfur bonds Peptide bonds are formed by removing water from an amine group and a carboxylic group ydrolysis breaks proteins into amino acids

21 Twenty ommon Amino Acids

22 Amino Acids Distributed to Water and Oil Most amino acids will be in produced water Nitrogen fertilizer similar to fish solubles Some amino acids to 1 st stage oil Lipophilic AA s s with hydrocarbon side chains About equal yield of oil:carbon:fuel-gas

23 Amino Acids Are Good Fertilizer Fish solubles and emulsions Same 20 amino acids irrespective of source Similar AA distribution Turkey, MSS, pig, cow, fish Produced water is DNA & pathogen free WT has Medical Infectious Waste permit for NY For MSS, lass A, lass B, lass TP

24 Plant Growth On Amino Acid Fertilizer ommercial Fertilizer WT TP Fertilizer

25 Plant Growth On Amino Acid Fertilizer ommercial Fertilizer WT TP Fertilizer

26 arthage Missouri TP Plant

27 arthage TP Plant

28 arthage TP Feed Storage Tank

29 arthage TP Reactor

30 arthage TP 2 nd Stage

31 arthage TP Tank Farm

32 Existing Infrastructure Utilized

33 Feedstock Delivery

34 arthage TP Feedstock Receiving

35 arthage TP Plant Interior

36 arthage TP Plant Interior

37 arthage TP Biofilter

38 Thermal Oxidizer

39 Vent Scrubber

40 arthage TP Lab

41 Lessons Learned

42 What We Knew Before We Turned the Key Pressures, temperatures and times Yields and estimated qualities Intermediate and finished products Basic characteristics of separation Approximate process efficiencies Information to commission design

43 What appened When We Turned It On Was the design perfect : No Did we make changes after we turned on: Yes Did we learn from commercial deployment: Yes Will we change design of second plant: Yes

44 We learned Simulating separation processes can be tricky Pilot-scale not same as full-scale

45 We learned 1 st stage separation complicated by emulsions

46 We learned Over-design doesn t always equal better design Reactor retention was increased from pilot Over-cooking contributed to emulsion problem

47 arthage TP ontrol Room

48 We Learned Over-automation reduces walking the deck

49 We learned Walking the deck is important

50 onclusions WT TP arthage plant operating 24/7 Optimizing operation at arthage Optimizing products at arthage Designing 2 nd animal-waste plant R&D on rubber and plastic R&D on municipal sewage sludge

51 Work AT MIT Life ycle Assessment for animal waste Protein/carbohydrate interaction Well known in cooking Browning cookies is an example Forms sludge during hydrothermal treatment Need to understand kinetics Need operating conditions to control