A Solution to the Growing Problem - University of Oklahoma...A Solution to the Growing Problem...
Transcript of A Solution to the Growing Problem - University of Oklahoma...A Solution to the Growing Problem...
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Municipal Solid Waste: Municipal Solid Waste: A Solution to the Growing ProblemA Solution to the Growing Problem
Jessica BeardJessica BeardBrant BennettBrant BennettJason BlackJason Black
Adam BymasterAdam BymasterAlex IbanezAlex Ibanez
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PurposePurpose
•• Investigate and select an alternative Investigate and select an alternative method of MSW disposalmethod of MSW disposal
•• Design a waste processing plant Design a waste processing plant •• Advance the previous deterministic model Advance the previous deterministic model
to optimize a construction and expansion to optimize a construction and expansion timelinetimeline
•• Select a feasible investment strategySelect a feasible investment strategy
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TodayToday’’s Agendas Agenda1. MSW in the United States1. MSW in the United States
-- City selectionCity selection-- Waste disposal methodsWaste disposal methods
2.2. Pyrolysis Processing PlantPyrolysis Processing Plant3.3. Producing Hydrogen from Synthetic GasProducing Hydrogen from Synthetic Gas
-- Other possible end productsOther possible end products4.4. MSW Processing Plant Capital CostsMSW Processing Plant Capital Costs5.5. Deterministic ModelDeterministic Model6.6. ResultsResults7.7. OwnershipOwnership
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BackgroundBackground•• Municipal Solid Waste in the United StatesMunicipal Solid Waste in the United States
–– CompositionComposition–– Waste DisposalWaste Disposal
MSW Production and Disposal, 1960-2001
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Waste Disposal in the U.S.Waste Disposal in the U.S.
•• Close to 210 Close to 210 million tons of million tons of MSW per year MSW per year
•• MethodsMethods–– LandfillingLandfilling–– IncinerationIncineration–– PyrolysisPyrolysis–– RecyclingRecycling
Recovery29.7%
Landfilling55.6%
Combustion14.7%
Recovery Landfilling Combustion
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City SelectionSelection•• Cities Considered:Cities Considered:
–– New York City, New YorkNew York City, New York–– Los Angeles, CaliforniaLos Angeles, California–– Detroit, MichiganDetroit, Michigan–– Hilo, HawaiiHilo, Hawaii
•• Basis of AnalysisBasis of Analysis–– Amount of MSW producedAmount of MSW produced–– Population and Population growthPopulation and Population growth–– Cost of current disposal methodCost of current disposal method
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Municipal Solid Waste Produced
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Municipal Solid Waste Municipal Solid Waste ProducedProduced
•• Total MSW Total MSW GenerationGeneration
•• Recycling RatesRecycling Rates•• Waste Disposal Waste Disposal
MethodsMethods–– NYCNYC——Transporting Transporting
MSWMSW–– DetroitDetroit——Incineration and Incineration and
LandfillingLandfilling–– HiloHilo——Transporting Transporting
MSW and LandfillingMSW and Landfilling–– Los AngelesLos Angeles——Landfilling Landfilling
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PopulationPopulation
•• Metropolitan Area Metropolitan Area PopulationsPopulations
•• NYC has largest NYC has largest metropolitan metropolitan populationpopulation
•• Hilo has a Hilo has a population under a population under a millionmillion
Metropolitan Area of City
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Population GrowthPopulation Growth•• Hilo has the largest Hilo has the largest
population growth but population growth but very small populationvery small population
•• New York also has New York also has large population large population growthgrowth
•• Detroit has smallest Detroit has smallest population growthpopulation growth
Population Growth
02468
101214161820
New York City Los Angeles Detroit Hilo
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Perc
ent G
row
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Price to Dispose of MSWPrice to Dispose of MSWPrice to Dispose of MSW
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•• Average PricesAverage Prices•• New York Fresh Kills New York Fresh Kills
Landfill ClosedLandfill Closed——Transporting Waste Out Transporting Waste Out of Stateof State
•• Cost of Incineration Cost of Incineration HighHigh
•• Hilo Running Out of Hilo Running Out of SpaceSpace
•• West Coast Has More West Coast Has More Space than East CostSpace than East Cost
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Location ChoiceLocation Choice……•• New York City:New York City:
–– Price to Dispose of MSW: $63.30Price to Dispose of MSW: $63.30–– Population of Metropolitan Area: 22 millionPopulation of Metropolitan Area: 22 million–– Amount of MSW in Metro: 46,000 tons/dayAmount of MSW in Metro: 46,000 tons/day–– Landfilling in NYCLandfilling in NYC
•• Prevention of landfilling in high density NYCPrevention of landfilling in high density NYC•• 9 private and 23 public landfills9 private and 23 public landfills——capacity of 60 capacity of 60
million tonsmillion tons•• 17 companies with three year base contracts and 17 companies with three year base contracts and
two 1 year extensionstwo 1 year extensions
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Disposal MethodsDisposal Methods•• Methods ConsideredMethods Considered
–– LandfillingLandfilling–– IncinerationIncineration–– PyrolysisPyrolysis
•• Basis of AnalysisBasis of Analysis–– Cost to build and operateCost to build and operate–– Environmental ConcernsEnvironmental Concerns–– Production of ProductsProduction of Products
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LandfillingLandfilling•• AdvantagesAdvantages
–– Small Capital InvestmentSmall Capital Investment–– Little MaintenanceLittle Maintenance–– Cheaper Disposal FeesCheaper Disposal Fees
•• DisadvantagesDisadvantages–– Environmental PollutionEnvironmental Pollution
•• Methane Carbon DioxideMethane Carbon Dioxide•• LeachateLeachate
–– Property Decrease in Property Decrease in ValueValue
Source: http://www.zerowasteamerica.org/Landfills.htm
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IncinerationIncineration
•• AdvantagesAdvantages–– Minimizes Landfill Minimizes Landfill
VolumeVolume–– Recovery of EnergyRecovery of Energy
•• DisadvantagesDisadvantages–– High Building and High Building and
Operation CostsOperation Costs–– Air EmissionsAir Emissions–– Toxic AshToxic Ash
Source: http://www.meniscusclients.com/portfolio/cwa/tech_info.htm
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PyrolysisPyrolysis•• AdvantagesAdvantages
–– Minimizes Landfill Minimizes Landfill VolumeVolume
–– Recovery of EnergyRecovery of Energy–– Production of Production of
Synthetic GasSynthetic Gas•• Disadvantages Disadvantages
–– Air EmissionsAir Emissions——–– LeachateLeachate–– SlagSlag——Landfilled or Landfilled or
used in road used in road foundationsfoundations
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Method ChoiceMethod Choice……
•• PyrolysisPyrolysis–– Land Constraints in NYCLand Constraints in NYC–– Production of SyngasProduction of Syngas
•• Mixture of CO, COMixture of CO, CO22 and Hand H22
•• Can lead to production of synthetic fuels, Can lead to production of synthetic fuels, hydrogen, ammonia, alcohols, aldehydes, hydrogen, ammonia, alcohols, aldehydes, carboxylic acidscarboxylic acids
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Pyrolysis ProcessPyrolysis Process
•• Why Separate Before Pyrolysis?Why Separate Before Pyrolysis?–– Enhance Profit / Reduce CostsEnhance Profit / Reduce Costs
•• Sell Recyclable Metals; Low Heat ValueSell Recyclable Metals; Low Heat Value•• Reduce Wear and Tear on EquipmentReduce Wear and Tear on Equipment•• Easier Than Separation After PyrolysisEasier Than Separation After Pyrolysis
–– Control Refuse PropertiesControl Refuse Properties•• Slag Seals Refuse if Proper ProportionsSlag Seals Refuse if Proper Proportions
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Front End SeparationFront End Separation
Waste Energy
13.9x109 Btu/D
Purox Feed Energy
13.8x109 Btu/D
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Purox Pyrolysis FacilityPurox Pyrolysis Facility
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DesulfurizationDesulfurization
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Wastewater PlantWastewater Plant
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Oxygen PlantOxygen Plant
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Oxygen Plant (cont.)Oxygen Plant (cont.)
•• Air SeparationAir Separation–– 78.1% N78.1% N22, 20.9% O, 20.9% O22, 0.934% Ar, 0.035% CO, 0.934% Ar, 0.035% CO22
•• 280 TPD O280 TPD O2 2 = 1 Purox Reactor= 1 Purox Reactor•• Equipment: Compressor, Heat Equipment: Compressor, Heat
Exchanger, Distillation ColumnsExchanger, Distillation Columns
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Oxygen Plant (cont.)Oxygen Plant (cont.)
•• Purpose:Purpose:–– Eliminate Nitrous OxidesEliminate Nitrous Oxides
•• Environmental aspectsEnvironmental aspects–– Increases concentration of reactantsIncreases concentration of reactants–– Raise reactor temperature to effectively Raise reactor temperature to effectively
destroy toxinsdestroy toxins
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End Product PossibilitiesEnd Product Possibilities•• HydrogenHydrogen•• AmmoniaAmmonia•• PolycarbonatesPolycarbonates•• Synthetic FuelSynthetic Fuel•• MethanolMethanol•• Dimethyl EtherDimethyl Ether•• Acetic Acid Acetic Acid
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End Product PossibilitiesEnd Product Possibilities
•• HydrogenHydrogenUses: fuel cells, alternative fuels, Uses: fuel cells, alternative fuels,
petroleum industry applicationspetroleum industry applications
(1) CH(1) CH44 + 2 H+ 2 H22O O 4 H4 H22 + CO+ CO22
(2) CO + H(2) CO + H22O O COCO22 + H+ H22
Sale Price: $2500/tonSale Price: $2500/ton
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End Product PossibilitiesEnd Product Possibilities
•• AmmoniaAmmoniaUses: fertilizers, refrigeration, processingUses: fertilizers, refrigeration, processing
NN22 + H+ H22 2 NH2 NH33
Sale Price: $200/tonSale Price: $200/ton--using Husing H22 ($2500/ton) and N($2500/ton) and N22 ($160/ton)($160/ton)
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End Product PossibilitiesEnd Product Possibilities•• PolycarbonatesPolycarbonates
Uses: drink bottles, CD/DVD substrates, audio/video Uses: drink bottles, CD/DVD substrates, audio/video cassettescassettes
(1) CO(1) CO22 + H+ H22 CO + HCO + H22OO(2) 2 NaCl + CO (2) 2 NaCl + CO 2 Na + 2 Na + PhosgenePhosgene(3) Phosgene + bisphenyl(3) Phosgene + bisphenyl--A A Polycarbonate + 2 HClPolycarbonate + 2 HCl
Sale Price: $66/ton (HCl $72/ton)Sale Price: $66/ton (HCl $72/ton)--using Husing H22 ($2500/ton)($2500/ton)--using bisphenylusing bisphenyl--A ($2000/ton) and NaCl ($46/ton)A ($2000/ton) and NaCl ($46/ton)
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End Product PossibilitiesEnd Product Possibilities
•• Synthetic FuelSynthetic FuelUses: diesel fuel, waxesUses: diesel fuel, waxes
CO + 2 HCO + 2 H22 CHCH22 + H+ H22OO
Sale Price: $630/tonSale Price: $630/ton-- using Husing H22 ($2500/ton)($2500/ton)
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End Product PossibilitiesEnd Product Possibilities•• MethanolMethanol
Potential Uses: MTBE, DME, Potential Uses: MTBE, DME,
(1) CO + H(1) CO + H22O O COCO22 + H+ H22
(2) CO + 2H(2) CO + 2H22 CHCH33OHOH(3) CO(3) CO22 + 3H+ 3H22 CHCH33OH + HOH + H22OO
Sale Price: $254/tonSale Price: $254/ton-- using Husing H22 ($2500/ton)($2500/ton)
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End Product PossibilitiesEnd Product Possibilities•• Dimethyl EtherDimethyl Ether
Uses: alternative fuel (developing countries)Uses: alternative fuel (developing countries)
(1) 3 CO + 3 H(1) 3 CO + 3 H22 CHCH33OCHOCH33 + CO+ CO22
(2) 2 CO + 4 H(2) 2 CO + 4 H22 CHCH33OCHOCH33 + H+ H22OO
Sale Price: $109/tonSale Price: $109/ton-- using Husing H22 ($2500/ton)($2500/ton)
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End Product PossibilitiesEnd Product Possibilities•• Acetic AcidAcetic Acid
Uses: photo film, vinyl acetate, vinegarUses: photo film, vinyl acetate, vinegar
CHCH33OH + CO OH + CO CHCH33COOHCOOH
Sale Price: $800/tonSale Price: $800/ton-- results from CHresults from CH33OH that results from OH that results from
HH22 ($2500/ton)($2500/ton)
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End Product ComparisonEnd Product Comparison
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Sale Price ($/ton)
Price ($/ton MSW)Revenue ($ MM/yr)
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Product PossibilitiesProduct Possibilities•• AmmoniaAmmonia•• PolycarbonatesPolycarbonates•• Synthetic FuelSynthetic Fuel•• MethanolMethanol•• Dimethyl EtherDimethyl Ether•• Acetic Acid Acetic Acid •• HydrogenHydrogen
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Synthetic GasSynthetic Gas
0.6%N2
12.5%CO2
47.9%H20
5.7%CH4
20.8%CO
12.5%H2
CompositionComponent
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Hydrogen PlantHydrogen Plant
Steam Reformation
Water-Gas Shift
CO2Removal
Pressure Swing
Adsorption
Syngas
H2O CO2CO, CO2, CH4, N2
99.999% Pure H2
H2O
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Steam ReformationSteam Reformation
• Coal fired furnace• Heat Load of 140 Million Btu/hr• Steam:Methane = 8• 170 tubes, 5-in ID, 40 ft. long• 380,000 lbs Nickel-Alumina Catalyst
CH4 + H2O 3H2 + CO
CO + H2O CO2 + H2
OVERALL REACTION:
CH4 + 2H2O CO2 + 4H2
∆HRX = 84,000 Btu/lbmol
T=1600 °F
P = 20 atm
33.8 MM Btu/hr
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Hydrogen PlantHydrogen Plant
Syngas:
24% H2
39.9% CO
10.9% CH4
24% CO2
1.2% N2
56% H2
15.8% CO
0.1% CH4
26.9% CO2
0.9% N2
Steam Reformation
3050 lbmol/hr 4380 lbmol/hr
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WaterWater--Gas ShiftGas Shift
• 300,000 lbs Chromia-promoted iron catalyst
• Steam:CO = 8• 4 X 36ft reactors
– 100 tubes– 3-in ID
• 2 X Heat Exchangers• Flash Drum
CO + H2O CO2 + H2
36.8 MM Btu/hr
9.8 MM Btu/hr
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Hydrogen PlantHydrogen PlantH2O H2O
56% H2
15.8% CO
0.1% CH4
26.9% CO2
0.9% N2
62.3% H2
1.5% CO
0.1% CH4
0.2% H2O
35.2% CO2
0.8% N2
Water-Gas Shift
4380 lbmol/hr 4960 lbmol/hr
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COCO22 RemovalRemoval
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Hydrogen PlantHydrogen Plant
62.3% H2
1.5% CO
0.1% CH4
0.2% H2O
35.2% CO2
0.8% N2
CO2Removal
4960 lbmol/hr 3203 lbmol/hr
96.4% H2
2.3% CO
0.2% CH4
0.2% H2O
0% CO2
1.2% N2
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Pressure Swing AdsorptionPressure Swing Adsorption
W=1022.2 HP
W=5551.58 HP
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Hydrogen PlantHydrogen Plant
Pressure Swing
Adsorption
99.99% Pure Hydrogen
3090 lbmol/hr3203 lbmol/hr
96.4% H2
2.3% CO
0.2% CH4
0.2% H2O
0% CO2
1.2% N2
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MSW Processing Plant MSW Processing Plant Capital CostsCapital Costs
•• Based on plant processing 1500 TPD Based on plant processing 1500 TPD MSWMSW
•• Capital InvestmentCapital Investment–– Purox Pyrolysis PlantPurox Pyrolysis Plant–– Hydrogen Production PlantHydrogen Production Plant
•• Production CostsProduction Costs–– Operating CostsOperating Costs–– Transportation CostsTransportation Costs
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Purox Pyrolysis Capital CostsPurox Pyrolysis Capital Costs
149.655.5TOTAL CAPITAL INVESTMENT
4.211.56Working Capital
6.902.56Startup Costs
11.594.30Interest during construction
126.947.1Construction
$ millions$ millionsItem
20041975
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Hydrogen Capital CostsHydrogen Capital Costs
$24,900,676Total Equipment Costs$3,700,000Storage Tanks X 12
$1,500Heat Exchanger$3,000,000CompressorStorage/Production
$2,201,000PSAPSA stuff
$485,000Refrigerator$114,000Pump
$3,400,000CO2 Storage Tank$126,000Flash Drum X 3$964,000Compressor X 4$26,000Slump Tank
$312,000Turbine$1,694,000StripperCO2 Removal
$112,000Flash Drum$8,000Heat Exchanger
$1,029,776High Temp. Reactor X 4Water-Gas Shift
$2,000,000Steam Reformer$5,727,400CompressorSteam Reformation
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Waste to Hydrogen TCIWaste to Hydrogen TCI& Production Costs& Production Costs
•• TCI of PlantTCI of Plant–– $300 million$300 million
•• Production CostsProduction Costs–– $56 million/year$56 million/year–– Utilities, Catalysts, LaborUtilities, Catalysts, Labor–– Do not account for transportation costsDo not account for transportation costs
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Deterministic ModelDeterministic Model
•• Advance the previous deterministic modelAdvance the previous deterministic model•• New additions:New additions:
–– Refined Plant Investment & Production Costs Refined Plant Investment & Production Costs –– Allowed plants to expand by incorporating Allowed plants to expand by incorporating
new capital costsnew capital costs–– Updated contracts and locationsUpdated contracts and locations–– Developed new transportation costsDeveloped new transportation costs
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Refined Plant Investment & Refined Plant Investment & Production CostsProduction Costs
y = 0.0358x - 3.9913
$0
$100
$200
$300
$400
$500
$600
0 5000 10000 15000
Capacity, TPDTP
C, M
illio
ns
Scaled Up Operating CostsScaled Up Operating CostsScaled Up TCIScaled Up TCI
y = 0.1356x - 20.722
0
500
1,000
1,500
2,000
2,500
0 5000 10000 15000
Capacity, TPD
FCI,
mill
ions
$
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Contracts & LocationsContracts & Locations
•• Updated contractsUpdated contracts–– Many contracts recently expiredMany contracts recently expired
•• Reconfigured mileageReconfigured mileage–– Account for highways and driving timesAccount for highways and driving times–– More accurate mileage from transfer More accurate mileage from transfer
location to possible facilitieslocation to possible facilities
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Plant Transportation CostsPlant Transportation Costs
• MSW Semi-Dump Trucks
• H2 Tanker Trucks
))/(#*()/(
#
))/(#*()/(#
2
2
2
daytripsCapacitydayH
trucks
daytripsCapacitydaywastetrucks
trucksH
producedH
MSWtrucksMSW
=
=
• MSW Trucks– Capacity = 15 tons of waste– $80,000 each– Mileage = 6 miles/gallon– Lifetime = 1MM miles +
• H2 Tanker Trucks– Capacity = 4.5 tons hydrogen– Tube Trailer = $340,000– Truck Cab = $110,000
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Private Enterprise Private Enterprise
•• PrivatePrivate–– Model will determine profitability based on Model will determine profitability based on
NPWNPW–– Determine if ROI is greater than 10%Determine if ROI is greater than 10%–– Raise money through investorsRaise money through investors
•• Public as an alternativePublic as an alternative–– Raise money through municipal bondsRaise money through municipal bonds–– Model will determine minimum disposal fee Model will determine minimum disposal fee
with out process losing moneywith out process losing money
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Mathematical ModelMathematical Model
•• PrePre--determined Factorsdetermined Factors–– Process: PyrolysisProcess: Pyrolysis–– Final Product: HydrogenFinal Product: Hydrogen
•• Implement deterministic, stochastic Implement deterministic, stochastic mathematical model for logistic planningmathematical model for logistic planning
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Deterministic Model
Pyrolysis- TCI & Operating Cost
Material Balances,Objectives,
& ConstraintsHydrogen- TCI
Processing/Production Plant ConsumersOwnership
TransportationSize/Capacity
Public
Private Location
Expansions attime t, plant j Transfer of wastes from
transfer station to plantTransfer of products
to consumers
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Importance of ModelImportance of Model•• Aid in planning of processAid in planning of process
–– Implement and control the most efficient and costImplement and control the most efficient and cost--effective flow of materials in relation to timeeffective flow of materials in relation to time
–– Account for current MSW disposal contracts Account for current MSW disposal contracts –– Encompass transport of MSW and final productsEncompass transport of MSW and final products–– Execute the right number, location, and capacity of Execute the right number, location, and capacity of
plantsplants–– Incorporate expansions in relation to time, money, Incorporate expansions in relation to time, money,
and the amount of trashand the amount of trash
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Private Plant LocationsPrivate Plant Locations
Oxford, NJ
Hempstead, NY
Islip, NY
Babylon,NY
Charlespoint,NY
Huntington, NY
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Private: Annual Waste Processed Private: Annual Waste Processed compared to Waste Availablecompared to Waste Available
• By 2014, 86% of MSW is processed
• Over 20 year span, 78% of MSW available is processed
• 197 MSW Semi-Trucks
0.000.501.001.502.002.503.003.504.004.50
1 3 5 7 9 11 13 15 17 19year
MM
tons
/y
Waste Processed Waste Available
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Private: Waste Processed/Private: Waste Processed/Expansions at Each PlantExpansions at Each Plant
0
500
1000
1500
2000
2500
Amount of Waste Processed (tons/day)
1 2 3 4 5 6
Year
Oxford, NJ
Hempstead,NYIslip, NY
Babylon, NY
Huntington,NYCharlespoint,NY
07 08 09 10 13 15
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Private: Revenue Private: Revenue and Operating Costsand Operating Costs
0
200
400
600
800
1000
1200
2007 2012 2017 2022 2027
year
($M
M/y
)
TotalRevenue
TotalOperatingCosts
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Private: Cumulative CashPrivate: Cumulative Cash
• Total Capital Investment (20 years)= $2.0 MMM
• NPW (20 years)= $198 MM• Return on Investment
= 12.5%• 508 Hydrogen Tankers• Disposal Fee $45/ton • Saves City of New York over
$54MM/y-$2
-$1
$0
$1
$2
$3
$4
$5
2007 2012 2017 2022 2027
year
$MM
M/y
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Investment Strategy
• Private Feasible– Total Capital Investment (20 years)
=$2.0 MMM– NPW (20 years) =$198 MM– Return on Investment
=12.5%
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Public as an Alternative
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Public Plant LocationsPublic Plant Locations
Oxford, NJ
Hempstead, NY
Islip, NY
Babylon,NY
Charlespoint,NY
Huntington, NY
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Public: Cumulative CashPublic: Cumulative Cash
-$1.50
-$1.00
-$0.50
$0.00
$0.50
$1.00
$1.50
$2.00
$2.50
$3.00
$3.50
2007 2012 2017 2022 2027
year
Cas
h Sa
ving
s($M
M/y
ear
B1 B2 B3
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Public: Cumulative Cash Public: Cumulative Cash with Bondswith Bonds
-$1.00
-$0.50
$0.00
$0.50
$1.00
$1.50
$2.00
$2.50
$3.00
2007 2012 2017 2022 2027
year
Cas
h Sa
ving
s($M
M/y
ear
B1 B2 B3
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Public: BondsPublic: BondsAll bonds are 10 year bonds at 4% interest• Bond 1
– Amount issued in 2007 = $974 MM– Pay off amount (w/interest) = $1.44 MMM
• Bond 2– Amount issued in 2011 = $136 MM– Pay off amount (w/interest) = $201 MM
• Bond 3– Amount issued in 2014 = $30 MM– Pay off amount (w/interest) = $44 MM
• Total Amount in Bonds = $1.14 MMM• Total Interest Paid = $5.5MM
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Public: Annual Waste Processed Public: Annual Waste Processed compared to Waste Availablecompared to Waste Available
• By 2015, 84% of MSW is processed
• Lifetime 69% waste processed• No taxes• Fee charged to city $35/ton saves
city $75 MM/y• TCI = $1.9 MMM
0.000.501.001.502.002.503.003.504.004.50
1 3 5 7 9 11 13 15 17 19 21year
MM
tons
/y
Waste Processed Waste Available
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Questions