NON TRADITIONAL FUEL LANDFILL GAS PROJECT"Utilization of Landfill Gas" CYTEC INDUSTRIES INC., FORTIER MANUFACTURING COMPLEX Presented By: Gregory J. Deis, Cytec Industries Inc. Non Traditional Fuels CHP Workshop January 30, 2008 Cytec Industries Inc. Fortier Manufacturing Complex Location: Waggaman, LA 15 miles from downtown New Orleans Size: 800 acres with approximately 430 employees History: Construction on the site was begun in 1952 and production was begun in 1953 and 1954. Annual Payroll: M$ 33.6 State and Local Taxes/Fees: M$ 4.7 Value of purchases from vendors in LA: M$ 254 2004 data Annual Production: 2.5 Billion Pounds Products: Acrylamide (AMD) Hydrogen Cyanide Methyl Methacrylate (MMA) Sulfuric Acid Acrylonitrile Melamine Oleum What Is Landfill Gas? ………….the biological off gas from the anaerobic decomposition of organic material ENVIRONMENTAL REVIEW ―A Green Project‖ Landfill Gas (LFG) 50% methane. . contributes to smog and global warming (greenhouse gas) Methane is ~21 X as effective as a green house gas as carbon Dioxide <1% non-methane organic compounds Burned in landfill flare to control emissions as required by regulation. 50% carbon dioxide If uncontrolled. The Land Fill—Where LFG Comes From . In the Dump Queue . At the Landfill ―Face‖ . The ―Cover‖ . A Landfill Gas Well . Landfill Gas Field . Landfill Flare . What Is Land Fill Gas? Land Fill Gas 430-580 BTU/SCF Natural Gas 1000-1080 BTU/SCF Composition CH4 91% CnH(2n+2) 5% CO2 2% O2 0% N2 2% Composition CH4 CnH(2n+2) CO2 O2 N2 50% Tr% 45% 1% 4% “Wet” (40F Dew pt) Delivered at <100 PSIG “Dry” Delivery at >200 PSIG . What could you do with LFG? Primary Uses Electric Generation Gas turbine/Combined Cycle Medium Btu (Direct use) Steam Boilers Direct fired Process Heater High Btu (Processed to Natural Gas) . Successful LFGTE Project (recipe) Landfill Characteristics 1-3 million tons or greater of waste in place 25 inches or greater of rainfall annually 700 scfm or greater of LFG production Market Characteristics Energy end user within 5 miles No significant pipeline ROW issues Stable energy consumption . What Will Did this Project Do? Project Drivers Energy cost reduction Overall reduction in CO2 emissions Environmentally Beneficial Project Knowledge gained will allow additional energy reductions in energy . Design Considerations Land Fill Gas High CO2 Content Lowers Flame Temperature Increased Flue Volume 3002 F ~5% More Natural Gas 3350 F ID Fan size? Note: FD fan is the Same!! Is Heat Transfer affected? ―Wet‖ (40F Dew pt) Materials of Construction HDPE/Stainless Carbon Steel . ―X .Heat is provided by combusting fuel with the spent acid in a ―Combustion Chamber‖ .The End User….Sulfuric Acid is thermally decomposed .Process Air used in the combustion chamber is preheated with Natural Gas and Landfill Gas in a Process Air Preheater .41‖ . Sulfuric Acid Regen Plant . Schematic of X-41 . Sulfuric Acid X-41 The End User…. Designed with Flue Gas Recycle Tempers the Firebox temperature Reduces Flame Temperature to reduce NOx Emission . Design Considerations ―Wet‖ Acid Gas (40F Dew pt) CO2 + H2O --- H+ + HCO3 Land Fill Gas Materials of Construction Burner Design HDPE/Stainless Must pass ~ 2x volume For same Heat Release Natural Gas Carbon Steel Increased Flue Volume +~5% . FGR.10% Natural Gas Burned in background to insure Bumpless Transfer X-41 modifications New burner. Controls etc) O2 trim results in overall fuel savings .Technical LFG design flow: 1.700 scfm – 90% Fuel Requirements met by LFG . The Concept…… . Community Partners . Option to Flaring— Compress for Pipeline Delivery . Start of Pipeline . Distribution Skid . Delivery Skid . Burner Controls . Milestones Sept 2004: Cytec/Renovar Purchase Agreement signed April 2005. Title V Permit signed approving project July 2005: X-41 Burner modified by CPL . 000 Refrigerators Delayed the Project by Three Months!! .Milestones AUGUST 29. 2005—Hurricane Katrina 78. Hub & Delivery skids installed by Renovar.Milestones Nov 2005: LFG Fuel Train installed. . System commissioned with NG Nov 2005: 4 mile HDPE pipeline installation begins Dec 2005: Compressor. Jan 2006: Mechanical Completion Jan 2006: First LFG sales from Renovar began February 2006: Project Dedication .Milestones Continued…. Community Partners . Plant Partners . Improved controls & operability of Air preheater .PROJECT BENEFITS Savings in Natural Gas: 1000 MM Btu/day Reduction in overall CO2: 61 short tons/day. 100 vehicles Reducing oil consumption by 49..700 barrels Planting 5. LFG Project Environmental Benefits Destroys methane and other organic compounds in LFG The annual reduction of greenhouse gases attributable to this project: Removing emissions equivalent to 4.800 acres of forest. .ENVIRONMENTAL REVIEW Continued…. Expected reduction of emissions of criteria pollutants. SO2.. Reduces odors and noise associated with landfill operations and flaring at the landfill site. PM Cytec application expected to reduce CO2 emissions .ENVIRONMENTAL REVIEW Continued…. CO. NOx. Project Permitting for Cytec..ENVIRONMENTAL REVIEW Continued…. Fortier Manufacturing Complex Early review of design logistics and expected emissions with LDEQ Gas analysis of LFG EPA Factors – No specific factors developed for LFG – Review compared to natural gas factors Renovar obtained permits for pipeline and skid construction including right-of-way access . Included public notice and EPA review . Project Permitting Continued… Emissions estimation for air preheater considering burner redesign Application development Agency Approval of Title V permit for Sulfuric Acid Plant -..ENVIRONMENTAL REVIEW Continued…. Landfill Gas (LFG) Project: Salient Features Project Drivers Energy cost reduction Environmentally-.Overall reduction in CO2 emissions Innovative Application Low NOx Process Air Preheater with Flue Gas Recirculation (FGR) capability . Renovar . EPA Jefferson Parish.WIN! WIN! For ALL Project Participants LDEQ. and Industry--Cytec. Recognition Solid Waste Association of North America’s ―SWANA‖ 2006 Bonze Award EPA’s Landfill Methane Outreach Program’s ―LMOP‖ 2006 Project of the Year American Chemistry Council Responsible CareEnergy Efficiency 2006 Public Outreach Greater New Orleans Business Roundtable 2006 . CYTEC’S. Continue working with State and Local Agencies to look for Environmentally Beneficial Projects. .FORTIER MANUFACTURING COMPLEX Considering more LFG projects at the site..THE FUTURE…. QUESTIONS? ………….. . Thank You! .