Biomass Gasification

Biomass Gasification
Technology Assessment
Consolidated Report
M. Worley and J. Yale
Harris Group Inc.
Atlanta, Georgia
NREL Technical Monitor: Abhijit Dutta
NREL is a national laboratory of the U.S. Department of Energy, Office of Energy

Efficiency & Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.
Subcontract Report
NREL/SR-5100-57085
November 2012
Contract No. DE-AC36-08GO28308
Biomass Gasification
Technology Assessment
Consolidated Report
M. Worley and J. Yale
Harris Group Inc.
Atlanta, Georgia
NREL Technical Monitor: Abhijit Dutta

Prepared under Subcontract No(s). ACO-0-40601-01, LFA-2-11480-01, LFA2-22480-01
Additional contributions and reviews were provided by Michael Talmadge and
Richard Bain, NREL
NREL is a national laboratory of the U.S. Department of Energy, Office of Energy

Efficiency & Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.
National Renewable Energy Laboratory

15013 Denver West Parkway
Golden, Colorado 80401
303-275-3000 www.nrel.gov
Subcontract Report
NREL/SR-5100-57085
November 2012
Contract No. DE-AC36-08GO28308
This publication was reproduced from the best available copy
submitted by the subcontractor and received minimal editorial review at NREL.
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Project 30300.00
Gasifier Technology Assessment
NREL
Golden, Colorado
August 3, 2012
REPORT 30300/01
GASIFIER TECHNOLOGY ASSESSMENT - CONSOLIDATED REPORT
TABLE OF CONTENTS
Section
Page
EXECUTIVE SUMMARY....................................................................................
1-1
INTRODUCTION ................................................................................................
1.
General ........................................................................................................
2.
Technologies Studied................................................................................
3.
Study Basis..................................................................................................
4.
Study Objectives ........................................................................................
5.
Modeling and Detailed Capital Cost Estimates ....................................
6.
Capital Cost Comparisons........................................................................
2-1
2-1
2-2
2-3
2-7
2-8
2-9
GASIFIER TECHNOLOGY DESCRIPTIONS ...............................................

1.
Gasifier Island Technology #1..............................................................
2.
3.
3-1
3-1
3-8
3-15
GASIFIER OPERATION AND PERFORMANCE...........................................

1.
Feedstock Type ..........................................................................................
2.
Feedstock Size ............................................................................................
3.
Feedstock Density......................................................................................
4.
Feedstock Moisture ...................................................................................
5.
Feedstock Ash Content .............................................................................
6.
Feedstock Contaminants ..........................................................................
7.
Ability to Handle Corrosive Materials ...................................................
8.
Carbon Conversion ..................................................................................
9.
Cold Gas Efficiency ..................................................................................
10. Heat Loss ...................................................................................................
11. Bed/Sorbent Media Type ........................................................................
12. Syngas H2/CO Volume Ratio .................................................................
13. Reactor Temperature ................................................................................
14. Reactor Pressure .......................................................................................
15. Fixed Bed, BFB, CFB Reactor Design Comparisons ............................
4-1
4-1
4-2
4-4
4-6
4-7
4-7
4-8
4-9
4-9
4-10
4-10
4-12
4-13
4-15
4-16
Report 30300/01
iii
ORDER OF MAGNITUDE CAPITAL COST ESTIMATES............................

1.
General ........................................................................................................
2.
Capital Cost Estimates ..............................................................................
3.
Nth Plant Cost Considerations ................................................................
4.
Basis of Estimates Direct Costs.............................................................
5.
Basis of Estimates Indirect and Other Costs.......................................
5-1
5-1
5-2
5-2
5-4
5-11
DETAILED CAPITAL COST ESTIMATE CFB GASIFIER..........................

1.
Technology Description............................................................................
2.
Model Basis and Assumptions ................................................................
3.
Excel Workbook Model Operation .........................................................
4.
Capital Cost Summary..............................................................................
5.
Basis of Estimate Direct Costs...............................................................
6.
Basis of Estimate Indirect and Other Costs ........................................
6-1
6-1
6-8
6-11
6-16
6-16
6-23
DETAILED CAPITAL COST ESTIMATE BFB GASIFIER ..........................

1.
2.
3.
4.
5.
6.
7-1
7-1
7-4
7-8
7-13
7-13
7-20
DETAILED CAPITAL COST ESTIMATE HP BIOMASS FEED.................

1.
2.
3.
4.
5.
6.
8-1
8-1
8-3
8-4
8-7
8-8
8-12
DETAILED CAPITAL COST ESTIMATE LP BIOMASS FEED..................

1.
2.
3.
4.
5.
6.
9-1
9-1
9-2
9-3
9-6
9-7
9-11
10
GASIFICATION COST COMPARISONS.........................................................

1.
General ........................................................................................................
2.
Composite BFB Gasifier Cost Estimate ..................................................
10-1
10-1
10-1
Report 30300/01
iv
Appendix
A
B
C
D
E-1
E-2
E-3
E-4
F-1
F-2
G-1
G-2
G-3
G-4
H-1
H-2
H-3
H-4
I
J
Order of Magnitude Estimates Flow Diagrams

Order of Magnitude Estimates Gasifier Operating Conditions
Order of Magnitude Estimates Gasifier Island Equipment Lists
Order of Magnitude Estimates Capital Cost Estimate Details
Detailed Estimate Equipment List CFB Gasifier Model
Detailed Estimate Equipment List BFB Gasifier Model
Detailed Estimate Equipment List HP Biomass Feed System Model
Detailed Estimate Equipment List LP Biomass Feed System Model
Detailed Estimate Mass Balance Flow Diagrams CFB Gasifier Model
Detailed Estimate Mass Balance Flow Diagrams BFB Gasifier Model
Detailed Estimate Process Flow Diagram, General Arrangement
Drawing, Isometric Drawings and Equipment Drawings CFB Gasifier
Model
Detailed Estimate Process Flow Diagram, General Arrangement
Drawing and Equipment Drawings BFB Gasifier Model
Detailed Estimate General Arrangement Drawings and Equipment
Drawings HP Biomass Feed System Model
Detailed Estimate General Arrangement Drawings and Equipment
Drawing LP Biomass Feed System Model
Detailed Estimate Capital Cost Estimate Details
Capital Cost Comparison Table
Gasification Vendor Comparison Matrix
Report 30300/01
Project 30300.00
NREL
Golden, Colorado
August 3, 2012
REPORT 30300/01
GASIFIER TECHNOLOGY ASSESSMENT CONSOLIDATED REPORT
SECTION 1
EXECUTIVE SUMMARY
Harris Group Inc. (HGI) was commissioned by the National Renewable Energy Laboratory
(NREL) in Golden, Colorado to assess gasification and tar reforming technologies. The
technology assessments assist NREL in understanding the economic, technical, and global
impacts of renewable technologies. They also provide direction, focus, and support for the
development and commercialization of various biomass conversion technologies. The
economic feasibility of the biomass technologies, as revealed by these assessments, provide
important information for governments, regulators, and private sector entities in
developing projects.
The goal of the technology assessments has been to solicit and review the technical and
performance data of gasifier systems and develop preliminary capital cost estimates for the
core equipment. Specifically, the assessments focused on gasification and tar reforming
technologies that are capable of producing a syngas suitable for further treatment and
conversion to liquid fuels. In order to improve confidence in the predicted economics of
these technologies, a thorough understanding of the basic capital cost and engineering
requirements for gasification and tar reforming technologies was necessary. These
assessments can be used by NREL to guide and supplement their research and
development efforts.
As expected, it was very difficult to obtain detailed information from gasification and tar
reforming technology vendors. Most vendors were not interested in sharing confidential
cost or engineering information for a study of this nature. However, HGI managed to
gather sufficient information to analyze three gasification and tar reforming systems as
follows.
Technology #1
o Gasifier feed rate of 1,000 oven dry metric tons/day of wood residue
composed of wood chips and bark, using oxygen blown autothermal (partial
oxidation) bubbling fluidized bed design.
Report 30300/01
1-1
o Tar Reformer reactor vessel filled with solid catalyst blocks designed to
crack tars. Oxygen blown for partial combustion of syngas to provide heat.
o Total Project Investment Cost - $ 70,590,000 (2011 dollars).

Technology #2
o Gasifier - feed rate of 1,000 oven dry metric tons/day of wood residue
composed of wood chips and bark, using allothermal (indirect heating)
circulating fluidized bed design. Heating of bed media occurs in a separate
combustor by combustion of char with air.
o Tar Reformer allothermal bubbling fluidized bed design.

Technology #3
o Gasifier - feed rate of 1,000 oven dry metric tons/day of wood residue
composed of wood chips and bark, using oxygen blown autothermal (partial
oxidation) bubbling fluidized bed design.
o Tar Reformer - unknown technology.

This report summarizes the equipment, general arrangement of the equipment, operating
characteristics and operating severity for each technology. The order of magnitude capital
cost estimates are supported by a basis-of-estimate write-up, which is also included in this
report.
This report also includes Microsoft Excel workbook models, which can be used to design
and price the following systems:
CFB gasifier and tar reforming system with an allothermal circulating fluid bed
gasification system and an allothermal circulating fluid bed syngas reforming system
BFB gasifier and cyclone system
High pressure biomass feed system
Low pressure biomass feed system
The models can be used to analyze various operating capacities and pressures. Each model
produces a material balance, equipment list, capital cost estimate, equipment drawings and
Report 30300/01
1-2
preliminary general arrangement drawings. Example outputs of each model are included
in the Appendices.
A Capital Cost Comparison Table is included in Appendix I, which compares the order of
magnitude cost estimates from the three gasification technologies with detailed cost
estimates from combinations of the Microsoft Excel models.
Report 30300/01
1-3
Project 30300.00
NREL
Golden, Colorado
August 3, 2012
REPORT 30300/01
SECTION 2
INTRODUCTION
1.
GENERAL
The National Bioenergy Center (NBC) supports the science and technology goals of
the U.S. Department of Energy (DOE) Biomass Program. NBC advances technology
for producing liquid fuels from biomass. Integrated systems analyses, techno
economic analyses, and life cycle assessments (LCAs) are essential to the Centers
research and development efforts. Analysis activities provide an understanding of
the economic, technical, and global impacts of renewable technologies. These
analyses also provide direction, focus, and support for the development and
commercialization of various biomass conversion technologies. The economic
feasibility and environmental benefits of biomass technologies revealed by these
analyses are useful for the government, regulators, and the private sector.
The National Renewable Energy Laboratory (NREL) recently published several
studies on thermochemical conversion of biomass for the production of ethanol via
gasification. These studies include:
Thermochemical Ethanol via Indirect Gasification and Mixed Alcohol
Synthesis of Lignocellulosic Biomass (NREL/TP-510-41168) detailing the
production of ethanol via indirect gasification of biomass based on a Battelle
Columbus Laboratory (BCL) gasifier design.
Thermochemical Ethanol via Direct Gasification and Mixed Alcohol
Synthesis of Lignocellulosic Biomass (NREL/TP-510-45913) describing the
production of ethanol via direct gasification of biomass using an Institute of
Gas Technology (IGT) gasifier design.
Techno-economics of the Production of Mixed Alcohols from
Lignocellulosic Biomass via High Temperature Gasification,
(Environmental Progress and Sustainable Energy. Vol. 29(2), July 2010; pp.
163-174.) describing the production of ethanol via entrained flow slagging
gasification of biomass.
Report 30300/01
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These reports demonstrate that there are great opportunities to apply various gasifier
technologies in the conversion of biomass to syngas for the production of renewable
fuels. Each of these reports shows that a substantial portion of a projects capital cost
is attributable to the gasifier and that the overall project cost increases with gasifier
design and operational complexity. The cost values used in these reports for the
gasifier economics are based on the small amount of data available in the literature
and are often cited as being out of date relative to current technology. In order to
improve confidence in the predicted economics of these technologies, a thorough
understanding of the basic capital cost and engineering requirements for gasifiers is
necessary.
In addition to studying gasification technologies, four Microsoft Excel models were
also created to help NREL with the development of detailed capital cost estimates for
gasification systems of various capacities and operating conditions.
2.
TECHNOLOGIES STUDIED
As expected, it was very difficult to obtain detailed information from gasification and
tar reforming technology vendors. Most vendors were not interested in sharing
confidential cost or engineering information for a study of this nature. However,
sufficient information was gathered to analyze three gasification and tar reforming
systems listed below.
2.1.
2.2.
2.3.
Technology #1
Gasifier - direct or autothermal bubbling fluidized bed design.
Tar Reformer - solid (blocks) catalyst filled reactor design.
Technology #2
Gasifier - indirect or allothermal circulating fluidized bed design.
Tar Reformer - bubbling fluidized bed design.
Technology #3
Gasifier - direct or autothermal bubbling fluidized bed design.
Tar Reformer design not revealed by vendor.
Report 30300/01
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3.
STUDY BASIS
3.1.
Feedstock Basis
Each of the reviewed technologies was adjusted to the same feedstock tonnage
basis so that practical comparisons could be made. This common basis is also
considered to be the nth plant design. The typical definition and
understanding of the nth plant is a plant utilizing technology that is
considered to be mature in nature and is both operationally and economically
optimized. In the case of cellulosic ethanol, HGI projects construction of such a
plant to be 10+ years in the future, assuming that a feasible and viable
economic market is developed.
The common basis was determined to be a gasifier feed rate of 1,000 metric
tons/day of dry cellulosic biomass. The feedstock was further limited to only
wood residue composed of wood chips and bark. The basis was limited to
wood because vendors are most experienced with woody feedstocks, and a
great amount of research data is available for those feedstocks. There are,
however, many other cellulosic biomass feedstocks that are viable with the
reviewed technologies. Feedstock flexibility is discussed further in Section 4 of
this report. A biomass moisture content range of 10-20% was also assumed as
part of the basis.
A major objective in choosing the production basis was to select a feedstock
capacity that could be processed in a single train consisting of separate gasifier
and tar reformer reactors/vessels. Such a configuration allows the design to
take advantage of economies of scale and lends itself to more economical
methods of fabrication and construction. In addition, the stated basis is within
the generally agreed upon range for suitable feedstock handling systems and
lends itself to many different types of cellulosic feedstocks. A design where
only virgin wood and/or pelletized or briquetted cellulosic material is
consumed would allow a slightly larger single reactor system to be feasible.
Flexibility in feedstock type and density are essential in accommodating
unknown future markets. A feed rate of 1,000 dry metric tons/day is also
considered to be more manageable with current mature designs of available
feedstock handling equipment. A 1,000 dry metric tons/day system is also
considered to be near the maximum size that could be modularized and/or
shop fabricated. Modularized systems lend themselves to potential cost
savings over stick built systems erected in the field.
Moisture content of the feedstock is also important for many reasons when
considering liquid fuels production in a GTL plant. Typically, drying biomass
to 10-20% moisture content is considered the optimum for minimizing the size
and cost of the entire GTL plant. Moisture in the biomass has several negative
Report 30300/01
2-3
impacts on the process. First, consumption of energy for drying (vaporization

of the moisture) lowers the reactor temperature and results in the production of
lower energy syngas and lower yields of syngas. Second, moisture in the
syngas increases the volumetric flow of syngas, requiring larger downstream
equipment such as; piping, cyclones, vessels, HRSGs, baghouses, synthesis
reactors, etc., and increasing the gasifier system capital cost. Third, water
vapor reduces the volumetric heat content of syngas and causes the gas to
become progressively harder to burn as the moisture content is increased. Note
that the third, moisture impact, only applies to a gas being produced for direct
combustion in equipment or engines. Also note that the biomass drying and
associated air emissions equipment that is required upstream of the gasification
equipment also greatly impacts the capital cost of the complete plant. A cost
benefit study is recommended to determine the optimum target biomass
moisture content and answer the many questions about process factors and
capital cost implications.
The feedstock particle size on the other hand is not strictly limited to a common
basis, as different technologies require and/or operate more efficiently at
various particle size distributions. Generally, the speed at which fuel particles
heat up (i.e. heat transfer rate) decreases as particle size increases, resulting in
the production of more char and less tar. Bed utilization and uniformity, for
instance, is important for efficient and consistent operation in a bubbling fluid
bed reactor. In many cases, bubbling fluid bed vendors target a biomass size of
approximately 2.0 to 2.5 minus, with a limit on the amount of smaller material
and fines content. On the other hand, circulating fluid bed reactors typically
need to maintain a minimum transport velocity, which is a function of the size
and density of the feedstock particles with a similar target biomass size of
approximately 2.0 to 2.5 minus. A smaller biomass size can benefit some
technologies; however, capital and operating costs increase with reduced
material size. Generally, the design of the feedstock handling and feeding
equipment has a large, if not overriding impact on the target size of the
biomass feedstock.
3.2.
Air Verses Oxygen Blown Gasifier Operation

This study was designed to investigate biomass gasification and tar reforming
technologies that are capable of producing synthesis gas (syngas) suitable for
biological or catalytic conversion to transportation fuels in a gas to liquids plant
(GTL). Syngas is defined as a gas mixture that contains varying amounts of
carbon monoxide and hydrogen, and very often some carbon dioxide, water,
light hydrocarbons (methane, ethane, etc.) and tars. Producing syngas that will
ultimately be converted to liquid fuels typically requires a gasifier that utilizes
oxygen and/or steam as the oxidant. Air can also be used as the oxidant and
means of fluidization; however, in order to supply the required amount of
Report 30300/01
2-4
oxygen from air, a large volume of nitrogen will be introduced, which dilutes
the syngas and reduces the concentration of hydrogen (H2) and carbon
monoxide (CO), thereby reducing the syngas heat value. In addition,
processing a dilute syngas stream requires much larger and more expensive
downstream equipment. Typically, a low heat value, dilute syngas is referred
to as a producer gas (pgas) and is only used as a fuel gas for repowering
natural gas fired unit operations or engines. Syngas, on the other hand, is
better suited for conversion to liquid fuels and chemicals.
The higher heating value (HHV) of syngas depends on the biomass type,
biomass moisture, combustion air/oxygen temperature and the reactor
configuration/type. Typical data is as follows:
Air blown autothermal or direct gasifiers produce a pgas with an
HHV of 140-160 Btu/scf, with a possible range of 120-210 Btu/scf.
O2 /steam blown autothermal or direct gasifiers produce a syngas
with an HHV of 350-400 Btu/scf, with a possible range of 320-560
Btu/scf.
Allothermal or indirect gasifiers produce a syngas with a heat value
typically around the higher range of the O2 /steam blown
autothermal configuration.
Conversion of H2 and CO to liquid hydrocarbons requires either a catalyst
(FischerTropsch process) or a biological process (INEOS, Coskata, Inc., etc.).
The H2 to CO ratio of the syngas is also of particular importance to the syngas
conversion process, although a variety of syngas compositions can be used.
3.3.
Reactor Type
Only bubbling fluid bed and circulating fluid bed designs were reviewed for
this report. Fixed bed and high temperature slagging gasifiers were not
reviewed at this time.
Product gases from fixed-bed versus fluidized bed gasifier configurations vary
significantly. Fixed-bed gasifiers are relatively easy to design and operate and
are best suited for small to medium-scale applications with thermal
requirements of up to a few mega watts thermal (MWt). For large scale
applications, fixed bed gasifiers may encounter problems with bridging of the
biomass feedstock and non-uniform bed temperatures. Bridging leads to
uneven gas flow, while non-uniform bed temperature may lead to hot spots
and ash deformation and slagging. Large scale applications are also
susceptible to temperature variations throughout the gasifier as a result of poor
Report 30300/01
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mixing in the reaction zone. Most fixed-bed gasifiers are air-blown and
produce low-energy pgas, although oxygen-blown designs have been tested.
HGIs assessment indicates that fixed-bed gasifiers are not ideal for producing
a syngas of sufficient quality for conversion to liquid hydrocarbons, and such
gasifier technology was not included in the study.
Similarly, high temperature slagging gasifier technologies were not included in
the study due to the cost prohibitive nature and the limited availability of
information and resources for processing biomass with those technologies.
Pressurized gasification systems lend themselves to economical syngas
production and can also be more flexible in production turndown depending
on the reactor design. Typically this is the case for both a pressurized bubbling
and circulating fluidized bed reactor, while the flexibility of an atmospheric
fluidized bed reactor is typically limited to narrower pressure and production
ranges. In summary, both designs are well suited for pressurized syngas
production. Pressurized designs require more costly reactors, but the
downstream equipment (gas cleanup equipment, heat exchangers, synthesis
reactors, etc.) will consist of fewer and less expensive components.
3.4.
Tar Reformer
In addition to the expense of the gasifier, another key contribution to the capital
cost for biomass GTL projects is the need for a tar reformer. The three
technologies that were reviewed in this study each included a different tar
reformer technology, thus three options were analyzed and are discussed as
part of the integrated gasification systems. Because Fischer-Tropsch catalysts
and biological matter are sensitive to poisoning by sulfur-containing
compounds as well as other contaminants, further syngas cleanup beyond tar
reforming is required prior to conversion to liquid hydrocarbons. Note that
while this assessment investigates tar reforming as an initial gas cleanup step, it
does not include an investigation of further gas cleanup or polishing
technologies.
Tar reforming technologies are utilized to breakdown or decompose tars and
heavy hydrocarbons into H2 and CO. This reaction increases the H2/CO ratio
of the syngas and reduces or eliminates tar condensation in downstream
process equipment. Tar reforming can be thermally and/or catalytically
driven. Thermal biomass tar reformer designs are typically fluid bed or fixed
bed type. Catalytic tar reformers are filled with heated loose catalyst material
or catalyst block material and can be fixed or fluid bed designs.
Report 30300/01
2-6
4.
STUDY OBJECTIVES
The objectives of this study were twofold. The first objective was to review technical
and performance data, determine the engineering requirements of applicable gasifier
systems and summarize those findings. The second goal was to prepare preliminary
capital cost estimates for the core gasification system equipment (Technologies #1, #2
& #3). The core equipment includes but is not limited to the following items:
Biomass feed system associated with the gasifier (the feedstock receiving,
handling and pre-processing equipment is not included)
Gasifier reactor(s)
Tar reforming system reactor(s)
Auxiliary equipment as follows:
o Cyclones
o Ash handling equipment
o Bed and/or sorbent media makeup equipment
o Startup equipment
o Blowers/compressors
o Air heaters
o Combustion equipment
o Air separation equipment (oxygen and nitrogen production)
Secondary equipment (e.g. control systems) and all contractor and owner supplied
materials (e.g. process instrumentation, cabling, concrete, structural steel, buildings,
piping etc.) are included in the capital costs estimates. For further information and
details on the cost estimates, see Section 5.
Note that this technology assessment not only estimates the current capital costs for
the gasification and tar reforming technologies, but it also includes a brief discussion
of the capital cost implications concerning nth plant designs.
Report 30300/01
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5.
MODELING AND DETAILED CAPITAL COST ESTIMATES

5.1.
Model Design
NRELs need for a technology model to analyze the impact of gasification
system design on capital costs for various design parameters (e.g. system
capacity, reactor pressures, design temperatures, etc.) led to the development of
four Microsoft Excel models.
5.1.1.
CFB Gasifier Model

This model is based on a circulating fluid bed design with an
allothermal circulating fluid bed gasification system and an
allothermal circulating fluid bed syngas reforming system. This
particular gasification process includes four fluid bed reactors: a
gasifier reactor and a char combustion reactor in the gasifying loop
and a syngas reformer reactor and syngas reformer bed media heating
reactor in the reforming loop. The model does not include biomass
feed equipment.
5.1.2.
BFB Gasifier Model

This model is based on a bubbling fluid bed design with an
autothermal bubbling fluid bed gasification system. This particular
gasification process includes a single fluid bed reactor and a single
syngas cyclone separator for removing particulates from syngas. The
model does not include a syngas reforming system or biomass feed
equipment.
5.1.3.
High Pressure Biomass Feed Model

This model is based on a two bin design with a lock hopper as the first
bin and a metering bin as the second bin.
5.1.4.
Low Pressure Biomass Feed Model

This model is based on a single metering bin design with a rotary
valve providing the pressure lock between the metering bin and the
gasifier.
5.2.
Model Outputs
From a set of input parameters entered into Design Criteria Input Tables
(Excel), the models produce the following output documents:
Material Balance (Excel)
Material Balance Flow Diagrams (Excel)
Report 30300/01
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Equipment List (Excel)

Equipment Drawings (Excel)
Drawing List (Excel)
Detailed Capital Cost Estimate (Excel)
The following documents are also produced, but they do not automatically
change when changes are made to the Excel model.
Process Flow Diagram (AutoCAD)
General Arrangement Drawing (AutoCAD)
Gasification/Syngas Reforming Building Isometric Drawing
(AutoCAD)
Gasification/Syngas Reforming Building Elevation Drawings
(AutoCAD)
6.
CAPITAL COST COMPARISONS

A Capital Cost Comparison Table is included in Appendix I, which compares the
order of magnitude cost estimates from the three gasification technologies with
detailed cost estimates from combinations of the Microsoft Excel models.
Report 30300/01
2-9
Project 30300.00
NREL
Golden, Colorado
August 3, 2012
REPORT 30300/01
SECTION 3
TECHNOLOGY DESCRIPTIONS
1.
GASIFIER ISLAND TECHNOLOGY #1

1.1.
General
The Technology #1 gasifier island consists of a pressurized, directly heated
biomass gasification system capable of producing a synthesis gas (syngas) that
can be converted to liquid fuels via catalytic or biological processes. This
particular gasification process employs a single, bubbling fluid bed reactor for
gasifying biomass with oxygen to produce syngas. A catalyst filled, fixed bed
reactor is used for tar reformation. The island includes a biomass handling and
feed system, a gasifier, a tar reformer, a bed media handling and feed system,
an oxygen handling and injection system, and an ash removal system.
The gasifier system is a direct or autothermal operation, meaning the energy
used for heating and maintaining the gasification reaction temperature is
supplied by the combustion of a portion of the biomass material processed.
The gasifier is designed to handle a variety of biomass feedstocks of varying
size and moisture contents. The gasifier feed rate is 1,000 oven dry metric
tons/day of biomass (wood residue composed of wood chips and bark) with a
20% moisture content and a higher heat value (HHV) of approximately 8,458
Btu/dry lb.
Oxygen is added to the gasifier to gasify the biomass feedstock and form
hydrogen and carbon monoxide. Dolomite bed material, medium pressure
steam, and recycled syngas are also added with the biomass to form and
stabilize the bubbling fluid bed.
The gasifier is operated at a temperature of approximately 1,560 F and a
pressure of 130 PSIG to produce 172,000 lbs/hr of wet syngas. Note that the
syngas production from the island (tar reformer outlet) is actually greater than
172,000 lbs/hr due to the additional oxygen and steam added to the tar
reformer.
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A flow diagram depicting the system is located in Appendix A.

1.2.
Biomass Storage and Metering System

The gasifier island begins with a biomass handling system. Dried biomass is
first deposited on an owner-supplied distribution conveyor, which transfers the
biomass to three parallel lines for pressurization and metering to the gasifier.
Each line is composed of atmospheric weigh bin storage silos, lock hoppers,
storage bins and screw conveyors. Each storage silo is equipped with a live
bottom screw to convey biomass to the center of the silo for discharge to a
reversing conveyor beneath the silo. The three reversing conveyors each feed a
pair of lock hopper bins (a total of 6 bins) to permit pressurization of the
biomass to the pressure of the gasifier. Nitrogen gas is used to pressurize the
lock hoppers, prior to exposing them to the gasifier pressure, and prevent hot
gases from entering the lock hoppers.
Each pair of lock hoppers is staged to allow the filling of one while the second
one is being discharged to a metering bin. To facilitate an automated
operation, the lock hoppers are equipped with pneumatic inlet and outlet slide
gates. Although lock hopper staging is a batch operation, the staging
frequency can be increased or decreased to keep an operating level in the much
larger downstream surge hoppers. The three surge hoppers are equipped with
bottom discharge screw conveyors for separately metering biomass to each of
the three gasifier in-feed screws.
The lock hoppers, surge hoppers, discharge metering screws and gasifier infeed screws are designed for a maximum allowable working pressure (MAWP)
of 130 PSIG, the operating pressure of the gasifier.
All other biomass unloading, handling and storage equipment is ownersupplied. These items include but are not limited to truck unloading,
screening/sizing, as received storage, drying, dryer air emissions abatement
equipment, dry storage, and all conveyance and transport equipment prior to
the weigh bin storage silos.
1.3.
Bed Media Storage and Metering System

Dolomite is used to form and stabilize the gasifiers bubbling fluid bed.
Dolomite is delivered by truck or railcar to the plant site where it is
pneumatically conveyed to a bed material storage silo. Bed material is
transferred by gravity from the storage silo to a weigh hopper and from there
to a lock hopper for pressurization to the gasifier pressure. Nitrogen gas is
used to pressurize the lock hopper to prevent hot gases from entering the lock
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hopper from the gasifier. The lock hopper is equipped with a bottom discharge
screw conveyor for metering bed material to one of the gasifier in-feed screws.
1.4.
Air Separation Plant

Equipment for the supply of oxygen and nitrogen are not part of the vendors
scope of supply. An oxygen rich gas stream can be supplied by either an air
separation plant (Vacuum-Pressure Swing Adsorption (VPSA) or cryogenic) or
a liquid oxygen system using purchased liquid oxygen. For the purposes of
this report, it was assumed that a VPSA air separation plant is used to produce
both oxygen and nitrogen. The air separation plant, oxygen receiver, oxygen
booster compressor and nitrogen receiver are included in the owners scope of
supply.
1.4.1.
Oxygen Gas Supply System

An oxygen rich gas stream, containing 90-92% oxygen by weight, is
needed to combust biomass in the gasifier. Oxygen rich gas from the
oxygen receiver at the air separation plant is pressurized by the
oxygen booster compressor to about 180 PSIG and is stored in a
vendor-supplied surge tank. Oxygen from the surge tank is routed
through a vendor-supplied heat exchanger, where medium pressure
steam is used to indirectly pre-heat the oxygen gas stream to
approximately 390 F for introduction to the gasifier.
1.4.2.
Inert Gas (Nitrogen) Supply System

Nitrogen gas is used throughout the gasifier island for the following
purposes:
Biomass storage and metering system pressurization.
Dolomite bed material storage and metering system
pressurization.
Ash handling systems pressurization.
Fire suppression and emergency shutdown systems.
Instrument gas.
A nitrogen booster compressor and two nitrogen storage tanks are
included as part of the vendors scope of supply. An emergency
booster compressor and high pressure nitrogen storage tank are also
included for the safety systems.
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1.5.
Steam Supply System

Medium pressure saturated steam is supplied by the owner at a pressure of
approximately 200 PSIG for oxygen heating, startup heating and gasifier
operation.
1.6.
Cooling Water Supply System

A closed loop high pressure cooling water system is included as part of the
gasifier package. Owner-supplied cooling water is required to indirectly cool
the high pressure cooling water system. The system includes two high
pressure circulation pumps, an expansion tank, and a heat exchanger.
1.7.
Gasifier
The gasifier partially combusts biomass feedstock with oxygen to form
hydrogen and carbon monoxide. The gasifier operates at a temperature of
approximately 1,560 F and a pressure of 130 PSIG. Due to the high
combustion temperature, the gasifier vessel is constructed with a refractory
lining to protect the integrity of the steel shell. Dolomite, medium pressure
steam and a recycled portion of syngas and ash are also introduced into the
bottom of the gasifier to form and stabilize the bubbling fluid bed. The upper
portion of the gasifier vessel allows the bed material and syngas to separate,
reducing the amount of solids carryover with the syngas.
As described above, three in-feed screw conveyors are used to feed dried
biomass and dolomite bed material to the bottom of the gasifier. Since the
pressurized in-feed screw conveyors are exposed to hot gases from the gasifier,
they are designed with water cooling coils for protection.
Syngas is discharged at the top of the gasifier vessel and routed to the gasifier
cyclone for particulate (char, bed material, un-reacted biomass, etc.) recovery.
1.8.
Ash/Char Discharge System

A portion of the dolomite bed material and ash from fuel combustion are
periodically removed from the bottom of the gasifier and discharged to an ash
removal screw conveyor. The water cooled screw conveyor is exposed to the
gasifier pressure and discharges dolomite and ash to a lock hopper where the
material is depressurized. The dolomite and ash then discharge to a conveyor
hopper for pneumatic transfer to an ash storage silo where material is
accumulated for disposal.
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1.9.
Gasifier and Tar Reformer Startup Burners

The gasifier is equipped with a light fuel oil (LFO) burner for pre-heating the
gasifier pressure vessels refractory lining and other downstream systems prior
to introduction of the biomass. The tar reformer is also equipped with a light
fuel oil burner at the top of the vessel for pre-heating purposes as well. Note
that natural gas can be substituted for LFO with a modification in burner
design. The LFO system also includes a booster pump and piping.
An air system, including an air compressor and an air receiver tank, is also
included for supplying combustion air to the startup burners.
1.10.
Dust Collection Cyclone

Syngas exits the gasifier and is routed through a refractory lined cyclone
separator vessel where ash and entrained bed material are removed. The bulk
of the entrained particulate is removed from the syngas in the cyclone. The
cyclone is efficient enough to keep particulate concentrations below a level
acceptable for the tar reformer. The particulate dust is returned through the
cyclone dropleg to the fluidized bed of the gasifier for further carbon
conversion.
1.11.
Tar Reformer
The tar reformer utilizes a catalyst to decompose tars and heavy hydrocarbons
into hydrogen and carbon monoxide. Without this decomposition the tars and
heavy hydrocarbons in the syngas will condense as the syngas is cooled in the
down-stream process equipment. In addition, the tar reformer increases the
hydrogen/carbon monoxide ratio for optimal conversion.
The tar reformer is a refractory lined steel vessel equipped with catalyst blocks.
The catalyst is a noble metal or a nickel enhanced material. Syngas is routed to
the top of the vessel and flows down through the catalyst blocks. Oxygen and
steam are added to the tar reformer at several locations along the flow path to
enhance the syngas composition and achieve optimum performance in the
reformer.
Medium pressure steam is also piped to nozzles on the tar reformer vessel to
provide pulsing steam for removal of ash dust from channels in the catalyst
blocks.
Syngas is routed from the tar reformer to downstream heat recovery and gas
cleanup unit operations. The tar reformer outlet is the boundary of the
vendors scope of supply.
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1.12.
Gasifier Control System

The gasifier system includes a digital distributed control system (DCS), which
integrates main logic, human interface, field bus, and distributed I/O devices.
All critical systems are double protected. The control system equipment and
I/O cabinets are located in an electrical room. A data collection and reporting
system is also included with the control system.
All field instruments for measuring pressure, temperature, flow, etc. are
included. In addition, special instruments such as various gas analysis devices
and special reactor bed level control devices are also included.
An instrument air supply system is not included in the vendors scope of
supply. However, since excess nitrogen is available from the air separation
plant (nitrogen receiver), nitrogen is used in place of instrument air. An
instrument air tank included in the vendors scope of supply is converted to a
nitrogen tank for surge capacity.
1.13.
Miscellaneous Systems
1.13.1.
Seal Water System

The seal water system includes both low pressure and high pressure
sub-systems. The high pressure seal water sub-system includes a seal
water tank, two seal water pumps, a seal water cooling heat exchanger
and associated piping. Process water is used for makeup to the seal
water system to account for any losses or blowdown.
1.13.2.
Process Air System

A compressed air system for general process needs is not included in
the vendors scope of supply. However, an owner-supplied system is
included and is comprised of an air compressor, an air dryer and a
receiver. The process air receiver supplies pressurized air for general
plant needs and is also used to supply compressed air to the air
separation plant for O2 and N2 generation.
1.13.3.
Flare Stack
During start-ups, shutdowns and emergency stop events, syngas is
routed to an owner-supplied flare stack for incineration and exhaust to
the atmosphere.
1.13.4.
Piping and Valves

Various gas piping is included in the vendors scope of supply,
consisting of items such as the gasifier to cyclone line, the cyclone to
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tar reformer line, and the cyclone dropleg return line to the gasifier.
All gas piping is refractory lined.
Most of the process piping is included in the vendors scope of supply,
consisting of services such as inert gas, LFO, instrument air, oxygen,
recycle gas, HP cooling water, HP seal water, HP feed water, and
dolomite pneumatic conveying. Note that distribution manifolds and
control valves are also included. All hot process piping is insulated.
All process valves are included.
1.13.5.
Electrical
All electrical systems are included in the vendors scope of supply,
consisting of items such as a distribution transformer, low voltage
switch-gear, power cabling, control cabling, cable ways, frequency
converters, grounding systems, UPS, motors and AC-drives, and
wiring to furnish power to automation and process protection systems.
An electrical room to house the switch gear and automation equipment
is part of the owners scope of supply. The electrical room will be
equipped with ventilation, air conditioning and filtering.
1.13.6.
Building/Structural
The main process equipment is located in an owner-supplied steel
building that includes all structural components as well as access to all
equipment. The building sits on a reinforced concrete floor with all
other elevated floors constructed from steel. The building also
includes an elevator, two staircases, three 10-ton cranes, and a hoist
shaft. Pipe bridges, platforms and steel structure as related to
equipment support are vendor supplied.
1.13.7.
Gasifier Safety Systems

All critical gasifier system components, valves and equipment are
protected by a safety logic system that is separate from the process
control system.
1.13.8.
Burner Safety Systems

The startup burners on the gasifier and tar reformer are equipped with
flame safety systems which are separate from the process control
system.
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1.14.
Utility Requirements
The utilities required for operation are as follows:
Oxygen at 90-92% purity, 68 F and 210 PSIG.
Nitrogen at 98% purity, 68 F and 210 PSIG.
Instrument air at 68 F and 130 PSIG, assume nitrogen.
Light fuel oil at 75 PSIG (note that natural gas can be substituted with a
modification in burner design).
Medium pressure steam at approximatley 200 PSIG, saturated.
Cooling water at 115 F and approximatley 45 PSIG.
Process water for makeup to high pressure seal water system, hose
stations and other users (temperature and pressure is unknown).
Potable water for emergency eye wash and showers.
Ambient air.
2.

2.1.
General
The Technology #2 gasifier island consists of an atmospheric, indirectly heated
biomass gasifier system capable of producing a syngas that can be converted to
liquid fuels via catalytic or biological processes. This particular gasification
process uses three fluid bed reactors: a gasification reactor, a gas conditioning
reactor (tar reformer) and a combustion reactor (heat source). The gasification
and combustion reactors employ circulating fluid beds, while the gas
conditioning reactor uses a bubbling fluid bed. The island includes a biomass
handling and feed system, a gasifier, a combustion reactor, a tar reformer, a
bed media handling and feed system, a combustion air system, an oxygen
handling and injection system, and an ash removal system.
The gasifier system is an indirect or allothermal operation, meaning the energy
applied indirectly by heating the bed material from the combustion of the char
in the combustion reactor.
size and moisture content. The gasifier feed rate is 1,000 metric tons/day of
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dry biomass (wood residue composed of wood chips and bark) with a 10%
moisture content. The chip size is specified as 2.0 inch minus with no fines
specification.
Saturated low to medium pressure steam at a pressure of approximately 20 to
150 PSIG is required and added to the gasifier for bed fluidization. A natural
mineral bed material (the exact composition has not been disclosed) is also
added with the biomass to form the fluidized bed. Note that oxygen is not
added to the gasifier reactor because the gasification reactions are driven by
indirect heating. Oxygen via air is however added to the combustion reactor to
produce the necessary heat which is transferred to the bed material.
The gasifier system is operated at a temperature of 1,560 F and a pressure of
1.0 PSIG to produce approximately 1,580,000 standard cubic feet per hour of
dry syngas.
2.2.

metered to the gasifier through four parallel lines of storage bins and screw
conveyors. The low operating pressure of the gasifier system produces syngas
with a pressure of approximately 1.0 PSIG. This low pressure operation allows
for a simpler biomass feed system.
Dried biomass is first deposited on an owner-supplied delivery conveyor,
which transfers the biomass to the inlet of a weigh bin. The weigh bin feeds a
lock hopper via a twin screw discharger and rotary discharge device. The lock
hopper then feeds a pressurized metering bin that conveys the biomass to the
gasifier via a screw conveyor. The lock hoppers, metering bins and in-feed
screws are all designed for pressurized operation.
screening/sizing, as-received storage, drying, dryer air emissions abatement
the weigh bin storage silos.
2.3.
Bed Media Storage and Metering System

The bed media makeup system meters bed material to the gasifier to make up
for any bed material lost as a result of carryover in the syngas and/or
combustor flue gas. The bed media is a natural mineral, although, the exact
composition has not been disclosed. The media is delivered by truck or railcar
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to the plant site where it is pneumatically conveyed to a bed material storage

silo by owner-supplied equipment. The media is discharged from the bed
media storage silo to another pneumatic conveyance system which feeds
directly into the bed material surge vessel. Bed media is systematically purged
from the bed material surge vessel to a water-cooled discharge screw conveyor
which moves purged material to an owner-supplied disposal system.
2.4.

Equipment for the supply of nitrogen is part of the vendors scope of supply.
The nitrogen gas stream is supplied by a VPSA air separation plant. An inert
gas generator could be substituted for the VPSA air separation plant if a cost
analysis showed it to be more economical.
2.4.1.
Oxygen Gas
Elemental oxygen is not required for the Technology #2 process.
Therefore, the air separation plants oxygen rich gas stream is vented
to the atmosphere.
2.4.2.

Nitrogen gas at 98% purity is used throughout the gasifier island for
the following purposes:
Bed media storage and metering system pressurization.
Instrument gas.
A nitrogen booster compressor and two nitrogen storage tanks are
included as part of the vendors scope of supply.
2.5.
Steam Supply System

Saturated, low to medium pressure steam is required and supplied by the
owner at a pressure of approximately 20 to 150 PSIG for startup heating and
gasifier bed fluidization.
2.6.

Owner-provided cooling water is supplied to the bed material disposal screw
conveyor.
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2.7.
Gasifier
The gasifier utilizes medium pressure steam and heat from the bed media to
gasify the biomass feedstock and form hydrogen and carbon monoxide.
Saturated 20 to 150 PSIG steam is injected at the bottom of the circulating fluid
bed reactor vessel, where it passes through a distributor to evenly distribute the
steam and facilitate fluidization. No air or oxygen is added to the gasifier. Due
to the high combustion temperature, the gasifier vessel is constructed with a
refractory lining to protect the integrity of the steel shell. Reheated bed
material is introduced into the bottom portion of the gasifier to provide heat
and help form the fluidized bed. The circulating fluid bed gasification reactor
is a non-coded vessel operating at atmospheric pressure.
Due to the fast fluidization and the high gas velocities, the biomass material
becomes thoroughly mixed with the bed material to enhance the heat and mass
transfer. The biomass is rapidly converted into syngas at a temperature of
approximately 1,560 F.
As described above, two in-feed screw conveyors are used to feed dried
biomass and bed material to the bottom of the gasifier. The in-feed screw
conveyors are not designed with any cooling systems.
No bed material is removed or purged from the gasifier, rather a portion of the
bed media is carried out with the syngas to the gasifier cyclones.
Syngas is discharged at the top of the gasifier vessel and is routed to the
cyclone for char and particulate removal.
2.8.
Gasifier Cyclone
Any unconverted biomass, along with the cooled bed material, is carried out of
the gasification reactor to two cyclones in series, where char and bed material
are separated from the syngas. The bed material and char exit from the bottom
of both gasifier cyclones and enter the ash surge bin. The bed material and char
are then fed to the bottom of the combustion reactor for combustion of the char
and reheating of the bed media.
Syngas exits the top of the second gasifier cyclone and enters the bottom of the
gas conditioning reactor for tar reforming.
2.9.
Combustion Reactor and Combustion Air System

The circulating fluid bed combustion reactor is a non-coded vessel operating at
atmospheric pressure. The fluid bed reactor is a refractory lined pressure
vessel with a distributor located at the bottom of the vessel to facilitate
Report 30300/01
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fluidization. A centrifugal fan blows ambient air through a combustion air

heater, where the air is indirectly heated to approximately 1,000 F with the
flue gas produced by the combustion reactor. The heated combustion air is
then injected beneath the distributor to achieve fluidization. The combustion
process consumes the char and reheats the bed material to approximately 1,000
C or 1,830 F. The remaining carbon is consumed in the combustion reactor,
resulting in a carbon-free ash.
2.10.
Combustion Cyclone
The reheated bed material is separated from the char combustion reactor flue
gas in a cyclone and is returned to the gas conditioning reactor for tar
reforming of the syngas. The flue gas then exits the top of the combustion
cyclone and is routed to the ash cyclone for further solids/dust removal.
2.11.
Combustion Reactor Startup Burner

The combustion reactor is equipped with a natural gas burner for pre-heating
the reactors refractory lining and to provide heat to the rest of the vessels in
the system to bring them up to operating temperature prior to introduction of
the biomass.
2.12.
Ash Cyclone and Char Discharge System

The flue gas stream from the combustion reactor is cleaned of any remaining
ash and particulate matter by the ash cyclone before exiting the system. After
cleaning, the hot flue gas at approximately 1,000 C or 1,830 F is then used to
heat combustion air for the combustion reactor. The cooled flue gas exits the
air heater and is pulled through an exhaust fan to a vent stack, where it is
vented to the atmosphere. Note that there is sufficient heat remaining in the
flue gas that it could be used for further heat recovery prior to venting.
Ash removed by the cyclone is discharged through a rotary valve to the ash
transfer screw conveyor. This screw conveyor is water-cooled. The ash
transfer screw conveyor discharges cooled ash to the ash bin for accumulation
prior to disposal. Ash is discharged from the ash bin to the ash discharge
screw conveyor where a small amount of process water is mixed with the ash
to form a damp mixture with a reduced tendency to create dust during
subsequent handling.
2.13.
Gas Conditioning Reactor (Tar Reformer)

Tar reforming is accomplished via an integral thermal conditioning reactor that
utilizes the heated bed material from the combustion reactor to provide heat for
the reactor. Heated bed material from the combustion reactor cyclone is routed
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to the top of the gas conditioning reactor, and syngas from the second gasifier
cyclone is routed to the bottom of the gas conditioning reactor. The upward
flowing syngas passes through a distributor, which is located near the bottom
of the vessel, to fluidize the bed material and form a bubbling fluid bed. Tar
reformed syngas is discharged from the top of the gas conditioning reactor.
Tar reforming occurs when water vapor in the incoming syngas is heated to a
sufficient temperature to cause steam reforming in the gas conditioning reactor,
converting condensable hydrocarbons (tars) to non-condensable lower
molecular weight molecules. The residence time in the conditioning reactor is
sufficient to also allow a water gas shift reaction to occur and generate
increased amounts of hydrogen in the syngas.
The steam reforming reactions and the water gas shift reaction are balanced
thermally so that no cooling of the circulating solids takes place. The
temperature of the bed material entering and exiting the gas conditioning
reactor is approximately 1,000 C or 1,830 F.
The gas conditioning reactor is a refractory lined, non-coded vessel operating at
atmospheric pressure. No air or oxygen is added to the gas conditioning
reactor. As the level of the bed material in the reactor increases, it reaches a
level where it continuously overflows into the bed material surge vessel from
which it is fed into the gasification reactor.
Syngas exits the top of the gas conditioning reactor and is routed to additional
owner-supplied equipment for further processing. The temperature of the
syngas at this point is approximately 1,000 C or 1,830 F. Typically, syngas is
routed through heat exchange equipment to cool the syngas and transfer heat
to a steam generator or water heating system. Additional cleanup of the cooled
syngas usually follows the heat exchange operation. Because of the significant
reduction in condensable material that occurred in the gas conditioning reactor,
the syngas can be cooled to low temperatures to increases the heat recovery
potential without the fear of buildup or fouling of the heat exchange surfaces.
2.14.

The gasifier system includes a programmable logic controller (PLC) based
control system with a human-machine interface (HMI) and the necessary
computer systems to operate the software.
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supply. However, since nitrogen is available from the air separation plant
(N2 receiver), nitrogen is used in place of instrument air. An instrument air
tank included in the vendors scope of supply is converted to a nitrogen tank
for surge capacity.
2.15.
2.15.1. Seal Water System
Seal water is not required for Technology #2.
2.15.2. Process Air System

separation plant for nitrogen generation.
2.15.3. Flare Stack
routed to an owner-supplied flare stack for incineration and exhaust to
the atmosphere.
2.15.4. Piping and Valves
All syngas piping and process piping is included in the vendors scope
of supply. All high temperature gas piping is refractory lined. All
other hot process piping will be externally insulated.
2.15.5. Electrical
consisting of items such as motor control centers (MCCs), power
cabling, control cabling, cable ways, UPS, motors, and wiring to
furnish power to automation and process protection systems.
2.15.6. Building/Structural
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The main process equipment is located in a vendor-supplied steel

structure that includes all structural components as well as access to all
equipment. The building sits on an owner furnished reinforced
concrete floor. The structure does not include a roof or siding.
2.15.7.

All critical components, valves and equipment are protected by a
safety logic system separate from the process control system.
2.15.8.

The startup burner on the combustion reactor is equipped with flame
safety systems which are separate from the process control system.
2.16.
Nitrogen at 98% purity, temperature and pressure is unknown.
Instrument air, temperature and pressure is unknown, assume nitrogen.
Natural gas, pressure is unknown.
Low to medium pressure steam at 20 to 150 PSIG, saturated.
Cooling water, temperature and pressure is unknown.
Process water for hose stations and other, temperature and pressure is
unknown.
Ambient air.
3.

3.1.
General
The Technology #3 gasifier island consists of a pressurized, directly heated
biomass gasification system capable of producing a syngas that can be
converted to liquid fuels via catalytic or biological processes. This particular
gasification process employs a single, bubbling fluid bed reactor for gasifying
biomass with oxygen and steam to produce syngas. The process utilizes a tar
reformer; however, the design was not revealed by the vendor. The island
includes a biomass handling and feed system, a gasifier, a tar reformer, a bed
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media handling and feed system, an oxygen handling and injection system,
and an ash removal system.
The gasifier system is a direct or autothermal operation, meaning the energy
supplied by the combustion of a portion of the biomass material processed.
size and moisture contents. The gasifier feed rate is 1,000 metric tons/day of
dry biomass (wood residue composed of wood chips and bark) with a 15%
moisture content. The chip size is specified as 2.5 minus and approximately
to thick. At least 25% of the chips by weight are 1 plus and to
thick. The acceptable percentage of fines is undefined at this point.
Oxygen and superheated medium pressure steam are mixed and added to the
gasifier to fluidize the bed and gasify the biomass feedstock to form hydrogen
and carbon monoxide. Silica sand or olivine bed material is also added with
the biomass to form and stabilize the bubbling fluid bed.
The gasifier is operated at a temperature of approximately 1,475 F and a
pressure of 38 PSIG to produce 153,000 lbs/hr of wet syngas with a higher heat
value of 4,216 Btu/wet lb. Note that the syngas production from the island (tar
reformer outlet) is actually greater than 153,000 lbs/hr due to the additional
oxygen and steam added to the tar reformer.
3.2.

first deposited on an owner-supplied distribution conveyor, which transfers the
biomass to six parallel feed lines for pressurization and metering to the gasifier.
Each line is composed of lock hoppers, metering bins and screw conveyors.
Nitrogen gas is used to pressurize the lock hoppers and metering bins, prior to
exposing them to the gasifier pressure, and prevent hot gases from entering the
metering screws and bins.
Each lock hopper and metering bin is equipped with a set of parallel screw
augers that turn simultaneously to create a live bottom that prevents bridging
and moves feedstock to a perpendicularly mounted, external screw conveyor.
The screw speed in each metering bin is adjusted using variable frequency
drives. The six air-lock metering bins are equipped with inlet and outlet
pneumatic slide gates. During operation, each metering vessel can be isolated
from the gasifier with double block and bleed valves to enable repairs, while
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maintaining high gasifier availability. During the metering vessel fill and
discharge cycle, the following sequence is used:
3.2.1.
Low level signal, control system timer, or operator initiates fill cycle
for a metering vessel.
3.2.2.
Feedstock outlet slide gate is closed.
3.2.3.
Metering vessel is depressurized.
3.2.4.
Feedstock inlet slide gate is opened to allow metering vessel to be

filled with biomass material that falls through drag chain conveyor.
3.2.5.
Feedstock inlet slide gate is closed to seal the metering vessel.
3.2.6.
Metering vessel is pressurized to process pressure.
3.2.7.
Feedstock outlet slide gate is opened to permit material to be conveyed

to the gasifier vessel.
3.2.8.
Repeat starting at (1).
The lock hoppers, metering bins, metering screw conveyors and gasifier in-feed
screws are designed for a maximum allowable working pressure (MAWP) of 50
PSIG.
screening/sizing, as-received storage, drying, dryer air emissions abatement
the six metering bins.
3.3.
Bed and Sorbent Media Storage and Metering System

Silica sand or olivine mineral is used to form and stabilize the gasifiers
bubbling fluid bed. The bed media is delivered by truck or railcar to the plant
site where it is pneumatically conveyed to a bed material storage silo. Bed
material is transferred by screw conveyor from the storage silo to a mix tank
surge vessel where it is mixed with recycled screened bed and sorbent media.
From the mix tank, bed media is transferred by gravity to a lock hopper and
from there to the gasifier via a pneumatic conveyor pressurized with nitrogen.
Nitrogen gas is used to pressurize the lock hopper to prevent hot gases from
back flowing into the hopper from the gasifier.
New sorbent media (limestone or dolomite) is separately injected into the
gasifier by using a screw conveyor to transfer sorbent media from a storage silo
to a lock hopper for pneumatic injection into the gasifier.
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3.4.

Equipment for the supply of oxygen and nitrogen are not part of the vendors
scope of supply. An oxygen-rich gas stream can be supplied by either an air
separation plant (Vacuum-Pressure Swing Adsorption (VPSA) or cryogenic) or
a liquid oxygen system using purchased liquid oxygen. For the purposes of
this report, it was assumed that a VPSA air separation plant is used to produce
both oxygen and nitrogen. The air separation plant, oxygen receiver, oxygen
booster compressor and nitrogen receiver are included in the owners scope of
supply.
3.4.1.
Oxygen Gas Supply System

An oxygen-rich gas stream, containing 90-92% oxygen by weight, is
needed to combust biomass in the gasifier. Oxygen-rich gas from the
oxygen receiver at the air separation plant is pressurized by the
oxygen booster compressor to about 180 PSIG and is stored in a
vendor supplied surge tank. Oxygen from the surge tank is mixed
with medium pressure superheated steam prior to introduction to the
gasifier. The oxygen surge tank is part of the owners scope of supply.
3.4.2.

Nitrogen gas is used throughout the gasifier island for the following
purposes:
Bed and sorbent material storage and metering system
pressurization.
Instrument gas.
A nitrogen booster compressor and a nitrogen storage tank are part of
the owners scope of supply.
3.5.
Steam Supply System

Medium pressure saturated steam is supplied by the owner at a pressure of
approximately 125 PSIG for oxygen heating, startup heating and gasifier
operation. Prior to entering the gasifier, the saturated steam is indirectly
superheated with syngas from the tar reformer.
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3.6.

Owner-supplied cooling water is required for the gasifier in-feed screws and
bed media cooling system.
3.7.
Gasifier
The gasifier partially combusts biomass feedstock with oxygen to form
hydrogen and carbon monoxide. The gasifier operates at a temperature of
approximately 1,475 F and a pressure of 38 PSIG. Due to the high combustion
temperature, the gasifier vessel is constructed with a refractory lining to protect
the integrity of the steel shell. Bed media and medium pressure superheated
steam are also introduced into the bottom of the gasifier to form and stabilize
the bubbling fluid bed.
As described above, six in-feed screw conveyors are used to feed dried biomass
to the bottom of the gasifier. Since the pressurized in-feed screw conveyors are
exposed to hot gases from the gasifier, they are designed with water cooling
coils for protection.
Syngas is discharged at the top of the gasifier vessel and routed to the gasifier
cyclone for particulate (char, bed material, un-reacted biomass, etc.) recovery.
Fluidizing bed media is periodically withdrawn from the gasifier for cleaning,
purging, and/or replenishment. The material being withdrawn consists of
primary bed media, sorbent media, and entrained tramp material (e.g., rocks,
metals and other non-combustibles). As material is withdrawn from the
gasifier it is cooled by a flow of fluidization steam. The partially cooled,
withdrawn material is discharged from the cone bottom of the gasifier into a
water-cooled, pressurized screw conveyor where its temperature is reduced to
< 400 F. The screw conveyor discharges the cooled material into a pressurized
surge vessel/lock hopper system to bring the material to atmospheric pressure.
The bed material is then conveyed to a screen where tramp material is
separated from the recyclable bed and sorbent media. Tramp material and
purged bed media are conveyed to a bunker for subsequent disposal.
3.8.
Dust Collection Cyclone

Syngas exits the gasifier and is routed through a refractory lined cyclone
separator vessel where ash and entrained bed material are removed. The bulk
of the entrained particulate is removed from the syngas in the cyclone. It is
assumed that the cyclone is efficient enough to keep particulate concentrations
below a level acceptable for the tar reformer; however, the design of the tar
reformer is unknown. The particulate dust is returned to the fluidized bed of
the gasifier for further carbon conversion.
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3.9.
Ash/Char Discharge System

Technology #3 depicts the recovered particulate material (ash and char) from
the gasifier cyclone being recycled back to the gasifier, with an option for
sending the ash to a conditioning and disposal system. Exercising this option
would involve the addition of a gas filtration step, typically following the tar
reformer reactor, for further particulate removal from the syngas. Ash
conditioning equipment associated with the gas filtration step would then be
sized to handle the particulate carryover from the cyclone. This system would
include a water-cooled ash removal screw conveyor, a lock hopper for
depressurization, and a conveyor hopper for pneumatic discharge to an ash
storage silo for accumulation of material prior to disposal. Note that this ash
conditioning and disposal equipment is outside the scope of this study and is
not included in the cost estimate.
3.10.
Gasifier and Tar Reformer Startup Burners

The gasifier is equipped with a natural gas burner for pre-heating the gasifier
pressure vessels refractory lining and other downstream systems prior to
introduction of the biomass. The tar reformer is also equipped with a natural
gas burner for pre-heating purposes as well.
An air system, including an air compressor and an air receiver tank, is also
included for supplying combustion air to the startup burners.
3.11.
Tar Reformer
The design of the tar reformer was not revealed by the vendor; however, it is
assumed to be a fixed bed design. Such a tar reformer utilizes a catalyst and
heat to assist in decomposing tars and heavy hydrocarbons into hydrogen,
carbon monoxide and other combustible gases. The use and type of catalyst is
unknown. Without this decomposition the tars and heavy hydrocarbons in the
syngas will condense as the syngas is cooled in the down-stream process
equipment. In addition, the tar reformer increases the hydrogen/carbon
monoxide ratio for optimal conversion.
The tar reformer is most likely a refractory lined steel vessel filled with a
catalyst material. The catalyst material type and structure is unknown. The
method of loading and or feeding the catalyst material to the tar reformer
reactor is also unknown. Syngas flows through the tar reformer vessel,
although the direction is unknown. Steam is added to the tar reformer to
adjust the syngas composition as needed to achieve optimum performance.
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Syngas is routed from the tar reformer to downstream heat recovery and gas
cleanup unit operations. The tar reformer outlet is the boundary of the
vendors scope of supply.
3.12.

The gasifier system includes AllenBradley ControlLogix Programmable
Automation Controllers (PAC) hardware, an engineering work station and one
operator work station, including humanmachine interface (HMI) software.
The PAC modules are mounted in control panels, prewired and delivered to
the jobsite with field wiring connections ready for installation. A controls
program for monitoring and controlling the process is also included.
This system controls most aspects of normal startup, continuous operation,
normal shutdown, soft shutdown, emergency shutdown and emergency stop
via proven and tested automated sequence controls. Such a control system
greatly reduces human error and provides a safer, more uniform operation of
the unit.
The gasifier control system modulates the gasifier air supply to achieve a
gasifier freeboard pressure appropriate for the required syngas capacity. The
gasifier freeboard pressure set-point is allowed to float as needed to achieve the
optimum gas velocity (or range) in the dense phase of the fluid bed reactor.
Gasifier temperatures are held to a set point value using feedback-control
modulation of the biomass feed rate.
supply. However, since nitrogen is available from the air separation plant
(N2 receiver), nitrogen is used in place of instrument air. An instrument
nitrogen tank for surge capacity is part of the owners scope of supply tank.
3.13.
3.13.1. Seal Water System
Seal water is not required for Technology #3.
3.13.2. Process Air System

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separation plant for oxygen and nitrogen generation.
3.13.3.
Flare Stack
routed to a vendor-supplied flare stack for incineration and exhaust to
the atmosphere.
3.13.4.
Piping and Valves

All syngas piping and process piping is included in the vendors scope
of supply. All high temperature gas piping is refractory lined. All
other hot process piping will be externally insulated.
3.13.5.
Electrical
consisting of items such as motor control centers (MCCs), power
cabling, control cabling, cable ways, UPS, motors, and wiring to
furnish power to automation and process protection systems.
3.13.6.
Building/Structural
The main process equipment is located in a vendor supplied steel
structure that includes all structural components as well as access to all
equipment. The building sits on an owner furnished reinforced
concrete floor. The structure does not include a roof or siding.
3.13.7.

All critical components, valves and equipment are protected by a
safety logic system separate from the process control system. Items in
the safety system include but are not limited to the following:
Pneumatically operated process control valves with appropriate
open/closed/last fail positioning.
Hard-wired e-stop circuit for critical process instrumentation.
Hard-wired components include code vessel rupture disks,
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strategically located emergency stop pushbuttons, and high

temperature limit switches for gasifier exit temperature.
Appropriate overpressure protection of ASME code stamped
vessels.
Redundant instrumentation for critical process conditions.
Robust control system with appropriate operator limits.
Uninterruptable power supply for gasifier control system to
provide ongoing operator access to equipment and process
conditions.
3.13.8.

The startup burners on the gasifier and the tar reformer are equipped
with flame safety systems which are separate from the process control
system.
3.14.
Oxygen at 90-92% purity, temperature and pressure is unknown.
Nitrogen at 98% purity, temperature and pressure is unknown.
Instrument air, temperature and pressure is unknown, assume nitrogen.
Natural gas, pressure is unknown.
Medium pressure steam at 125 PSIG, saturated.
Cooling water, temperature and pressure is unknown.
Process water for hose stations and other, temperature and pressure is
unknown.
Ambient air.
Report 30300/01
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Project 30300.00
NREL
Golden, Colorado
August 3, 2012
REPORT 30300/01
SECTION 4
GASIFIER OPERATION AND PERFORMANCE
1.
FEEDSTOCK TYPE
Bubbling fluid bed (BFB) and circulating fluid bed (CFB) gasifiers are both capable of
gasifying a wide range of biomass materials.
Generally anything with organic content can be gasified to produce a usable syngas.
Disregarding logistics and biomass availability, the ability of the feedstock handling
system to convey and feed biomass material will generally determine the range of
feedstock types that a gasifier can efficiently process. Depending on the feedstock
type and as-delivered characteristics, the feedstock processing system could
potentially require equipment to screen-out over sized material, reduce particle size,
remove fines, remove metals, remove dense contaminants, increase bulk density, etc.,
to optimize the gasification process. Although a broad range of feedstock types can be
gasified, the efficiency and production rates for each type of gasifier can vary greatly
with feedstock type and characteristics.
Biomass types with potential for gasification are listed below:
Wood chips - sawmill residuals, whole log chips, etc.
Waste wood - bark, sawdust, other sawmill waste, etc.
Agricultural waste.
Crop residues - corn stover, wheat straw, etc.
Municipal Solid Waste (MSW) or Refuse Derived Fuel (RDF).
Construction and demolition waste.
Switchgrass.
Sorghum, bagasse, energy canes, miscanthus etc.
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Ultimately, flexibility must be designed into the feedstock handling system to take
advantage of a variety of feedstocks that might be available over time. The reliability
of the feedstock handling system is often taken for granted; however, it is usually the
weak link within a gasification system. A thorough economic analysis must be
performed to determine the optimal gasifier and feedstock handling system design for
the type and amount of feedstock being processed. For example, gasifying a high
bulk density biomass pellet at 10% moisture content can improve a gasifier
production rate, efficiency, reliability, syngas quality and capital cost, while a lower
grade residue or refuse type feedstock will be less expensive but increase the capital
cost of the feedstock handling system.
2.
FEEDSTOCK SIZE
BFB and CFB gasifiers are similar in their ability to efficiently process a variety of
feedstock particle sizes; however, a CFB design is a bit more flexible. Industry experts
would typically agree that a feedstock size of 2.0-2.5 minus is ideal for either
technology.
Uniform bed formation in a fluid bed reactor is very important for efficient bed
utilization and consistent operation during gasification of the biomass material. In
order to enhance the mixing and uniformity of a bubbling fluid bed, the biomass is fed
to the bed at multiple feed points around the circumference of the reactor vessel. In
addition, the fluidization medium, whether air, oxygen, steam, or some combination
of these substances, should be uniform in composition and should be introduced in
multiple locations.
A BFB design is generally more sensitive to bed utilization. The size of biomass
particles greatly affects the rate of gasification and the ability of the biomass to
migrate to the center of the bed in a BFB design. With small particles, the gasification
is very quick, and unburned material might not make it to the center of the bed,
resulting in oxygen slip and a void center in the BFB reactor. If all or a majority of the
biomass material quickly gasifies, there will be insufficient char to maintain a uniform
bed. For this reason, more detail is required in designing the in-feed system with the
proper number of in-feed points and controlling and/or monitoring the size particle
distribution of the feedstock material. A BFB will generally require additional feed
points that must be balanced for larger particle sizes. A CFB design, on the other
hand, operates at a higher velocity and incorporates recycling of the char and bed
material, resulting in complete mixing regardless of feedstock size. Note that CFB
designs are more flexible but are still limited by the amount of very fine material that
they can process.
The design of the feedstock handling and gasifier feed equipment has a large, if not
overriding impact on the acceptable size of the biomass feedstock. Typically what
you can reliably feed and distribute uniformly into a BFB or CFB bed is considered
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acceptable by most gasifier technology providers. Acceptable feedstock size targets

are listed below.
The target feedstock size for both a BFB and CFB gasifier is approximately 2.0-2.5
minus with a thickness of to . Larger sizes are acceptable if the thickness
remains near to ; however, the thickness will typically increase as length
increases with less expensive size reduction devices such as tub grinders. Also,
2.0-2.5 minus material reduces the bridging potential in bins and silos when
compared to larger material, which tends to contain more stringy material depending
on the feedstock type.
A feedstock handling system designed to accept residues must be capable of handling
a feedstock containing 4.0-6.0 minus material. Forest, urban and agricultural
residues typically contain 4.0-6.0 minus material. A rule of thumb for design
purposes is to assume that approximately 30% of residue material will be 3.0 plus.
The 3.0 plus material can be removed with a scalping screen. The over sized material
is then hogged to 2.0-2.5 minus and reintroduced into the biomass feed stream.
Directly gasifying large amounts of lightweight, low density material reduces gasifier
production and must be weighed against the cost of densifying the material prior to
gasification. In order to maintain bed uniformity when gasifying large amounts of
minus material, a properly designed gasifier in-feed system is required. Modifications
to the gasifier operation (fluidization steam flow, etc.) might also be necessary in
order to process large amounts smaller material. Fixed bed gasifiers, on the other
hand, will usually have a strict limitation of approximately 10-15% for minus
material to prevent air flow restriction through the bed.
Most gasifier technology providers, regardless of the reactor design, prefer to densify
(pelletize or briquette) very lightweight, fine material when it is the majority of the
feedstock. RDF feedstocks and feedstocks containing 100% sawdust fall into this
category.
Feedstocks containing large amounts of minus material should gasify without any
problems in either a BFB or CFB, depending on the percentage of small, very fine
particles. Due to high velocities in the gasifier reactor, small, lightweight biomass
particles such as sawdust and fines are quickly carried up the gasifier without
spending sufficient time in the fluidization zone to form a cohesive bed. While this is
more of a problem in a BFB than a CFB, very large amounts of fine material will also
cause operational issues in a CFB design. The reason a CFB more easily handles fine,
lightweight material is its ability to recirculate the char, unreacted biomass and bed
media. Recirculation enables the unreacted material to finish reacting on its second or
third pass through the gasifier vessel. However, this flexibility is only applicable for a
single vessel CFB design, where the recirculated material is reintroduced back to the
gasifier. In a dual vessel indirect design, the recovered char and unreacted biomass
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are combusted in a separate combustion reactor. In the dual vessel indirect design,
heavy fines loading is typically not acceptable for optimal operation, because much of
the fines can carry over to the combustion reactor and greatly reduce carbon
conversion in the gasifier.
Many gasifier technology providers suggest an additional feedstock size specification
to limit the amount of small material in the feedstock. Specifying that 20-25% of the
feedstock by weight should contain 1 plus material to optimize bed uniformity and
bed utilization and limit the amount of fines is typical.
The advantage of a fluid bed is its uniform and efficient heat transfer capability and
fast reaction kinetics. Biomass must be uniformly introduced into the reactor to fully
utilize the bed, maximize fluid bed capabilities and maintain efficient conversion.
Uniform distribution of the feedstock is more important than actual feedstock particle
size characteristics.
Syngas quality is expected to be similar whether using small or large feedstock
material, as long as the design of the gasifier and particle size distribution contribute
to uniform feed and uniform bed formation.
3.
FEEDSTOCK DENSITY
Feedstock density considerations are similar for both BFB and CFB gasifiers. Dense
feedstocks benefit both technologies in similar ways.
Equipment is available to compress small biomass particles into very dense briquettes
or pellets (40 lb/ft3 for instance) to improve material handling characteristics as well
as energy density.
A gasifier system benefits from dense feedstock material. As feedstock density
increases, the following benefits are experienced:
The size and capital cost of the feedstock handling equipment decreases.
The size and capital cost of the gasifier reactor decreases and/or the production
increases as a result of:
o Increased residence time within the gasifier.
o More predicable operation resulting from improved biomass distribution and a
more uniform bed.
o Reduction in the required reactor volume
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The reliability of the feedstock handling and in-feed systems increases, resulting in
improved operating uptime.
Feedstock density is dependent on the type of biomass being used and the extent of
pretreatment. Densifying a biomass feedstock is typically beneficial to the gasification
process; however, it is rarely cost effective unless the gasification process is
pressurized, which is still not always cost effective. The savings with a pressurized
system are realized by the reduction in feedstock and gasifier equipment size and
capital cost. Also, more reliable operating conditions and better equipment uptime
reduces operating costs and offsets some of the higher feedstock cost.
Overcoming the pressure of a pressurized gasifier requires pressurization of the
biomass feed equipment with an inert gas (N2, CO2, etc.), including the void space
among the biomass particles. Since a dense feedstock has less void space, it requires
the addition of less inert gas for pressurization. This reduces the amount of syngas
dilution resulting from the inert gas.
A typical biomass densification plant that produces packaged wood pellets at 10%
moisture identifies their costs as follows.
Raw material cost of approximately $40-$60/short ton produced.
Packaging cost of approximately $20/short ton produced.
Drying and densification cost of approximately $70/short ton produced, which
consists mostly of labor, electricity, and die wear costs.
Total operating cost on the order of $150-$160/short ton produced.
If a pellet plant produces briquettes for gasification rather than pellets for a packaged
product, the wood only needs to be dried to 15% moisture rather than 10% moisture,
and the drying and densification cost is reduced from $70/short ton of pellets to
approximately $50-$60/short ton of briquettes. This incremental cost of $50-$60/short
ton can easily double the raw material cost for gasification. Note that the drier,
densified biomass will require less heat for drying in the gasifier, which will mitigate
some of the added cost and benefit the operation of both BFB and CFB gasifiers.
The cost of densification should decline over time as the technologies mature and
become optimized for certain raw material characteristics. The cost reduction for
feedstock densification in the nth plant is estimated to be the same or very similar to
that for the gasification system at 10-15%. Further discussion about nth plant costs
can be found in Section 5.
The particle size and bulk density of the feedstock can impact the minimum
fluidization velocity and the optimal operation of either the BFB or CFB gasifier. A
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CFB reactor is generally the most flexible type of gasifier with regard to feedstock
solids size and density. The size and density of feedstock particles determines the
required minimum transport velocity, although the operating velocity of a properly
designed circulating fluid bed reactor is generally far enough above the minimum
transport velocity to ensure proper operation. High velocities may, however, result in
accelerated equipment erosion. Similarly, a properly designed BFB gasifier should be
designed to permit adjustment of the bed velocity to accommodate various feedstock
sizes and densities.
Syngas quality is expected to be similar whether using raw or densified feedstock
material, provided the gasifier and feed system design includes equipment for
uniform feed and uniform bed formation.
4.
FEEDSTOCK MOISTURE
BFB and CFB gasifiers each have similar responses to variations in feedstock moisture
content. Gasifier operation is a function of the moisture content of the biomass
material being used. The biomass conversion efficiency and production rate typically
decrease with increasing moisture content, because the process consumes more
carbon (directly heated gasifier) or uses more of the available heat (indirectly heated
gasifier) to heat and vaporize the water to the syngas temperature. Indirect
gasification systems experience a drop in temperature due to the consumption of
additional heat, producing more char and subsequently increasing the amount of char
combustion gases, which would ultimately increase the hot gas flow to the gasifier in
a self-correcting type of action. It would, however, result in a lower carbon
conversion in the gasifier and negatively affect the syngas composition and quality.
An increase in biomass moisture may also have an impact on syngas composition
and/or quality by producing more CO2 and diluting the syngas. In addition, a higher
moisture biomass increases the syngas volume and lowers the H2 and CO
concentration of the syngas, while requiring larger downstream processing equipment
for the same biomass consumption rate.
Most gasifier technology providers require feedstock with a target range moisture
content of 10-20%. A 20% moisture content is typically the fiber saturation point, with
the remaining water being chemically bound. It is typically cost effective and
beneficial for syngas quality to remove free water in an external dryer prior to
gasification; however, studies have even been conducted to analyze the cost benefit of
bypassing drying and gasifying raw biomass at 45-50% moisture content. These
studies imply that having the gasifier accept the moisture and the associated lower
efficiency, is still a better choice economically than drying, as long as there is a use for
waste heat in the plant, be it in distillation, heating, chilled water, or other beneficial
use, and, the air emissions limits are similar to the U.S., making the dryer expensive
due to the necessary equipment (WESP and RTO) for air emission abatement. Note
that this assumes use of a direct fired rotary wood dryer. A thorough cost benefit
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analysis is always recommended to determine the economical extent of feedstock

drying.
Water in the feedstock is also necessary to drive the water gas shift reaction; however,
with a moisture content in the 15-20% range there is substantially more water than is
needed for the water gas shift reaction to reach equilibrium.
High moisture content in the feedstock, which translates into high moisture content in
the syngas, also puts a condensing load on downstream cooling and filtering
equipment.
The impact of feedstock moisture on heat value and energy density is typically only a
concern when combusting the syngas in an engine for power production because an
oxygen blown system has a higher tolerance, both economically and technically, for
moisture in the reactor. This study of course is focused on producing a syngas for
conversion to liquid hydrocarbons, which benefits from the highest H2 and CO
concentrations that are economically achievable.
5.
FEEDSTOCK ASH CONTENT

The amount of ash in different types of feedstock varies widely (0.1% for wood and
up to 15% for some agricultural products) and influences the design of the ash
removal and handling system.
6.
FEEDSTOCK CONTAMINANTS
BFB and CFB gasifiers are not overly sensitive to contaminants in the feedstock;
however, contaminant removal is typically beneficial depending on the contaminant
type.
Macro contaminants such as dirt and rocks are more of a nuisance and can be
removed from the feedstock with certain preprocessing equipment or in a bed media
recycle and screening system. Similarly, intermittent purging and disposal of the bed
material will remove the dirt and rocks as well.
Metals, on the other hand can be more of an issue. Metal in the form of wire or
stringy pieces can form balls that defluidize the bed if the size and number of balls are
large enough. Removal of ferrous metals is fairly easily accomplished with magnetic
preprocessing equipment and is always recommended if the feedstock has any chance
of containing metal material.
Micro contaminants such as alkalis, chlorine, and sulfur compounds are not beneficial
to the gasification environment because they can generate corrosive compounds,
agglomerate and form buildup that can attack the gasifier refractory. A sorbent
material such as limestone, magnesium oxide and/or dolomite is typically used as the
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bed media or to supplement the bed media to help capture and remove the alkali,
chlorine, and sulfur compounds. Not all of the alkali, chlorine, and sulfur compounds
are easily or economically removed; therefore, buildup is inevitable if these
compounds are present in the feedstock. The sticky buildup will coat the refractory
surfaces and attract bed media. Buildup will also occur on the bed media itself,
causing agglomeration and the formation of balls known as sand babies. These sand
babies must then be screened-out in a fashion similar to rocks or dirt before they can
defluidize the bed. Excessive coating of the bed media can also reduce its heat
transfer characteristics and interfere with the carbon conversion efficiency. Typically,
the use of a sorbent material will reduce the agglomeration potential for sufficient
worry-free operation.
Cooling of the syngas, combined with sorbent addition, allows much of the micro
contaminants to condense and be filtered out in solid form. This filtration step is
typically included all gasification processes; however, the filtration step is not always
in the same location. Usually, the filtration step is after tar reformation. Cooling of
the syngas via heat recovery is also typical prior to filtration to promote the
condensation of the contaminants in solid form, and to fall below the maximum
feasible filter media temperature which is currently approximately 850 F. Another
option to reduce build up and volatilization of the alkali, chlorine, and sulfur
compounds is to maintain a lower gasification temperature; however, this is not
applicable in a BFB or CFB gasifier because the operating temperatures are already
above this point. Fixed bed gasifier temperatures are typically kept below 1,200 F to
reduce the potential for volatilization.
Understanding feedstock composition is critical to determining and estimating the
cost of a contaminant abatement strategy. The bottom line is that feedstocks
containing macro and micro contaminants can be gasified in either a BFB or CFB, as
long as efforts are made to control, minimize or remove and dispose of those
contaminants.
7.
ABILITY TO HANDLE CORROSIVE MATERIALS

Similar to solid contaminants, corrosive alkali, chlorine and sulfur compounds can
also be present in feedstocks. Corrosive materials affect both BFB and CFB gasifiers in
a similar manner and must be accounted for in the gasifier and refractory design.
Proper metallurgy and refractory design typically mitigates any excessive corrosion
problems, however, some feedstocks can contain large amounts of potentially
corrosive materials and may require blending with cleaner feedstocks to extend
refractory life.
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8.
CARBON CONVERSION
Carbon conversion efficiency is defined as the amount of carbon in the fuel, minus the
amount of solid carbon leaving the gasifier, divided by the amount of carbon in the
fuel. In other words carbon conversion is the amount of carbon converted to usable
syngas. Carbon conversion is influenced by biomass particle size, biomass type,
temperature, and residence time in the gasifier.
In the indirect dual CFB reactor design, the unconverted biomass (char) is sent to the
combustor where it is completely combusted to produce the heat for the gasification
reactor. As a result, the fuel conversion in an indirect gasifier system, similar to
Technology #2, is essentially 100%; however, the carbon conversion in the gasification
reactor section typically varies between 70% and 90%. Carbon conversion generally
increases with increasing temperature. For the indirect dual CFB reactor design this
makes the process self-regulating; if the temperature in the reactor drops, the amount
of char produced increases, combustion of the additional char produces more heat in
the combustor, and the recirculation rate of bed material from the combustor to the
gasifier carries the additional heat to the gasifier reactor.
Carbon conversion for BFB and CFB gasifiers is generally very similar, however a CFB
can have a higher conversion because the char is recycled back to the reactor and
theoretically has more total residence time in the reactor. Note that some BFB designs
can also recycle the char carryover back to the gasifier bed, thus improving the carbon
conversion.
Technology vendors #1 and #2 did not disclose typical carbon conversion efficiencies;
however, technology vendor #3 claims a carbon conversion of 97.1% for a poplar
(hardwood) feedstock and 84.4% for a densified RDF feedstock.
9.
COLD GAS EFFICIENCY

The fraction of the feedstocks chemical energy or heating value, which remains in the
product syngas, is termed the cold gas efficiency. Most commercial-scale
gasification processes have a cold gas efficiency of at least 65% and some exceed 80%.
Note that the cold gas efficiency does not account for the sensible heat available in the
syngas, only the chemical energy available.
Technology vendor #1 did not disclose their typical cold gas efficiency; however,
technology vendor #2 claims a cold gas efficiency of 70-75% for RDF, while
technology vendor #3 claims a cold gas efficiency of 80.9% for a poplar (hardwood)
feedstock, and 73.0% for a densified RDF feedstock.
In theory, a CFB can have slightly higher cold gas efficiency due to more efficient
exposure to radiant heat transfer. However, operating costs for a CFB gasifier will be
higher than for a BFB gasifier because of the larger fan power requirement and the
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abrasion and wear that occurs due to the higher velocities and turbulence. For further
comparisons see Reactor Design and Comparisons below.
10.
HEAT LOSS
Note that the sensible heat losses and the thermal efficiency should be very similar for
either a BFB or CFB design. The overall gasifier and tar reformer island thermal
efficiency obviously depends on the extent of the heat recovery which falls outside of
the scope of this study.
11.
BED/SORBENT MEDIA TYPE

A mineral type bed material, resistant to the high heat environment, is typically used
to assist in heat transfer and facilitate the chemical reactions inside the gasifier and tar
reformer. Sorbent material is also typically added for control of alkalis, chlorine and
sulfur, and to reduce the potential of ash agglomeration and subsequent choking of
the bed. Some bed media such as dolomite can act as both the bed and sorbent
material.
There is also a great potential for in-bed additives in terms of tar reduction. These bed
additives can act as catalysts for promoting several chemical reactions in the gasifier
and/or tar reformer. The presence of additives influences the gas composition and
the heating value of the product gas. The use of catalytically active materials during
biomass gasification can promote char gasification, change the product gas
composition and reduce tar formation. Although experts agree on the potential for inbed additives, there is not yet a consensus on the optimal material and optimal
conditions. This is partly due to the fact that feedstock flexibility is very important in
gasifier design, and changing feedstock characteristics and composition can affect the
activity of a bed-additive/catalyst. The bottom line is that further research needs to
be directed at finding a catalytically active fluidizable bed material for biomass
gasification and tar reformation.
Catalysts that have been studied or trialed include nickel based catalysts, dolomites
and magnesites, zeolites, olivine, silica sand, engineered clays and iron catalysts.
Sorbent materials include dolomite, limestone and magnesium oxide.
11.1.
Ni-based catalysts
Examples - NiO/olivine, Ni/dolomite, Ni/Dolomite+Silica binder,
Ni-WO3/Dolomite, Ni/Al2O3, NiCuMo/SiO2-Al2O3.
Notes - Ni-based catalysts have been found to be effective, however, they tend
to deactivate quickly due to carbon deposition and poisoning in the presence of
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H2S. Ni-based catalysts are also very expensive for single use without
regeneration.
11.2.
Dolomite - CaMg(CO3)2
Notes - Dolomite is the most popular and most studied material. Although
dolomite has been proven to be an effective bed additive in terms of tar
reduction and prevention of bed agglomeration, it has some critical limitations.
Dolomite is softer than other minerals and thus gets eroded by silica sand
particles, also some dolomite particles break during calcination and give rise to
a large proportion of fines. Thus, there is a problem of carryover of solids from
the bed. Dolomite is, however, more resistant to attrition than limestone.
11.3.
Zeolites - microporous aluminosilicate minerals

Notes Zeolites can be used as high-surface-area binders to support catalysts
or can be used as a bed material on their own. They are similar in effectiveness
to silica sand and high alumina clays.
11.4.
Olivine - (Mg,Fe)2SiO4
Notes Olivine is a mineral containing magnesium, iron and silica. It is very
resistant to attrition (greater than dolomite), and its activity is comparable to
dolomite.
11.5.
Silica Sand
Notes - Silica sand and limestone were the first additives used in gasifiers to
improve gasification. Silica is still widely used, however further development
is leading some technology providers toward olivine or engineered materials
such as crushed fired clay with high alumina content. Silica sand is also the
cheapest media used today.
11.6.
Limestone
Notes Limestone has been used for quite some time (with silica sand as
mentioned above) and is very effective as a sorbent to reduce or prevent
agglomeration of the bed. It is, however, the softest sorbent material with the
least resistance to attrition and can result in large particulate and dust
carryover.
11.7.
Magnesium Oxide
Notes MgO is also widely used as a sorbent to minimize agglomeration.
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11.8.
Engineered Clays
Notes Engineered materials such as crushed fired clay with high alumina
content is a very effective heat transfer material and is very resistant to
attrition.
An economic and process analysis is recommended for the selection of the best
bed/sorbent material. The selection should be based on the anticipated
feedstock composition, expected media life, as well as the gasifier and
refractory design as gleaned from pilot scale operating data.
12.
SYNGAS H2/CO VOLUME RATIO

Typically an allothermal (indirect) gasification system will produce syngas with a
higher H2 to CO ratio than an autothermal (direct) system. In an allothermal system
there is no need for the incomplete combustion or partial oxidation (volatile products
and some of the char reacts with O2 to form CO2 and CO) step to take place because
the heat required to volatilize the organic (biomass) material is added indirectly. As a
result, most of the biomass reacts with CO2 and water vapor to produce CO and H2 in
the gasification/steam reforming reactions. After the water-gas-shift reaction reaches
equilibrium in the gasifier, the total resulting H2 concentration from the allothermal
gasifier is typically greater.
A higher H2 to CO ratio is beneficial in the gas synthesis step when converting syngas
to liquid hydrocarbons in a FischerTropsch process. The ideal ratio depends on the
catalyst being used. Cobalt and iron are well known catalysts, but each has a different
optimal H2/CO ratio. For cobalt-based catalysts, the optimal H2/CO ratio is around
1.8-2.1. Iron-based catalysts, on the other hand, can tolerate significantly lower
H2/CO ratios than cobalt because the iron-based catalysts promote additional H2
formation by way of a water-gas-shift reaction in the FischerTropsch process. This
can be important for syngas derived from biomass, which tends to have a relatively
low H2/CO ratio (<1.0). The optimal H2/CO ratio for biological synthesis processes is
unknown.
The following H2/CO ratios were specified by the technology providers for the fuels
listed.
12.1.
Technology #1
Gasifier outlet H2/CO ratio is 1.30, and tar reformer outlet H2/CO ratio is 1.19.
The biomass feed stock is southern pine wood chip and bark mixture with the
following analysis:
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Carbon
49.72 % wt. dry

4-12
12.2.
Hydrogen
5.67 % wt. dry
Nitrogen
0.2 % wt. dry
Sulfur
0.02 % wt. dry
Oxygen
42.31 % wt. dry
Chlorine
0.000122 % wt. dry
Ash
2.08 % wt. dry
Technology #2
Gasifier outlet H2/CO ratio is unknown, and tar reformer outlet H2/CO ratio is
1.74.
The biomass feed stock is hybrid poplar wood chips with the following
analysis:
12.3.
Carbon
50.88 % wt. dry
Hydrogen
6.04 % wt. dry
Nitrogen
0.17 % wt. dry
Sulfur
0.09 % wt. dry
Oxygen
41.9 % wt. dry
Chlorine
unknown
Ash
0.92 % wt. dry
Technology #3
Gasifier outlet H2/CO ratio is 0.72, and tar reformer outlet H2/CO ratio is
unknown.
The biomass feed stock is hybrid poplar wood chips with the same analysis as
that shown above in technology #2.
13.
REACTOR TEMPERATURE
The first step in the gasification process is the drying or driving off of the moisture
contained in the feedstock. The subsequent step is a pyrolysis step where volatiles are
released at temperatures up to approximately 1,300 F. The material that remains is
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activated carbon or char material. In an autothermal (direct) gasification process the

next step is incomplete combustion or partial oxidation of the carbon to produce heat.
An allothermal (indirect) gasification process, on the other hand, skips the combustion
step and moves directly to the final reduction step. In the reduction step the carbon
reacts with CO2 and water vapor to produce CO and H2. Typically the reduction
reactions occur at temperatures between 1,400 F and 1,600 F for gasification system
that produces dry ash and 1,650 F to 1,800 F for a gasification system that produces a
slag type ash.
Both the BFB and CFB gasification technologies operate within the dry ash
temperature range and are not expected to have drastic temperature related
differences.
The following gasification and tar reforming temperatures were given by the
technology providers.
13.1.
13.2.
13.3.
Technology #1
Gasifier outlet - 1,560 F
Tar reformer outlet 1,600 F
Technology #2
Tar reformer outlet 1,830 F
Technology #3
Tar reformer outlet unknown
Higher gasification and tar reforming temperatures would result in the following:
Increase in carbon conversion
Reduction in tar content
Reduction in methane and higher hydrocarbons content
Maximized H2 and CO production
Increased slagging and agglomeration potential
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14.
REACTOR PRESSURE
Gasifier operating pressure affects not only equipment cost and size but also the
interfaces with the rest of the GTL plant, including the necessary gas cleanup systems.
Since gas synthesis processes operate at elevated pressures, the syngas generated by
low pressure gasifiers must be compressed. This favors low temperature gas cleaning
since the syngas must be cooled prior to compression in any case. High pressure
gasification favors hot, pressurized cleanup of the syngas and operation of
downstream equipment at high temperature and sufficiently high pressure to
accommodate flow control and equipment pressure drops.
14.1.
Gasification Pressure by Technology

Technology #1 130 PSIG
14.2.
Pressurized System Advantages

Lower level of internal power consumption
Reduced air space per mass of fuel, which increases the syngas production
rate for a given reactor volume.
Reduced reactor volume and investment costs required for a given
throughput. However, such a vessel requires more steel and a code stamp,
which increases the investment cost. Overall, the investment cost would
still decrease with increased pressure.
Decreased sintering of the ash.
14.3.
Pressurized System Disadvantages

A more complicated pressurized feed system is required; however, with
densified fuel a reduction in feed system equipment size and/or count can
be realized.
The need for high pressure syngas cleanup devices, which are still in an
early stage of development.
Higher methane content in the syngas
A more complex installation, which will lead to high specific investment
costs for low capacity installations.
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15.
FIXED BED, BFB, CFB REACTOR DESIGN COMPARISONS

The following is a discussion of the advantages of fluid bed (BFB and CFB) versus
fixed bed (down and updraft) gasifier designs. Note that the discussion does not
compare or contrast entrained flow designs due to their inherent difficulty in
gasifying biomass and their relatively high investment costs.
15.1.
Advantages - Fluidized Bed versus Fixed Bed

Relatively smaller volumes required due to high heat exchange and reaction
rates resulting from the intense mixing of the bed.
Wider range of acceptable feedstock particle sizes, density, moisture and
ash content.
More scalable and applicable for large installations.
More uniform and narrow temperature profile without hot spots.
Higher conversion rates possible resulting in less unconverted carbon.
15.2.
Disadvantages - Fluidized Bed versus Fixed Bed

More complicated design.
Higher specific investment cost.
Possibly higher tar and dust content (except fixed bed updraft design can
contain 10-20% tars).
Higher gas temperature vaporizes alkali metals, which leads to the need for
sorbent material.
Incomplete carbon burn out.
More complex operation. Must control the supply of biomass, oxygen and
steam as well as the reactor pressure.
Higher power consumption due to compression of gas stream if
pressurized.
15.3.
Advantages of CFB Design versus BFB Design

The fluidized bed in a BFB reactor acts similarly to the bed in a continuous
stirred reactor, which enables some of the biomass and tar to escape/slip
from the bed. This problem is much less likely to occur in a CFB design.
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Uniform feedstock introduction and proper bed utilization minimizes the

escape of any biomass and tar.
CFB designs have a bit more fuel flexibility to process larger amounts of
lightweight, fine material.
A CFB reactor requires the bed material and char to leave the reactor and be
circulated back to the gasifier via cyclone(s), thus a swedged (a continuous
stacked cylinder vessel with a smaller diameter lower section and a larger
diameter upper section) gasifier is not necessary for disengagement of the
solids. The resulting reactor cross-sectional area will be smaller for a CFB at
the same throughput, but since residence time is an important process
variable to guarantee complete pyrolysis, then either optimal feedstock
particle sizes must be fed to the gasifier, or the CFB must be taller so that
there is sufficient volume to achieve the desired residence time. While a
sweged BFB reactor can be more complicated to fabricate, a CFB reactor
may have to be taller. Considering all factors and depending on the reactor
design, a CFB reactor (alone) will typically only be slightly less expensive
than a BFB reactor at the same throughput.
A CFB reactor can be scaled-up to a much larger capacity than a BFB;
however, pressurized BFBs can be very large scale. For biomass
gasification, HGIs opinion is that a single, pressurized BFB reactor can be
designed to handle all the woodchip feedstock that can be economically
procured from the land surrounding a greenfield installation. Thus both
designs are well suited for operation at the proposed feedstock rate of 1,000
oven dry metric tons per day. Note that a CFB has a much broader window
of acceptable gas velocity and that the whole reactor volume is usable,
which gives a CFB a scale-up advantage.
A CFB reactor generally has a better turn down capability than a low or
atmospheric pressure BFB because bed utilization is not as big an issue as it
is for a BFB design. Assuming atmospheric pressure operation, a BFB may
be able to accomplish a 3:1 turndown, and a CFB may be able to achieve a
5:1 turndown. However, assuming a pressurized BFB design, reducing the
reactor pressure makes a 10:1 turndown possible, while maintaining the gas
velocity within an operating window acceptable for optimal BFB operation.
Note that the turndown for a pressurized CFB reactor should be similar to
that of the BFB design.
A consensus seems to be that char conversion is slightly higher for CFB
designs due to the recycling of the char; however, based on published data
for biomass gasification, there seems to be no statistical difference in the
carbon conversion between the two designs. Although a CFB has the ability
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to manage zoning of oxidation/pyrolysis, it is handicapped by the limited

particle collection efficiency of a cyclone. Since biomass is typically highly
friable, it quickly turns to fine particles that blow through the cyclone and
dont get another opportunity to pass through the gasifier. A BFB with
underbed feedstock introduction has a similar advantage of zoning the
oxidation/pyrolysis. With an underbed feedstock design, carbon
conversions greater than 96% have been demonstrated using woody
feedstocks. The bottom line is that the design of the BFB reactor really
determines if there is any advantage or disadvantage in char conversion
between the two designs.
Carbon burn-out is sometimes considered higher in a CFB; however, the
same argument that was offered in the char conversion discussion above
applies.
15.4.
Disadvantages of CFB Design versus BFB Design

The balance of plant or auxiliary equipment for CFB designs is generally
more costly due to the higher costs associated with larger fans/compressors
and the associated larger horsepower drives for the same throughput. This
is especially true when comparing a CFB to a low or atmospheric pressure
BFB; however, pressurized BFB designs will have compressors that are
similar in size to those used on CFB designs.
Heat exchange within the fluidized bed can be more efficient in a BFB
design, assuming optimal bed utilization and uniformity.
A BFB may yield a slightly more uniform syngas, especially when operating
with variable feedstocks; however, this depends on the characteristics of the
feedstock and how frequently the feedstock type is changed. Ultimately,
proper design determines how well each reactor responds to changes in
feedstock.
A BFB design exhibits a nearly uniform temperature distribution
throughout the reactor, while a CFB reactor develops a temperature
gradient in the direction of solid flow. When temperature control is
important (managing ash chemistry and promoting the most efficient
gasification reactions), the BFB is generally preferred. Note, however, that
an indirect or allothermal CFB design, rather than a direct or autothermal
CFB design will exhibit much less in the way of temperature gradients.
A CFB design generally exhibits higher abrasion and wear due to the higher
velocities within the reactor and cyclone. Therefore, care must be taken
when designing the refractory and metallurgy of the reactor and cyclone.
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This challenge also typically results in higher refractory maintenance costs

for CFB designs.
Because of the overall design, a CFB is a bit more complex to operate than a
BFB. The main control parameters in a BFB are gas velocity, temperature
and pressure. In a CFB, the media recirculation rate, which establishes the
axial temperature profile, adds another level of operational complexity.
BFB reactors are generally of swedged design (a continuous stacked
cylinder vessel with a smaller diameter lower section and a larger diameter
upper section). Gas rising from the lower section to the larger diameter
upper section decreases in velocity below the fluidization velocity and
disengages from the bed. This large diameter diengagment zone also
improves residence time and thus improves syngas composition. Biomass
reacts so fast that many BFB vendors do not employ this design, and it has
been abandoned to some degree based on the added cost of the swedged
design.
In general there are fewer, proven CFB gasifiers in operation, and less data
is available than for BFB designs.
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Project 30300.00
NREL
Golden, Colorado
August 3, 2012
REPORT 30300/01
SECTION 5
ORDER OF MAGNITUDE CAPITAL COST ESTIMATES
1.
GENERAL
The cost estimates for the three gasifier technologies are order of magnitude or
feasibility capital grade estimates. According to The Association for the Advancement
of Cost Engineering (AACE), these are considered Class 4 capital cost estimates.
The cost estimates are based on the written project descriptions in Section 3 of this
report. Overall process flow diagrams and preliminary equipment lists were
developed to help define the scope for each technology. Quotes were obtained for the
major equipment components and scaling factors were used to put the prices for all
three technologies on a common capacity basis. The remaining cost inputs were
factored from the major equipment pricing and did not include material takeoffs.
According to AACE, the expected level of accuracy for a Class 4 estimate is as follows:
Low: -15% to -30%
High: +20% to +50%
The estimates are also considered to be in current 2011 dollars. A discussion of the
nth plant costs follows in this section.
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2.
CAPITAL COST ESTIMATES

Order of magnitude capital cost estimates in 2011 dollars for installation of 1,000 oven
dry metric tons per day biomass gasification and tar reformer systems are shown
below.
Total Installed Cost - Technology #1 - $71,497,300
Additional details of the order of magnitude estimates are shown in Appendix D.
3.
NTH PLANT COST CONSIDERATIONS

Operating in competitive markets makes individuals, enterprises and industries
improve, innovate and become more efficient. This fact is at the heart of the
experience curve or learning curve phenomenon. This phenomenon holds true for
industrial process industries, including energy technologies. History tells us that
experience accumulates with time and that unit costs decrease with experience,
therefore unit costs for a given technology are expected to decrease with time. In
addition, total installed costs also follow this phenomenon to a point. Emerging
technologies are also subject to these capital cost reductions over time; however, costs
generally level out once the technology and industry matures.
Biomass conversion to liquid fuels is an immature industry with only a handful of
commercial installations operating or near the construction phase. As the basis for
this discussion, it is assumed that cellulosic conversion to liquid fuels will become a
viable industry and produce a marketable product over the next 10 to 15 years. This
implies that the industry will become mature by the end of this 10 to 15 year period,
and we refer to this mature industry as the nth plant. Over this time period, based
on the learning curve phenomenon, it is also expected that the technology providers,
fabricators and engineering firms will innovate and become more efficient and that
capital costs and installation costs will decrease.
It is our estimate that the capital costs for gasification and tar reformation equipment
will decrease 10-15% over the next 10 to 15 years. It is also noted that the 10 to 15%
reduction is based on constant dollars.
The following list summarizes our reasoning for the potential decrease in the capital
costs for gasification and tar reformation equipment over the next 10 to 15 years.
Technology provider engineering costs will come down for an nth plant due to
the repetition and reuse of previous designs.
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Engineering consultant costs will decrease because technology providers will

begin to engineer and design more complete installation packages.
Future competition will generally lead to more competitive bidding and a
reduction in vendor profit margin, thus reducing equipment capital costs.
A reduction in technology provider margins used to cover initial R&D costs will
decrease, thus reducing equipment capital costs.
Process contingency and engineering contingency will decrease because designs
will be more compete and optimized for the nth plant.
Inovation and improvements in design will lead to reliability and uptime
improvements for the same cost. This will not factor directly into capital costs,
unless the improvements allow for a downsizing of the original design that leads
to a reduction in equipment size and/or removal of backup/spare equipment. As
an example, a system that was originally designed for two parallel feed lines, each
with the capability to deliver 50% of the rated system capacity, might be replaced
by a new, improved and more reliable single feed system sized at 100% of the
rated capacity, which could reduce the nth plant feed system cost by 50%.
Process intensification will lead to process changes that reduce energy, increase
yields and reduce size and cost of equipment. Process intensification is a
paradigm shift in process design, development and implementation. As an
example, process intensification often invovles one or more of the following:
o A move from batch to continuous processing.
o Use of intensive reactor technologies with high mixing and heat transfer rates
(e.g. FlexReactor, HEX Reactors) in place of conventional stirred tanks.
o Implementation of a multidisciplinary methodology which considers
opportunities to improve the process technology and underlying chemistry at
the same time.
o Use of 'Plug and Play' process technology to provide flexibility in a
multiproduct environment.
Possible examples of process intensification related to gasification and tar

reformation are:
o Improvements in reforming catalysts that eliminate the need for regeneration.
o Implementation of catalytic gasification to eliminate the need for a tar reformer.
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o Development of higher pressure systems that permit the use of smaller volume
reactors.
Use of modular design techniques will lead to improvments in fabrication,
shipping and construction costs.
Taking advantage of economies of scale will lead to the design of larger capacity
plants, typically resulting in a decrease in the marginal cost of increased
production.
Use of a conventional construction approach (owner procured equipment,
engineering and construction management) as a replacement for the engineer,
procure and construct (EPC) approach (reduced owner risk and easier access to
capital) used by immature industries will reduce overall installation costs for nth
plant construction.
Changes in consumables will decrease operating costs as follows:
o A reduction in oxygen usage will reduce the size and cost of the air separation
plant.
o More resistant or longer lasting bed and sorbent materials could decrease the
storage and feeding equipment size and cost.
o A reduction in steam usage will decrease the steam generation system size and
cost.
o Optimization/integration of cooling demand will reduce cooling water system
size and cost.
4.
BASIS OF ESTIMATES DIRECT COSTS

Note that the basis of estimate for many of the direct costs is common for the three
technologies. The similarities and differences are explained below.
4.1.
Land
The cost of land is not included in the three capital cost estimates.
4.2.
Civil/Earthwork
For each of the three technologies the project site is assumed to be a relatively
flat, greenfield site, free of equipment and buildings. The site requires minimal
grading, cut and backfill to prepare it for construction. An allowance is
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included in the estimates for general site preparation (grading, cut and backfill)
for the gasifier islands as well as the air separation plants.
Allowances are included in the three estimates for excavation and backfill
requirements related to the gasifier island foundation. The gasifier island
structure, including the tar reformer, is expected to be approximately 50 wide,
100 long and 100 tall for all three technologies. All equipment itemized in the
equipment lists, with the exception of the following, is expected be included in
the common gasifier island structure.
Air separation plant (O2 and N2, different for all three technologies).
Ash silo (Technology #1 and Technology #2).
Combustion reactor stack (Technology #2 only).
Allowances are also included in the three estimates for excavation and backfill
requirements related to the air separation plant foundations. Technology #1
and Technology #3 are expected to use on the order of 30,000 to 32,000 lb/hr of
oxygen (92% purity). The estimated layout for a VPSA air separation plant at
this production rate is approximately 70 wide by 150 long. Technology #2
does not use oxygen; however, it includes a small air separation plant for
nitrogen production. The estimated layout for this plant is approximately 20
wide by 40 long.
The following civil/earthwork items are also included in the capital cost
estimates:
Storm water collection systems, ditches and containment systems (retention
pond, etc.).
Roadways around gasification and air separation plant only.
Paving around gasification and air separation plant only.
Civil/earthwork related to a process sewer system within the gasification
and air separation plant boundaries only.
Civil/earthwork related to a sanitary sewer system within the gasification
and air separation plant boundaries only (assumed to tie into a municipal
system).
Civil/earthwork related to a natural gas supply line within the gasification
and air separation plant boundaries only (assumed to tie into a municipal
system).
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4.3.
Buildings
The three estimates each include two buildings: an electrical room and a
control room.
An electrical room is included to house the secondary switch gear, MCCs and
automation equipment. The room will be equipped with ventilation, air
conditioning and filtering. The estimate includes a factor for the electrical
room with allowances for all electrical, mechanical and plumbing typical of an
industrial electrical building. The electrical room is estimated to be
approximately 25 wide, 100 long and 17 tall.
A control room is included to house the control stations and associated
computer hardware for operation of the control systems and will also include
restrooms. The control room will be equipped with ventilation, air
conditioning and filtering. The estimate includes a factor for the control room
with allowances for all electrical, mechanical and plumbing typical of an
industrial control room building. The control room is estimated to be
approximately 25 wide, 50 long and 17 tall.
The following items are not included in the capital cost estimates:
4.4.
Lockers.
Lunch rooms (cafeterias).
Office space or meeting space.
Equipment Foundations and Supports

The main process equipment for all three technologies is located in steel
structures which include all structural components, as well as access to all
equipment. The structure does not include a roof or siding. The steel and
erection of the structure is included in the three vendor packages.
The entire gasifier island structure will sit on foundations that are optimized
for the arrangement of building columns and actual loads. The entire structure
will also sit on a curbed concrete slab. The area will be sloped to a u-drain
which will drain to a storm water system (piping and retention pond) that is
included in the estimate. The air separation plant will include a combination of
foundations and slabs depending on equipment loads. Mat type foundations
are used. All mat foundations include rebar rather than mesh, and include
form work, hardware (anchor bolts, iron, etc.), concrete, finishing and
stripping. The estimate includes factors for all of the above items.
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The loads of the gasification and tar reforming equipment are expected to
necessitate piles. The number of piles depends on the site location and the soil
conditions. For the purposes of these estimates, the soils are assumed to have a
3,000-4,000 psi bearing pressure for foundation design. A factor is included for
piles and pile caps for these soil conditions. The air separation plant
equipment is not expected to require piles.
No structures or bridges are included to support interconnecting piping
between the gasifier island and the remaining process areas. Piping is assumed
to terminate at the gasifier island structure boundary, with the exception of the
O2, N2 and flue gas piping/ductwork. All piping supports within the gasifier
island boundary are included in the estimate.
4.5.
Piping
All syngas piping, ductwork, process piping, manual process valves, dampers
and expansion joints are included in the three vendor packages. All high
temperature gas piping is refractory lined. All other hot process piping is
externally insulated. Refractory and insulation is also included in the vendor
packages.
Installation of the above piping/ductwork and related items is included in the
vendor packages.
The following additional items are also included in the estimates:
Wash up hose stations.
Eyewash and shower stations.
Piping related to storm water runoff systems.
Natural gas piping within the gasification island boundary.
Process water piping within the gasification island boundary.
Potable water piping within the gasification island boundary.
Cooling water piping within the gasification island boundary.
Steam piping within the gasification island boundary.
Fire water systems (piping, hydrants, sprinklers etc.) for the gasifier island
only.
The following items are not included in the estimates:
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Natural gas piping (including the source tie-in) outside of the gasification
island boundary.
Process water piping (including the source tie-in) outside of the gasification
island boundary.
Potable water piping (including the source tie-in) outside of the gasification
island boundary.
Cooling water piping outside of the gasification island boundary.
Steam piping outside of the gasification island boundary.
Fire water source tie-in.
4.6.
Electrical
Most of the electrical systems and associated installation costs are included in
the vendor packages. The electrical systems include: MCCs, motor cabling and
control cabling, terminations, conduit, cable ways, control systems
uninterrupted power supplies (UPS), motors, lightning protection, lighting,
grounding and wiring to supply power to automation and process protection
systems.
The following additional electrical items are also included in the capital cost
estimates:
Unit substations (transformers/primary switch/secondary switch gear).
The substations would normally be located outside in a curbed area. The
secondary switch gear would normally be located inside the electrical
building.
Cable and conduit for the power distribution feeders between the
transformers and the indoor switchgear, and between the switchgear and
the MCCs.
The following electrical items are not included in the capital cost estimates:
High voltage feeder and breaker.
Medium voltage feeder (this feeder will feed a single substation or loop feed
multiple unit substations).
Report 30300/01
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4.7.
Instrumentation
A programmable logic controller (PLC) based control system with a human
machine interface (HMI) and the necessary computer software and hardware to
operate the gasifier system is included in each of the vendor packages. The
estimates also include the installation of the PLC and HMI, and the associated
control system equipment (I/O racks, etc.). PLC programming and
programming software is also included.
All field instruments for the measurement and control of such parameters as
pressure, temperature and flow, and their installation costs, are included in the
estimates. Special instruments such as various gas analysis devices and special
reactor bed level control devices and their installation are also included. Field
instruments and transducers are 4-20mA type with twisted shield pair wiring
and discrete devices are normally 120VAC.
All actuated valves (control valves) and dampers and their installation are
included in the estimate.
Technology #2 will also require a continuous emissions monitoring system
(CEMS) to monitor emissions from the combustion reactor stack, which is
included in the Technology #2 estimate.
4.8.
Insulation and Painting

Labor as well as materials related to insulation of equipment and piping is
included in the estimates.
An allowance is also included for general painting of equipment.
4.9.
Equipment
Major gasification and tar reforming equipment and erection pricing was
provided in vendor quotations for all three technologies. The erection pricing
was adjusted by taking advantage of HGIs cost estimating experience.
Detailed equipment lists located in Appendix D show the equipment that is
included in the estimates.
The following items are specifically not included in the estimates:
Natural gas compression (if necessary).
Process water treatment system (filters, pumps, tanks, etc.).
Potable water system (pumps, tanks, etc.).
Report 30300/01
5-9
Cooling water system (cooling tower, pumps, etc.).
Steam generation system (heat recovery steam generator or fired boiler).
Fire water system (pumps, tanks, etc.).
Waste water treatment facility.
Note that rather than using an over the fence oxygen source, air separation
plants are included as indicated in the equipment lists. For information
purposes only, the costs and operating conditions for an example over the
fence VPSA oxygen supply system are listed below. Note that this information
is for a 243 tons per day supply system at 92% purity. This flow rate does not
represent the actual demand of any of the technologies analyzed. For
comparison sake, technology #1 requires a total of 473 tons per day of oxygen
at 92% purity.
4.10.
O2 capacity
243 stpd @ 92% purity & 10 psig
Plot size
approx 70 x 150
Unit power
1/12 kW/thousand cubic feet
Largest motor
2,500 HP
Total connected load
4500 kvA
Condensate
5 gal/day
Cost
$150,000 /month
Liquid O2 backup
$9,000 /month
Demolition
It is assumed that the gasifier system is erected on a greenfield site, thus no
demolition is included in any of the estimates.
4.11.
Labor
Total direct labor costs were determined by applying hourly labor rates to
work hour estimates. The estimated labor rates are based on union wage rates
for the Southeastern United States. No added labor costs for overtime work
were taken into account in the estimate. The labor rates are fully loaded rates,
thus all contractor premium pay, indirects and markups are included in the
base rate.
Report 30300/01
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All equipment work hour estimates were derived using factors.

5.
BASIS OF ESTIMATES INDIRECT AND OTHER COSTS
Note that the indirect and other costs are common for the three estimates as follows:
5.1.
5.2.
Contractor indirect costs included in the labor rate:
Home office job management costs.
Statutory taxes and insurance.
Welfare and fringes.
Workers compensation.
Contractor's general liability insurance.
Small tools / consumables.
Field office job management costs.
Support craft - fire watch, snorkel watch, cleanup, warehousing.
Scaffolding.
Temporary construction power, air, ice, water, toilets, barricades.
Rental of construction equipment and required supplies and services.
Field office and miscellaneous expenses.
Supervision (above first level 'pusher' foreman).
Casual overtime premium pay (i.e., not scheduled).
Contractor markup.
Indirect Costs
Direct costs and contractor's indirect costs are combined in the estimates and
result in the total construction cost, otherwise known as total installed cost
(TIC). To this were added the following indirect costs:
Report 30300/01
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5.2.1.
Engineering (Consultant)
Engineering costs are included at a rate of 10.0% of the total direct cost.
This rate includes both feasibility and detailed design engineering.
5.2.2.
Owner Engineering
Owner engineering costs are included at a rate of 2.0% of the total
direct cost. This includes the owners engineering and oversight
efforts.
5.2.3.
Pre-Project Cost
Pre-project costs such as those associated with surveying, soil testing,
ecological studies, etc. are included at a rate of 0.5% of the total
construction cost.
5.2.4.
Construction Management
Construction Management costs are included at a rate of 2.0% of the
total construction cost.
5.2.5.
Environmental or Legislative Costs

Environmental or legislative costs such as those associated with
environmental permitting are included at a rate of 1.0% of the total
construction cost.
5.2.6.
Capitalized Spares
The costs of recommended spare parts are included at a rate of 3.0% of
the total construction cost.
5.2.7.
Sales Taxes
Sales taxes are included for owner and contractor furnished materials,
including equipment, consumables and rentals. Sales taxes are
included at a rate of 3.5% of the total construction cost, which
approximates a 7.0% sales tax on the sum of the owner and contractor
furnished materials.
5.2.8.
Freight
Freight costs are included at a rate of 3.0% of the owner direct cost of
equipment and materials.
Report 30300/01
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5.3.
Contingency
This category covers unforeseen costs that are expected but not identified at the
time of the estimate. Contingency costs are included at a rate of 20% of the
total direct and indirect costs. The percentage is based on HGI experience and
the class of the estimate. Contingency is used to cover unanticipated additional
costs that may develop during detailed engineering and construction such as:
Higher than anticipated labor rates that are caused by changes in local
conditions but not caused by extended strikes.
Minor changes in equipment and material specifications and pricing.
Minor changes in construction that are agreed to be within the scope of the
estimate.
Items encountered during design or constructions that were unaccounted
for or not determinable at the time the estimate was prepared.
It is expected that contingency funds will be used. Contingency is not intended
to cover escalation of major, unanticipated costs nor does it cover increases in
project costs due to scope changes.
The contingency factor is applied to the sum of the total construction cost and
indirect costs, and the combined total is called the Process Plant & Equipment
(PP&E) cost.
5.4.
Additional Indirect Costs

The following indirect costs are added to the PP&E cost to produce the grand
total, otherwise known as the total project investment (TPI) for the estimates:
5.4.1.
Escalation
Escalation costs are not included.
5.4.2.
Capitalized Interest
Capitalized interest costs are not included.
5.4.3.
Deferred Start-Up Costs
Deferred start-up costs are not included.
Report 30300/01
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5.4.4.
Working Capital
Working capital is not included.
5.4.5.
Operator Training
Operator training costs are included at a rate of 1.0% of the total
construction cost.
5.4.6.
Start-Up
Startup and commissioning services are included at a rate of 1.0% of
5.5.
Cost Exclusions
The following costs are not included in this estimate:
Any costs beyond startup.
Costs for lost production.
Report 30300/01
5-14
Project 30300.00
NREL
Golden, Colorado
August 3, 2012
REPORT 30300/01
SECTION 6
DETAILED CAPITAL COST ESTIMATE CFB GASIFIER
1.
TECHNOLOGY DESCRIPTION
1.1.
General
To assist in the design and cost estimating of gasifier systems, four Microsoft
Excel workbook models were developed (CFB gasifier, BFB gasifier, high
pressure biomass feed system and low pressure biomass feed system). The
models can be used to analyze the impact of various design parameters on
capital costs. Each model produces a material balance, equipment list, capital
cost estimate, equipment drawings and preliminary general arrangement
drawings. Example outputs of each model are included in the Appendixes.
The Circulating Fluid Bed Gasification System Model (CFB gasifier model),
which is discussed below, is based on an allothermal circulating fluid bed
gasification system with an allothermal circulating fluid bed syngas reforming
system. This particular gasification process uses four fluid bed reactors: a
gasifier reactor, a char combustion reactor in the gasifying loop, a syngas
reformer reactor and reformer bed media heating reactor in the reforming loop.
The CFB gasifier model requires a gasifier reactor pressure input in the range of
20-150 PSIG and a biomass feed rate input in order to size the entire
gasification system. Pressure drop inputs are used to establish the design
pressures for all of the other reactors, cyclones and pressure vessels.
1.2.

Dried biomass is metered to the gasifier reactor through four parallel lines of
storage bins and screw conveyors. The number of lines can be reduced,
depending on the production rate of the system. Dried biomass is transported
to the gasifier/reformer building by a conveyor. The biomass delivery
conveyor and biomass feed system are outside the battery limits of the cost
estimate, although a proposed biomass feed system is described.
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The biomass is deposited in a weigh-bin. The weigh bin feeds a lock hopper
via twin screw dischargers. Actuated gate type vales are used to isolate the
inlet and outlet lines on the lock hopper. Biomass is discharged from the lock
hopper to a pressurized metering bin, equipped with live bottom screws, that
feeds a transfer screw conveyor. Transferred biomass is discharged to the
gasifier feed screw.
The lock hoppers, metering bins, transfer screws and gasifier feed screws are
all designed for pressurized operation. A somewhat simpler biomass feed
system can be used when the gasifier reactor is operated at low pressure.
All other biomass unloading, handling and storage equipment is outside the
battery limits of the CFB gasifier model. These items include but are not
limited to truck unloading, screening, storage, drying, dryer air emissions
abatement equipment, dry storage, and all conveyance and transport
equipment prior to the weigh bins.
1.3.
Gasifier Reactor
The gasifier is designed for a wood chip biomass feed and uses steam and hot
bed media to gasify the wood chips and form hydrogen and carbon monoxide.
All of the oxygen for the gasification process is supplied by the water
molecules in the steam and no other air or oxygen gas is added. The biomass
and hot bed media are both introduced near the bottom of the upflow gasifier
reactor. Medium pressure steam is introduced into the bottom of the gasifier
reactor through a refractory insulated distribution header to facilitate
fluidization. No air or oxygen is added to the gasifier; however, nitrogen gas
may be used to pressurize the biomass feed system and to assist with
fluidization during startups. Nozzles are either refractory lined or water
cooled. Due to the high gasifier temperature (approximately 1,560 F), the
reactor vessel is completely lined with refractory to protect the integrity of the
steel shell.
The gasifier reactor is sized to accommodate the expanding gas stream as it
passes up through the vessel. This is accomplished by using a small diameter
lower section combined with a larger diameter upper section. All of the bed
media, some partially gasified biomass (char particles) and syngas exit at the
top of the reactor. The syngas and entrained solids are routed through a large
diameter duct to the primary gasifier cyclone. Due to the fast fluidization and
the high gas velocities, the biomass material becomes thoroughly mixed with
the bed material to enhance the heat and mass transfer and rapidly convert the
biomass into syngas. NREL provided the composition (Reference Phillips et
al., NREL/TP-510-41168) of the syngas produced by this type of circulating
fluid bed gasification reactor.
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1.4.
Gasifier Cyclones
The entrained char and bed media mixture in the syngas from the gasifier
reactor is separated by two cyclones mounted in series. The bed media and
char mixture is discharged from the bottom cones of both the primary cyclone
(Gasifier Reactor No.1 Cyclone) and secondary cyclone (Gasifier Reactor No.2
Cyclone) through refractory lined pipes to a solids collection bin (Gasifier
Reactor Cyclone Solids Collection Bin). The solids discharge lines from the two
cyclones enter the collection bin through vertical drop legs. Solids levels are
maintained in the drop legs by the differential pressure between the cyclones
and the collection bin to form a seal. Steam is added at the bottom of the
collection bin to fluidize the contents and transport the bed media and char to
the overflow line feeding the char combustion reactor. Nitrogen gas may be
used for fluidization during startups.
Syngas exits from the top of the secondary gasifier cyclone and is routed
through a large diameter duct to a header that feeds the bottom of the syngas
reformer reactor.
1.5.
Gasifier Reactor Startup Burner

The gasifier reactor is equipped with a natural gas/process syngas burner for
pre-heating the refractory linings and the bed media in the gasifier and the
syngas reformer reactors, and their cyclones, bed media collection bins and the
interconnecting gas ducts and bed media lines during startups.
1.6.
Char Combustion Reactor and Combustion Air System

The bed media and char mixture from the gasifier cyclones collection bin enters
the char combustion reactor through a side wall nozzle near the bottom of the
reactor. The circulating fluid bed combustion reactor is a pressure vessel,
which operates at a somewhat lower pressure (approximately 10 PSIG) than
the gasifier reactor. The reactor is refractory lined and is equipped with an air
distribution header located at the bottom of the vessel to facilitate fluidization.
A centrifugal fan blows ambient air through an air heater located in the flue gas
duct on the discharge of the secondary char combustion cyclone, where the air
is indirectly heated to approximately 800 F. The heated combustion air is then
routed through a duct to the char combustion reactor air distributor to combust
the char and promote fluidization. The combustion process produces a hot flue
gas stream (approximately 1,800 F) containing carbon-free ash and reheated
bed media.
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1.7.
Char Combustion Cyclones

A mixture of entrained ash and bed media in the syngas from the char
combustion reactor is separated by two cyclones mounted in series. Most of
the bed media and a small percentage of the ash are discharged from the
bottom cone of the primary cyclone (Char Combustion Reactor No.1 Cyclone)
through a refractory lined pipe to a solids collection bin (Char Combustion
Reactor No.1 Cyclone Solids Collection Bin). The solids discharge line enters
the collection bin through a vertical drop leg. A solids level is maintained in
the drop leg by the differential pressure between the cyclone and the collection
bin to form a seal. Steam is added at the bottom of the collection bin to fluidize
the contents and transport the bed media and char to the overflow line feeding
the gasifier reactor. Nitrogen gas may be used for fluidization during startups.
The syngas, entrained ash and depleted bed media (small particle size) from
the primary cyclone are ducted to the secondary cyclone where the remaining
ash and bed media are removed. Flue gas exits from the top of the char
combustion secondary cyclone and is ducted to the char combustion reactor air
heater. The cooled flue gas is then pulled through an exhaust fan to a vent
stack, where it is vented to the atmosphere. The fan and vent stack are outside
the battery limit of the capital cost estimate. Note that there is sufficient heat
remaining in the flue gas that it could be used for further heat recovery prior to
venting.
1.8.
Char Combustion Reactor Startup Burner

The char combustion reactor is equipped with a natural gas/process syngas
burner for pre-heating the refractory linings and the bed media in the char
combustion reactor, its cyclones, bed media collection bin and the
interconnecting gas ducts during startups.
1.9.
Gasifier Loop Ash Discharge System

The ash and bed media mixture discharged from the bottom cone of the
secondary char combustion reactor cyclone is routed through a refractory lined
pipe to the gasifier loop depleted bed media and ash cooling screw conveyor.
The screw conveyor is water-cooled. A rotary valve in the discharge chute
from the screw conveyor is used to maintain a seal on the secondary cyclone.
Cooled ash and bed media are discharged from the screw conveyor to the
gasifier loop depleted bed media and ash storage bin for accumulation until
offloaded for disposal. A water misting spray is used to dampen the ash as it is
discharged from the cooling screw to reduce dusting in the storage bin. Bin
discharge is outside the battery limit.
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1.10.
Gasifier Loop Bed Media Makeup System

The gasifier loop bed media makeup system begins with a truck unloading
station for receipt and offloading of bed media. Trucks equipped with self
contained blowers will connect to a pneumatic line feeding the top of the
gasifier loop bed media feed bin. Bed Media is discharged from the feed bin to
a blower equipped pneumatic transfer line, which transfers bed media to the
char combustion reactor.
1.11.
Syngas Reformer Reactor

The syngas reformer reactor is a circulating fluid bed reactor designed to
convert hydrocarbon molecules in syngas to carbon monoxide and hydrogen
using steam and hot catalytic bed media. Syngas from the gasifier loop and hot
bed media (the heat source) are both introduced at the bottom of the upflow
reformer reactor, with the syngas fluidizing the bed media. Medium pressure
steam is introduced into the bottom of the syngas reformer reactor through a
refractory insulated distribution header. No air or oxygen is added to the
reformer. Nozzles are either refractory lined or water cooled. Due to the high
reformer reactor temperature (approximately 1.652 F), the reactor vessel is
completely lined with refractory to protect the integrity of the steel shell.
The reformer reactor is a cylindrical vessel sized to accommodate syngas from
the gasifier as well as syngas from a supplementary source such as natural gas.
Reformed syngas and all of the bed media exit at the top of the reactor and are
routed through a large diameter duct to the primary reformer cyclone.
1.12.
Syngas Reformer Cyclones

The entrained bed media in the reformed syngas from the reformer reactor is
separated by two cyclones mounted in series. Bed media is discharged from
the bottom cones of both the primary cyclone (Syngas Reformer Reactor No.1
Cyclone) and secondary cyclone (Syngas Reformer Reactor No.2 Cyclone)
through refractory lined pipes to a solids collection bin (Syngas Reformer
Reactor Cyclone Solids Collection Bin). The solids discharge lines from the two
cyclones enter the collection bin through vertical drop legs. Solids levels are
maintained in the drop legs by the differential pressure between the cyclones
and the collection bin to form a seal. Steam is added at the bottom of the
collection bin to fluidize the contents and transport the bed media to the
overflow line feeding the reformer bed media heating reactor.
Reformed syngas exits from the top of the secondary reformer cyclone and is
routed through a large diameter duct to the battery limit of the
gasifier/reformer building.
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1.13.
Reformer Bed Media Heating Reactor and Burner System

Bed media from the reformer cyclones collection bin enters the reformer bed
media heating reactor through a side wall nozzle near the bottom of the
reactor. The circulating fluid bed reactor is a pressure vessel, which operates at
a somewhat lower pressure (approximately 10 PSIG) than the reformer reactor.
The reactor is refractory lined and is equipped with a natural gas/process
syngas burner assembly for heating the bed media. The combustion products
from the burner provide the gas to facilitate fluidization. A centrifugal fan
blows ambient air through an air heater located in the flue gas duct on the
discharge of the secondary reformer bed media heating cyclone, where the air
is indirectly heated to approximately 800 F. The heated combustion air is then
routed through a duct to the reformer bed media heating reactor burner.
1.14.
Reformer Bed Media Heating Reactor Cyclones

Entrained bed media in the syngas from the reformer bed media heating
reactor is separated by two cyclones mounted in series. Most of the bed media
is discharged from the bottom cone of the primary cyclone (Reformer Bed
Media Heating Reactor No.1 Cyclone) through a refractory lined pipe to a
solids collection bin (Reformer Bed Media Heating Reactor No.1 Cyclone Solids
Collection Bin). The solids discharge line enters the collection bin through a
vertical drop leg. A solids level is maintained in the drop leg by the differential
pressure between the cyclone and the collection bin to form a seal. Steam is
added at the bottom of the collection bin to fluidize the contents and transport
the bed media to the overflow line feeding the syngas reformer reactor.
The reformed syngas and entrained, depleted, small particle size bed media
from the primary cyclone are ducted to the secondary cyclone where the
remaining bed media is removed. Flue gas exits from the top of the reformer
bed media heating reactor secondary cyclone and is ducted to the bed media
heating reactor air heater. The cooled flue gas is then pulled through an
exhaust fan to a vent stack, where it is vented to the atmosphere. The fan and
vent stack are outside the battery limit of the capital cost estimate. Note that
there is sufficient heat remaining in the flue gas that it could be used for further
heat recovery prior to venting.
1.15.
Reformer Loop Ash Discharge System

The bed media and leftover ash (carryover from the gasifier loop) discharged
from the bottom cone of the secondary reformer bed media heating reactor
cyclone is routed through a refractory lined pipe to the reformer loop depleted
bed media and ash cooling screw conveyor. The screw conveyor is watercooled. A rotary valve in the discharge chute from the screw conveyor is used
Report 30300/01
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to maintain a seal on the secondary cyclone. Cooled bed media is discharged

from the screw conveyor to the reformer loop depleted bed media storage bin
for accumulation until offloaded for disposal. A water misting spray is used to
dampen the ash as it is discharged from the cooling screw to reduce dusting in
the storage bin. Bin discharge is outside the battery limit.
1.16.
Reformer Loop Bed Media Makeup System

The reformer loop bed media makeup system begins with a truck unloading
station for receipt and offloading of bed media. Trucks equipped with self
contained blowers will connect to a pneumatic line feeding the top of the
reformer loop bed media feed bin. Bed Media is discharged from the feed bin
to a blower equipped pneumatic transfer line, which transfers bed media to the
reformer bed media heating reactor.
1.17.
Utilities
The gasifier/reformer building is equipped with piping from the battery limits
to the point of use. The following utilities are required:
1.17.1. Steam to provide medium pressure steam at a pressure of 20-150
PSIG for the gasifier and syngas reformer reactors and to provide
fluidizing steam for the four cyclone solids collection bins.
1.17.2. Cooling Water System cooling water supply and return for the
depleted bed media and ash cooling water screw conveyors.
1.17.3. Flare Stack - during start-ups, shutdowns and emergency stop events,
syngas is routed to a flare stack outside the battery limits of the
gasifier/reformer building for incineration and exhaust to the
atmosphere.
1.17.4. Natural Gas to provide fuel for the gasifier reactor startup burner,
the char combustion reactor startup burner and the reformer bed
media heating reactor burner.
1.17.5. Supplemental Syngas to provide feed gas for the reformer loop when
the gasifier loop is shutdown.
1.17.6. Instrument Air to provide air for operation of valve actuators, etc.
1.17.7. Plant Air to provide air for building services and cleanup.
1.17.8. Hose Station Water to provide water for building services and
cleanup.
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1.17.9. Potable Water to provide water for emergency eye wash stations and
showers.
2.
MODEL BASIS AND ASSUMPTIONS

2.1.
The CFB gasifier model is a material balance model, not a material and energy
balance model. The CFB gasifier model provides inputs for the estimated
temperature in each of the four reactors.
2.2.
The CFB gasifier model requires inputs for scheduled and unscheduled
downtime from which the total annual operating hours are calculated. The
operating hours and an input of the annual capacity (short tons/year) are then
used as the basis for calculating the design operating rate (short tons/hour) for
the model.
2.3.
Dried biomass is metered to the gasifier reactor through four parallel lines of
storage bins and screw conveyors. The CFB gasifier model does not
automatically calculate the size, cost or weight of this equipment when the
biomass feed rate changes but provides for input of the cost and weight values
in the 04-Equip List spreadsheet (see Appendix E). Depending on the biomass
feed rate, the number of lines can be reduced be inputting zero values for the
cost and weight of each piece of equipment on a given line or by reducing the
cost and weight of the equipment on each line. The biomass feed lines include
lock hoppers to isolate the feed lines from the gasifier for pressures up to 150
PSIG. If desired, the lock hoppers can be eliminated for low pressure operation
by inputting zero values in the 04-Equip List spreadsheet for the cost and
weight of the lock hoppers.
2.4.
The biomass composition and physical properties were provided by NREL.

These values were used in the Excel workbook example shown in this report.
However, the biomass composition can be changed by adjusting the values in
the 06-Design Criteria spreadsheet.
2.5.
The CFB gasifier model example shown in this report specifies the dried
biomass moisture content at 5.0%. However, the biomass moisture content is
an input value which can be changed in the 06-Design Criteria spreadsheet.
2.6.
Not all the input values in the 06-Design Criteria spreadsheet are used in
calculations. Some values (e.g. biomass bulk density and biomass type) are
provided for information only.
2.7.
Bed media is considered to be inert for calculations in the model. Moisture

content of the bed media is an input value in the 06-Design Criteria
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spreadsheet. There are inputs for two types of bed media, Type-A for the
gasifier loop and Type-B for the reformer loop.
2.8.
The CFB gasifier model provides inputs for nitrogen gas composition, physical
properties and feedrate to the process in the 06-Design Criteria spreadsheet.
All of the nitrogen is added to the gasifier reactor even if it is actually added
elsewhere. This was done to simplify the model since any nitrogen added
would eventually end up in the reformed syngas stream.
2.9.
The CFB gasifier model provides inputs for oxygen gas composition and
physical properties. Oxygen can be added to the gasifier reactor, and an input
for oxygen feedrate is provided in the 06-Design Criteria spreadsheet. The
workbook example used in this report does not use any oxygen, and the
feedrate input value is set to zero. If oxygen is used, the workbook will
automatically reduce the amount of steam added to the gasifier reactor.
2.10. The CFB gasifier model provides inputs for natural gas composition and
physical properties in the 06-Design Criteria spreadsheet. Natural gas is used
as the fuel source for heat generation in the reformer bed media heating
reactor. The natural gas feed rate is automatically calculated to provide the
heat needed to reheat the bed media fed to the reformer bed media heating
reactor. Natural gas is also used in the gasifier reactor and the char combustion
reactor during startups; however, since the material balance is a steady state
model, this additional natural gas is not part of the material balance.
2.11. The CFB gasifier model provides inputs for air composition and physical
properties in the 06-Design Criteria spreadsheet. Air is used for combustion
oxidation in the char combustion reactor and the reformer bed media heating
reactor.
2.12. The CFB gasifier model provides inputs for steam pressure and degrees of
superheat. There are two locations where steam is added to the process, one is
the gasifier reactor and other is the syngas reformer reactor. Inputs for the
addition of fluidization steam to the bed media solids collection bins are not
provided. However, if fluidization steam were added, it would end up in the
four reactor vessels. In the case of the gasification reactor and the syngas
reformer reactor bin fluidization steam would diminish the steam added
directly, but the total steam would remain the same. In the case of the char
combustion reactor the bin fluidization steam would, however, slightly
increase the total water vapor in the flue gas.
2.13. The gasifier syngas composition and physical properties for an allothermal
circulating fluid bed gasification reactor were provided by NREL. These values
were used in the Excel workbook example shown in this report. However, the
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gasifier syngas composition can be changed by adjusting the values in the 06

Design Criteria spreadsheet.
2.14. The CFB gasifier model provides inputs in the 06-Design Criteria spreadsheet
for composition and physical properties of a supplemental syngas stream.
Supplemental syngas can replace or supplement the gasifier loop syngas. The
supplemental syngas is added to the syngas header feeding the bottom of the
syngas reformer reactor.
2.15. Syngas reforming calculations involve converting carbon in the hydrocarbon
gases to carbon monoxide with the oxygen from water molecules. The CFB
gasifier model provides cells in the 06-Design Criteria spreadsheet for inputting
the percent conversion of each hydrocarbon compound, which might be a
function of the catalytic bed media chosen. Some of the water molecules are
provided by the water vapor present in the incoming syngas. The remaining
amount of water is determined by calculation and forms the basis for the
amount of steam added to the syngas reformer reactor. The hydrogen from the
reacted water molecules increases the overall hydrogen content of the reformed
syngas. Since the CFB gasifier model does not include an energy balance, heats
of reaction are not used in any calculations.
2.16. The CFB gasifier model is designed for a gasifier reactor pressure input in the
range of 20-150 PSIG. These inputs are made in the 06-Design Criteria
spreadsheet. Differential pressure values are entered for the other three
reactors (char combustion reactor, syngas reformer reactor, and reformer bed
media heating reactor) to provide the motive force for moving bed media and
syngas through the system.
2.17. The gasifier loop is designed for a maximum temperature of 1,900 F. The
reformer loop is designed for a maximum temperature of 2,000 F. These
values are important for the selection of refractory linings in all high
temperature vessels, ducts and lines. The refractory linings used in the CFB
gasifier model are based on a steel shell skin temperature of 300 F. If a
different skin temperature is desired, the refractory inputs also need to be
changed.
2.18. The CFB gasifier model provides cells in the 06-Design Criteria spreadsheet for
the design of each piece of refractory lined equipment (reactors, cyclones, ducts
and lines). The refractory thickness is not automatically calculated but requires
an entry specifying the refractory thickness for each piece of equipment.
2.19. The CFB gasifier model designs refractory lined reactors, cyclones and tanks
from two basic shapes: cylinders and cones (or frustums of a cone). The
vessels are designed in sections and a cost and weight is automatically
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calculated for each section using data from the material balance and lookup
tables containing unit weights and costs. The design includes nozzles, support
lugs, refractory anchors, inserts (e.g. distribution headers for air and steam)
and refractory. The total cost is broken into a material cost and a fabrication
cost.
2.20. The CFB gasifier model provides cells in the 06-Design Criteria spreadsheet for
eleven nozzles on each vessel (i.e. reactors, cyclones and tanks). Some nozzles
are automatically sized while others require an input.
2.21. Reactor diameters are calculated from an input of the gas upflow velocity
target, and the reactor heights are calculated from an input of the retention time
target.
2.22. Equipment items named lines are used to transport bed media and ash and
are relatively free of gases (e.g. drop legs from cyclones to collection bins).
These lines are not automatically sized and require a size input in the 06
Design Criteria spreadsheet.
2.23. Refractory lined ducts and lines require flanges every 10 feet to provide
sections that can reasonably lined with refractory. The CFB gasifier model
automatically adds flanges to account for this requirement. Each duct and line
contains one expansion joint.
2.24. The gasification and syngas reforming equipment is all located in a single
multi-story building.
2.25. The gasifier/reformer building is comprised of (1) 35 x 40 gasifier bay and
(11) 25 x 25 bays for the rest of the system. The footprint does not
automatically change with changes is the overall system design. The footprint
is used to determine the number of piles and the quantity of concrete needed
for the foundation. The bay sizes are changeable input values in the 03-Cost
Est and can be modified as desired.
2.26. The weight of structural steel, grating, handrails, etc. for building construction
is automatically calculated from the total equipment weight.
3.
EXCEL WORKBOOK MODEL OPERATION

The CFB gasifier model is an Excel workbook containing 51 Excel spreadsheet tabs
that interact to produce a capital cost estimate for an allothermal circulating fluid bed
gasification and an allothermal circulating fluid bed syngas reforming system. The
CFB gasifier model includes a mass balance, equipment list and capital cost estimate,
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and it produces a set of equipment drawings for the reactor vessels, cyclones and
tanks.
3.1.
Excel Options
Before manipulating the CFB gasifier model, the Excel Options entry screen
must be accessed. Under the Formulas selection, the Enable iterative
calculation box must be selected and set for 100 Maximum Iterations and 0.001
Maximum Change. Under the Advanced selection, the Allow editing
directly in cells box must be turned deselected. With Allow editing directly
in cells turned off, the operator is able to jump from a cell containing a
formula to the referenced cell by double clicking on the cell with the formula.
This is important in navigating the Excel workbook.
3.2.
Cell Colors
3.2.1.
Bright Yellow - Cells backlighted in bright yellow are input cells

containing values that can be altered.
3.2.2.
Light Yellow - Cells backlighted in light yellow are input cells

containing values that can be altered but which normally remain the
same.
3.2.3.
Bright Green - Cells backlighted in bright green contain constants that

are not to be altered.
3.2.4.
Pink - Cells backlighted in pink contain a reference to cells in another

spreadsheet(s) within the model and may display the referenced cell or
use it in a calculation.
3.2.5.
Lavender - Cells backlighted in lavender are usd in the materials

spreadsheets (e.g. spreadsheets 07-Plate Steel) to display material
values and prices obtained from vendors.
3.2.6.
White Cells backlighted in white contain calculations that reference

cells only within the same spreadsheet.
3.2.7.
Light Green - Cells backlighted in light green contain text used for line
item headings that do not normally need to be changed. However, this
text may be changed without affecting any calculations in the model.
3.2.8.
Medium Blue - Cells backlighted in medium blue contain text used for
column headings that do not normally need to be changed. However,
this text may be changed without affecting any calculations in the
model.
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3.2.9.
Light Blue - Cells backlighted in light blue contain text used for subcolumn headings that do not normally need to be changed. However,
model.
3.2.10. Dark Blue (With White Text) - Cells backlighted in dark blue contain
references to other cells in the workbook and are only used for
navigating (double clicking) to jump to other points in the workbook.
3.3.
Individual Spreadsheet Descriptions

3.3.1.
00-Color Codes & Tab Index: This spreadsheet contains descriptions

for each cell color used in the spreadsheets and provides a tab index
with descriptions.
3.3.2.
01Contact List: This spreadsheet contains a list of NREL, HGI and

equipment vendor contacts who participated in this project.
3.3.3.
02-Dwg List: This spreadsheet is the control document for assigning

drawing numbers and names to material balance drawings (MB-1-XX)
and equipment drawings (EQ-1-XX).
3.3.4.
03-Cost Est: This spreadsheet contains the capital cost estimate

summary and cost estimate details.
Inputs are made for quantities of materials, unit prices and
labor rates for site preparation (civil earthwork) equipment
foundations, non refractory lined pipe (e.g. steam, natural gas,
water), electrical equipment and wiring (motors are included
with equipment), insulation and painting, and demolition.
Inputs are made for the gasifier/reformer building footprint
and factors for calculating structural steel quantities as a
function of the total weight of all equipment and refractory
lined ducts and pipe.
Inputs are made for calculating factored costs (e.g.
instrumentation, engineering, contingency, etc.) as a
percentage of capital costs.
3.3.5.
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04-Equip List: This spreadsheet is the control document for assigning

equipment names and equipment numbers. Also, the spreadsheet
provides cells for inputting the biomass feed system costs and weights.
6-13
3.3.6.
05-Map: This spreadsheet is a navigation tool for locating specific

pieces of equipment in the 06-Design Criteria spreadsheet. This
spreadsheet also displays brief summaries of all the refractory lined
reactors, cyclones, tanks, ducts and lines.
3.3.7.
06-Design Criteria: This spreadsheet is the primary document for

entering/changing data inputs.
3.3.8.
07-MB: This spreadsheet contains all of the material balance

calculations. There are no data input cells in this spreadsheet except
for the naming of some streams.
3.3.9.
08-Plate Steel: This spreadsheet contains a lookup table which lists

plate steel cost as a function of plate thickness for plate steel
manufactured from ASME SA-516, Grade 70 carbon steel. All vessels
(reactors, cyclones and tanks) are priced based on this grade of steel.
The table also shows the maximum allowable stress for the steel plate
at various temperatures.
3.3.10. 09-Fab Cost: This spreadsheet contains a lookup table which lists
vessel fabrication cost as a function of total vessel weight for vessels
fabricated with ASME SA-516, Grade 70 carbon steel.
3.3.11. 10-Nozzles & Flanges: This spreadsheet contains a lookup table which
lists nozzle and flange dimensions and properties as a function of
diameter.
3.3.12. 11-Pipe & Duct: This spreadsheet contains a lookup table which lists
pipe and duct dimensions and properties as a function of diameter.
For diameters from to 24 the pipe and duct are manufactured
from ASME SA-106, Grade B carbon steel. For diameters from 26 to
96 the pipe and duct are manufactured from ASME SA-516, Grade 70
carbon steel. All refractory lined pipes and ducts are priced based on
this grade of steel.
3.3.13. 12-Exp Joints: This spreadsheet contains a lookup table which lists
expansion joint properties and cost as a function of diameter.
3.3.14. 13-Vessel-Anchors: This spreadsheet contains a lookup table which
lists refractory anchor properties and costs for a refractory system that
will prevent vessel skin temperatures from exceeding 300 F.
3.3.15. 14-Vessel-Refractory: This spreadsheet contains a lookup table which
lists refractory properties and costs for a refractory system that will
prevent vessel skin temperatures from exceeding 300 F.
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3.3.16. 15-Nozzle-Anchors: This spreadsheet contains a lookup table which

will prevent nozzle skin temperatures from exceeding 300 F.
3.3.17. 16-Nozzle-Refractory: This spreadsheet contains a lookup table which
prevent nozzle skin temperatures from exceeding 300 F.
3.3.18. 17-Sat Stm: This spreadsheet contains a Saturated Steam Table which
is used as a lookup table for steam properties.
3.3.19. 18-Water: This spreadsheet contains a lookup table for water
properties.
3.3.20. 19-Sheet Steel Allowable Stress: This spreadsheet contains a lookup
table for determining the maximum allowable stress in tension for
carbon and low alloy steel.
3.3.21. 20-Weld Joint Eff: This spreadsheet contains a lookup table that lists
the weld efficiency for steel subjected to various degrees of
radiographic examination.
3.3.22. 21-Steel Info: This spreadsheet contains a list of acceptable materials of
construction for various components of fabricated vessels, ducts and
lines.
3.3.23. 22-Columns: This spreadsheet contains a lookup table for assigning an
identification number to columns in other lookup tables.
3.3.24. 23-Excel Help: This spreadsheet contains examples of a number of
formulas used in the workbook.
3.3.25. 24-Scratch Sheet: This spreadsheet is to be used for making temporary
calculations.
3.3.26. MB-1-01 Thru MB-1-06: These 6 spreadsheets contain the material
balance flow diagrams.
3.3.27. EQ-1-01 Thru EQ-1-20: These 20 spreadsheets contain the equipment
drawings of the reactors, cyclones and tanks.
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4.
CAPITAL COST SUMMARY

The capital cost estimate in the CFB gasifier model is considered a Class 3 budgetary
estimate according to The Association for the Advancement of Cost Engineering
(AACE) guidelines.
The cost estimate is the end product of the CFB gasifier model. Pricing and pricing
guidelines were obtained from vendors in order to populate the material pricing
lookup tables in the model. The costs of all the major equipment are calculated in the
model. The remaining cost inputs are factored from the major equipment pricing and
are shown in the 03-Cost Est spreadsheet tab in the model.
Cost estimates produced by the model are stated in 2011 dollars. According to AACE,
the expected level of accuracy for a Class 3 estimate should average +40%/-20%.
The capital cost estimate from the CFB gasifier model is shown in Appendix H for
installation of a 1,000 oven dry metric tons per day biomass gasification and tar
reformer system.
5.
BASIS OF ESTIMATE DIRECT COSTS

A summary of the methods and assumptions that were used in preparing the detailed
capital cost estimate are listed below:
5.1.
Labor
work hour estimates. Note that the estimate assumes an average hourly labor
rate of $85 for most of the installation, erection and construction activities. The
estimated labor rate is loosely based on union wage rates for the Southeastern
United States. It is understood that most crafts and disciplines charge differing
rates, however to simplify the estimate a single average rate was used. The
labor rate is modifiable by the user to represent a location of higher or lower
labor rates.
No added labor costs for overtime work were taken into account in the
estimate. The labor rates are fully loaded rates, thus all contractor premium
pay, indirects and markups are included in the base rate.
5.2.
Land
The cost of land is not included in the capital cost estimate.
5.3.
Civil/Earthwork
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6-16
5.3.1.
Site Clearing
The project site is assumed to be a relatively flat, greenfield site, free of
equipment and buildings. The prepared site is assumed to only
account for the area that the gasifier island structure occupies, thus an
assumption of 200 by 200 is used. This 200 by 200 site rounds to
approximately one acre of area that requires clearing and grubbing.
Note that clearing and grubbing refers to removing trees and brush
from the site, grinding the stumps and removing the wood chips.
Note that an allowance for equipment rental associated with site
clearing is also included.
Fill and compaction is required for the same assumed area. A 3 cut
depth was assumed for the volume calculations.
The unit price and the labor hours per unit for the site clearing
activities was taken from the Harris Group estimating database which
is based on typical industry practices and pricing.
5.3.2.
Foundation Preparation
Based on the preliminary design of the gasifier structure as seen in
drawing GA-01, located in Appendix G, the foundation area was
estimated. An assumption for excavation and backfill depth was made
resulting in the volume of excavation and backfill used for the pricing.
Note that an allowance for equipment rental associated with
foundation preparation is also included.
The unit price and the labor hours per unit for the excavation and
backfill was taken from the Harris Group estimating database which is
based on typical industry practices and pricing.
5.3.3.
Piles
The loads of the gasification and tar reforming equipment are expected
to necessitate piles. The number of piles depends on the site location
and the soil conditions. For the purposes of this estimate, the soils are
assumed to have a 3,000-4,000 psi bearing pressure for foundation
design. A factor is included for the pile density and pile length for
these assumed soil conditions. Both the pile density and pile length
can be modified if actual soil conditions are known. Note that an
allowance for equipment rental associated with pile driving is also
included.
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The unit price and the labor hours per unit for the installation of the
piles was taken from the Harris Group estimating database which is
5.3.4.
Other
The following Civil/Earthwork items are NOT included in the capital
cost estimate:
Trenching and backfill for any underground utilities. This
could include natural gas lines, electrical feeders, fire water
piping, process or sanitary sewer lines, storm water drainage
piping/culverts, etc.
Storm water collection systems, ditches and containment
systems (retention pond, etc.).
Roadways and/or paving.
5.4.
Buildings
5.4.1.
Gasifier Island Structure

Based on the equipment sizing and loads, the gasifier island structure
was preliminarily designed and sized. Drawings of the structure are
located in Appendix G. Note that the estimate only includes the
structural steel, miscellaneous access steel, grating and guardrail, and
access stairs. The estimate calculates the steel quantities based on
ratios of the various steel categories to the total equipment weight. It
does not include any masonry or carpentry work, sprinkler systems,
roofing or siding.
steel was taken from the Harris Group estimating database which is
5.4.2.
Gasifier Island Foundation

The entire gasifier island structure will sit on foundations that are
optimized for the arrangement of building columns and actual loads,
however to simplify the estimate, a 30 slab throughout is assumed.
The slab will be sloped to a u-drain which will drain to a storm water
system (piping and retention pond) that is NOT included in the
estimate. Mat type foundations are used. All mat foundations include
rebar rather than mesh, and include form work, hardware (anchor
Report 30300/01
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bolts, iron, etc.), concrete, finishing and stripping. The estimate

includes factors for all of the above items.
mat foundation was taken from the Harris Group estimating database
which is based on typical industry practices and pricing.
5.4.3.
5.5.
Miscellaneous Building Items Not Included
An electrical/MCC/controls room.
An operator control room.
Locker room.

Large equipment will require concrete pedestals for support. An allowance is
included for large equipment pedestal volume.
The unit price and the labor hours per unit for the installation of the equipment
foundations was taken from the Harris Group estimating database which is
5.6.
Piping
All refractory lined syngas piping/ductwork and expansion joints are included
in the equipment section of the estimate. The remaining process piping,
manual and check valves are included in the piping estimate.
An allowance for piping was made for 1, 2, 3 4 and 6 carbon steel piping.
These allowances are meant to account for process items such as, natural gas,
process water, potable water, cooling water, inert gas, process air, and steam.
The unit price and the labor hours per unit for the installation of the piping was
taken from the Harris Group estimating database which is based on typical
industry practices and pricing.
between the gasifier island and any other process areas. Piping is assumed to
terminate at the gasifier island structure boundary. All piping supports within
the gasifier island boundary are included in the estimate.
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6-19
5.6.1.
Piping Items Included in Cost Estimate

5.6.2.
Piping Items Not Included in Cost Estimate

Any piping outside the gasifier island boundary.
Piping related to process and/or sanitary sewer systems.
Fire water systems (piping, hydrants, sprinklers etc.).
5.7.
Electrical
5.7.1.
Only the installation of the motors is currently included in the

electrical systems estimate. Allowances for 5, 10, 25, 50, 100, 200 and
250 horsepower motors are included. The estimate includes an
allowance for 200 of motor wiring and conduit, terminations, motor
and motor starter.
5.7.2.
motors was taken from the Harris Group estimating database which is
5.7.3.
Electrical Items Not Included in Cost Estimate

MCCs
Control cabling, terminations, conduit, and cable ways.
Control systems uninterrupted power supplies (UPS).
Lightning protection.
Lighting.
Grounding.
Unit substations (transformers/primary switch/secondary
switch gear).
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Medium voltage feeder (this feeder will feed a single

substation or loop feed multiple unit substations).
Cable and conduit for the power distribution feeders between
the transformers and the indoor switchgear, and between the
switchgear and the MCCs.
5.8.
Instrumentation
The estimate includes one allowance for all of the instrumentation and controls
equipment and installation, based on a percentage of the project direct costs.
Field instruments and transducers are 4-20mA type with twisted shield pair
wiring and discrete devices are normally 120VAC.
5.8.1.
Items Included in Instrumentation Allowance

All field instruments for the measurement and control of such
parameters as pressure, temperature and flow. The wiring,
termination, and installation costs are also included.
A programmable logic controller (PLC) based control system
with a human machine interface (HMI).
The necessary computer software and hardware to operate the
control system.
Control system I/O racks.
Actuated valves and valve hook up.
5.8.2.
Items Not Included in Instrumentation Allowance

Special instruments such as various gas analysis devices and
special reactor bed level control devices and their installation.
Any continuous emissions monitoring system (CEMS) to
monitor air emissions.
5.9.
Process Insulation and Painting

An allowance for 200 of 4 piping insulation is included for the steam piping
only.
An allowance for high temperature indicating paint for use on the reactors,
ducts and cyclones is included.
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Labor as well as materials related to the above insulation and painting is

The unit price and the labor hours per unit for the insulation and painting was
Process equipment insulation is NOT included in the capital cost estimate.
5.10.
Equipment
5.10.1.
Fuel Handling And Storage Systems

The gasifier island fuel handling and storage systems were priced
based on vendor quotes and vendor correspondence. The fuel
handling and storage systems are not variable in size or cost based on
the gasifier process throughput or sizing. Modifying the count or size
must be done manually.
The base system includes 4 complete fuel handling and storage
systems. Note also that the fuel handling and storage systems are a
lock hopper type design with a weigh bin and a metering bin included.
A lock hopper system is only needed for higher pressure applications,
however this feed system is thought to be the worst case, or highest
cost scenario. The user must manually change the feed system count
or pricing to better represent a low pressure system, or a system with
lower production rates.
5.10.2.
Reactors, Cyclones and Bins

The reactors (gasifier, char combustor, reformer, and reformer heater),
cyclones and bins are sized in the model based on a user provided
production rate. The total steel is then calculated and priced.
Installation is included based on vendor information. Refractory cost
and installation is also included.
5.10.3.
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Miscellaneous Equipment Included
Gasifier loop bed media makeup system.
Reformer loop bed media makeup system.
Char combustor bed media and ash disposal system.
Reformer heater bed media and ash disposal system.

6-22
Flare system.
5.10.4.
Miscellaneous Equipment Not Included

Inert gas system.
Natural gas compression (if necessary).
Steam generation system (heat recovery steam generator or
fired boiler).
Flue gas scrubbers or other abatement equipment.
Flue gas ID fans.
Stack.
5.11.
Demolition
6.
BASIS OF ESTIMATE INDIRECT AND OTHER COSTS

6.1.

6.1.1.
6.1.2.
6.1.3.
6.1.4.
6.1.5.
6.1.6.
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6.2.
6.1.7.
6.1.8.
6.1.9.
Scaffolding.
6.1.10.
6.1.11.
6.1.12.
6.1.13.
6.1.14.
6.1.15.
Contractor markup.
Indirect Costs
6.2.1.
6.2.2.
Owner Engineering
efforts.
6.2.3.
Pre-Project Cost
construction cost.
6.2.4.
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6.2.5.

construction cost.
6.2.6.
Capitalized Spares
6.2.7.
Sales Taxes
6.2.8.
Freight
6.3.
Contingency
6.3.1.
6.3.2.
6.3.3.
Minor changes in construction that are agreed to be within the scope of

the estimate.
6.3.4.
Items encountered during design or constructions that were

unaccounted for or not determinable at the time the estimate was
prepared.
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It is expected that contingency funds will be used. Contingency is not intended

to cover escalation of major, unanticipated costs nor does it cover increases in
project costs due to scope changes.
The contingency factor is applied to the sum of the total construction cost and
indirect costs, and the combined total is called the Process Plant & Equipment
(PP&E) cost.
6.4.

6.4.1.
Escalation
Escalation costs are not included.
6.4.2.
Capitalized interest costs are not included.
6.4.3.
Deferred start-up costs are not included.
6.4.4.
Working Capital
Working capital is not included.
6.4.5.
Operator Training and Start-Up

Operator training and startup and commissioning costs are included at
a rate of 2.0% of the total construction cost.
6.5.
Cost Exclusions
6.5.1.
6.5.2.
Report 30300/01
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Project 30300.00
NREL
Golden, Colorado
August 3, 2012
REPORT 30300/01
SECTION 7
DETAILED CAPITAL COST ESTIMATE BFB GASIFIER
1.
1.1.
General
To assist in the design and cost estimating of gasifier systems, four Microsoft
Excel workbook models were developed (CFB gasifier, BFB gasifier, high
pressure biomass feed system and low pressure biomass feed system). The
models can be used to analyze the impact of various design parameters on
capital costs. Each model produces a material balance, equipment list, capital
cost estimate, equipment drawings and preliminary general arrangement
drawings. Example outputs of each model are included in the Appendixes.
The Bubbling Fluid Bed Gasification System Model (BFB gasifier model) is
based on a bubbling fluid bed design using a single gasifier reactor vessel. The
gasifier is designed to use oxygen to combust a portion of the biomass material
(autothermal) to generate the heat required for gasification of the biomass.
Steam is also added to provide the motive force to keep the bed material in
suspension in the bottom section of the gasifier reactor.
The BFB gasifier model requires a gasifier reactor pressure input, which may be
as high as 600 PSIG, and a biomass feed rate input to size the entire system. A
pressure drop input is used to establish the design pressures for the gasifier
cyclone.
1.2.

Dried biomass is metered to the gasifier reactor through parallel lines of
storage bins and screw conveyors. The number of biomass feed lines is
calculated as a function of the diameter of the bubbling fluid bed section of the
gasifier reactor vessel and the diameter of the screw feeders. The cost of the
biomass feed system is calculated in a separate workbook model; therefore, the
feed system cost is not included in the BFB gasifier model.
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1.3.
Gasifier Reactor
The gasifier is designed for a wood chip or pellet biomass feed and uses steam
and oxygen, along with bed media, to produce a bubbling fluid bed to gasify
the wood chips and form hydrogen and carbon monoxide. Oxygen for the
gasification process is added to the steam line prior to introduction to the
gasifier reactor vessel. All of the oxygen bound in the biomass and the
elemental oxygen added to the gasifier is converted to either carbon monoxide
or carbon dioxide Depending on the desired oxygen content in the syngas,
water molecules in the steam or in the biomass can provide oxygen and
generate additional hydrogen. The biomass is introduced near the bottom of
the upflow gasifier reactor. Steam and oxygen are introduced into the bottom
of the gasifier reactor through a refractory insulated distribution header to
facilitate fluidization. Nitrogen gas is used to pressurize the biomass feed
system and to assist with fluidization during startups.
Nozzles are either refractory lined or water cooled. Due to the high gasifier
temperature (approximately 1,600 F), the reactor vessel is completely lined
with refractory insulation to protect the integrity of the steel shell.
The gasifier reactor is sized to accommodate the expanding gas stream as it
passes up through the vessel. This is accomplished by using a small diameter
lower section combined with a larger diameter upper section. A small portion
of the bed media, some partially gasified biomass (char particles) and syngas
exit at the top of the reactor. The syngas and entrained solids are routed
through a large diameter duct to the gasifier cyclone. NREL provided the
composition (Reference Phillips et al., NREL/TP-510-41168) of the syngas
produced by this type of gasification reactor.
1.4.
Gasifier Cyclone
The entrained char and bed media mixture in the syngas from the gasifier
reactor is separated by a single cyclone. The ash, char and bed media mixture
is discharged from the bottom cone of the gasifier cyclone back into the gasifier.
1.5.

The gasifier reactor is equipped with a natural gas burner for pre-heating the
refractory linings and the bed media in the gasifier, cyclone, interconnecting
refractory lined gas ducts and solids transport lines during startups.
1.6.
Ash Discharge System

The ash, char and bed media mixture is discharged from the bottom of the
gasifier reactor to the ash cooling screw conveyor. The screw conveyor is
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water-cooled. Cooled ash, char and bed media are discharged from the cooling
screw conveyor to the ash discharge hopper, which is maintained at the same
pressure as the gasifier reactor. An ash lock hopper is located directly below
the ash discharge hopper to provide a means to depressurize the ash for
disposal. The ash, char and bed media mixture is discharged into the ash lock
hopper by gravity through an inlet block valve. The lock hopper outlet block
valve is located on the discharge side of the ash lock hopper discharge screw
conveyor. The ash, char and bed media mixture is conveyed by the lock
hopper discharge screw conveyor to the battery limits of the system.
1.7.
Bed Media Makeup System

The gasifier bed media makeup system begins with a truck unloading station
for receipt and offloading of bed media. Trucks equipped with self contained
blowers will connect to a pneumatic line feeding the top of the bed media
storage bin. Bed media is discharged from the storage bin to a pneumatic
transporter which uses pressurized nitrogen to transfer bed media to the
gasifier reactor.
1.8.
Utilities
The gasifier/reformer building is equipped with piping from the battery limits
to the point of use. The following utilities are required:
1.8.1.
Steam to provide high pressure steam at a pressure of 150-600 PSIG

to the gasifier reactor for fluidization of the bubbling fluidized bed.
1.8.2.
Cooling Water System cooling water supply and return for the ash
cooling water screw conveyor.
1.8.3.
Natural Gas to provide fuel for the gasifier reactor startup burner.
1.8.4.
Instrument Air to provide air for operation of valve actuators, etc.
1.8.5.
Plant Air to provide air for building services and cleanup.
1.8.6.
Hose Station Water to provide water for building services and

cleanup.
1.8.7.
Potable Water to provide water for emergency eye wash stations and
showers.
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7-3
2.

2.1.
The BFB gasifier model is a material balance model; it does not have an energy
balance component.
2.2.
The BFB gasifier model requires inputs for scheduled and unscheduled
downtime from which the total annual operating hours are calculated. The
operating hours and an input of the annual capacity (metric tons/year) are
then used as the basis for calculating the design operating rate
(short tons/hour) for the model.
2.3.
Dried biomass is metered to the gasifier reactor through injection screw

conveyors. The BFB gasifier model calculates the number of injection screw
conveyors. The equipment for the biomass feed system (single or multiple
lines is not included in the cost estimate.
2.4.
The biomass composition and physical properties were provided by NREL.

These values were used in the Excel workbook example shown in this report.
However, the biomass composition can be changed by adjusting the values in
the 06-Design Criteria spreadsheet.
2.5.
The BFB gasifier model example shown in this report specifies the dried
biomass moisture content at 5.0%. However, the biomass moisture content is
an input value which can be changed in the 06-Design Criteria spreadsheet.
2.6.
calculations. Some values (e.g. biomass bulk density and biomass type) are
provided for information only.
2.7.
Bed media is considered to be inert for calculations in the model. Moisture

content of the bed media is an input value in the 06-Design Criteria
spreadsheet and the BFB GASIFIER MODEL accounts for this contribution to
the moisture content of the syngas.
2.8.
The BFB gasifier model provides inputs in the 06-Design Criteria spreadsheet
for nitrogen gas composition, physical properties and feedrate to the process.
All of the nitrogen required for pressurization, seals, etc. is added to the
gasifier reactor even if it is actually added elsewhere. This was done to
simplify the model since any nitrogen added would eventually end up in the
syngas stream.
2.9.
Natural gas is used in the gasifier reactor startup burner during startups;
however, since the material balance is a steady state model, this natural gas
usage is not part of the material balance.
Report 30300/01
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2.10. The BFB gasifier model provides inputs in the 06-Design Criteria spreadsheet
for oxygen gas composition, physical properties and an oxygen to biomass
percentage. The oxygen feed rate to the gasifier reactor is calculated as a
percentage of the oven dry biomass being added. Oxygen is added to the
steam line feeding the gasifier reactor.
for degrees of superheat and feedrate to the process. The steam pressure is a
function of the gasifier reactor pressure.
2.12. The BFB gasifier model provides an input in the 06-Design Criteria spreadsheet
for gasifier reactor pressure. The BFB gasifier model is designed for a gasifier
reactor pressure input in the range of 150-600 PSIG.
2.13. The gasifier reactor is designed for a maximum temperature of 1,900 F. This
temperature is important for the selection of refractory linings in all high
temperature vessels, ducts and lines. The refractory linings used in the BFB
gasifier model are based on a steel shell skin temperature of 300 F. If a
different skin temperature is desired, the refractory inputs will also need to be
changed.
2.14. The gasifier syngas composition and the char composition for an autothermal
bubbling fluid bed gasification reactor are calculated from algorithms
published in Technical Report NREL/TP-510-45913, Appendix G, Table G-1
GTI Gasifier Correlation, pg 107, July 2009, provided by NREL. The algorithm
constants are inputs in the 06-Design Criteria spreadsheet. Using these
algorithms the following syngas and char components are calculated as a
function of the biomass composition and the oxygen feedrate:
Syngas - Hydrogen as H2
Syngas - Carbon Monoxide as CO
Syngas - Carbon Dioxide as CO2
Syngas - Methane as CH4
Syngas - Ethylene as C2H4
Syngas - Ethane as C2H6
Syngas - Benzene as C6H6
Syngas - Naphthalene (Tars) as C10H8
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Char - Nitrogen as N
Char - Sulfur as S
Char - Oxygen as O
2.15. Drawing SK-2-01 Gasification Reaction Diagram depicts the calculation

sequence for determining the ultimate composition of the syngas and char
produced from biomass, oxygen gas, steam, nitrogen gas and bed media in the
gasifier.
2.15.1. A portion of the carbon (C) in the biomass is converted to compounds
in the syngas as determined by the NREL algorithms, thus accounting
for the amount of carbon dioxide (CO2), carbon monoxide (CO) and all
of the hydrocarbons (CxHx) in the syngas. The remainder of the carbon
(C) in the biomass becomes part of the char.
2.15.2. A portion of the sulfur (S) in the biomass becomes part of the char as
determined by the NREL algorithms. The remainder of the sulfur (S)
in the biomass is converted to hydrogen sulfide (H2S) in the syngas.
2.15.3. A portion of the nitrogen (N) in the biomass becomes part of the char
as determined by the NREL algorithms. The remainder of the nitrogen
(N) in the biomass is converted to ammonia (NH3) in the syngas. All
of the nitrogen (N) in the oxygen gas and nitrogen gas remains as
nitrogen (H2) gas in the syngas.
2.15.4. A portion of the oxygen (O) in the biomass becomes part of the char as
determined by the NREL algorithms. The remainder of the oxygen (O)
in the biomass, plus all of the oxygen from the oxygen gas and the
nitrogen gas, is used in the formation of carbon dioxide (CO2) and
carbon monoxide (CO) in the syngas. However, since the total amount
of oxygen from these three sources is insufficient to satisfy the amount
needed to form carbon dioxide (CO2) and carbon monoxide (CO) in
the syngas, additional oxygen (O) is furnished from decomposition of
water that is present in the system.
2.15.5. A portion of the water (H2O) carried into the gasifier with the biomass,
bed media makeup, oxygen gas, hydrogen gas and steam is
decomposed to make up the shortfall in the amount of oxygen needed
to form carbon dioxide (CO2) and carbon monoxide (CO) in the
syngas. The remainder of the water carried into the gasifier will
remain as water vapor in the syngas.
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2.15.6. Hydrogen (H) in the biomass plus the hydrogen released by water
decomposition mentioned above is used to provide the hydrogen
required for the formation of hydrocarbons (CxHx), hydrogen sulfide
(H2S), ammonia (NH3) and hydrogen gas (H2) in the syngas. Excess
hydrogen (H) becomes part of the char.
2.16. All of the char formed in the gasifier reactor is carried over to the gasifier
cyclone. The BFB gasifier model provides an input in the 06-Design Criteria
spreadsheet for entering the percentage of char which is carried over in the
syngas from the gasifier cyclone. The remaining char is recycled back to the
gasifier reactor from the gasifier cyclone where it is discharged to the ash
collection system.
2.17. The BFB gasifier model calculates the quantity of bed media in the bubbling
fluid based on the volume of the small diameter lower cylinder section of the
gasifier reactor. The BFB gasifier model provides inputs in the 06-Design
Criteria spreadsheet for entering the percentage of bed media which is carried
over in the syngas from the gasifier reactor to the gasifier cyclone and the
percentage of bed media which is discharged from the gasifier reactor to the
ash discharge system. These bed media losses are used to determine the bed
media makeup flowrate.
2.18. The BFB gasifier model provides an input in the 06-Design Criteria spreadsheet
for entering the percentage of ash which is carried over in the syngas from the
gasifier reactor to the gasifier cyclone. A second input is provided for entering
the percentage of ash which is carried over in the syngas from the gasifier
cyclone. The remaining ash is recycled back to the gasifier reactor from the
gasifier cyclone where it is discharged to the ash collection system.
2.19. The BFB gasifier model provides cells in the 06-Design Criteria spreadsheet for
the design of each piece of refractory lined equipment (reactor, cyclone, ducts
and lines). The refractory thickness is not automatically calculated but requires
an entry specifying the refractory thickness for each piece of equipment.
2.20. The BFB gasifier model designs refractory lined reactors, cyclones and tanks
from three basic shapes: cylinders, cones (or frustums of a cone) and flat
plates. The vessels are designed in sections and a cost and weight is
automatically calculated for each section using data from the material balance
and lookup tables containing unit weights and costs. The design includes
nozzles, support lugs, refractory anchors, inserts (e.g. distribution headers for
oxygen and steam) and refractory. The total cost is broken into a material cost
and a fabrication cost.
Report 30300/01
7-7
for thirteen nozzles on the gasifier reactor and gasifier cyclone and fourteen
nozzles on tanks and bins. Some nozzles are automatically sized while others
require an input.
2.22. The gasifier reactor diameter is calculated from an input of the gas upflow
velocity target, and the reactor height is calculated from an input of the
retention time target.
2.23. Equipment items named lines are where refractory lined steel lines are
required for the transport of hot bed media and ash which is relatively free of
gases (drop legs from gasifier cyclone to gasifier reactor and from gasifier
reactor to ash discharge system). These lines are automatically sized from a
solids velocity target input in the 06-Design Criteria spreadsheet.
2.24. Refractory lined ducts and lines require flanges every 10 feet (a changeable
value in the 06-Design Criteria spreadsheet) to provide access for installation of
refractory linings. The BFB gasifier model automatically adds flanges to
account for this requirement. Each duct and line also contains one expansion
joint.
2.25. The gasification equipment is all located in a single multi-story building.
2.26. The gasifier/reformer building is comprised of (4) 30 x 30 bays. There are
inputs in the 03-Cost Est spreadsheet, but they do not automatically change
with changes is the overall system design. The footprint is used to determine
the number of piles and the quantity of concrete needed for the foundation.
2.27. The weight of structural steel, grating, handrails, etc. for building construction
is automatically calculated from the total equipment weight.
3.

The BFB gasifier model is an Excel workbook containing 38 Excel spreadsheet tabs
that interact to produce a capital cost estimate for an allothermal circulating fluid bed
gasification and an allothermal circulating fluid bed syngas reforming system. The
BFB gasifier model includes a mass balance, equipment list and capital cost estimate,
and it produces a set of equipment drawings for the reactor vessel, cyclone and tanks.
3.1.
Excel Options
Before manipulating the BFB gasifier model, the Excel Options entry screen
must be accessed. Under the Formulas selection, the Enable iterative
Report 30300/01
7-8
directly in cells box must be turned deselected. With Allow editing directly
in cells turned off, the operator is able to jump from a cell containing a
formula to the referenced cell by double clicking on the cell with the formula.
This is important in navigating the Excel workbook.
3.2.
Cell Colors
3.2.1.

3.2.2.

same.
3.2.3.

3.2.4.

3.2.5.
Lavender - Cells backlighted in lavender are used in the materials

3.2.6.

3.2.7.
item headings that do not normally need to be changed. However,
model.
3.2.8.
model.
3.2.9.
Light Blue - Cells backlighted in light blue contain text used for subcolumn headings that do not normally need to be changed. However,
model.
Report 30300/01
7-9
3.3.

3.3.1.

with descriptions.
3.3.2.

3.3.3.

drawing numbers and names to material balance drawings (MB-2-XX)
and equipment drawings (EQ-2-XX).
3.3.4.

Inputs are made for quantities of materials, unit prices and labor
rates for site preparation (civil earthwork) equipment foundations,
non refractory lined pipe (e.g. steam, natural gas, water), electrical
equipment and wiring (motors are included with equipment),
insulation and painting, and demolition.
Inputs are made for the gasifier building footprint and factors for
calculating structural steel quantities as a function of the total
weight of all equipment and refractory lined ducts and pipe.
Inputs are made for calculating factored costs (e.g. instrumentation,
engineering, contingency, etc.) as a percentage of capital costs.
3.3.5.

3.3.6.
05-Map: This spreadsheet is a navigation tool for locating specific

pieces of equipment in the 06-Design Criteria spreadsheet. This
spreadsheet also displays brief summaries of all the refractory lined
reactors, cyclones, tanks, screw conveyors, ducts and lines.
3.3.7.

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7-10
3.3.8.
07-MB: This spreadsheet contains all of the material balance

calculations. There are no data input cells in this spreadsheet except
for the naming of some streams.
3.3.9.

3.3.10.
09-Fab Cost: This spreadsheet contains a lookup table which lists

3.3.11.
10-900# Nozzles & Flanges: This spreadsheet contains a lookup table

which lists nozzle and flange dimensions and properties as a function
of diameter.
3.3.12.

of diameter.
3.3.13.
12-900# Pipe & Duct: This spreadsheet contains a lookup table which
lists pipe and duct dimensions and properties as a function of
diameter. For diameters from to 24 the pipe and duct are
manufactured from ASME SA-106, Grade B carbon steel. For
diameters from 26 to 96 the pipe and duct are manufactured from
ASME SA-516, Grade 70 carbon steel. All refractory lined pipes and
ducts are priced based on this grade of steel.
3.3.14.
13-150# Pipe & Duct: This spreadsheet contains a lookup table which
3.3.15.
14-Exp Joints: This spreadsheet contains a lookup table which lists

3.3.16.
15-Vessel-Anchors: This spreadsheet contains a lookup table which

will prevent vessel skin temperatures from exceeding 300 F.
Report 30300/01
7-11
3.3.17. 16-Vessel-Refractory: This spreadsheet contains a lookup table which

prevent vessel skin temperatures from exceeding 300 F.
3.3.18. 17-Nozzle-Anchors: This spreadsheet contains a lookup table which
will prevent nozzle skin temperatures from exceeding 300 F.
3.3.19. 18-Nozzle-Refractory: This spreadsheet contains a lookup table which
prevent nozzle skin temperatures from exceeding 300 F.
3.3.20. 19-Screw Conv: This spreadsheet contains a lookup table for
determining the weight, cost and horsepower for pressurized screw
conveyors as a function of screw diameter and trough shell thickness.
3.3.21. 20-Motors: This spreadsheet contains lookup table for determining
weight and cost of motors as a function of horsepower.
3.3.22. 21-Spare: Not Used
3.3.23. 22-Sat Stm: This spreadsheet contains a Saturated Steam Table which
is used as a lookup table for steam properties.
3.3.24. 23-Water: This spreadsheet contains a lookup table for water
properties.
lines.
Report 30300/01
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calculations.
3.3.31. MB-2-01 Thru MB-2-02: These 2 spreadsheets contain the material
balance flow diagrams.
drawings of the reactors, cyclones and tanks.
4.

The detailed capital cost estimate in the BFB gasifier model is considered a Class 3
budgetary estimate according to The Association for the Advancement of Cost
Engineering (AACE) guidelines.
The cost estimate is the end product of the CFB gasifier model. Pricing and pricing
guidelines were obtained from vendors in order to populate the material pricing
lookup tables in the model. The costs of all the major equipment are calculated in the
model. The remaining cost inputs are factored from the major equipment pricing and
are shown in the 03-Cost Est spreadsheet tab in the model.
The capital cost estimate from the BFB gasifier model is shown in Appendix H for
installation of a 1,000 oven dry metric tons per day biomass gasification system.
5.

A summary of the methods and assumptions that were used in preparing the detailed
capital cost estimate is listed below:
5.1.
Labor
labor rates.
Report 30300/01
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5.2.
Land
5.3.
Civil/Earthwork
5.3.1.
Site Clearing
The project site is assumed to be a relatively flat, greenfield site, free of
equipment and buildings. The prepared site is assumed to only
account for the area that the gasifier island structure occupies, thus an
assumption of 60 by 60 is used. The cost for clearing and grubbing
this site is included in the estimate. Note that clearing and grubbing
refers to removing trees and brush from the site, grinding the stumps
and removing the wood chips. Note that an allowance for equipment
rental associated with site clearing is also included.
Fill and compaction is required for the same assumed area. A 3 cut
depth was assumed for the volume calculations.
The unit price and the labor hours per unit for the site clearing
activities was taken from the Harris Group estimating database which
is based on typical industry practices and pricing.
5.3.2.
Foundation Preparation
Based on the preliminary design of the gasifier structure as seen in
drawing GA-01, located in Appendix G, the foundation area was
estimated. An assumption for excavation and backfill depth was made
resulting in the volume of excavation and backfill used for the pricing.
Note that an allowance for equipment rental associated with
foundation preparation is also included.
The unit price and the labor hours per unit for the excavation and
backfill was taken from the Harris Group estimating database which is
5.3.3.
Piles
The loads of the gasification and tar reforming equipment are expected
to necessitate piles. The number of piles depends on the site location
Report 30300/01
7-14
and the soil conditions. For the purposes of this estimate, the soils are
assumed to have a 3,000-4,000 psi bearing pressure for foundation
design. A factor is included for the pile density and pile length for
these assumed soil conditions. Both the pile density and pile length
can be modified if actual soil conditions are known. Note that an
allowance for equipment rental associated with pile driving is also
included.
piles was taken from the Harris Group estimating database which is
5.3.4.
Other
The following Civil/Earthwork items are NOT included in the capital
cost estimate:
Trenching and backfill for any underground utilities. This could
include natural gas lines, electrical feeders, fire water piping, process
or sanitary sewer lines, storm water drainage piping/culverts, etc.
Storm water collection systems, ditches and containment systems
(retention pond, etc.).
Roadways and/or paving.
5.4.
Buildings
5.4.1.
Gasifier Island Structure

Based on the equipment sizing and loads, the gasifier island structure
was preliminarily designed and sized. Note that the estimate only
includes the structural steel, miscellaneous access steel, grating and
guardrail, and access stairs. The estimate calculates the steel quantities
based on ratios of the various steel categories to the total equipment
weight. It does not include any masonry or carpentry work, sprinkler
systems, roofing or siding.
steel was taken from the Harris Group estimating database which is
5.4.2.
Report 30300/01
Gasifier Island Foundation
7-15
The entire gasifier island structure will sit on foundations that are
optimized for the arrangement of building columns and actual loads,
however to simplify the estimate, a 30 slab throughout is assumed.
The slab will be sloped to a u-drain which will drain to a storm water
system (piping and retention pond) that is NOT included in the
estimate. Mat type foundations are used. All mat foundations include
rebar rather than mesh, and include form work, hardware (anchor
bolts, iron, etc.), concrete, finishing and stripping. The estimate
includes factors for all of the above items.
mat foundation was taken from the Harris Group estimating database
which is based on typical industry practices and pricing.
5.4.3.
5.5.
Miscellaneous Building Items Not Included
An electrical/MCC/controls room.
An operator control room.
Locker room.

Large equipment will require concrete pedestals for support. An allowance is
included for large equipment pedestal volume.
The unit price and the labor hours per unit for the installation of the equipment
foundations was taken from the Harris Group estimating database which is
5.6.
Piping
All refractory lined syngas piping/ductwork and expansion joints are included
in the equipment section of the estimate. The remaining process piping,
manual and check valves are included in the piping estimate.
An allowance for piping was made for 1, 2, 3 4 and 6 carbon steel piping.
These allowances are meant to account for process items such as, natural gas,
process water, potable water, cooling water, inert gas, process air, and steam.
Report 30300/01
7-16
5.6.1.
5.6.2.
5.7.
Piping Items Included in Cost Estimate
Piping Items Not Included Cost Estimate
Electrical
5.7.1.
Only the installation of the motors is currently included in the

electrical systems estimate. Allowances for 5, 10, 25, 50, 100, 200 and
250 horsepower motors are included as needed.
5.7.2.
5.7.3.
Electrical Items Not Included in Cost Estimate
Report 30300/01
MCCs
Control cabling, terminations, conduit, and cable ways.
Lighting.
7-17
Grounding.
Unit substations (transformers/primary switch/secondary switch
gear).
Medium voltage feeder (this feeder will feed a single substation or
loop feed multiple unit substations).
transformers and the indoor switchgear, and between the
5.8.
Instrumentation
5.8.1.

A programmable logic controller (PLC) based control system with a
human machine interface (HMI).
control system.
5.8.2.

Any continuous emissions monitoring system (CEMS) to monitor
air emissions.
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5.9.

An allowance for 200 of 4 piping insulation is included for the steam piping
only.
An allowance for high temperature indicating paint for use on the reactors,
ducts and cyclones is included.
Labor as well as materials related to the above insulation and painting is
The unit price and the labor hours per unit for the insulation and painting was
Process equipment insulation items are not included in the capital cost
estimate.
5.10.
Equipment
5.10.1.
Reactors, Cyclones and Bins

The gasifier, gasifier cyclone, bed media makeup bins, bed media
makeup screw conveyor, ash discharge system bins and ash discharge
screw conveyors are sized in the model based on a user provided
production rate. The total steel is then calculated and priced.
Equipment installation is included based on vendor information.
Refractory cost and installation is also included.
5.10.2.
Miscellaneous Equipment Included

Bed media makeup system.
Ash disposal system.
5.10.3.
Miscellaneous Equipment Not Included

Inert gas system other than ability to add nitrogen gas to the
gasification system for equipment sizing purposes.
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Steam generation system (heat recovery steam generator or fired

boiler).
Gas scrubbers or other abatement equipment.
Stack.
5.11.
Demolition

6.

6.1.
6.1.1.
6.1.2.
6.1.3.
6.1.4.
6.1.5.
6.1.6.
6.1.7.
6.1.8.
6.1.9.
Scaffolding.
6.1.10.
6.1.11.
6.1.12.
6.1.13.
6.1.14.
Report 30300/01
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6.1.15.
6.2.
Contractor markup.
Indirect Costs
6.2.1.
6.2.2.
Owner Engineering
efforts.
6.2.3.
Pre-Project Cost
construction cost.
6.2.4.
6.2.5.

construction cost.
6.2.6.
Capitalized Spares
6.2.7.
Sales Taxes
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7-21
6.2.8.
Freight
6.3.
Contingency
6.4.
6.3.1.
6.3.2.
6.3.3.

the estimate.
6.3.4.

prepared.
6.3.5.
It is expected that contingency funds will be used. Contingency is not

intended to cover escalation of major, unanticipated costs nor does it
cover increases in project costs due to scope changes.
6.3.6.
The contingency factor is applied to the sum of the total construction

cost and indirect costs, and the combined total is called the Process
Plant & Equipment (PP&E) cost.

6.4.1.
Escalation - Escalation costs are not included.
6.4.2.
Capitalized Interest - Capitalized interest costs are not included.
6.4.3.
Deferred Start-Up Costs - Deferred start-up costs are not included.
Report 30300/01
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6.5.
6.4.4.
Working Capital - Working capital is not included.
6.4.5.
Operator Training and Start-Up - Operator training and startup and

commissioning costs are included at a rate of 2.0% of the total
construction cost.
Cost Exclusions
6.5.1.
6.5.2.
Report 30300/01
7-23
Project 30300.00
NREL
Golden, Colorado
August 3, 2012
REPORT 30300/01
SECTION 8
DETAILED CAPITAL COST ESTIMATE HIGH PRESSURE BIOMASS FEED
1.
1.1.
General
The High Pressure Biomass Feed System Model (HP biomass feed model) is
used to design biomass feed systems feeding gasifiers operating at pressures
up to 600 psig. The number of feed lines is a function of the gasifier reactor
vessel diameter and the diameter of the biomass feed augers; however, the
number is independent of the biomass feed rate. The HP biomass feed model
produces a detailed capital cost estimate for purchasing and installing a single
line biomass feed system and can be multiplied by the number of required feed
lines to determine the cost of a complete system. The cost estimate does not
include building/support structure costs as these are included in the gasifier
models.
1.2.
Biomass Transport to Biomass Feed System

Single or multiple (up to four) biomass feed system lines are to be fed by a
bucket elevator and conveyor system which will transport biomass to the lock
hopper inlet chutes of each feed system line. The cost of the bucket elevator
and conveyor is not a part of the HP biomass feed model.
1.3.
Biomass Pressurization and Metering System Equipment

Biomass from the lock hopper inlet chute feeds a cylindrical lock hopper. A
rotating screw reclaim device at the bottom of the lock hopper is used to move
biomass to a center discharge nozzle. The lock hopper inlet and outlet nozzles
are equipped with rotary disc valves to permit the lock hopper to pressurized
to the gasifier pressure when the valves are closed. The lock hopper is
mounted high in the gasifier building structure so that a cylindrical metering
bin can be mounted directly below the lock hopper. The lock hopper and
metering bin will be mounted high enough to allow the metering bin to
discharge to a transfer screw conveyor and then to the gasifier feed auger. The
Report 30300/01
8-1
bottom of the metering bin is also equipped with a rotating screw reclaim
device to move biomass to the center discharge nozzle. A horizontal transfer
screw conveyor is used to transport biomass to a vertically oriented chute
feeding the gasifier feed auger. The chute between the transfer screw conveyor
and the gasifier feed auger is equipped with a rotary disc block valve to isolate
the bulk of the feed system line from the gasifier feed auger, thus permitting
maintenance of an individual biomass feed line while the gasifier continues
operating with feed from one of the other feed lines. A pressure equalization
line connects the lock hopper and the metering bin.
1.4.
Biomass Storage and Metering System Operation

The sequence of steps for delivering biomass to the gasifier is as follows:
1.4.1.
The lock hopper inlet valve is in the open position
1.4.2.
The lock hopper outlet valve is in the closed position
1.4.3.
The lock hopper vent valve is opened to allow air to vent from the lock
hopper while it is being filled with biomass.
1.4.4.
Biomass is conveyed by the bucket elevator and conveyor system to

the lock hopper inlet chute. The biomass passes through the open inlet
valve to begin filling the lock hopper.
1.4.5.
When the lock hopper is full of biomass the lock hopper vent valve is
closed.
1.4.6.
The lock hopper inlet valve is closed.
1.4.7.
The nitrogen gas line ball valve is opened to pipe nitrogen gas into the
lock hopper and pressurize the lock hopper to the gasifier pressure.
1.4.8.
A ball valve on the pressure equalization line is opened and the

pressures are equalized between the lock hopper and the metering bin.
1.4.9.
The lock hopper outlet valve is opened.
1.4.10. The lock hopper rotating discharge screw is started and feeds biomass
to the center discharge chute; the biomass then passes through the
open lock hopper outlet valve and into the metering bin.
1.4.11. The metering bin rotating discharge screw (this is always running
during normal operation) feeds biomass to the center discharge chute
which is connected to the transfer screw conveyor.
Report 30300/01
8-2
1.4.12. The horizontal transfer screw conveyor conveys biomass to the vertical
chute which feeds the gasifier injection auger. The vertical chute is
equipped with an expansion joint and an open transfer screw
conveyor chute discharge block valve (this valve is always open
during normal operation).
1.4.13. When the lock hopper is empty the lock hopper outlet valve is closed.
1.4.14. The lock hopper vent valve is opened to vent the lock hopper to
atmosphere through the vent filter and depressurize the lock hopper.
1.4.15. The lock hopper inlet valve is opened.
1.4.16. The sequence is repeated.
2.

2.1.
The HP biomass feed model requires inputs for scheduled and unscheduled
downtime from which the total annual operating hours are calculated.
2.2.
calculations. Some values (e.g. biomass temperature) are provided for
information only.
2.3.
The HP biomass feed model provides an input in the 05-Design Criteria

spreadsheet for gasifier reactor pressure. The HP biomass feed model is
designed for a gasifier reactor pressure input in the range of 150-600 PSIG.
2.4.
The HP biomass feed model provides an input in the 05-Design Criteria

spreadsheet for gasifier reactor temperature. The gasifier reactor is designed
for a maximum temperature of 1,900 F.
2.5.
The HP biomass feed model provides cells in the 05-Design Criteria

spreadsheet for the design of each piece of equipment (lock hopper, metering
bin, screw reclaim devices and screw conveyors).
2.6.
The HP biomass feed model designs the hoppers and bins from three basic
shapes: cylinders, cones (or frustums of a cone) and flat plates. The vessels are
designed in sections and a cost and weight is automatically calculated for each
section using data from the material balance and lookup tables containing unit
weights and costs. The design includes nozzles and support lugs. The total
cost is broken into a material cost and a fabrication cost.
2.7.
The HP biomass feed model provides inputs in the 05-Design Criteria

spreadsheet for fourteen nozzles on hoppers and bins.
Report 30300/01
8-3
3.
2.8.
The HP biomass feed model includes one expansion joint between the transfer
screw conveyor and the gasifier feed auger.
2.9.
All the biomass feed system equipment is to be located in a multi-story gasifier

building. The HP biomass feed model does not include any costs for a building
or support structure.

The HP biomass feed model is an Excel workbook containing 24 Excel spreadsheet
tabs that interact to produce a detailed capital cost estimate for a single line biomass
feed system. The HP biomass feed model includes an equipment list and capital cost
estimate, and it produces an equipment drawings for the lock hopper and metering
bin.
3.1.
Excel Options
Before manipulating the HP biomass feed model, the Excel Options entry
screen must be accessed. Under the Formulas selection, the Enable iterative
directly in cells box must be deselected. With Allow editing directly in cells
turned off, the operator is able to jump from a cell containing a formula to the
referenced cell by double clicking on the cell with the formula. This is
important in navigating the Excel workbook.
3.2.
Cell Colors
3.2.1.

3.2.2.

same.
3.2.3.

3.2.4.

3.2.5.

Report 30300/01
8-4
3.2.6.

3.2.7.
model.
3.2.8.
model.
3.2.9.
Light Blue - Cells backlighted in light blue contain text used for
sub-column headings that do not normally need to be changed.
However, this text may be changed without affecting any calculations
in the model.
3.3.

3.3.1.

with descriptions.
3.3.2.

3.3.3.

drawing numbers and names to equipment drawings (EQ-3-XX).
3.3.4.

Report 30300/01
8-5
3.3.5.

3.3.6.

3.3.7.

3.3.8.

3.3.9.

of diameter.
3.3.10. 09-150# Nozzles & Flanges: This spreadsheet contains a lookup table
of diameter.
3.3.11. 10-900# Pipe & Duct: This spreadsheet contains a lookup table which
Report 30300/01
8-6

lines.
calculations.
drawings for the lock hopper and metering bin.
4.

The detailed capital cost estimate in the HP biomass feed model is considered a
Class 3 budgetary estimate according to The Association for the Advancement of Cost
Report 30300/01
8-7
The detailed capital cost estimate is produced by the HP biomass feed model. Pricing
and pricing guidelines were obtained from vendors in order to populate the material
pricing lookup tables in the model. The costs of all the major equipment are
calculated in the model. The remaining cost inputs are factored from the major
equipment pricing and are shown in the 03-Cost Est spreadsheet tab in the model.
The capital cost estimate from the HP biomass feed system model is shown in
Appendix H for installation of a 500 oven dry metric tons per day single line.
5.

Below is a summary of the methods and assumptions that were used in preparing the
detailed capital cost estimate.
5.1.
Labor
labor rates.
5.2.
Land
5.3.
Civil/Earthwork
5.3.1.
Site Clearing N/A
5.3.2.
Foundation Preparation N/A
5.3.3.
Piles N/A
5.3.4.
Other N/A
Report 30300/01
8-8
5.4.
Buildings
Buildings are not included in the capital cost estimate for the biomass feed
system. Building structures to house and support biomass feed equipment are
included in the gasifier cost estimates.
5.5.

Equipment foundations are not included in the capital cost estimate for the
biomass feed system. Equipment foundations to support biomass feed
equipment are included in the gasifier cost estimates.
5.6.
Piping
Expansion joints are included in the equipment section of the estimate. The
remaining process piping, manual and check valves are included in the piping
estimate.
An allowance for piping was made for required sizes of carbon steel piping.
These allowances are meant to account for process items such as potable water
and nitrogen.
The following piping items are not included in the capital cost estimate:
5.7.
Electrical
5.7.1.
Report 30300/01
Allowances for 5, 10, 25, 50, 100, 200 and 250 horsepower motors are
included as needed.
8-9
5.7.2.
5.7.3.
The following Electrical items are NOT included in the capital cost
estimate:
MCCs
Lighting.
Grounding.
gear).
5.8.
Instrumentation
5.8.1.

Report 30300/01
8-10

control system.
5.8.2.

air emissions.
5.9.

No insulation is included.
Labor and materials related to painting are included in the estimate.
The unit price and the labor hours per unit for painting were taken from the
Harris Group estimating database which is based on typical industry practices
and pricing.
5.10.
Equipment
5.10.1. Hoppers and Bins
5.10.2. Miscellaneous Equipment Not Included
5.11.
Demolition
Report 30300/01
8-11
6.

6.1.
6.2.
6.1.1.
6.1.2.
6.1.3.
6.1.4.
6.1.5.
6.1.6.
6.1.7.
6.1.8.
6.1.9.
Scaffolding.
6.1.10.
6.1.11.
6.1.12.
6.1.13.
6.1.14.
6.1.15.
Contractor markup.
Indirect Costs
6.2.1.
6.2.2.
Report 30300/01
Owner Engineering
8-12

efforts.
6.2.3.
Pre-Project Cost
construction cost.
6.2.4.
6.2.5.

construction cost.
6.2.6.
Capitalized Spares
6.2.7.
Sales Taxes
6.2.8.
Freight
6.3.
Contingency
Report 30300/01
8-13
6.4.
6.3.1.
6.3.2.
6.3.3.

the estimate.
6.3.4.

prepared.
6.3.5.

6.3.6.


6.5.
6.4.1.
6.4.2.
6.4.3.
6.4.4.
6.4.5.

construction cost.
Cost Exclusions
6.5.1.
6.5.2.
Report 30300/01
8-14
Project 30300.00
NREL
Golden, Colorado
August 3, 2012
REPORT 30300/01
SECTION 9
DETAILED CAPITAL COST ESTIMATE LOW PRESSURE BIOMASS FEED
1.
1.1.
General
The Low Pressure Biomass Feed System Model (HP biomass feed model) is
used to design biomass feed systems feeding gasifiers operating at pressures
up to 150 psig. The number of feed lines is a function of the gasifier reactor
vessel diameter and the diameter of the biomass feed augers; however, the
number is independent of the biomass feed rate. The HP biomass feed model
produces a detailed capital cost estimate for purchasing and installing a single
line biomass feed system and can be multiplied by the number of required feed
lines to determine the cost of a complete system. The cost estimate does not
include building/support structure costs as these are included in the gasifier
models.
1.2.
Biomass Transport to Biomass Feed System

Single or multiple (up to four) biomass feed system lines are to be fed by a
bucket elevator and conveyor system which will transport biomass to the
metering bin inlet chutes of each feed system line. The cost of the bucket
elevator and conveyor is not a part of the HP biomass feed model.
1.3.
Biomass Pressurization and Metering System Equipment

Biomass from the metering bin inlet chute feeds an atmospheric cylindrical
metering bin. A rotating/traveling screw reclaim device at the bottom of the
metering bin is used to move biomass to a center discharge nozzle. The
metering bin is to be mounted high enough in the gasifier support building to
allow biomass to free fall through a vertical chute into an atmospheric transfer
screw conveyor. The horizontal transfer screw conveyor discharges biomass to
a vertically oriented chute feeding the gasifier feed auger. The chute between
the transfer screw conveyor and the gasifier feed auger is equipped with a
rotary valve designed to meter biomass to the gasifier feed auger and provide a
Report 30300/01
9-1
seal between the atmospheric pressure in the transfer screw conveyor and the
gasifier pressure in the gasifier feed auger.
The chute between the transfer screw conveyor and the gasifier feed auger is
also equipped with a knife gate block valve to isolate the bulk of a single feed
system line from its dedicated gasifier feed auger, thus permitting maintenance
of an individual biomass feed line while the gasifier continues operating with
feed from one of the other feed lines.
2.

2.1.
The HP biomass feed model requires inputs for scheduled and unscheduled
downtime, from which the total annual operating hours are calculated.
2.2.
calculations. Some values (e.g. biomass temperature) are provided for
information only.
2.3.
The LP biomass feed model provides an input in the 05-Design Criteria

spreadsheet for gasifier reactor pressure. The LP biomass feed model is
designed for a gasifier reactor pressure input in the range of 20-150 PSIG.
2.4.
The LP biomass feed model provides an input in the 05-Design Criteria

spreadsheet for gasifier reactor temperature. The gasifier reactor is designed
for a maximum temperature of 1,900 F.
2.5.
The LP biomass feed model provides cells in the 05-Design Criteria spreadsheet
for the design of each piece of equipment (metering bin, screw reclaim devices
and screw conveyors).
2.6.
The LP biomass feed model designs the metering bins from three basic shapes:
cylinders, cones (or frustums of a cone) and flat plates. The vessels are
designed in sections and a cost and weight is automatically calculated for each
section using data from the material balance and lookup tables containing unit
weights and costs. The design includes nozzles and support lugs. The total
cost is broken into a material cost and a fabrication cost.
2.7.
The LP biomass feed model provides inputs in the 05-Design Criteria
spreadsheet for fourteen nozzles on the bins.
2.8.
The LP biomass feed model includes one expansion joint in the chute between
the transfer screw conveyor and the gasifier feed auger.
2.9.
All the biomass feed system equipment is to be located in a multi-story gasifier

building. The LP biomass feed model does not include any costs for a building
Report 30300/01
9-2
or support structure. The building or support structure costs are included in

the gasifier models.
3.

The LP biomass feed model is an Excel workbook containing 23 Excel spreadsheet
tabs that interact to produce a detailed capital cost estimate for a single line biomass
feed system. The LP biomass feed model includes an equipment list and capital cost
estimate, and it produces an equipment drawing for the metering bin.
3.1.
Excel Options
Before manipulating the LP biomass feed model, the Excel Options entry
screen must be accessed. Under the Formulas selection, the Enable iterative
directly in cells box must be deselected. With Allow editing directly in cells
turned off, the operator is able to jump from a cell containing a formula to the
referenced cell by double clicking on the cell with the formula. This is
important in navigating the Excel workbook.
3.2.
Cell Colors
3.2.1.

3.2.2.

same.
3.2.3.

3.2.4.

3.2.5.

3.2.6.

Report 30300/01
9-3
3.2.7.
model.
3.2.8.
model.
3.2.9.
Light Blue - Cells backlighted in light blue contain text used for
sub-column headings that do not normally need to be changed.
However, this text may be changed without affecting any calculations
in the model.
3.3.

3.3.1.

with descriptions.
3.3.2.

3.3.3.

drawing numbers and names to equipment drawings (EQ-4-XX).
3.3.4.

Report 30300/01
9-4

3.3.5.

3.3.6.

3.3.7.

3.3.8.

3.3.9.

of diameter.
3.3.10. 09-150# Nozzles & Flanges: This spreadsheet contains a lookup table
of diameter.
Report 30300/01
9-5
lines.
calculations.
3.3.23. EQ-4-01: This spreadsheet contains an equipment drawing for the
metering bin.
4.

The detailed capital cost estimate in the LP biomass feed model is considered a Class 3
budgetary estimate according to The Association for the Advancement of Cost
The detailed capital cost estimate is produced by the LP biomass feed model. Pricing
and pricing guidelines were obtained from vendors in order to populate the material
pricing lookup tables in the model. The costs of all the major equipment are
Report 30300/01
9-6
calculated in the model. The remaining cost inputs are factored from the major
equipment pricing and are shown in the 03-Cost Est spreadsheet tab in the model.
The capital cost estimate from the LP biomass feed system model is shown in
Appendix H for installation of a 500 oven dry metric tons per day single line.
5.

Below is a summary of the methods and assumptions that were used in preparing the
detailed capital cost estimate.
5.1.
Labor
labor rates.
5.2.
Land
5.3.
Civil/Earthwork
5.3.1.
Site Clearing N/A
5.3.2.
Foundation Preparation N/A
5.3.3.
Piles N/A
5.3.4.
Other N/A
Report 30300/01
9-7
5.4.
Buildings
Buildings are not included in the capital cost estimate for the biomass feed
system. Building structures to house and support biomass feed equipment are
included in the gasifier cost estimates.
5.5.

Equipment foundations are not included in the capital cost estimate for the
biomass feed system. Equipment foundations to support biomass feed
equipment are included in the gasifier cost estimates.
5.6.
Piping
Expansion joints are included in the equipment section of the estimate. The
remaining process piping, manual and check valves are included in the piping
estimate.
An allowance for piping was made for required sizes of carbon steel piping.
These allowances are meant to account for process items such as potable water
and nitrogen.
The following piping items are not included in the capital cost estimate:
5.7.
Electrical
5.7.1.
Report 30300/01
Allowances for 5, 10, 25, 50, 100, 200 and 250 horsepower motors are
included as needed.
9-8
5.7.2.
5.7.3.
The following Electrical items are NOT included in the capital cost
estimate:
MCCs
Lighting.
Grounding.
gear).
5.8.
Instrumentation
5.8.1.

Report 30300/01
9-9

control system.
5.8.2.

air emissions.
5.9.

No insulation is included.
Labor and materials related to painting are included in the estimate.
The unit price and the labor hours per unit for painting were taken from the
Harris Group estimating database which is based on typical industry practices
and pricing.
5.10.
Equipment
5.10.1. Hoppers and Bins
5.10.2. Miscellaneous Equipment Not Included
5.11.
Demolition
Report 30300/01
9-10
6.

6.1.
6.2.
6.1.1.
6.1.2.
6.1.3.
6.1.4.
6.1.5.
6.1.6.
6.1.7.
6.1.8.
6.1.9.
Scaffolding.
6.1.10.
6.1.11.
6.1.12.
6.1.13.
6.1.14.
6.1.15.
Contractor markup.
Indirect Costs
6.2.1.
6.2.2.
Report 30300/01
Owner Engineering
9-11

efforts.
6.2.3.
Pre-Project Cost
construction cost.
6.2.4.
6.2.5.

construction cost.
6.2.6.
Capitalized Spares
6.2.7.
Sales Taxes
6.2.8.
Freight
6.3.
Contingency
Report 30300/01
9-12
6.4.
6.3.1.
6.3.2.
6.3.3.

the estimate.
6.3.4.

prepared.
6.3.5.

6.3.6.


6.5.
6.4.1.
6.4.2.
6.4.3.
6.4.4.
6.4.5.

construction cost.
Cost Exclusions
6.5.1.
6.5.2.
Report 30300/01
9-13
Project 30300.00
NREL
Golden, Colorado
August 3, 2012
REPORT 30300/01
SECTION 10
GASIFICATION COST COMPARISONS
1.
GENERAL
An analysis was conducted comparing the order of magnitude capital cost estimates
shown in Appendix D for the three gasification technologies with the Excel
gasification and biomass feed model budgetary capital cost estimates shown in
Appendix H. The comparisons are presented in the spreadsheet shown in
Appendix I. The capital cost comparison spreadsheet includes a column for each of
the following systems:
2.
1.1.
Technology #2 CFB System
1.2.
Excel Model CFB System
1.3.
Technology #1 BFB Oxygen Blown System
1.4.
Technology #3 BFB Oxygen Blown System
1.5.
Excel Model BFB System (Without Air Separator, Reformer or Biomass Feed
Lines)
1.6.
Composite System BFB System (With Air Separator, Reformer and (4)
Biomass Feed Lines)
1.7.
Excel Model High Pressure Biomass Feed System (Single Line)
COMPOSITE BFB GASIFIER COST ESTIMATE

In order to compare the Excel BFB model cost estimate to the cost estimates for
Technologies #1 and #3 (both BFB systems), a composite BFB system (Item-1.6 above)
was created by combining the Excel BFB model with other components to create a BFB
system comparable to Technologies #1 & #3. This composite BFB system is composed
of the following:
Report 30300/01
10-1
2.1.
The equipment costs for four HP biomass feed lines (Item-1.7 above) were used
as was included in Technologies #1 and #3.
2.2.
Because the BFB gasifier model in Item 1.5 above does not include a tar
reforming system, a cost estimate was needed for the tar reforming equipment.
The gasifier equipment (gasifier, cyclone, bed media feed system and ash
system) was estimated to be similar to the equipment required for a tar
reforming system; therefore, the BFB gasifier model (Item 1.5 above) equipment
cost was used twice to account for both the gasifier system and the tar reformer
system in the BFB composite system in Item 1.6 above.
2.3.
Air separation plant equipment from Item-1.4 above.
2.4.
Process air system equipment from Item-1.4 above.
2.5.
Oxygen system equipment from Item-1.4 above.
2.6.
Nitrogen system equipment from Item-1.4 above.
2.7.
Flare stack equipment from Item-1.3 above).
2.8.
Individually identified ducts from Item-1.5 above, were entered a second time
to cover the costs for the reformer system ducts.
Report 30300/01
10-2
APPENDIX A
ORDER OF MAGNITUDE ESTIMATES
FLOW DIAGRAMS
Report 30300/01
LIGHT FUEL OIL OR

NATURAL GAS
SYNGAS @ 1,560 F
LFO BOOSTER
PUMP (0147)
PROCESS WATER
BED MEDIA
UNLOADING (0138)
PNEUMATIC
(0139)
MP
STM
SEAL
WATER
TANK
BED MEDIA
STORAGE
SILO
(0140 &
0141)
WEIGH BIN
(0102, 0103,
0104 & 0105)
BIOMASS
FLARE
STACK
(0176)
(0101)
RETURN
BLOWDOWN
(0157)
(0181)
SEAL WATER
PUMPS (X2)
(0183 & 184)
SEAL WATER
COOLER
(0182)
(0106)
GASIFIER
(BFB)
(0145)
WEIGH
HOPPER
(0141)
LOCK
HOPPER
NO. 1
(0107)
PULSE
TANK
(0159)
TO VARIOUS
USERS
1,000 ODMTPD
2.0" MINUS
LOCK
HOPPER
NO. 1
(0108)
FEEDING
SCREWS
(X3)
(0113)
LOCK
HOPPER
(0143)
MP
STM
MP
STM
(0144)
ASH
CONVEYOR
HOPPER
(0152)
ASH REMOVAL
SCREW (0150)
METERING
BIN
(0110)
TAR
REFORMER
(SOLID
BLOCK
CATALYST)
(0158)
ASH
LOCK
HOPPER
(0151)
STARTUP
BURNER (0146)
(0109)
STARTUP
BURNER
(0160)
CYCLONE
(0156)
COMPOSITION
(% BY VOL DRY BASIS)
(BIOMASS DEPENDENT)
H2
37.5
CO
31.5
CO2
21.5
CH4
2.0
N2
4.4
(0153)
(0111)
(0112)
SYNGAS @
1,600 F AND 130 PSIG
CW
FEED SYSTEM (X3)

RECYCLED GAS
TO VARIOUS
USERS
POTABLE WATER
CW
(0177)
COMBUSTION
AIR
RECEIVER
(0149)
AMBIENT AIR
TO VARIOUS
USERS
MP STEAM
TO VARIOUS
USERS
COOLING WATER
ASH TO DISPOSAL
(0155)
MP
STM
EMERGENCY
N2 BOOSTER
COMPRESSOR
(0174)
TO VARIOUS
USERS
TECHNOLOGY NO. 1
SCOPE OF DELIVERY
HP COOLING
WATER PUMPS
(X2)
(0179 & 180)
N2
SUPPLY
TANK NO. 1
(0172)
EMERGENCY
HP N2
STORAGE
TANK
(0175)
COMBUSTION AIR
COMPRESSOR
(0148)
SYNGAS TO HEAT
REC. & FILTRATION
ASH
STORAGE
SILO
(0154)
COOLING
WATER
HEATX (0178)
N2 BOOSTER
COMPRESSOR
(0171)
N2
SUPPLY
TANK NO. 2
(0173)
TO PROCESS
AND PURGE
INST. N2
TANK
(0170)
O2 @
392 F
O2
SUPPLY
TANK
(0168)
TO
INSTRUMENTS
O2 HEATER
(0169)
COOLING WATER
RETURN
CONDENSATE
N2
RECEIVER
(0166)
AIR DRYER
(0162)
PROCESS AIR
COMPRESSOR
(0161)
AIR
SEPARATION
PLANT (0164)
CONDENSATE
O2
RECEIVER
(0165)
PROCESS AIR
RECEIVER
(0163)
O2 BOOSTER
COMPRESSOR
(0167)
Reference Drawings
Drawing No.
Harris Group Inc.
Revisions
Title
Rev
Date
By
Description
12/29/10
MWW
INITIAL CONCEPT FOR CLIENT REVIEW
01/12/11
MWW
ISSUED FOR FINAL REPORT
Rev
Date
By
Description
Engineering for Optimum Performance
GASIFIER ASSESSMENT STUDY
www.harrisgroup.com
Subconsultant:
Drawn: MWW
Check:
GASIFIER ISLAND - TECHNOLOGY #1

PROCESS FLOW DIAGRAM
Engr:
Check:
Appr:
PMgr:
Project No:
Drawing:
30074.00
F-100
Rev:
NATURAL GAS
BED MEDIA
UNLOADING (0238)
SYNGAS TO HEAT
REC. & FILTRATION
PNEUMATIC
(0239)
SYNGAS
@ 1,830 F
BED MEDIA
STORAGE
SILO
(0240 &
0241))
SYNGAS
FLARE
STACK
(0273)
N2
(0244)
NO. 1
(0247)
(0243)
(0242)
ASH
CYCLONE
(0260)
COMPOSITION
(BIOMASS DEPENDENT)
H2
43.9
CO
25.3
CO2 19.1
CH4 10.6
C2H4 0.7
C2H6 0.0
N2
0.9
NO. 2
(02489
COMBUSTION
CYCLONE
(0254)
GASIFICATION
CYCLONES
(0248)
(0250)
ASH, CHAR AND BED MATERIAL
FEED SYSTEM (X4)
(0261)
ASH TRANSFER
SCREW
CONVEYOR
(0262)
(0255)
BIOMASS
(0201)
WEIGH BIN
(0202, 0203
& 0205)
1,000 ODMTPD
2.0" MINUS
GASIFICATION
REACTOR
1,560 F
(CFB)
(0245)
(0204)
N2
COMBUSTION
REACTOR
1,830 F
(CFB)
(0253)
REHEATED BED
MATERIAL @ 1,830 F
LOCK
HOPPER
(0206)
(0207)
BED MATERIAL
1,830 F
GAS
CONDITIONING
REACTOR
1,830 F
(BFB)
(0252)
BED
MATERIAL
SURGE
VESSEL
(0246)
CW
CW
ASH BIN
(0263)
ASH
SURGE
VESSEL
(0251)
DUST
SUPRESSION
PROCESS
WATER
STARTUP
BURNER (0257)
METERING
BIN
(0208 & 0209)
ASH DISCHRAGE
SCREW
CONVEYOR
(0264)
(0210)
ASH TO DISPOSAL
BED MATERIAL
DISPOSAL
SCREW
CONVEYOR
(0275)
CW
BED MATERIAL TO
DISPOSAL
CW
LP / MP STEAM
CW
COMBUSTION
AIR HEATER
(0258)
CW
AMBIENT AIR
COMBUSTION
AIR FAN
(0259)
TO VARIOUS
USERS
COOLING WATER
PROCESS WATER
TO VARIOUS
USERS
POTABLE WATER
TO VARIOUS
USERS
INST. N2
TANK
(0270)
AIR
SEPARATION
PLANT (0268)
TECHNOLOGY NO. 2
SCOPE OF DELIVERY
TO
INSTRUMENTS
N2
SUPPLY
TANK
(0272)
N2
RECEIVER
(0269)
COOLING WATER
RETURN
EXHAUST
STACK
(0274)
FLUE GAS FAN

(0256)
TO PROCESS
AND PURGE
N2 BOOSTER
COMPRESSOR
(0271)
TO VARIOUS
USERS
AIR DRYER
(0266)
PROCESS AIR
COMPRESSOR
(0265)
CONDENSATE
PROCESS AIR
RECEIVER (0267)
Reference Drawings
Drawing No.
Harris Group Inc.
Revisions
Title
Rev
Date
By
Description
12/29/10
MWW
01/12/11
MWW
Rev
Date
By
Description
www.harrisgroup.com
Subconsultant:
Drawn: MWW
Check:

Engr:
Check:
Appr:
PMgr:
Project No:
Drawing:
30074.00
F-200
Rev:
NATURAL GAS
BIOMASS
SYNGAS @
1,475 F AND 38 PSIG
(0301)
1,000 ODMTPD
2.0" MINUS
SORBENT
UNLOADING (0356)
LOCK
HOPPER/
WEIGH BIN
(0302 &
0303)
PNEUMATIC
(0357)
COMPOSITION
(BIOMASS DEPENDENT)
H2
23.9
CO
33.1
CO2 26.8
CH4
9.2
C2H4 3.4
N2
2.0
FLARE
STACK
(0386)
SORBENT
MEDIA
STORAGE
SILO
(0358 &
0359)
(0304)
METERING
BIN
(0305 &
0306)
(0352)
STARTUP
BURNER
(0365)
TAR
REFORMER
(0373)
(0307)
(0353)
PNEUMATIC
(0349)
CYCLONE
(0364)
GASIFIER
(BFB)
(0363)
(0360)
BED MEDIA
UNLOADING (0348)
ASH
CONDITIONING
(0308)
BED MEDIA
STORAGE
SILO
(0350 &
0351)
N2
IN-FEED SCREW
(0309)
DENSE
PHASE
CONV.
BIN
(0361)
N2
DENSE
PHASE
CONV.
BIN
(0354)
CW
FEED SYSTEM (X6)
STARTUP
BURNER
(0366)
CW
(0362)
(0355)
N2
COOLING WATER
TO VARIOUS
USERS
PROCESS WATER
TO VARIOUS
USERS
(0372)
SCREEN
(0371)
(0368)
LOCK
HOPPER
NO. 2
(0370)
LOCK
HOPPER
NO. 1
(0369)
CW
CW
TRAMP MATERIAL
TO DISPOSAL
AMBIENT AIR
AIR COMPRESSOR (0367
MP STEAM
TO
INSTRUMENTS
TECHNOLOGY NO. 3
SCOPE OF DELIVERY
TO VARIOUS
USERS
POTABLE WATER
INST.
N2
TANK
(0382)
AIR DRYER
(0375)
AIR
SEPARATION
PLANT (0377)
AMBIENT AIR
PROCESS AIR
COMPRESSOR
(0374)
CONDENSATE
TO PROCESS
AND PURGE
N2 BOOSTER
COMPRESSOR
(0383)
PROCESS AIR
RECEIVER
(0376)
SYNGAS
COOLER
(0385)
N2
SUPPLY
TANK
(0384)
N2
RECEIVER
(0379)
SYNGAS TO HEAT
REC. & FILTRATION
O2
SUPPLY
TANK
(0381)
O2
RECEIVER
(0378)
O2 BOOSTER
COMPRESSOR
(0380)
Reference Drawings
Drawing No.
Harris Group Inc.
Revisions
Title
Rev
Date
By
Description
12/29/10
MWW
01/12/11
MWW
Rev
Date
By
Description
www.harrisgroup.com
Subconsultant:
Drawn: MWW
Check:

Engr:
Check:
Appr:
PMgr:
Project No:
Drawing:
30074.00
F-300
Rev:
APPENDIX B
GASIFIER OPERATING CONDITIONS
Report 30300/01
OPERATING CONDITIONS - TECHNOLOGY #1
HARRIS GROUP PROJECT NO.: 30074.00

PROJECT NAME: GASIFIER TECHNOLOGY ASSESSMENT
CLIENT: NATIONAL RENEWABLE ENERGY LABORATORY (NREL)
LOCATION: GOLDEN, COLORADO
DATE: 02/28/2011
DESCRIPTION
UNITS
VALUE (at 1,000

ODMTPD)
REMARKS
BIOMASS TO GASIFIER
UNITS
VALUE
REMARKS
10
Biomass - Consumption Rate - Wet
metric tons wet biomass / day
1,134
11
metric tons wet biomass / hr
47.3
12
short tons wet biomass / day
1,250.0
13
short tons wet biomass / hr
52.1
14
lbs wet biomass / hr
104,168
15
16
Biomass - LHV - Wet
BTU / lb wet biomass
6,333
17
Biomass - HHV - Wet
6,766
18
19
metric tons dry biomass / day
907
20
Biomass - Consumption Rate - Dry
metric tons dry biomass / hr
37.8
1,000
21
short tons dry biomass / day
22
short tons dry biomass / hr
41.7
23
lbs dry biomass / day
2,000,034
24
lbs dry biomass / hr
83,335
25
26
Biomass - LHV - Dry
BTU / lb dry biomass
7,916
27
Biomass - HHV - Dry
8,458
wt% water / wet biomass
20.0
28
29
Biomass - Moisture Content
30
Biomass - Temperature
31
77.0
Biomass - Feed Pressure
psig
130.0
32
Biomass - Bulk Density
lb/ft3
33
Biomass - Size Distribution
14.98
80% < 1.3"
34
35
Biomass - Type
36
Biomass - Ultimate Analysis
Souther Pine chip and

bark mixture
37
Carbon
% wt. (dry basis)
49.72
38
Hydrogen
% wt. (dry basis)
5.67
39
Nitrogen
% wt. (dry basis)
0.20
40
Sulfur
% wt. (dry basis)
0.02
41
Oxygen
% wt. (dry basis)
42.31
42
Chlorine
% wt. (dry basis)
0.000122
43
Ash
% wt. (dry basis)
2.08
UNITS
VALUE
44
45
BED MATERIAL TO GASIFIER
46
Bed Material - Consumption Rate - As is
47
48
Bed Material - Temperature
49
Bed Material - Feed Pressure
lb / hr
934
short tons / day
11.2
77.0
psig
130.0
kg/m3
1,300.0
lb/ft3
81.2
hr
200.3
day
8.3
REMARKS
24.7 lb bed material / metric ton of dry biomass
50
51
Bulk Density (Uncompacted Dolomite)
52
53
54
55
Bed Media Storage Silo
w/ bin vent

DATE: 02/28/2011
UNITS
VALUE (at 1,000

ODMTPD)
56
ft3
2,305.8
57
m3
65.3
DESCRIPTION
REMARKS
based on tech #1 vendor quote
58
59
Height
ft
20.0
60
Diameter
ft
12.1
61
62
63
Bed Media Weigh Hopper
64
ft3
166.0
m3
4.7
65
66
Bed Media Lock/Surge Hopper
67
ft3
14.0
m3
0.4
UNITS
VALUE
lb/hr
13,175
392.0
200.0
psig
203.0
68
69
STEAM TO GASIFIER
70
Steam - Flow
71
Steam - Temperature
72
Steam - Temperature
73
Steam - Pressure
REMARKS
348.5 lb steam / metric ton of dry biomass
74
75
STANDARD CONDITIONS
76
Standard Conditions - Temperature
77
Standard Conditions - Pressure
60.0
psia
14.696
78
79
Normal Conditions - Temperature
80
Normal Conditions - Pressure
32.0
psia
14.696
lbs O2 / hr
25,633
wt% O2 / oxygen gas
92.00
lbs oxygen gas / hr
27,862
81
82
OXYGEN REQUIREMENTS TO GASIFIER
83
Oxygen Required by Gasifier
84
Oxygen Gas - Oxygen Composition
85
Oxygen Gas - Mass Required by Gasifier
86
Oxygen - Temperature
392.0
87
200.0
88
Oxygen - Pressure
psig
203.0
Oxygen Gas - Average Molecular Weight
lbs oxygen gas / lb-mole
32.0
678.1 lb 100% O2 / metric ton of dry biomass
89
90
The average molecular weight will change if oxygen gas

composition changes.
91
Oxygen Gas - Moles Required by Gasifier
lb-moles oxygen gas / hr
870.7
92
Oxygen Gas - Volume Required by Gasifier
ft3 oxygen gas / hr
312,614
93
ft3 oxygen gas / min
5,210
94
ft3 oxygen gas / hr
330,417
At Standard Conditions
95
5,507
short tons O2 / day
307.6
@ 100% purity
short tons oxygen gas / day
334.3
At Normal Conditions
96
97
98
Oxygen Gas - Required by Gasifier
99
100
RECYCLE GAS TO GASIFIER

8
DESCRIPTION
UNITS
DATE: 02/28/2011
VALUE (at 1,000
ODMTPD)
REMARKS
unknown
101
102
103
NITROGEN USAGE
unknown
104
105
106
GASIFIER OUTPUT
107
Syngas - Clean Gas - Production Rate
UNITS
VALUE
lbs syngas / hr
156,055
108
Syngas - Pressure
109
Syngas - Temperature
psig
C
130.0
850
110
1,562
111
Syngas - LHV - Dry
BTU / lb dry syngas
112
Syngas - HHV - Dry
BTU / lb dry syngas
REMARKS
4128.4 lb syngas / metric ton of dry biomass
113
114
Syngas - Composition
115
CO
116
117
CO2
118
119
H2
120
121
H2O
122
123
N2
124
125
CH4 (methane)
126
127
C2H4 (ethylene)
32.98
% (by vol. wet)
21.68
% (by vol. dry)
0.00
% (by vol. wet)
3.60
% (by vol. dry)
4.60
% (by vol. wet)
6.41
% (by vol. dry)
8.18
0.19
% (by vol. dry)
0.25
C6H6 (benzene)
% (by vol. wet)
0.19
% (by vol. dry)
0.25
CxHy (tars)
% (by vol. wet)
0.0531
% (by vol. dry)
0.07
H2S+COS
% (by vol. wet)
0.0068
% (by vol. dry)
0.01
NH3+HCN
% (by vol. wet)
0.14
% (by vol. dry)
0.18
HCl
% (by vol. wet)
0.0008
% (by vol. dry)
0.00
% (by vol. wet)
100.01
140
141
25.83
% (by vol. dry)
% (by vol. wet)
138
139
% (by vol. wet)
C2H6 (ethane)
136
137
27.90
0.15
134
135
21.85
% (by vol. dry)
0.19
132
133
25.41
% (by vol. wet)
% (by vol. dry)
130
131
19.90
% (by vol. dry)
% (by vol. wet)
128
129
% (by vol. wet)
Total
142
143
H2/CO ratio
1.30
144
145
ASH PRODUCTION
UNITS
VALUE
146
Bottom Ash Discharge
lb / hr
962
REMARKS
25.5 lb ash / metric ton of dry biomass

8
DESCRIPTION
UNITS
147
148
DATE: 02/28/2011
VALUE (at 1,000
ODMTPD)
short tons / day
11.5
77.0
Bottom Ash - Temperature
REMARKS
149
150
Filter Ash Discharge
151
152
lb / hr
2,819
short tons / day
33.8
77.0
Filter Ash - Temperature
74.6 lb ash / metric ton of dry biomass
153
154
Total Ash
155
lb / hr
3,781
short tons / day
45.4
UNITS
VALUE
lb/hr
4,600
203.0
156
157
STEAM TO TAR REFORMER
158
Steam - Flow
159
Steam - Temperature
160
Steam - Temperature
95.0
161
Steam - Pressure
psig
392.0
lbs O2 / hr
7,261
REMARKS
162
163
OXYGEN REQUIREMENTS TO TAR REFORMER
164
Oxygen Required by Tar Reformer
165
166
167
168
169
Oxygen - Pressure
wt% O / oxygen gas
92.00
lbs oxygen gas / hr
7,893
392.0
200.0
psig
203.0
32.0
170
171

172
246.6
173
ft3 oxygen gas / hr
88,558
174
1,476
175
ft3 oxygen gas / hr
93,601
176
1,560
178
short tons O2 / day
87.1
@ 100% purity
179
94.7
UNITS
VALUE
lbs syngas / hr
168,723
psig
130.0
177
180
181
TAR REFORMER OUTPUT
182
183
184
Syngas - Pressure
185
871
186
1,600
187
Syngas - LHV - Dry
BTU / lb dry syngas
188
Syngas - HHV - Dry
BTU / lb dry syngas
189
190
191
192
CO
% (by vol. wet)
24.64
% (by vol. dry)
31.46
REMARKS

8
DESCRIPTION
193
CO2
194
195
H2
196
197
H2O
198
199
N2
200
201
CH4 (methane)
202
203
37.52
% (by vol. wet)
24.00
% (by vol. dry)
0.00
% (by vol. wet)
3.48
% (by vol. dry)
4.44
% (by vol. wet)
1.54
% (by vol. dry)
0.03
% (by vol. wet)
0.005
% (by vol. dry)
0.01
C6H6 (benzene)
% (by vol. wet)
0.050
% (by vol. dry)
0.06
CxHy (tars)
% (by vol. wet)
0.0041
% (by vol. dry)
0.01
H2S+COS
% (by vol. wet)
0.0059
% (by vol. dry)
0.01
NH3+HCN
% (by vol. wet)
0.0095
% (by vol. dry)
0.01
HCl
% (by vol. wet)
0.0007
% (by vol. dry)
0.00
Total
% (by vol. wet)
100.01
216
217
29.39
% (by vol. dry)
C2H6 (ethane)
214
215
21.53
% (by vol. wet)
1.97
212
213
16.86
% (by vol. dry)
0.022
210
211
% (by vol. wet)
% (by vol. wet)
208
209
VALUE (at 1,000

ODMTPD)
C2H4 (ethylene)
206
207
UNITS
% (by vol. dry)
204
205
DATE: 02/28/2011
REMARKS
218
219
H2/CO ratio
1.19
220
221
OTHER
222
Parasitic Load
223
UNITS
MW
VALUE
REMARKS
unknown
hp
224
U:\30074.00\0100 Project Administration\0500 Final Report\10 - Appendix D - Capital Cost Estimate Details\[2011-0228 - Cost Estimate & Equip List - Technology-1.xls]Op Conditions
3/1/11 11:44 AM

DATE: 02/28/2011
DESCRIPTION
UNITS
VALUE (at 1,000

ODMTPD)
REMARKS
BIOMASS TO GASIFIER
UNITS
VALUE
REMARKS
10
1,111
11
46.3
12
1,224.8
13
51.0
14
102,066
15
16
Biomass - LHV - Wet
7,254
17
Biomass - HHV - Wet
7,804
18
19
1,000
20
41.7
1,102
21
22
45.9
23
2,204,623
24
91,859
25
26
Biomass - LHV - Dry
8,060
27
Biomass - HHV - Dry
8,671
10.0
28
29
30
31
psig
32
lb/ft3
33
2.0" minus
34
35
Biomass - Type
36
Hybrid Poplar
37
Carbon
% wt. (dry basis)
50.88
38
Hydrogen
% wt. (dry basis)
6.04
39
Nitrogen
% wt. (dry basis)
0.17
40
Sulfur
% wt. (dry basis)
0.09
41
Oxygen
% wt. (dry basis)
41.90
42
Chlorine
% wt. (dry basis)
43
Ash
% wt. (dry basis)
0.92
UNITS
VALUE
unknown
44
45
46
47
lb / hr
REMARKS
unknown
short tons / day
48
49
F
psig
50
51
52
kg/m3
1,300.0
lb/ft3
81.2
hr
200.3
day
8.3
53
54
55
w/ bin vent, based on tech #1 quote

8
DESCRIPTION
UNITS
56
ft3
57
m3
DATE: 02/28/2011
VALUE (at 1,000
ODMTPD)
REMARKS
unknown
58
59
Height
ft
60
Diameter
ft
20.0
unknown
ft3
unknown
61
62
63
64
m3
65
66
67
ft3
unknown
m3
68
69
STEAM TO GASIFIER
70
Steam - Flow
71
Steam - Temperature
72
Steam - Temperature
73
Steam - Pressure
UNITS
VALUE
lb/hr
12,000
366.0
185.6
psig
150.0
REMARKS
74
75
STANDARD CONDITIONS
76
77
60.0
psia
14.696
78
79
80
32.0
psia
14.696
81
82
83
84
85
86
87
88
Oxygen - Pressure
lbs O2 / hr
wt% O2 / oxygen gas
92.00
lbs oxygen gas / hr
F
C
psig
89
90
32.0

91
0.0
92
ft3 oxygen gas / hr
93
94
ft3 oxygen gas / hr
95
96
97
98
99
100
short tons O2 / day
0.0
0.0
@ 100% purity

8
DESCRIPTION
UNITS
DATE: 02/28/2011
VALUE (at 1,000
ODMTPD)
101
REMARKS
unknown
102
103
NITROGEN USAGE
104
unknown
105
106
GASIFIER OUTPUT
107
UNITS
VALUE
scfh
108
scfm
109
lbs syngas / hr
REMARKS
unknown
110
Syngas - Pressure
111
psig
C
850
112
1,562
Syngas Calorific Value
MJ/Nm3
113
114
115
unknown
Btu/scf
N = 0C & 1 atm or 101.325 kPa, S = 60 F & 1 atm
116
117
unknown
118
CO
% (by vol. dry)
119
CO2
% (by vol. dry)
120
H2
% (by vol. dry)
121
H2O
% (by vol. dry)
122
N2
% (by vol. dry)
123
CH4 (methane)
% (by vol. dry)
124
C2H4 (ethylene)
% (by vol. dry)
125
C2H6 (ethane)
% (by vol. dry)
126
C6H6 (benzene)
% (by vol. dry)
127
CxHy (tars)
% (by vol. dry)
128
H2S+COS
% (by vol. dry)
129
NH3+HCN
% (by vol. dry)
130
HCl
% (by vol. dry)
131
Total
0.00
132
133
H2/CO ratio
unknown
134
135
136
Steam - Flow
UNITS
VALUE
lb/hr
137
Steam - Temperature
138
Steam - Temperature
139
Steam - Pressure
psig
140
141
142
lbs O2 / hr
2
143
144
145
146
wt% O / oxygen gas
92.00
lbs oxygen gas / hr
REMARKS

8
DESCRIPTION
UNITS
147
Oxygen - Pressure
psig
DATE: 02/28/2011
VALUE (at 1,000
ODMTPD)
REMARKS

148
149
32.0
150
0.0
151
ft3 oxygen gas / hr
152
153
ft3 oxygen gas / hr
154
155
156
157
short tons O2 / day
0.0
0.0
UNITS
VALUE
scfh
1,580,000
scfm
26,333
@ 100% purity
158
159
TAR REFORMER OUTPUT
160
161
REMARKS
37920 scf syngas / metric ton of dry biomass
162
163
Syngas - Pressure
psig
1.0
164
1,000
165
1,832
Syngas Calorific Value
MJ/Nm3
15.5
Btu/scf
393.6
166
167
168
14-17 range from vendor

N = 0C & 1 atm or 101.325 kPa, S = 60 F & 1 atm
169
170
171
CO
% (by vol. dry)
25.30
172
CO2
% (by vol. dry)
19.10
173
H2
% (by vol. dry)
43.90
174
H2O
% (by vol. dry)
0.00
175
N2
% (by vol. dry)
0.90
176
CH4 (methane)
% (by vol. dry)
10.60
0.70
177
C2H4 (ethylene)
% (by vol. dry)
178
C2H6 (ethane)
% (by vol. dry)
0.00
179
C6H6 (benzene)
% (by vol. dry)
0.00
180
CxHy (tars)
% (by vol. dry)
0.00
181
H2S+COS
% (by vol. dry)
0.00
182
NH3+HCN
% (by vol. dry)
0.00
183
HCl
% (by vol. dry)
0.00
184
Total
100.50
185
186
H2/CO ratio
1.74
187
188
CHAR COMBUSTOR
189
Bed Material Temperature from Combustion Reactor
190
UNITS
VALUE
850
1,562
lb/hr
200,000
REMARKS
Same as tar reformation temp. from vendor
191
192
Combustion Air Flow Rate
4800 lb air / metric ton of dry biomass

8
DESCRIPTION
UNITS
DATE: 02/28/2011
VALUE (at 1,000
ODMTPD)
193
scfh
194
scfm
1,000
538
scfh
2,800,000
scfm
46,667
195
Combustion Air Temperature
196
REMARKS
from vendor
197
198
Flue Gas Flow Rate
199
200
Flue Gas Temperature
201
1,000
1,832
UNITS
VALUE
MW
4.0
hp
5,364
67200 scf syngas / metric ton of dry biomass
from vendor
202
203
OTHER
204
Parasitic Load
205
REMARKS
96.0 kW / metric ton of dry biomass
206
3/1/11 11:44 AM

DATE: 02/28/2011
DESCRIPTION
UNITS
VALUE (at 1,000

ODMTPD)
REMARKS
BIOMASS TO GASIFIER
UNITS
VALUE
REMARKS
10
1,176
11
49.0
12
1,296.8
13
54.0
14
108,070
15
16
Biomass - LHV - Wet
6,851
17
Biomass - HHV - Wet
7,370
18
19
1,000
20
41.7
1,102
21
22
45.9
23
2,204,623
24
91,859
25
26
Biomass - LHV - Dry
8,060
27
Biomass - HHV - Dry
8,671
15.0
28
29
30
31
psig
32
lb/ft3
33
F
38.0
9.60
2.0" minus
34
35
Biomass - Type
36
Hybrid Poplar
37
Carbon
% wt. (dry basis)
50.88
38
Hydrogen
% wt. (dry basis)
6.04
39
Nitrogen
% wt. (dry basis)
0.17
40
Sulfur
% wt. (dry basis)
0.09
41
Oxygen
% wt. (dry basis)
41.90
42
Chlorine
% wt. (dry basis)
43
Ash
% wt. (dry basis)
0.92
UNITS
VALUE
lb / hr
230
short tons / day
2.8
unknown
44
45
46
47
48
49
REMARKS
5.5 lb bed material / metric ton of dry biomass
F
psig
38.0
kg/m3
1,300.0
lb/ft3
81.2
hr
200.3
day
8.3
50
51
52
53
54
55
w/ bin vent

DATE: 02/28/2011
UNITS
VALUE (at 1,000

ODMTPD)
56
ft3
566.9
57
m3
16.1
DESCRIPTION
REMARKS
58
59
Height
ft
15.0
60
Diameter
ft
6.9
61
62
63
64
ft3
166.0
m3
4.7
65
66
67
ft3
14.0
m3
0.4
UNITS
VALUE
lb/hr
16,337
489.0
68
69
STEAM TO GASIFIER
70
Steam - Flow
71
Steam - Temperature
72
73
Steam - Superheated Temperature
74
75
Steam - Pressure
253.9
1,000.0
537.8
psig
125.0
REMARKS
76
77
STANDARD CONDITIONS
78
79
60.0
psia
14.696
80
81
82
32.0
psia
14.696
lbs O2 / hr
29,043
wt% O2 / oxygen gas
92.00
lbs oxygen gas / hr
31,568
83
84
85
86
87
88
89
90
Oxygen - Pressure
unknown
psig
91
92
32.0

93
986.5
94
ft3 oxygen gas / hr
354,199
95
5,903
96
ft3 oxygen gas / hr
374,371
97
6,240
99
short tons O2 / day
348.5
@ 100% purity
100
378.8
98
101

8
102
DESCRIPTION
UNITS
DATE: 02/28/2011
VALUE (at 1,000
ODMTPD)
REMARKS

unknown
103
104
105
NITROGEN USAGE
unknown
106
107
108
GASIFIER OUTPUT
UNITS
VALUE
lbs syngas / hr
152,799
psig
38.0
109
110
Syngas - Pressure
111
802
112
1,475
BTU / scf
362
REMARKS
113
114
Syngas - HHV - Dry
@ 60 F & 14.73 psi
115
116
117
CO
118
119
CO2
120
121
H2
122
123
H2O
124
125
N2
126
127
CH4 (methane)
128
129
23.87
% (by vol. wet)
27.90
% (by vol. dry)
0.00
% (by vol. wet)
1.50
% (by vol. dry)
2.08
% (by vol. wet)
6.70
% (by vol. dry)
3.33
% (by vol. wet)
0.50
% (by vol. dry)
0.69
C6H6 (benzene)
% (by vol. wet)
0.00
% (by vol. dry)
0.00
CxHy (tars)
% (by vol. wet)
0.4900
% (by vol. dry)
0.68
H2S+COS
% (by vol. wet)
0.0000
% (by vol. dry)
0.00
NH3+HCN
% (by vol. wet)
0.06
% (by vol. dry)
0.08
HCl
% (by vol. wet)
0.0008
% (by vol. dry)
0.00
Total
% (by vol. wet)
99.95
142
143
17.20
% (by vol. dry)
C2H6 (ethane)
140
141
26.79
% (by vol. wet)
9.30
138
139
19.30
% (by vol. dry)
2.40
136
137
% (by vol. wet)
% (by vol. wet)
134
135
33.17
C2H4 (ethylene)
132
133
23.90
% (by vol. dry)
% (by vol. dry)
130
131
% (by vol. wet)
144
145
H2/CO ratio
0.72
146
147
UNITS
VALUE
REMARKS

8
UNITS
VALUE (at 1,000

ODMTPD)
lbs syngas / hr
152,799
1st column is tech #1 flow
lb/hr
4,504
29.5 lb steam / klb syngas
DESCRIPTION
148
Syngas - Clean Gas - Production Rate (from Gasifier)
149
Steam - Flow
DATE: 02/28/2011
150
Steam - Temperature
151
Steam - Temperature
152
Steam - Pressure
REMARKS
unknown
psig
153
154
155
Syngas - Clean Gas - Production Rate (from Gasifier)
156
lbs syngas / hr
152,799
lbs O2 / hr
7,110
lbs O2 / hr
7,110
wt% O2 / oxygen gas
92.00
lbs oxygen gas / hr
7,728
157
158
159
160
161
162
Oxygen - Pressure
1st column is tech #1 flow

46.5 lb 100% O2 / klb syngas
unknown
psig
163
164
165
166
ft oxygen gas / hr
3
32.0

241.5
86,711
167
ft oxygen gas / min
1,445
168
ft3 oxygen gas / hr
91,649
169
1,527
171
short tons O2 / day
96.0
@ 100% purity
172
92.7
UNITS
VALUE
lbs syngas / hr
164,413
170
173
174
TAR REFORMER OUTPUT
175
176
Syngas - Pressure
REMARKS
Estimate
psig
177
178
179
Syngas - LHV - Dry
BTU / lb dry syngas
180
Syngas - HHV - Dry
BTU / lb dry syngas
unknown
181
182
183
unknown
CO
184
185
% (by vol. dry)

CO2
% (by vol. wet)
H2
% (by vol. wet)
H2O
% (by vol. wet)
N2
% (by vol. wet)
CH4 (methane)
% (by vol. wet)
186
187
% (by vol. dry)
188
189
% (by vol. dry)
190
191
% (by vol. dry)
192
193
% (by vol. wet)
% (by vol. dry)
0.00
0.00
0.00
0.00
0.00

8
DESCRIPTION
194
195
UNITS
VALUE (at 1,000

ODMTPD)
% (by vol. dry)
0.00
C2H4 (ethylene)
% (by vol. wet)
C2H6 (ethane)
% (by vol. wet)
C6H6 (benzene)
% (by vol. wet)
CxHy (tars)
% (by vol. wet)
H2S+COS
% (by vol. wet)
NH3+HCN
% (by vol. wet)
HCl
% (by vol. wet)

% (by vol. dry)
0.00
Total
% (by vol. wet)
0.00
196
% (by vol. dry)
197
198
% (by vol. dry)
199
200
% (by vol. dry)
201
202
% (by vol. dry)
203
204
% (by vol. dry)
205
206
% (by vol. dry)
207
208
209
DATE: 02/28/2011
REMARKS
0.00
0.00
0.00
0.00
0.00
0.00
210
211
H2/CO ratio
unknown
212
213
OTHER
214
Gasifier Compressor Load
215
UNITS
VALUE
MW
0.52
hp
695
REMARKS
216
217
218
Other Gasifier Island Equipment Load
MW
2.26
hp
3,030
219
3/1/11 11:44 AM
APPENDIX C
GASIFIER ISLAND EQUIPMENT LISTS
Report 30300/01
REV
A
DATE
1/14/2011
BY
JRY
NREL Gasifier Technology Assessment - Technology - #1

REV
PROJECT:
DATE:
REV Area - Type -
PROJECT NAME: GASIFIER TECHNOLOGY

ASSESSMENT
30074.00
1/14/2011
Eq No
DESCRIPTION
PFD
Mechanical Equipment List
VENDOR
MODEL
QUANT.
DESIGN
ELECTRICAL
SIZE (EA)
CAPACITY
HEAD/PRESS
HP (total)
RPM
VOLTS
MATERIAL
RFP No.
QUOTE INFO
FOB SHOP
NO/DATE/VALID
REMARKS
BIOMASS FUEL HANDLING & STORAGE SYSTEM DISTRIBUTION CONVEYOR

Drag chain conveyor, , , ,
- -
0101
Biomass Delivery Conveyor
F-100
Vendor-05
TBD
- -
M -
0101
Biomass Delivery Conveyor Motor
F-100
Vendor-05
TBD
,,,,
BIOMASS FUEL HANDLING & STORAGE SYSTEM LINE-1

Rotation Spreader, , , ,
- -
0102
Biomass Line-1 - Weigh Bin Inlet Distribution

Spreader
F-100
Vendor-01
included
- -
M -
0102

Spreader Motor
F-100
Vendor-01
included
- -
0103
Biomass Line-1 - Weigh Bin
F-100
Vendor-01
included
- -
0104
Biomass Line-1 - Weigh Bin Bottom Screw

Discharger
F-100
Vendor-01
included
- - M1 -
0104

Discharger Rotation Motor
F-100
Vendor-01
included
- - M2 -
0104

Discharger Travel Motor
F-100
Vendor-01
included
- -
0105
Biomass Line-1 -Weigh Bin Vent Filter
F-100
Vendor-01
included
- -
0106
Biomass Line-1 - Lock Hopper Reversing Feed

Conveyor
F-100
Vendor-01
included
- -
M -
0106

Conveyor Motor
F-100
Vendor-01
included
- -
0107
Biomass Line-1 - Lock Hopper No.1
F-100
Vendor-01
included
Pressure vessel, Inlet shutoff valve, Outlet shutoff

valve, ,
- -
0108
F-100
Vendor-01
included

valve, ,
- -
0109
Biomass Line-1 - Lock Hopper Discharge

Conveyor
F-100
Vendor-01
included
- -
M -
0109

Conveyor Motor
F-100
Vendor-01
included
- -
0110
Biomass Line-1 -Metering Bin
F-100
Vendor-01
included
- -
0111
Biomass Line-1 - Metering Bin Live Bottom

Discharge Screws
F-100
Vendor-01
included
Reclaimer with multiple screws discharging to a screw

conveyor, , , ,
- -
M -
0111

Discharge Screws Motor
F-100
Vendor-01
included
Single motor and drive mechanism used to drive

multiple screws , , , ,
- -
0112
Biomass Line-1 - Metering Bin Discharge Screw

Conveyor
F-100
Vendor-01
included
- -
M -
0112

Conveyor Motor
F-100
Vendor-01
included
- -
0113
Biomass Line-1 - Gasifier Feed Screw
F-100
Vendor-01
included
- -
M -
0113
Biomass Line-1 - Gasifier Feed Screw Motor
F-100
Vendor-01
included
,,,,
Weighing hopper, Atmospheric vessel, , ,
Reclaimer / discharger screw conveyor, , , ,
,,,,
,,,,
Fabric filter, , , ,
Screw conveyor, , , ,
,,,,
,,,,
Pressure vessel, , , ,
Metering screw, Pressurized , , ,

,,,,
Screw conveyor, Water cooled, , ,
,,,,

- -
0114

Spreader
F-100
Vendor-01
included
- -
M -
0114

Spreader Motor
F-100
Vendor-01
included
- -
0115
F-100
Vendor-01
included
,,,,
REV
A
DATE
1/14/2011
BY
JRY

REV
PROJECT:
DATE:
REV Area - Type -

ASSESSMENT
30074.00
1/14/2011
Eq No
DESCRIPTION
PFD
VENDOR
MODEL
QUANT.
DESIGN
ELECTRICAL
SIZE (EA)
CAPACITY
HEAD/PRESS
HP (total)
RPM
VOLTS
MATERIAL
RFP No.
QUOTE INFO
FOB SHOP
NO/DATE/VALID
REMARKS
- -
0116

Discharger
F-100
Vendor-01
included
- - M1 -
0116

F-100
Vendor-01
included
- - M2 -
0116

F-100
Vendor-01
included
- -
0117
F-100
Vendor-01
included
- -
0118

Conveyor
F-100
Vendor-01
included
- -
M -
0118

Conveyor Motor
F-100
Vendor-01
included
- -
0119
F-100
Vendor-01
included

valve, ,
- -
0120
F-100
Vendor-01
included

valve, ,
- -
0121

Conveyor
F-100
Vendor-01
included
- -
M -
0121

Conveyor Motor
F-100
Vendor-01
included
- -
0122
F-100
Vendor-01
included
- -
0123

Discharge Screws
F-100
Vendor-01
included

conveyor, , , ,
- -
M -
0123

F-100
Vendor-01
included

- -
0124

Conveyor
F-100
Vendor-01
included
- -
M -
0124

Conveyor Motor
F-100
Vendor-01
included
- -
0125
F-100
Vendor-01
included
- -
M -
0125
F-100
Vendor-01
included
,,,,
,,,,
,,,,
,,,,

,,,,
,,,,

- -
0126

Spreader
F-100
Vendor-01
included
- -
M -
0126

Spreader Motor
F-100
Vendor-01
included
- -
0127
F-100
Vendor-01
included
- -
0128

Discharger
F-100
Vendor-01
included
- - M1 -
0128

F-100
Vendor-01
included
- - M2 -
0128

F-100
Vendor-01
included
- -
0129
F-100
Vendor-01
included
- -
0130

Conveyor
F-100
Vendor-01
included
- -
M -
0130

Conveyor Motor
F-100
Vendor-01
included
- -
0131
F-100
Vendor-01
included
,,,,
,,,,
,,,,
,,,,
valve, ,
REV
A
DATE
1/14/2011
BY
JRY

REV
PROJECT:
DATE:
REV Area - Type -

ASSESSMENT
30074.00
1/14/2011
Eq No
DESCRIPTION
PFD
VENDOR
MODEL
QUANT.
DESIGN
ELECTRICAL
SIZE (EA)
CAPACITY
HEAD/PRESS
HP (total)
RPM
VOLTS
MATERIAL
RFP No.
QUOTE INFO
FOB SHOP
NO/DATE/VALID
REMARKS
valve, ,
- -
0132
F-100
Vendor-01
included
- -
0133

Conveyor
F-100
Vendor-01
included
- -
M -
0133

Conveyor Motor
F-100
Vendor-01
included
- -
0134
F-100
Vendor-01
included
- -
0135

Discharge Screws
F-100
Vendor-01
included

conveyor, , , ,
- -
M -
0135

F-100
Vendor-01
included

- -
0136

Conveyor
F-100
Vendor-01
included
- -
M -
0136

Conveyor Motor
F-100
Vendor-01
included
- -
0137
F-100
Vendor-01
included
- -
M -
0137
F-100
Vendor-01
included
,,,,

,,,,
,,,,
BED MEDIA STORAGE & HANDLING

Truck unloading station, Dolomite material, , ,
A
- -
0138
Bed Media - Recieving Station
F-100
Vendor-07
$38,800
- -
0139
Bed Media - Pneumatic Unloading Conveyor
F-100
Vendor-06
included
- -
0140
Bed Media - Storage Silo
F-100
Vendor-01
included
- -
0141
Bed Media - Storage Silo Vent Filter
F-100
Vendor-01
included
- -
0142
Bed Media - Weigh Hopper
F-100
Vendor-01
included
Atmospheric vessel, Bottom discharge fluidizing air

system, , ,
- -
0143
Bed Media - Lock Hopper
F-100
Vendor-01
included

valve, ,
- -
0144
Bed Media - Lock Hopper Discharge Conveyor
F-100
Vendor-01
included
Metering screw conveyor, Pressurized , Outlet shutoff

valve, ,
- -
M -
0144
Bed Media - Lock Hopper Discharge Conveyor

Motor
F-100
Vendor-01
included
Pressurized air is the motive power source, , , ,

Atmospheric vessel, Bottom discharge fluidizing air
system, Outlet shutoff valve, ,
,,,,
GASIFIER
- -
0145
Gasifier
F-100
Vendor-01
$14,528,047
- -
0146
Gasifier - Startup Burner
F-100
Vendor-01
included
- -
0147
Gasifier - Startup Burner - Light Fuel Oil Booster

Pump
F-100
Vendor-01
included
- -
M -
0147
Gasifier - Startup Burner - Light Fuel Oil Booster

Pump Motor
F-100
Vendor-01
included
- -
0148
Gasifier - Combustuon Air Compressor
F-100
Vendor-01
included
- -
M -
0148
Gasifier - Combustuon Air Compressor Motor
F-100
Vendor-01
included
- -
0149
Gasifier - Combustuon Air Receiver
F-100
Vendor-01
included
Fluidized bed auto thermal gasifier, Pressure vessel,

Refractory lined, Fired with biomass fuel & oxygen,
Fluidizing bed composed of dolomite, medium
pressure steam, recycled syngas & ash
Horizontal pressure vessel fire box, Natural gas or
light fuel oil burner, Refractory lined, ,
Oil pump, , , ,
,,,,
Screw compressor, Air cooled, Oil free operation, ,
Variable frequeny drive, , , ,
REV
A
DATE
1/14/2011
BY
JRY

REV
PROJECT:
DATE:
REV Area - Type -

ASSESSMENT
30074.00
1/14/2011
Eq No
DESCRIPTION
PFD
VENDOR
MODEL
QUANT.
DESIGN
ELECTRICAL
SIZE (EA)
CAPACITY
HEAD/PRESS
HP (total)
RPM
VOLTS
MATERIAL
RFP No.
QUOTE INFO
FOB SHOP
NO/DATE/VALID
REMARKS
GASIFIER ASH REMOVAL SYSTEM

A
- -
0150
Gasifier Ash Removal - Screw Conveyor
F-100
Vendor-01
included
- -
M -
0150
Gasifier Ash Removal - Screw Conveyor Motor
F-100
Vendor-01
included
- -
0151
Gasifier Ash Removal - Lock Hopper
F-100
Vendor-01
included
- -
0152
Gasifier Ash Removal - Conveyor Hopper
F-100
Vendor-01
included
- -
0153
Gasifier Ash Removal - Pneumatic Conveyor
F-100
Vendor-01
included
- -
0154
Gasifier Ash Removal - Ash Storage Silo
F-100
Vendor-01
included
- -
0155
Gasifier Ash Removal - Ash Transfer Conveyor
F-100
Vendor-05
$40,000
- -
M -
0155

Motor
F-100
Vendor-05
included
Screw conveyor, Pressurized, Water cooled,

Discharge shutoff valave,
,,,,
Atmospheric vessel, Nitrogen gas pneumatic
discharge, , ,
Pressurized nitrogen gas motive power source, , , ,
Atmospheric vessel, , , ,
,,,,
SYNGAS ASH REMOVAL SYSTEM

Pressure vessel, Refractory lined, , ,
A
- -
0156
Syngas Ash Removal - Cyclone
F-100
Vendor-01
included
- -
0157
Syngas Ash Removal - Cyclone Rotary Discharger
F-100
Vendor-01
included
- -
M -
0157
Syngas Ash Removal - Cyclone Rotary Discharger

Motor
F-100
Vendor-01
included
Metering device, Pressurized , , ,

,,,,
SYNGAS TAR REFORMER

A
- -
0158
Tar Reformer
F-100
Vendor-01
included
Pressure vessel, Refractory lined, Internal catalyst

support trays, Packed with catalyst blocks,
- -
0159
Tar Reformer - Pulse Tank
F-100
Vendor-01
included
Pressure vessel, Steam receiver tank for periodic

back flow pulsing of catalyst blocks to clean catalyst, ,
,
- -
0160
Tar Reformer - Burner
F-100
Vendor-01
included
Horizontal pressure vessel fire box, Natural gas or

light fuel oil burner, Refractory lined, ,
PROCESS AIR SYSTEM

A
- -
0161
Process Air - Compressor
F-100
Vendor-10
$50,000
- -
M -
0161
Process Air - Compressor Motor
F-100
Vendor-10
included
- -
0162
Process Air - Dryer
F-100
Vendor-11
included
- -
0163
Process Air - Receiver Tank
F-100
Vendor-10
included

,,,,
AIR SEPARATION SYSTEM

- -
0164
Air Separation Plant - Oxygen / Nitrogen

Separator
F-100
Vendor-04
$7,198,807
- -
0165
Air Separation Plant - Oxygen Gas Receiver Tank
F-100
Vendor-04
included
- -
0166
Air Separation Plant - Nitrogen Gas Receiver

Tank
F-100
Vendor-04
included
Oxygen System - Booster Compressor
F-100
Vendor-10
$50,000
OXYGEN SYSTEM
A
- -
0167
REV
A
DATE
1/14/2011
BY
JRY

REV
PROJECT:
DATE:
REV Area - Type -

ASSESSMENT
30074.00
1/14/2011
Eq No
DESCRIPTION
PFD
VENDOR
MODEL
QUANT.
DESIGN
ELECTRICAL
SIZE (EA)
CAPACITY
HEAD/PRESS
HP (total)
RPM
VOLTS
MATERIAL
RFP No.
QUOTE INFO
FOB SHOP
NO/DATE/VALID
REMARKS
- -
M -
0167
Oxygen System - Booster Compressor Motor
F-100
Vendor-10
included
- -
0168
Oxygen System - Oxygen Gas Supply Tank
F-100
Vendor-01
included
- -
0169
Oxygen System - Oxygen Heater
F-100
Vendor-01
included
Pressure vessel, Oxygen supply for gasifier & tar

remover combustion, , ,
Indirect heat supplied by medium pressure steam, , , ,
NITROGEN SYSTEM
Pressure vessel, Nitrogen supply for instrumentation
operation, , ,
- -
0170
Nitrogen System - Instrument Nitrogen Gas

Supply Tank
F-100
Vendor-01
included
- -
0171
Nitrogen System - Booster Compressor
F-100
Vendor-01
included
- -
M -
0171
Nitrogen System - Booster Compressor Motor
F-100
Vendor-01
included
- -
0172
Nitrogen System - Process Nitrogen Gas Supply

Tank No.1
F-100
Vendor-01
included
Pressure vessel, High pressure nitrogen, Nitrogen

supply for biomass feed system, gasifier,tar reformer
pressurization & purge requirements, ,
- -
0173

Tank No.2
F-100
Vendor-01
included
Pressure vessel, Low pressure nitrogen, Nitrogen

- -
0174
Nitrogen System - Emergency Booster

Compressor
F-100
Vendor-01
included
- -
M -
0174
Nitrogen System - Emergeny Booster Compressor

Motor
F-100
Vendor-01
included
- -
0175
Nitrogen System - Emergency Nitrogen Gas

Storage Tank
F-100
Vendor-01
included
0176
Syngas Flare Stack
F-100
Vendor-12
$25,000


supply for emergency shutdowns to prevent fires and
explosions, ,
FLARE STACK
Screw compressor, , , ,
A
- -
ASH SCREW COOLING WATER SYSTEM

,,,,
A
- -
0177
Ash Screw Cooling Water - Storage Tank
F-100
Vendor-01
included
- -
0178
Ash Screw Cooling Water - Heat Exchanger
F-100
Vendor-01
included
- -
0179
Ash Screw Cooling Water - No.1 Pump
F-100
Vendor-01
included
- -
M -
0179
Ash Screw Cooling Water - No.1 Pump Motor
F-100
Vendor-01
included
- -
0180
F-100
Vendor-01
included
- -
M -
0180
F-100
Vendor-01
included
Indirect heat exchanger with clean ash screw cooling

water on one side being cooled by cold mill water on
the other side, , , ,
Centrifugal pump, , , ,
,,,,
,,,,
SEAL WATER SYSTEM

,,,,
A
- -
0181
Seal Water - Storage Tank
F-100
Vendor-01
included
- -
0182
Seal Water - Heat Exchanger
F-100
Vendor-01
included
- -
0183
Seal Water Water - No.1 Pump
F-100
Vendor-01
included
- -
M -
0183
Seal Water Water - No.1 Pump Motor
F-100
Vendor-01
included
- -
0184
F-100
Vendor-01
included
Indirect heat exchanger with clean seal water on one

side being cooled by cold mill water on the other side,
,,,
,,,,
REV
A
DATE
1/14/2011
BY
JRY

REV
PROJECT:
DATE:
REV Area - Type -

ASSESSMENT
30074.00
1/14/2011
Eq No
DESCRIPTION
PFD
VENDOR
MODEL
QUANT.
F-100
Vendor-01
DESIGN
ELECTRICAL
SIZE (EA)
CAPACITY
HEAD/PRESS
HP (total)
RPM
VOLTS
MATERIAL
RFP No.
QUOTE INFO
FOB SHOP
NO/DATE/VALID
included
REMARKS
,,,,
- -
M -
0184
REV
A
DATE
1/14/2011
BY
JRY

REV
PROJECT:
DATE:
REV Area - Type -

ASSESSMENT
30074.00
1/14/2011
Eq No
DESCRIPTION
PFD
VENDOR
MODEL
QUANT.
DESIGN
ELECTRICAL
SIZE (EA)
CAPACITY
HEAD/PRESS
HP (total)
RPM
VOLTS
MATERIAL
RFP No.
QUOTE INFO
FOB SHOP
NO/DATE/VALID
REMARKS

- -
0201
Biomass Delivery Conveyor
F-200
Vendor-05
TBD
- -
M -
0201
Biomass Delivery Conveyor Motor
F-200
Vendor-05
TBD
,,,,

- -
0202
F-200
Vendor-02
included
- -
0203
Biomass Line-1 - Weigh Bin Live Bottom

Discharge Screws
F-200
Vendor-02
included

conveyor, , , ,
- -
M -
0203

F-200
Vendor-02
included

- -
0204
Biomass Line-1 - Weigh Bin Rotary Discharger
F-200
Vendor-02
included
- -
M -
0204

Motor
F-200
Vendor-02
included
- -
0205
Biomass Line-1 - Weigh Bin Vent Filter
F-200
Vendor-02
included
- -
0206
Biomass Line-1 - Lock Hopper
F-200
Vendor-02
included
- -
0207
Biomass Line-1 - Lock Hopper Rotary Discharger
F-200
Vendor-02
included
- -
M -
0207

Motor
F-200
Vendor-02
included
- -
0208
Biomass Line-1 - Metering Bin
F-200
Vendor-02
included
- -
0209

Discharge Screws
F-200
Vendor-02
included

conveyor, , , ,
- -
M -
0209

F-200
Vendor-02
included

- -
0210
Biomass Line-1 - Gasifier Fuel Metering Screw

Conveyor
F-200
Vendor-02
included
- -
M -
0210

Conveyor Motor
F-200
Vendor-02
included
Rotary pocket feeder discharge device, , , ,

,,,,
,,,,
,,,,
,,,,

A
- -
0211
F-200
Vendor-02
included
- -
0212

Discharge Screws
F-200
Vendor-02
included

conveyor, , , ,
- -
M -
0212

F-200
Vendor-02
included

- -
0213
F-200
Vendor-02
included
- -
M -
0213

Motor
F-200
Vendor-02
included
- -
0214
F-200
Vendor-02
included
- -
0215
F-200
Vendor-02
included
- -
0216
F-200
Vendor-02
included
- -
M -
0216

Motor
F-200
Vendor-02
included

,,,,
,,,,
,,,,
REV
A
DATE
1/14/2011
BY
JRY

REV
PROJECT:
DATE:
REV Area - Type -

ASSESSMENT
30074.00
1/14/2011
Eq No
DESCRIPTION
PFD
VENDOR
MODEL
QUANT.
DESIGN
ELECTRICAL
SIZE (EA)
CAPACITY
HEAD/PRESS
HP (total)
RPM
VOLTS
MATERIAL
RFP No.
QUOTE INFO
FOB SHOP
NO/DATE/VALID
REMARKS
- -
0217
F-200
Vendor-02
included
- -
0218

Discharge Screws
F-200
Vendor-02
included

conveyor, , , ,
- -
M -
0218

F-200
Vendor-02
included

- -
0219
Biomass Line-2 - Gasifier Fuel MeteringScrew

Conveyor
F-200
Vendor-02
included
- -
M -
0219

Conveyor Motor
F-200
Vendor-02
included
,,,,

- -
0220
F-200
Vendor-02
included
- -
0221

Discharge Screws
F-200
Vendor-02
included

conveyor, , , ,
- -
M -
0221

F-200
Vendor-02
included

- -
0222
F-200
Vendor-02
included
- -
M -
0222

Motor
F-200
Vendor-02
included
- -
0223
F-200
Vendor-02
included
- -
0224
F-200
Vendor-02
included
- -
0225
F-200
Vendor-02
included
- -
M -
0225

Motor
F-200
Vendor-02
included
- -
0226
F-200
Vendor-02
included
- -
0227

Discharge Screws
F-200
Vendor-02
included

conveyor, , , ,
- -
M -
0227

F-200
Vendor-02
included

- -
0228

Conveyor
F-200
Vendor-02
included
- -
M -
0228

Conveyor Motor
F-200
Vendor-02
included

,,,,
,,,,
,,,,
,,,,

A
- -
0229
F-200
Vendor-02
included
- -
0230

Discharge Screws
F-200
Vendor-02
included

conveyor, , , ,
- -
M -
0230

F-200
Vendor-02
included

- -
0231
F-200
Vendor-02
included
- -
M -
0231

Motor
F-200
Vendor-02
included
- -
0232
F-200
Vendor-02
included
- -
0233
F-200
Vendor-02
included

,,,,
,,,,
REV
A
DATE
1/14/2011
BY
JRY

REV
PROJECT:
DATE:
REV Area - Type -

ASSESSMENT
30074.00
1/14/2011
Eq No
DESCRIPTION
PFD
VENDOR
MODEL
QUANT.
DESIGN
ELECTRICAL
SIZE (EA)
CAPACITY
HEAD/PRESS
HP (total)
RPM
VOLTS
MATERIAL
RFP No.
QUOTE INFO
FOB SHOP
NO/DATE/VALID
REMARKS
- -
0234
F-200
Vendor-02
included
- -
M -
0234

Motor
F-200
Vendor-02
included
- -
0235
F-200
Vendor-02
included
- -
0236

Discharge Screws
F-200
Vendor-02
included

conveyor, , , ,
- -
M -
0236

F-200
Vendor-02
included

- -
0237

Conveyor
F-200
Vendor-02
included
- -
M -
0237

Conveyor Motor
F-200
Vendor-02
included
,,,,
,,,,

Truck unloading station, Typically silica material, , ,
A
- -
0238
F-200
Vendor-07
$38,800
- -
0239
F-200
Vendor-06
included
- -
0240
F-200
Vendor-02
included
- -
0241
F-200
Vendor-02
included
- -
0242
Bed Media - Nitrogen Gas Pneumatic Conveyor Rotary Feeder
F-200
Vendor-02
included
- -
M -
0242
Bed Media - Nitrogen Gas Pneumatic Conveyor Rotary Feeder Motor
F-200
Vendor-02
included
- -
0243
Bed Media - Nitrogen Gas Pneumatic Conveyor
F-200
Vendor-02
included
- -
0244
Bed Media - Nitrogen Gas Pneumatic Conveyor Blower
F-200
Vendor-02
included
- -
M -
0244
Bed Media - Nitrogen Gas Pneumatic Conveyor Blower Motor
F-200
Vendor-02
included

Pressurized nitrogen gas motive power source, , , ,
,,,,
Material is routed through a closed pipe , , , ,
Pressurized nitrogen gas motive force, , , ,
,,,,
GASIFICATION
A
- -
0245
Gasification Reactor - Vessel
F-200
Vendor-02
$14,330,003
- -
0246
Gasification Reactor - Heated Bed Material Surge

Vessel
F-200
Vendor-02
included
- -
0247
Gasification Reactor - Cyclone No.1
F-200
Vendor-02
included
- -
0248
Gasification Reactor - Cyclone No.1 - Rotary

Discharger
F-200
Vendor-02
included
- -
M -
0248

Discharger Motor
F-200
Vendor-02
included
- -
0249
F-200
Vendor-02
included
- -
0250

Discharger
F-200
Vendor-02
included
- -
M -
0250

Discharger Motor
F-200
Vendor-02
included
- -
0251
Gasification Reactor - Ash Surge Vessel
F-200
Vendor-02
included
Circulating fluidized bed allo thermal gasifier, Fluidized

bed composed of biomass, externally heated bed
material & medium pressure steam, Atmospheric
Cone shaped bottom, , , ,
,,,,
,,,,
,,,,
TAR REFORMING
REV
A
DATE
1/14/2011
BY
JRY

REV
PROJECT:
DATE:
REV Area - Type A
- -

ASSESSMENT
30074.00
1/14/2011
Eq No
DESCRIPTION
PFD
VENDOR
MODEL
QUANT.
DESIGN
ELECTRICAL
SIZE (EA)
CAPACITY
HEAD/PRESS
HP (total)
RPM
VOLTS
MATERIAL
RFP No.
QUOTE INFO
FOB SHOP
NO/DATE/VALID
0252
Gas Conditioning Reactor - Vessel
F-200
Vendor-02
included
REMARKS
Bubbling fluidized bed tar reformer, Fluidized bed
composed of externally heated bed material & clean
gasifier syngas, Atmospheric vessel, Refractory lined,
COMBUSTION
A
- -
0253
Combustion Reactor - Vessel
F-200
Vendor-02
included
- -
0254
Combustion Reactor - Cyclone
F-200
Vendor-02
included
- -
0255
Combustion Reactor - Cyclone - Rotary

Discharger
F-200
Vendor-02
included
- -
M -
0255
Combustion Reactor - Cyclone - Rotary

Discharger Motor
F-200
Vendor-02
included
- -
0256
Combustion Reactor - Flue Gas Fan
F-200
Vendor-02
included
- -
M -
0256
Combustion Reactor - Flue Gas Fan Motor
F-200
Vendor-02
included
- -
0257
Combustion Reactor - Startup Burner
F-200
Vendor-02
included
Circulating fluidized bed combustion reactor, Fluidized

bed composed of of ash, char, bed material &
combustion air, Atmospheric vessel, Refractory lined,
,,,,
,,,,
,,,,
Horizontal pressure vessel fire box, Refractory lined,

Natural gas burner, ,
COMBUSTION AIR SYSTEM

A
- -
0258
Combustion Air - Heater
F-200
Vendor-02
included
- -
0259
Combustion Air - Fan
F-200
Vendor-02
included
- -
M -
0259
Combustion Air - Fan Motor
F-200
Vendor-02
included
,,,,
,,,,
ASH REMOVAL SYSTEM

A
- -
0260
Ash - Cyclone
F-200
Vendor-02
included
- -
0261
Ash - Cyclone Rotary Discharger
F-200
Vendor-02
included
- -
M -
0261
Ash - Cyclone Rotary Discharger Motor
F-200
Vendor-02
included
- -
0262
Ash - Transfer Screw Conveyor
F-200
Vendor-02
included
- -
M -
0262
Ash - Transfer Screw Conveyor Motor
F-200
Vendor-02
included
- -
0263
Ash - Ash Storage Bin
F-200
Vendor-02
included
- -
0264
Ash - Storage Bin Discharge Screw Conveyor
F-200
Vendor-02
included
- -
M -
0264
Ash - Storage Bin DischargeScrew Conveyor

Motor
F-200
Vendor-02
included
- -
0275
Bed Material Disposal - Screw Conveyor
F-200
Vendor-02
included
- -
M -
0275
Bed Material Disposal - Screw Conveyor Motor
F-200
Vendor-02
included
,,,,
,,,,
,,,,
Screw conveyor, Process water added to supress dust
, Ash discharged as a moist solid suitable for soil
ammendment, ,
,,,,
,,,,
PROCESS AIR SYSTEM

A
- -
0265
F-200
Vendor-10
$50,000
- -
M -
0265
F-200
Vendor-10
included
- -
0266
Process Air - Dryer
F-200
Vendor-11
included

,,,,
-
REV
A
DATE
1/14/2011
BY
JRY

REV
PROJECT:
DATE:
REV Area - Type -

ASSESSMENT
30074.00
1/14/2011
Eq No
DESCRIPTION
PFD
VENDOR
MODEL
QUANT.
F-200
Vendor-10
DESIGN
ELECTRICAL
QUOTE INFO
FOB SHOP
NO/DATE/VALID
included
MATERIAL
RFP No.
SIZE (EA)
CAPACITY
HEAD/PRESS
HP (total)
RPM
VOLTS
REMARKS
- -
0267

A
- -
0268

Separator
F-200
Vendor-02
included
- -
0269

Tank
F-200
Vendor-02
included
Screw compressor, Air cooled, Oil free operation,

Oxygen is vented to atmosphere,
NITROGEN SYSTEM
A
- -
0270

Supply Tank
F-200
Vendor-02
included
- -
0271
F-200
Vendor-02
included
- -
M -
0271
F-200
Vendor-02
included
- -
0272

Tank
F-200
Vendor-02
included

operation, , ,
STACKS

REV
A
DATE
1/14/2011
BY
JRY
NREL Thermochemical Ethanol Production - Technology - #3

REV
PROJECT:
DATE:
REV Area - Type -

ASSESSMENT
30074.00
1/14/2011
Eq No
DESCRIPTION
PFD
VENDOR
MODEL
QUANT.
DESIGN
ELECTRICAL
SIZE (EA)
CAPACITY
HEAD/PRESS
HP (total)
RPM
VOLTS
MATERIAL
RFP No.
QUOTE INFO
FOB SHOP
NO/DATE/VALID
REMARKS

- -
0301
Biomass Distribution Conveyor
F-300
Vendor-05
TBD
- -
M -
0301
Biomass Distribution Conveyor Motor
F-300
Vendor-05
TBD
,,,,

A
- -
0302
Biomass Line-1 - Lock Hopper Weigh Bin
F-300
Vendor-03
included
- -
0303
Biomass Line-1 - Lock Hopper Weigh Bin Live

Bottom Discharge Device
F-300
Vendor-03
included
- -
M -
0303

Bottom Discharge Device Motor
F-300
Vendor-03
included
- -
0304

Discharge Screw Conveyor
F-300
Vendor-03
included
- -
M -
0304

Discharge Screw Conveyor Motor
F-300
Vendor-03
included
- -
0305
F-300
Vendor-03
included
- -
0306

Discharge Device
F-300
Vendor-03
included
- -
M -
0306

Discharge Device Motor
F-300
Vendor-03
included
- -
0307
Biomass Line-1 - Metering Bin Discharge

Conveyor
F-300
Vendor-03
included
- -
M -
0307

Conveyor Motor
F-300
Vendor-03
included
- -
0308
Biomass Line-1 - Transfer Conveyor
F-300
Vendor-03
included
- -
M -
0308
Biomass Line-1 - Transfer Conveyor Motor
F-300
Vendor-03
included
- -
0309

Conveyor
F-300
Vendor-03
included
- -
M -
0309

Conveyor Motor
F-300
Vendor-03
included
Pressure vessel, Pressurized with nitrogen, Inlet and

outlet pneumatic slide gates, ,
Proprietary, , , ,
,,,,
Screw conveyor, Pressurized with nitrogen, , ,
,,,,
Proprietary, , , ,
,,,,
,,,,
,,,,
Screw conveyor, Pressurized with nitrogen, Water
cooled, ,
,,,,

A
- -
0310
F-300
Vendor-03
included
- -
0311

F-300
Vendor-03
included
- -
M -
0311

F-300
Vendor-03
included
- -
0312

F-300
Vendor-03
included
- -
M -
0312

F-300
Vendor-03
included
- -
0313
F-300
Vendor-03
included
- -
0314

Discharge Device
F-300
Vendor-03
included
- -
M -
0314

F-300
Vendor-03
included
- -
0315

Conveyor
F-300
Vendor-03
included

Proprietary, , , ,
,,,,
,,,,
Proprietary, , , ,
,,,,
REV
A
DATE
1/14/2011
BY
JRY

REV
PROJECT:
DATE:
REV Area - Type -

ASSESSMENT
30074.00
1/14/2011
Eq No
DESCRIPTION
PFD
VENDOR
MODEL
QUANT.
DESIGN
ELECTRICAL
SIZE (EA)
CAPACITY
HEAD/PRESS
HP (total)
RPM
VOLTS
MATERIAL
RFP No.
QUOTE INFO
FOB SHOP
NO/DATE/VALID
REMARKS
,,,,
- -
M -
0315

Conveyor Motor
F-300
Vendor-03
included
- -
0316
F-300
Vendor-03
included
- -
M -
0316
F-300
Vendor-03
included
- -
0317

Conveyor
F-300
Vendor-03
included
- -
M -
0317

Conveyor Motor
F-300
Vendor-03
included

,,,,
cooled, ,
,,,,

A
- -
0318
F-300
Vendor-03
included
- -
0319

F-300
Vendor-03
included
- -
M -
0319

F-300
Vendor-03
included
- -
0320

F-300
Vendor-03
included
- -
M -
0320

F-300
Vendor-03
included
- -
0321
F-300
Vendor-03
included
- -
0322

Discharge Device
F-300
Vendor-03
included
- -
M -
0322

F-300
Vendor-03
included
- -
0323

Conveyor
F-300
Vendor-03
included
- -
M -
0323

Conveyor Motor
F-300
Vendor-03
included
- -
0324
F-300
Vendor-03
included
- -
M -
0324
F-300
Vendor-03
included
- -
0325

Conveyor
F-300
Vendor-03
included
- -
M -
0325

Conveyor Motor
F-300
Vendor-03
included

Proprietary, , , ,
,,,,
,,,,
Proprietary, , , ,
,,,,
,,,,
,,,,
cooled, ,
,,,,

A
- -
0326
F-300
Vendor-03
included
- -
0327

F-300
Vendor-03
included
- -
M -
0327

F-300
Vendor-03
included
- -
0328

DischargeScrew Conveyor
F-300
Vendor-03
included
- -
M -
0328

F-300
Vendor-03
included
- -
0329
F-300
Vendor-03
included
- -
0330

Discharge Device
F-300
Vendor-03
included

Proprietary, , , ,
,,,,
,,,,
Proprietary, , , ,
REV
A
DATE
1/14/2011
BY
JRY

REV
PROJECT:
DATE:
REV Area - Type -

ASSESSMENT
30074.00
1/14/2011
Eq No
DESCRIPTION
PFD
VENDOR
MODEL
QUANT.
DESIGN
ELECTRICAL
SIZE (EA)
CAPACITY
HEAD/PRESS
HP (total)
RPM
VOLTS
MATERIAL
RFP No.
QUOTE INFO
FOB SHOP
NO/DATE/VALID
REMARKS
,,,,
- -
M -
0330

F-300
Vendor-03
included
- -
0331

Conveyor
F-300
Vendor-03
included
- -
M -
0331

Conveyor Motor
F-300
Vendor-03
included
- -
0332
F-300
Vendor-03
included
- -
M -
0332
F-300
Vendor-03
included
- -
0333

Conveyor
F-300
Vendor-03
included
- -
M -
0333

Conveyor Motor
F-300
Vendor-03
included

,,,,
,,,,
cooled, ,
,,,,

A
- -
0334
F-300
Vendor-03
included
- -
0335

F-300
Vendor-03
included
- -
M -
0335

F-300
Vendor-03
included
- -
0336

F-300
Vendor-03
included
- -
M -
0336

F-300
Vendor-03
included
- -
0337
F-300
Vendor-03
included
- -
0338

Discharge Device
F-300
Vendor-03
included
- -
M -
0338

F-300
Vendor-03
included
- -
0339

Conveyor
F-300
Vendor-03
included
- -
M -
0339

Conveyor Motor
F-300
Vendor-03
included
- -
0340
F-300
Vendor-03
included
- -
M -
0340
F-300
Vendor-03
included
- -
0341

Conveyor
F-300
Vendor-03
included
- -
M -
0341

Conveyor Motor
F-300
Vendor-03
included

Proprietary, , , ,
,,,,
,,,,
Proprietary, , , ,
,,,,
,,,,
,,,,
cooled, ,
,,,,

A
- -
0342
F-300
Vendor-03
included
- -
0343

F-300
Vendor-03
included
- -
M -
0343

F-300
Vendor-03
included
- -
0344

F-300
Vendor-03
included
- -
M -
0344

F-300
Vendor-03
included

Proprietary, , , ,
,,,,
,,,,
REV
A
DATE
1/14/2011
BY
JRY

REV
PROJECT:
DATE:
REV Area - Type -

ASSESSMENT
30074.00
1/14/2011
Eq No
DESCRIPTION
PFD
VENDOR
MODEL
QUANT.
DESIGN
ELECTRICAL
SIZE (EA)
CAPACITY
HEAD/PRESS
HP (total)
RPM
VOLTS
MATERIAL
RFP No.
QUOTE INFO
FOB SHOP
NO/DATE/VALID
- -
0345
F-300
Vendor-03
included
- -
0346

Discharge Device
F-300
Vendor-03
included
- -
M -
0346

F-300
Vendor-03
included
- -
0347

Conveyor
F-300
Vendor-03
included
- -
M -
0347

Conveyor Motor
F-300
Vendor-03
included
- -
0348
F-300
Vendor-03
included
- -
M -
0348
F-300
Vendor-03
included
- -
0349

Conveyor
F-300
Vendor-03
included
- -
M -
0349

Conveyor Motor
F-300
Vendor-03
included
REMARKS
Proprietary, , , ,
,,,,
,,,,
,,,,
cooled, ,
,,,,

Truck unloading station, Typically silica material, , ,
A
- -
0348
F-300
Vendor-07
$38,800
- -
0349
F-300
Vendor-06
included
- -
0350
F-300
Vendor-09
$116,300
- -
0351
F-300
Vendor-08
included
- -
0352
Bed Media - Transfer Screw Conveyor
F-300
Vendor-03
included
- -
M -
0352
Bed Media - Transfer Screw Conveyor Motor
F-300
Vendor-03
included
- -
0353
Bed Media - Recycled Media Mixing Hopper
F-300
Vendor-03
included
- -
0354
Bed Media - Dense Phase Conveyor Bin
F-300
Vendor-03
included
- -
0355
Bed Media - Pneumatic Metering Conveyor
F-300
Vendor-03
included
Bed material and recycled char, Pressurized nitrogen

is the motive power source, , ,
Truck unloading station, Typically limestone for

removal of chlorine and sulfur, , ,

Atmospheric vessel, Bottom discharge, , ,
Metering screw conveyor, Pressurized , , ,
,,,,
Atmospheric vessel, Bottom discharge , , ,
SORBENT MEDIA STORAGE & HANDLING

A
- -
0356
Sorbent Media - Recieving Station
F-300
Vendor-07
$58,750
- -
0357
Sorbent Media - Pneumatic Unloading Conveyor
F-300
Vendor-06
included
- -
0358
Sorbent Media - Storage Silo
F-300
Vendor-09
$176,250
- -
0359
Sorbent Media - Storage Silo Vent Filter
F-300
Vendor-08
included
- -
0360
Sorbent Media - Transfer Conveyor
F-300
Vendor-03
included
- -
M -
0360
Sorbent Media - Transfer Conveyor Motor
F-300
Vendor-03
included
- -
0361
Sorbent Media - Dense Phase Conveyor Bin
F-300
Vendor-03
included
- -
0362
Sorbent Media - Pneumatic Metering Conveyor
F-300
Vendor-03
included

Atmospheric vessel, Bottom discharge, , ,
Metering screw conveyor, Pressurized , , ,
,,,,
Pressurized nitrogen is the motive power source, , , ,
REV
A
DATE
1/14/2011
BY
JRY

REV
PROJECT:
DATE:
REV Area - Type -

ASSESSMENT
30074.00
1/14/2011
Eq No
DESCRIPTION
PFD
VENDOR
MODEL

QUANT.
DESIGN
SIZE (EA)
CAPACITY
ELECTRICAL
HEAD/PRESS
HP (total)
RPM
VOLTS
MATERIAL
RFP No.
QUOTE INFO
FOB SHOP
NO/DATE/VALID
REMARKS
GASIFIER
- -
0363
Gasifier
F-300
Vendor-03
$14,248,916
- -
0364
Gasifier - Cyclone
F-300
Vendor-03
included
- -
0365
Gasifier - Cyclone - Rotary Discharger
F-300
Vendor-03
included
- -
M -
0365
Gasifier - Cyclone - Rotary Discharger Motor
F-300
Vendor-03
included
- -
0366
F-300
Vendor-03
included
- -
0367
Gasifier - Startup Burner - Air Compressor
F-300
Vendor-03
included
- -
M -
0367
Gasifier - Startup Burner - Air Compressor Motor
F-300
Vendor-03
included
Bubbling fluid bed auto thermal gasifier, Pressure

vessel, Refractory lined, Fired with biomass, oxygen &
steam, Fluidized bed composed of bed media, sorbent
media, & biomass
,,,,
Horizontal pressure vessel fire box, Natural gas
burner, Refractory lined, ,
,,,,
GASIFIER BED MEDIA CLEANING SYSTEM

Screw conveyor, Pressurized, Water cooled, ,
A
- -
0368
Gasifier Bed - Discharge Screw Conveyor
F-300
Vendor-03
included
- -
M -
0368
Gasifier Bed - Discharge Screw Conveyor Motor
F-300
Vendor-03
included
- -
0369
Gasifier Bed Cleaning - Lock Hopper No.1
F-300
Vendor-03
included
- -
0370
Gasifier Bed Cleaning - Lock Hopper No.2
F-300
Vendor-03
included
- -
0371
Gasifier Bed Cleaning - Screen
F-300
Vendor-03
included
- -
0372
Gasifier Bed Cleaning - Rejects Conveyor
F-300
Vendor-03
included
- -
M -
0372
Gasifier Bed Cleaning - Rejects Conveyor Motor
F-300
Vendor-03
included
0373
Tar Reformer
F-300
Vendor-03
included
,,,,
Pressure vessel, Pressurized with nitrogen, , ,
Pressure vessel, Pressurized with nitrogen, , ,
Atmospheric, , , ,
Atmospheric, , , ,
,,,,
TAR REFORMER
A
- -
PROCESS AIR SYSTEM

A
- -
0374
F-300
Vendor-10
$50,000
- -
M -
0374
F-300
Vendor-10
included
- -
0375
Process Air - Dryer
F-300
Vendor-11
included
- -
0376
F-300
Vendor-09
included

,,,,

,,,,
- -
0377

Separator
F-300
Vendor-04
$7,186,112
- -
0378
F-300
Vendor-09
included
- -
0379

Tank
F-300
Vendor-09
included
REV
A
DATE
1/14/2011
BY
JRY

REV
PROJECT:
DATE:
REV Area - Type -

ASSESSMENT
30074.00
1/14/2011
Eq No
DESCRIPTION
PFD
VENDOR
MODEL
QUANT.
DESIGN
ELECTRICAL
SIZE (EA)
CAPACITY
HEAD/PRESS
HP (total)
RPM
VOLTS
MATERIAL
RFP No.
QUOTE INFO
FOB SHOP
NO/DATE/VALID
REMARKS
OXYGEN SYSTEM
A
- -
0380
F-300
Vendor-10
$50,000
- -
M -
0380
F-300
Vendor-10
included
- -
0381
F-300
Vendor-09
included
Pressure vessel, Oxygen supply for gasifier & tar

remover combustion, , ,

operation, , ,
NITROGEN SYSTEM
A
- -
0382

Supply Tank
F-300
Vendor-09
$75,000
- -
0383
F-300
Vendor-10
included
- -
M -
0383
F-300
Vendor-10
included
- -
0384

Tank
F-300
Vendor-09
included
Pressure vessel, Nitrogen supply for biomass feed

system, gasifier,tar reformer pressurization & purge
requirements, , ,
0385
F-300
Vendor-03
included
Indirect heat exchanger with hot syngas on one side

being used to superheat steam on the other side, , , ,
0386
Syngas Flare Stack
F-300
Vendor-03
included

SYNGAS COOLER
A
- -
FLARE STACK
,,,,
A
- -
APPENDIX D
CAPITAL COST ESTIMATE DETAILS
Report 30300/01
CLASS 4 COST ESTIMATE - TECHNOLOGY #1

DATE: 01/14/2011
DESCRIPTION
% / QTY
EQUIP. NO.
PURCHASER
CATEGORY
AREA
SEQUENCE
MATERIAL
UNIT
UNIT PRICE
CONTRACTOR LABOR
OWNER FURN. CONTR. FURN

TOTAL
TOTAL
L.H./ UNIT
LABOR
HOURS
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
GRAND TOTAL
Summary By Work Category
11
12
Civil / Earthwork
2.0%
487,300
3,630
73.25
265,898
170,500
923,698
13
Buildings
2.3%
460,000
7,000
52.00
364,000
274,000
1,098,000
14
Equipment Foundations/Supports
13.2%
3,124,000
39,050
73.50
2,870,175
210,650
6,204,825
15
Piping
7.6%
2,010,000
27,900
56.00
1,562,400
3,572,400
16
Electrical
9.0%
2,116,692
33,598
63.00
2,116,692
4,233,383
17
Instrumentation
5.0%
1,175,940
19,599
60.00
1,175,940
2,351,880
18
Process Insulation / Painting
2.0%
470,376
9,698
48.50
470,376
940,752
19
Equipment
58.9%
21,930,654
91,000
62.00
5,642,000
140,000
27,712,654
20
Demolition
0.0%
21
Total Direct Cost
21,930,654
9,844,307
231,476
62.50
14,467,480
795,150
47,037,591
22
Contractor Premium Pay (% of Total Labor)
included in rate
23
Contractor's Indirects (% of Total Labor)
included in rate
included in rate
24
Contractor's Markup (% of Materials & Sub Contracts)
25
Total Construction Cost (aka Total Installed Cost)
26
Engineering Consultant (% of Direct Cost)
10.0%
4,703,759
27
Owner Engineering (% of Direct Cost)
2.0%
940,752
28
Pre-Project Cost (% of Construction Cost)
0.5%
235,188
29
Construction Management (% of Construction Cost)
2.0%
940,752
30
Environmental or Legislative Costs (% of Construction Cost)
1.0%
470,376
31
Capitalized Spares (% of Construction Cost)
3.0%
1,411,128
32
Sales Taxes (% of Construction Cost)
3.5%
1,646,316
33
Freight (% of Owner Material Direst Cost)
3.0%
34
Total Indirects
35
Sub-Total Direct and Indirects
36
Contingency (% of Sub-Total Direct and Indirects)
37
Total Process Plant & Equipment (PP&E)
38
Escalation (% of Sub-Total Direct and Indirects)
excluded
39
Capitalized Interest (% of Sub-Total Direct and Indirects)
excluded
40
Deferred Start-Up Costs (% of Sub-Total Direct and Indirects)
excluded
41
Working Capital (% of Sub-Total Direct and Indirects)
excluded
42
Operator Training (% of Construction Cost)
1.0%
43
Start-Up (% of Construction Cost)
1.0%
44
Grand Total (aka Total Project Investment)
45
21,930,654
9,844,307
231,476
62.50
14,467,480
795,150
47,037,591
657,920
11,006,190
58,043,781
20.0%
11,608,756
69,652,537
470,376
470,376
70,593,289

DATE: 01/14/2011
DESCRIPTION
% / QTY
EQUIP. NO.
PURCHASER
CATEGORY
AREA
SEQUENCE
MATERIAL
UNIT
UNIT PRICE
CONTRACTOR LABOR

TOTAL
TOTAL
L.H./ UNIT
LABOR
HOURS
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
GRAND TOTAL
11
12
Civil / Earthwork
1.7%
354,400
2,640
73.25
193,380
124,000
671,780
13
Buildings
2.8%
460,000
7,000
52.00
364,000
274,000
1,098,000
14
12.7%
2,556,000
31,950
73.50
2,348,325
172,350
5,076,675
15
Piping
9.0%
2,010,000
27,900
56.00
1,562,400
3,572,400
16
Electrical
9.0%
1,791,996
28,444
63.00
1,791,996
3,583,992
17
Instrumentation
5.0%
995,553
16,593
60.00
995,553
1,991,106
18
2.0%
398,221
8,211
48.50
398,221
796,443
19
Equipment
57.8%
16,836,734
97,500
62.00
6,045,000
150,000
23,031,734
20
Demolition
0.0%
21
Total Direct Cost
16,836,734
8,566,170
220,238
62.20
13,698,875
720,350
39,822,129
22
included in rate
23
included in rate
included in rate
24
25
26
10.0%
3,982,213
27
2.0%
796,443
28
0.5%
199,111
29
2.0%
796,443
30
1.0%
398,221
31
3.0%
1,194,664
32
3.5%
1,393,775
33
3.0%
34
Total Indirects
35
36
37
16,836,734
8,566,170
220,238
62.20
13,698,875
720,350
39,822,129
505,102
9,265,970
49,088,100
20.0%
9,817,620
58,905,720
38
excluded
39
excluded
40
excluded
41
excluded
42
1.0%
43
1.0%
44
45
398,221
398,221
59,702,162

DATE: 01/14/2011
DESCRIPTION
% / QTY
EQUIP. NO.
PURCHASER
CATEGORY
AREA
SEQUENCE
MATERIAL
UNIT
UNIT PRICE
CONTRACTOR LABOR

TOTAL
TOTAL
L.H./ UNIT
LABOR
HOURS
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
GRAND TOTAL
11
12
Civil / Earthwork
2.0%
487,300
3,630
73.25
265,898
170,500
923,698
13
Buildings
2.3%
460,000
7,000
52.00
364,000
274,000
1,098,000
14
13.2%
3,124,000
39,050
73.50
2,870,175
210,650
6,204,825
15
Piping
7.6%
2,010,000
27,900
56.00
1,562,400
3,572,400
16
Electrical
9.0%
2,120,413
33,657
63.00
2,120,413
4,240,827
17
Instrumentation
5.0%
1,178,007
19,633
60.00
1,178,007
2,356,015
18
2.0%
471,203
9,716
48.50
471,203
942,406
19
Equipment
59.0%
22,000,128
91,000
62.00
5,642,000
140,000
27,782,128
20
Demolition
0.0%
21
Total Direct Cost
22,000,128
9,850,924
231,586
62.50
14,474,096
795,150
47,120,298
22
included in rate
23
included in rate
included in rate
24
25
26
10.0%
4,712,030
27
2.0%
942,406
28
0.5%
235,601
29
2.0%
942,406
30
1.0%
471,203
31
3.0%
1,413,609
1,649,210
22,000,128
9,850,924
231,586
62.50
14,474,096
795,150
47,120,298
32
3.5%
33
3.0%
34
Total Indirects
35
36
37
38
excluded
39
excluded
40
excluded
41
excluded
42
1.0%
43
1.0%
44
45
660,004
11,026,470
58,146,768
20.0%
11,629,354
69,776,122
471,203
471,203
70,718,528
CLASS 4 COST ESTIMATE COMPARISON

DATE: 01/14/2010
EQUIP. NO.
PURCHASER
CATEGORY
AREA
SEQUENCE
Technology #1
DESCRIPTION
OWNER
FURNISHED
Technology #2
OWNER
FURNISHED
GRAND TOTAL
Technology #3
OWNER
FURNISHED
GRAND TOTAL
GRAND TOTAL
11
12
Civil / Earthwork
923,698
671,780
923,698
13
Buildings
1,098,000
1,098,000
1,098,000
14
6,204,825
5,076,675
6,204,825
15
Piping
3,572,400
3,572,400
3,572,400
16
Electrical
4,233,383
3,583,992
4,240,827
17
Instrumentation
2,351,880
1,991,106
2,356,015
18
19
Equipment
20
Demolition
940,752
21,930,654
27,712,654
796,443
16,836,734
23,031,734
942,406
22,000,128
27,782,128
--
--
--
47,037,591
39,822,129
47,120,298
21
Total Direct Cost
22
included
included
included
23
included
included
included
24
25
26
27
28
included
included
included
47,037,591
39,822,129
47,120,298
4,703,759
3,982,213
4,712,030
940,752
796,443
942,406
235,188
199,111
235,601
29
940,752
796,443
942,406
30
470,376
398,221
471,203
31
1,411,128
1,194,664
1,413,609
32
1,646,316
1,393,775
1,649,210
33
657,920
505,102
660,004
34
Total Indirects
11,006,190
9,265,970
11,026,470
58,146,768
35
58,043,781
49,088,100
36
11,608,756
9,817,620
11,629,354
37
69,652,537
58,905,720
69,776,122
38
excluded
excluded
excluded
39
excluded
excluded
excluded
40
excluded
excluded
excluded
41
excluded
excluded
excluded
42
470,376
398,221
471,203
43
470,376
398,221
471,203
44
70,593,289
59,702,162
70,718,528
45
APPENDIX E-1
DETAILED ESTIMATE
EQUIPMENT LIST
CFB GASIFIER MODEL
Report 30300/01
2
3
4
5
6
EQUIPMENT LIST INPUT - CFB

PROJECT NAME: CFB GASIFICATION MODEL
CLIENT: NATIONAL RENEWABLE ENERGY LABORATORY
DATE: 08/03/2012
7
8
EQ. NO.
DESCRIPTION
QTY
SHORT
DESCRIPTION
E=EQUIP
M=MOTOR
COST
SHIPPING
WEIGHT
LBS
SIZE / CAPACITY
HEAD/PRESS
MOTOR
HP
MOTOR
RPM
REMARK
10
11
12
13
101
tank
$210,000
80,000
Based on Process Baron quote
14
102
Biomass Line-1 - Weigh Bin No.1 Outfeed Screw
conveyor
Incl
Incl
15
102-M
Biomass Line-1 - Weigh Bin No.1 Outfeed Screw Motor
motor
Incl
Incl
16
103
conveyor
Incl
Incl
17
103-M
Biomass Line-1 - Weigh

W eigh Bin No.2 Outfeed Screw Motor
motor
Incl
Incl
Based on Process Baron

Baron q
quote
uote
18
104
filter
Incl
Incl
19
105
tank
$75,000
18,000
Based on Process Carbona quote
20
106
Biomass Line-1 - Lock Hopper Inlet Shutoff Valve
tank
Incl
Incl
21
107
Biomass Line-1 - Lock Hopper Outlet Shutoff Valve
tank
Incl
Incl
22
108
Biomass Line-1 - Pressurized Metering Bin
tank
$120,000
40,000
109
Biomass Line-1 - Pressurized Metering Bin Live Bottom

Screws
discharger
Incl
Incl
24
109-M

Screws Motor
motor
Incl
Incl
25
110
Biomass Line-1 - Transfer Screw
discharger
$17,000
15,000
Price based on Buckeye project/Bill Atwood
26
110-M
Biomass Line-1 - Transfer Screw Motor
motor
Incl
Incl
27
111
Biomass Line-1 - Gasifier Injection Screw
conveyor
$34,000
20,000
28
111-M
Biomass Line-1 - Gasifier Injection Screw Motor
motor
Incl
Incl
23
29
Water cooled
30
112
tank
$210,000
80,000
31
113
conveyor
Incl
Incl
32
113-M
motor
Incl
Incl
33
114
conveyor
Incl
Incl
2
3
4
5
6

DATE: 08/03/2012
7
8
EQ. NO.
QTY
SHORT
DESCRIPTION
E=EQUIP
M=MOTOR
COST
SHIPPING
WEIGHT
LBS
motor
Incl
Incl

DESCRIPTION
SIZE / CAPACITY
HEAD/PRESS
MOTOR
HP
MOTOR
RPM
REMARK
10
34
114-M
35
115
filter
Incl
Incl
36
116
tank
$75,000
18,000
37
117
tank
Incl
Incl
38
118
tank
Incl
Incl
39
119
tank
$120,000
40,000
40
120

Screws
discharger
Incl
Incl
41
120-M

Screws Motor
motor
Incl
Incl
42
121
discharger
$17,000
15,000
43
121-M
motor
Incl
Incl
44
122
conveyor
$34,000
20,000
45
122-M
motor
Incl
Incl
46
Water cooled
47
123
tank
$210,000
80,000
48
124
conveyor
Incl
Incl
49
124-M
motor
Incl
Incl
50
125
conveyor
Incl
Incl
51
125-M
motor
Incl
Incl
52
126
filter
Incl
Incl
53
127
tank
$75,000
18,000
54
128
tank
Incl
Incl
55
129
tank
Incl
Incl
2
3
4
5
6

DATE: 08/03/2012
7
8
EQ. NO.
DESCRIPTION
QTY
SHORT
DESCRIPTION
E=EQUIP
M=MOTOR
COST
SHIPPING
WEIGHT
LBS
SIZE / CAPACITY
HEAD/PRESS
MOTOR
HP
MOTOR
RPM
REMARK
10
56
130
tank
$120,000
40,000
131

Screws
discharger
Incl
Incl
58
131-M

Screws Motor
motor
Incl
Incl
59
132
discharger
$17,000
15,000
60
132-M
motor
Incl
Incl
61
133
conveyor
$34,000
20,000
62
133-M
motor
Incl
Incl
57
Water cooled

64
134
tank
$210,000
80,000
65
135
conveyor
Incl
Incl
66
135-M
motor
Incl
Incl
67
136
conveyor
Incl
Incl
68
136-M
motor
Incl
Incl
69
137
filter
Incl
Incl
70
138
tank
$75,000
18,000
71
139
tank
Incl
Incl
72
140
tank
Incl
Incl
73
141
tank
$120,000
40,000
142

Screws
discharger
Incl
Incl
75
142-M

Screws Motor
motor
Incl
Incl
76
143
discharger
$17,000
15,000
77
143-M
motor
Incl
Incl
74
2
3
4
5
6

DATE: 08/03/2012
7
8
QTY
SHORT
DESCRIPTION
E=EQUIP
M=MOTOR
COST
SHIPPING
WEIGHT
LBS
conveyor
$34,000
20,000
motor
Incl
Incl
Gasifier Reactor
tank
$821,963
410,824
EQ. NO.
DESCRIPTION
SIZE / CAPACITY
HEAD/PRESS
MOTOR
HP
MOTOR
RPM
REMARK
10
78
144
79
144-M
80
GASIFIER REACTOR & CYCLONES
81
145
82
146
burner
$50,000
8,000
83
147
Duct-01 - From Gasifier Reactor To Gasifier Reactor

No.1 Cyclone
duct
$649,975
169,495
84
148
Gasifier Reactor No.1 Cyclone
tank
$511,015
486,741
85
149
Line-01 - From Gasifier Reactor No.1 Cyclone To

Gasifier Reactor Cyclones Solids Collection Bin
line
$124,188
33,143
86
150
tank
$496,632
81,940
87
151
Duct-02 - From Gasifier Reactor No.1 Cyclone To

duct
$562,066
142,145
88
152
tank
$504,655
479,285
89
153
Line-05 - From Gasifier Reactor No.2 Cyclone To

line
$200,579
61,684
90
154
Duct-03 - From Gasifier Reactor No.2 Cyclone To Duct14 - From Duct-03 & Duct-13 To Syngas Reformer
Reactor
duct
$1,235,358
486,255
91
155
Line-06 - From Gasifier Reactor Cyclones Solids

Collection Bin To Char Combustion Reactor
line
$279,658
108,486
92
156
Duct-17 - From Duct-15 - From Char Conbustion

Reactor Air Blower To Char Combustion Reactor
Startup Burner To Gasifier Reactor Startup Burner
duct
$306,772
226,014
93
GASIFIER LOOP BED MEDIA MAKEUP SYSTEM
94
157
Gasifier Loop Bed Media Truck Unloading Station
truck unloading
station
$5,000
250
95
158
Line-02 - From Gasifier Loop Bed Media Truck

Unloading Station To Gasifier Loop Bed Media Feed
Bin
line
$31,196
13,377
96
159
Gasifier Loop Bed Media Feed Bin
tank
$109,246
22,046
Water cooled
2
3
4
5
6

DATE: 08/03/2012
7
8
EQ. NO.
QTY
SHORT
DESCRIPTION
E=EQUIP
M=MOTOR
COST
SHIPPING
WEIGHT
LBS
Gasifier Loop Bed Media Makeup Blower
blower
$35,000
3,000
Gasifier Loop Bed Media Makeup Blower Motor
motor
Incl
400
Line-03 - From Gasifier Loop Bed Media Makeup

Blower To Char Combustion Reactor
line
$41,937
20,342
DESCRIPTION
10
97
160
98
160-M
99
161
100
CHAR COMBUSTION REACTOR
101
162
Char Combustion Reactor
tank
$896,893
379,343
102
163
Char Combustion Reactor Air Heater
heat exchanger
$159,000
25,000
103
164
Char Conbustion Reactor Air Blower
blower
$262,500
20,000
104
164-M
Char Conbustion Reactor Air Blower Motor
motor
Incl
350
105
165
burner
$50,000
8,000
106
166
Duct-15 - From Char Conbustion Reactor Air Blower

To Char Combustion Reactor Startup Burner
duct
$484,442
118,328
107
CHAR COMBUSTION CYCLONES
108
167
Duct-04 - From Char Combustion Reactor To Char

Combustion Reactor No.1 Cyclone
duct
$768,435
178,471
109
168
Char Combustion Reactor No.1 Cyclone
tank
$785,028
758,731
110
169
Line-07 - From Char Combustion Reactor No.1

Cyclone To Char Combustion Reactor No.1 Cyclone
Solids Collection Bin
line
$246,648
73,857
111
170
Char Combustion Reactor No.1 Cyclone Solids

Collection Bin
tank
$490,073
81,022
112
171

Cyclone Solids Collection Bin To Gasifier Reactor
line
$279,658
108,486
113
172
Duct-05 - From Char Combustion Reactor No.1

Cyclone To Char Combustion Reactor No.2 Cyclone
duct
$718,530
160,420
114
173
tank
$780,928
752,354
SIZE / CAPACITY
HEAD/PRESS
MOTOR
HP
MOTOR
RPM
REMARK
2
3
4
5
6

DATE: 08/03/2012
7
8
EQ. NO.
DESCRIPTION
QTY
SHORT
DESCRIPTION
E=EQUIP
M=MOTOR
COST
SHIPPING
WEIGHT
LBS
10
115
174

Cyclone To Char Combustion Loop Depleted Bed
Media & Ash Cooling Screw Conveyor
line
$189,828
67,502
116
175
Duct-06 - From Char Combustion Reactor No.2

Cyclone To Battery Limit (Flue Gas)
duct
$644,279
144,076
117
CHAR COMBUSTION BED MEDIA & ASH DISPOSAL
118
176
Char Combustion Loop Depleted Bed Media & Ash

Cooling Screw Conveyor
conveyor
$20,000
5000
119
176-M

Cooling Screw Conveyor Motor
motor
Incl
400
120
177

Cooling Screw Conveyor Outlet Pocket Feeder
conveyor
$7,000
900
121
177-M

Cooling Screw Conveyor Outlet Pocket Feeder Motor
motor
Incl
400
122
178
Line-19 - From Char Combustion Loop Depleted Bed

Media & Ash Cooling Screw Conveyor To Gasifier
Loop Depleted Bed Media & Ash Storage Bin
line
$14,367
2,308
123
179
Gasifier Loop Depleted Bed Media & Ash Storage Bin
tank
$109,246
22,046
124
SYNGAS REFORMER & CYCLONES
125
180
Duct-13 - From Supplemental Gas Battery Limits To

duct
$541,728
132,263
126
181
Duct-14 - From Duct-03 & Duct-13 To Syngas

Reformer Reactor
duct
$702,848
161,594
127
182
tank
$1,522,654
600,175
128
183
Duct-07 - From Syngas Reformer Reactor To Syngas

Reformer Reactor No.1 Cyclone
duct
$1,199,771
353,009
129
184
Syngas Reformer Reactor No.1 Cyclone
tank
$992,813
966,290
130
185
Line-10 - From Syngas Reformer Reactor No.1

Cyclone To Syngas Reformer Reactor Cyclones Solids
Collection Bin
line
$179,003
43,104
131
186
Syngas Reformer Reactor Cyclones Solids Collection

Bin
tank
$498,006
82,129
132
187
Duct-08 - From Syngas Reformer Reactor No.1

Cyclone To Syngas Reformer Reactor No.2 Cyclone
duct
$1,199,771
353,009
SIZE / CAPACITY
HEAD/PRESS
MOTOR
HP
MOTOR
RPM
REMARK
2
3
4
5
6

DATE: 08/03/2012
7
8
EQ. NO.
DESCRIPTION
QTY
SHORT
DESCRIPTION
E=EQUIP
M=MOTOR
COST
SHIPPING
WEIGHT
LBS
10
133
188
tank
$992,813
966,290
134
189
Line-14 - From Syngas Reformer Reactor No.2

Cyclone To Syngas Reformer Reactor Cyclones Solids
Collection Bin
line
$183,783
57,426
135
190
Duct-09 - From Syngas Reformer Reactor No.2

Cyclone To Battery Limit (Reformed Syngas)
duct
$1,199,771
353,009
136
191
Line-15 - From Syngas Reformer Reactor Cyclones

Solids Collection Bin To Reformer Bed Media Heating
Reactor
line
$326,966
125,189
137
REFORMER LOOP BED MEDIA MAKEUP SYSTEM
138
192
Reformer Loop Bed Media Truck Unloading Station
truck unloading
station
$5,000
250
139
193
Line-11 - From Reformer Loop Bed Media Truck

Unloading Station To Reformer Loop Bed Media Feed
Bin
line
$33,835
13,377
140
194
Reformer Loop Bed Media Feed Bin
tank
$109,246
22,046
141
195
Reformer Loop Bed Media Makeup Blower
blower
$35,000
3,000
142
195-M
Reformer Loop Bed Media Makeup Blower Motor
motor
Incl
400
143
196
Line-12 - From Reformer Loop Bed Media Makeup

Blower To Reformer Bed Media Heating Reactor
line
$44,576
20,342
144
REFORMER BED MEDIA HEATING REACTOR
145
197
Reformer Bed Media Heating Reactor
tank
$593,440
269,725
146
198
Reformer Bed Media Heating Reactor Air Heater
heat exchanger
$159,000
25,000
147
199
Reformer Bed Media Heating Reactor Air Blower
blower
$262,500
20,000
148
199-M
Reformer Bed Media Heating Reactor Air Blower Motor
motor
Incl
350
149
200
Reformer Bed Media Heating Reactor Burner
burner
$75,000
10,000
150
201
Duct-16 - From Reformer Bed Media Heating Reactor

Air Heater To Reformer Bed Media Heating Reactor
duct
$208,339
59,120
SIZE / CAPACITY
HEAD/PRESS
MOTOR
HP
MOTOR
RPM
REMARK
2
3
4
5
6

DATE: 08/03/2012
7
8
EQ. NO.
DESCRIPTION
QTY
SHORT
DESCRIPTION
E=EQUIP
M=MOTOR
COST
SHIPPING
WEIGHT
LBS
10
151
REFORMER BED MEDIA HEATING CYCLONES
152
202

To Reformer Bed Media Heating Reactor No.1 Cyclone
duct
$438,507
157,602
153
203
Reformer Bed Media Heating Reactor No.1 Cyclone
tank
$193,670
174,580
154
204
Line-16 - From Reformer Bed Media Heating Reactor

No.1 Cyclone To Reformer Bed Media Heating Reactor
No.1 Cyclone Solids Collection Bin
line
$183,783
57,426
155
205

Solids Collection Bin
tank
$491,894
81,276
156
206

No.1 Cyclone Solids Collection Bin To Syngas
Reformer Reactor
line
$326,966
125,189
157
207

No.1 Cyclone To Reformer Bed Media Heating Reactor
No.2 Cyclone
duct
$438,507
157,602
158
208
tank
$193,670
174,580
159
209

No.2 Cyclone To Reformer Loop Depleted Bed Media
line
$218,098
86,412
160
210

No.2 Cyclone To Battery Limit (Flue Gas)
duct
$438,507
157,602
161
REFORMER HEATER BED MEDIA & ASH DISPOSAL
162
211
Reformer Loop Depleted Bed Media Cooling Screw

Conveyor
conveyor
$20,000
5000
163
211-M

Cooling Screw Conveyor Motor
motor
Incl
400
164
212

Cooling Screw Conveyor Outlet Pocket Feeder
feeder
$7,000
900
165
212-M

Cooling Screw Conveyor Outlet Pocket Feeder Motor
motor
Incl
400
166
213
Line-20 - From Reformer Loop Depleted Bed Media

Cooling Screw Conveyor To Reformer Loop Depleted
Bed Media Storage Bin
line
$17,006
2,308
167
214
Reformer Loop Depleted Bed Media Storage Bin
tank
$109,246
22,046
SIZE / CAPACITY
HEAD/PRESS
MOTOR
HP
MOTOR
RPM
REMARK
2
3
4
5
6

DATE: 08/03/2012
7
8
EQ. NO.
DESCRIPTION
QTY
SHORT
DESCRIPTION
E=EQUIP
M=MOTOR
COST
SHIPPING
WEIGHT
LBS
burner
$6,000
1500
SIZE / CAPACITY
HEAD/PRESS
MOTOR
HP
MOTOR
RPM
REMARK
10
168
169
FLARE SYSTEM
215
Stack Flare Burner
U:\30251.00\4200 Process\4215 Design Data\01 - HGI Files\Workbooks\CFB Gasifier Model\[2012-08-03 - CFB Gasifier Model.xlsx]04Equip List
8/2/12 6:41 PM
APPENDIX E-2
DETAILED ESTIMATE
EQUIPMENT LIST
BFB GASIFIER MODEL
Report 30300/01
2
3
4
5
6
EQUIPMENT LIST INPUT - BFB

PROJECT NAME: BFB BIOMASS GASIFICATION SYSTEM
DATE: 08/03/2012
7
8
EQ. NO.
DESCRIPTION
QTY
SHORT
DESCRIPTION
D = DUCT
E = EQUIP
L = LINE
M = MOTOR
V = VESSEL
COST
SHIPPING
WEIGHT
LBS
SIZE / CAPACITY
6.3' Dia X 9.1' Dia X

35.9 Hi
HEAD/PRESS
MOTOR
HP
MOTOR
RPM
REMARK
10
11
12
GASIFIER REACTOR & CYCLONE
13
101
Gasifier Reactor
reactor
$546,361
227,776
14
102
burner
$150,000
3,000
15
103
Duct-01 (Refractory Lined) - From Gasifier Reactor To

Gasifier Cyclone
duct
$161,893
18,169
16
104
Gasifier Cyclone
tank
$160,924
77,227
17
105
Line-01 (Refractory
(Refractory Lined) - Fr
From
om Gasifier Cyclone T
To
o
Gasifier Reactor
line
$191,879
46,161
18
106
Duct-02 (Refractory Lined) - From Gasifier Cyclone To

Battery Limit
duct
$201,035
32,952
19
107
Line-02 (Refractory Lined) - From Gasifier Reactor To

Ash Cooling Screw Conveyor
line
$130,945
19,760
20
Includes refractory lined combustion chamber, burner

& burner management system.
5.3' Dia X 13.7 Hi
BED MEDIA MAKEUP SYSTEM

The unloading station cost is a function of the speed at
which a truck is to be unloaded. All trucks will be the
same size, therefore this is a fixed cost estimated as
shown.
21
108
Bed Media Truck Unloading Station
truck unloading
station
$8,500
750
22
109
Piping - From Bed Media Truck Unloading Station To

line
Incl
Incl
23
110
tank
$105,819
15,575
12.0' Dia X 22.5 Hi
24
111
Bed Media Nitrogen Tank
tank
$83,111
14,200
6.0' Dia X 11.0 Hi
25
112
Piping - From Bed Media Nitrogen Tank To Bed Media

Pneumatic Transporter
line
$2,500
350
This is estimated to be a fixed cost regardless of

system capacity.
26
113
Bed Media Pneumatic Transporter
tank
$250,000
3,000

system capacity.
27
114
Piping - From Bed Media Pneumatic Transporter To

Gasifier Reactor
line
Incl
Incl
conveyor
$159,497
16,466
Ash Cooling Screw Conveyor Motor
motor
Incl
Incl
28
ASH REMOVAL SYSTEM
29
115
30
115-M
18.0'' Dia X 5.0 Long
30
2
3
4
5
6
EQUIPMENT LIST INPUT - BFB

PROJECT NAME: BFB BIOMASS GASIFICATION SYSTEM
DATE: 08/03/2012
7
8
EQ. NO.
DESCRIPTION
QTY
SHORT
DESCRIPTION
D = DUCT
E = EQUIP
L = LINE
M = MOTOR
V = VESSEL
COST
SHIPPING
WEIGHT
LBS
SIZE / CAPACITY
HEAD/PRESS
MOTOR
HP
MOTOR
RPM
REMARK
10
31
116
Piping - From Ash Cooling Screw Conveyor To Ash

Discharge Hopper
line
$5,000
500
32
117
Ash Discharge Hopper
tank
$165,732
27,288
33
118
Ash Lock Hopper Inlet Block Valve
valve
$15,000
2,000
34
119
Piping - From Ash Discharge Hopper To Ash Lock

Hopper
line
$5,000
500
35
120
Ash Lock Hopper
tank
$165,185
27,208
9.0' Dia X 19.5 Hi
36
121
Ash Lock Hopper Discharge Screw Conveyor
conveyor
$310,935
31,714
18.0'' Dia X 12.0

Long
37
121-M
Ash Lock Hopper Discharge Screw Conveyor Motor
motor
Incl
400
38
122
Ash Lock Hopper Outlet Block Valve
valve
$15,000
2,000
39
123
Piping - From Ash Lock Hopper To Battery Limit
line
$8,000
500
U:\30251.00\4200 Process\4215 Design Data\01 - HGI Files\Workbooks\BFB Gasifier Model\[2012-08-03 - BFB Gasifier Model.xlsx]04Equip List

system capacity.
9.0' Dia X 19.5 Hi
This valve is estimated to be a 24" dome valve with a
fixed cost regardless of system capacity.
system capacity.
65
This valve is estimated to be a 24" dome valve with a
fixed cost regardless of system capacity.
system capacity.
8/2/12 6:48 PM
APPENDIX E-3
DETAILED ESTIMATE
EQUIPMENT LIST
HP BIOMASS FEED SYSTEM MODEL
Report 30300/01
2
3
4
5
6
EQUIPMENT LIST INPUT - HP BIOMASS FEED SYSTEM

PROJECT NAME: HP BIOMASS FEED SYSTEM - SINGLE LINE
DATE: 08/03/2012
7
8
EQ. NO.
DESCRIPTION
QTY
SHORT
DESCRIPTION
D = DUCT
E = EQUIP
L = LINE
M = MOTOR
V = VESSEL
COST
SHIPPING
WEIGHT
LBS
SIZE / CAPACITY
HEAD/PRESS
MOTOR
HP
MOTOR
RPM
REMARK
10
11
12
BIOMASS FEED LINE

Pricing for this equipment is a function of the biomass
feed rate and an HGI estimated cost factor.
13
101
Biomass Lock Hopper Feed Equipment
conveyor
$250,000
14
102
Biomass Lock Hopper Feed Chute
chute
$15,000
1,500
15
103
Biomass Lock Hopper Inlet Block Valve
valve
$75,000
1,000
16
104
Biomass Lock Hopper
vessel
$176,400
38,413
14.0' Dia X 28.0 Hi
17
105
Biomass Lock Hopper Bottom Reclaimer
screw conveyor
SC
$232,100
23,676
24.5'' Dia X 7.0 Long
18
105-M
Biomass Lock Hopper Rotating Dischrage Screw Motor
motor
Incl
Incl
19
106
Biomass Lock Hopper Outlet Block Valve
valve
$75,000
1,000
20
107
Biomass Lock Hopper Vent Filter
vent
$15,000
750
21
108
Biomass Lock Hopper Vent Filter Valve
valve
$15,000
600
22
109
Biomass Metering Bin
vessel
$197,100
41,501
15.0' Dia X 30.0 Hi
23
110
Biomass Metering Bin Rotating Dischrage Screw
screw conveyor
SC
$248,300
25,278
24.5'' Dia X 7.5 Long
24
110-M
Biomass Metering Bin Rotating Dischrage Screw Motor
motor
Incl
Incl
25
111
Biomass Transfer Screw Conveyor
screw conveyor
SC
$764,300
76,423
26
111-M
Biomass Transfer Screw Conveyor Motor
motor
Incl
Incl
27
112
Biomass Transfer Screw Conveyor Discharge

Expansion Joint
motor
$57,500
300
28
113
Biomass Transfer Screw Conveyor Discharge Chute
chute
$15,000
1,500

system capacity.
29
114

Block Valve
valve
$75,000
1,000

system capacity.
30
115
Gasifier Injection Auger
screw conveyor
SC
$244,300
24,618

system capacity.
Reclaimer with single rotating screw, which pivets

around bottom of hopper to move biomass to a center
discharge chute.
35
system capacity.
35
24.5' 'Dia X 23.5 Long
25
24.5'' Dia X 6.0 Long
2
3
4
5
6
EQUIPMENT LIST INPUT - HP BIOMASS FEED SYSTEM

PROJECT NAME: HP BIOMASS FEED SYSTEM - SINGLE LINE
DATE: 08/03/2012
7
8
EQ. NO.
DESCRIPTION
QTY
SHORT
DESCRIPTION
motor
D = DUCT
E = EQUIP
L = LINE
M = MOTOR
V = VESSEL
COST
SHIPPING
WEIGHT
LBS
Incl
Incl
SIZE / CAPACITY
HEAD/PRESS
MOTOR
HP
MOTOR
RPM
REMARK
10
31
115-M
Gasifier Injection Auger Motor
U:\30251.00\4200 Process\4215 Design Data\01 - HGI Files\Workbooks\HP Biomass Feed Model\[2012-08-03 - HP Biomass Feed
Model.xlsx]04-Equip List
10
8/2/12 6:48 PM
APPENDIX E-4
DETAILED ESTIMATE
EQUIPMENT LIST
LP BIOMASS FEED SYSTEM MODEL
Report 30300/01
2
3
4
5
6
EQUIPMENT LIST INPUT - LP BIOMASS FEED SYSTEM

PROJECT NAME: LP BIOMASS FEED SYSTEM - SINGLE LINE
DATE: 08/03/2012
7
8
EQ. NO.
DESCRIPTION
QTY
SHORT
DESCRIPTION
D = DUCT
E = EQUIP
L = LINE
M = MOTOR
V = VESSEL
COST
SHIPPING
WEIGHT
LBS
SIZE / CAPACITY
HEAD/PRESS
MOTOR
HP
MOTOR
RPM
REMARK
10
11
12
BIOMASS FEED LINE

Pricing for this equipment is a function of the biomass
feed rate and an HGI estimated cost factor.
13
101
Biomass Metering Bin Distributor
conveyor
$250,000
14
102
Biomass Metering Bin Feed Chute
chute
$15,000
1,500
15
103
vessel
$196,700
41,305
15.0' Dia X 30.0 Hi
16
104
Biomass Metering Bin Reclaim Screw
screw conveyor
SC
$248,300
25,278
24.5'' Dia X 7.5 Long
17
104-M
Biomass Metering Bin Reclaim Screw Motor
motor
Incl
Incl
18
105
screw conveyor
SC
$764,300
76,423
19
105-M
motor
Incl
Incl
20
106
Biomass Transfer Chute
chute
$15,000
1,500
21
107
Biomass Transfer Chute Expansion Joint
motor
$57,500
300
22
108
Biomass Transfer Chute Rotary Valve
valve
$120,000
2,000
23
108-M
Biomass Transfer Chute Rotary Valve Motor
motor
Incl
Incl
24
109
Biomass Transfer Chute Block Valve
valve
$75,000
1,000
25
110
screw conveyor
SC
$244,300
24,618
26
110-M
motor
Incl
Incl
U:\30251.00\4200 Process\4215 Design Data\01 - HGI Files\Workbooks\LP Biomass Feed Model\[2012-08-03 - LP Biomass Feed
Model.xlsx]04-Equip List
35
24.5' 'Dia X 23.5 Long
25
system capacity.

system capacity.

system capacity.
24.5'' Dia X 6.0 Long
10
8/2/12 7:02 PM
APPENDIX F-1
DETAILED ESTIMATE
MASS BALANCE FLOW DIAGRAMS
CFB GASIFIER MODEL
Report 30300/01
BATTERY LIMITS
X
CF
NITROGEN
NITROGEN FROM BATTERY LIMITS

TO GASIFIER REACTOR
0
0
0
0
0
0
0
0
0
0.00
80
0
15
0
BH
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
CHAR FROM GASIFIER REACTOR TO

SYNGAS ENTRAINMENT
14,093
1,038
2,070
10
7
0
0
0
17,218
0.00
1,562
BB
BATTERY LIMITS
L
BIOMASS
BIOMASS FROM BIOMASS STORAGE

TO GASIFIER
50,333
6,558
46,074
168
89
0
910
0
104,132
5.00
80
147
145
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
BN
147
BT
BZ
BED MEDIA FROM GASIFIER

REACTOR TO SYNGAS
ENTRAINMENT
ASH FROM GASIFIER REACTOR TO

SYNGAS ENTRAINMENT
0
0
0
0
0
0
929
0
929
0.00
1,562
147
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
0
0
0
0
0
0
0
5,154,012
5,154,012
0.00
1,562
DUST FREE SYNGAS FROM GASIFIER

REACTOR TO GASIFIER REACTOR
NO.1 CYCLONE
147
36,240
9,925
78,970
158
82
0
0
0
125,376
35.53
1,562
25
40
56,143
CHAR, ASH & BED MEDIA IN SYNGAS

FROM GASIFIER REACTOR TO
GASIFIER REACTOR NO.1 CYCLONE
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
14,093
1,038
2,070
10
7
0
929
5,154,012
5,172,159
0.00
1,562
147
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
145
147
DUCT-01
DUST FREE SYNGAS IN MIDDLE

(ZONE-2) OF GASIFIER REACTOR
GASIFIER
REACTOR
18,120
7,457
59,280
79
41
0
0
0
84,977
52.44
1,562
25
40
39,342
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
TO: MB-1-02
CL
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
AV
SYNGAS FROM GASIFIER REACTOR

TO GASIFIER REACTOR NO.1
CYCLONE
BATTERY LIMITS
BATTERY LIMITS
AD
AJ
OXYGEN
OXYGEN BLAST FROM OXYGEN

HEADER TO GASIFIER REACTOR
145
OXYGEN, STEAM & BIOMASS

WATER VAPOR IN BOTTOM (ZONE-1)
OF GASIFIER REACTOR
0
4,989
39,590
0
0
0
0
0
44,579
100.00
1,562
25
40
22,540
147
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR
LBS/
HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
AP
OXY & STM
OXYGEN & STEAM FROM OXYGEN &

STEAM HEADER TO GASIFIER
REACTOR
0
4,406
34,966
0
0
0
0
0
39,372
100.00
392
174
189
1,765
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORI
CHLORINE
NE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
0
0
0
0
0
0
0
0
0
0.00
172
0
15
0
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
STEAM
STEAM FROM STEAM HEADER TO

GASIFIER REACTOR
0
4,406
34,966
0
0
0
0
0
39,372
100.00
392
174
189
1,765
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
171
50,333
10,964
81,040
168
89
0
929
5,154,012
5,297,535
0.84
1,562
25
40
56,143
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
FROM: MB-1-03
R
171
SOLIDS FROM CHAR COMBUSTION

REACTOR NO.1 CYCLONE SOLIDS
COLLECTION BIN TO GASIFIER
REACTOR
0
0
0
0
0
0
19
5,154,012
5,154,031
0.00
1,635
LBS/HR
LBS/H
R - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
LINE-08
NATIONAL RENEWABLE ENERGY LABORATORY

GOLDEN, COLORADO
MATERIAL BALANCE DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
U:\30251.00\4200 Process\4215 Design Data\01 - HGI Files\Workbooks\CFB Gasifier Model\[2012-08-03 - CFB Gasifier
Model.xlsx]MB-1-01
DESCRIPTION
DRN
CKD
APRVD
GASIFIER REACTOR
PROJ NO.:
30300.00
DWG NO.:
MB-1-01
DATE:
08/03/12
8/3/12 9:01 AM
TO: MB-1-04
CX
147
DUCT-02
GASIFIER
REACTOR NO.1
CYCLONE
DUCT-01
98.0%
FROM: MB-1-01
CL
98.0%
147
149

TO GASIFIER REACTOR NO.1
CYCLONE
50,333
10,964
81,040
168
89
0
929
5,154,012
5,297,535
0.84
1,562
25
40
56,143
LINE-01
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
CR
36,522
9,946
79,012
158
82
0
19
103,080
228,819
19.47
1,547
24
39
57,166
149
SOLIDS FROM GASIFIER REACTOR

NO.1 CYCLONE TO GASIFIER
REACTOR CYCLONES SOLIDS
COLLECTION BIN
13,811
1,018
2,028
10
7
0
910
5,050,932
5,068,716
0.00
1,547
151

REACTOR NO.2 CYCLONE
151
148
154
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
DD
DUCT-03
152
GASIFIER
REACTOR NO.2
CYCLONE
98.0%
98.0%
DJ

NO.2 CYCLONE TO SYNGAS
REFORMER REACTOR
36,246
9,926
78,971
158
82
0
0
2,062
127,445
34.95
1,537
23
38
58,391
153
153
LINE-05
276
20
41
0
0
0
18
101,019
101,374
0.00
1,537
150
GASIFIER
REACTOR
CYCLONES
SOLIDS
COLLECTION
BIN
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
TO: MB-1-03
DV
14,088
1,038
2,069
10
7
0
928
5,151,950
5,170,090
0.00
1,547

GOLDEN, COLORADO
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]MB-1-02
DESCRIPTION
DRN
CKD
APRVD
155

CYCLONES SOLIDS COLLECTION BIN
TO CHAR COMBUSTION REACTOR
155
DATE
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM

COLLECTION BIN
LINE-06
REV.
154
GASIFIER CYCLONES
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PROJ NO.:
30300.00
DWG NO.:
MB-1-02
DATE:
08/03/12
8/3/12 9:01 AM
EH
TO: MB-1-01
R
ET
FLUE GAS FROM CHAR

COMBUSTION REACTOR TO CHAR
COMBUSTION REACTOR NO.1
CYCLONE
171
SOLIDS FROM CHAR COMBUSTION

COLLECTION BIN TO GASIFIER
REACTOR
0
0
0
0
0
0
19
5,154,012
5,154,031
0.00
1,635
167
14,088
1,394
48,593
164,389
7
0
928
5,259,196
5,488,596
0.23
1,650
15
30
98,255
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
168
167
DUCT-04
2.0%
98.0%
FROM: MB-1-02
DV
155
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
EB
EZ
LINE-09
169
BED MEDIA FROM CHAR

CYCLONE TO CHAR COMBUSTION
COLLECTION BIN
0 LBS/HR - CARBON
0 LBS/HR - HYDROGEN
0 LBS/HR - OXYGEN
0 LBS/HR - NITROGEN
0 LBS/HR - SULFUR
0 LBS/HR - CHLORINE
19 LBS/HR - ASH
5,154,012 LBS/HR - BED MEDIA
5,154,031 LBS/HR - TOTAL
0.00 % MOISTURE
1,635 F
161
0
235
45,562
164,379
0
0
0
0
210,176
1.00
800
15
30
55,764
LINE-03
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
176
CHAR
COMBUSTION
LOOP DEPLETED
BED MEDIA & ASH
COOLING SCREW
CONVEYOR
FF
177
178
ASH & DEPLETED BED MEDIA FROM

CHAR COMBUSTION LOOP
DEPLETED BED MEDIA & ASH
COOLING SCREW CONVEYOR TO
GASIFIER LOOP DEPLETED BED
0 LBS/HR - CARBON
0 LBS/HR - HYDROGEN
0 LBS/HR - OXYGEN
0 LBS/HR - NITROGEN
0 LBS/HR - SULFUR
0 LBS/HR - CHLORINE
892 LBS/HR - ASH
103,080 LBS/HR - BED MEDIA
103,972 LBS/HR - TOTAL
0.00 % MOISTURE
200 F
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
179
GASIFIER LOOP
DEPLETED BED
MEDIA & ASH
STORAGE BIN
BATTERY LIMIT
GOLDEN, COLORADO
DATE
DESCRIPTION
174
CHAR
COMBUSTION
LOOP DEPLETED
BED MEDIA & ASH
COOLING SCREW
CONVEYOR
OUTLET POCKET
FEEDER
REV.
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
ASH & DEPLETED BED MEDIA FROM

CHAR COMBUSTION REACTOR NO.2
LOOP DEPLETED BED MEDIA & ASH
COOLING SCREW CONVEYOR
0 LBS/HR - CARBON
0 LBS/HR - HYDROGEN
0 LBS/HR - OXYGEN
0 LBS/HR - NITROGEN
0.00000 LBS/HR - SULFUR
0 LBS/HR - CHLORINE
892 LBS/HR - ASH
0.00 % MOISTURE
1,625 F
166
AIR FROM CHAR COMBUSTION

REACTOR AIR HEATER TO CHAR
COMBUSTION REACTOR
BATTERY LIMIT
0
121
962
0
0
0
0
107,246
108,329
1.00
120
98.0%
BATTERY LIMIT
LINE-06
SOLIDS FROM GASIFIER LOOP BED

MEDIA MAKEUP BLOWER TO CHAR
COMBUSTION REACTOR
98.0%
FROM: MB-1-05
LINE-08
161
14,088
1,394
48,593
164,389
7
0
18
2,104
230,593
5.40
1,625
13
28
104,102
174
EN
171
155
DP
CHAR
COMBUSTION
REACTOR NO.2
CYCLONE
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
175
FLUE GAS FROM CHAR

CYCLONE TO BATTERY LIMITS
173
LINE-07

TO CHAR COMBUSTION REACTOR
14,088
1,038
2,069
10
7
0
928
5,151,950
5,170,090
0.00
1,547
FL
DUCT-06
169
CHAR COMBUSTION
REACTOR NO.1
CYCLONE SOLIDS
COLLECTION BIN
CHAR
COMBUSTION
REACTOR
14,088
1,394
48,593
164,389
7
0
910
105,184
334,565
3.72
1,635
14
29
100,956
CHAR
COMBUSTION
REACTOR NO.1
CYCLONE
170
162
DUCT-05
BATTERY LIMITS
175
FLUE GAS FROM CHAR

172
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
172
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]MB-1-03
DESCRIPTION
DRN
CKD
APRVD
CHAR COMBUSTION REACTOR & CYCLONES
PROJ NO.:
30300.00
DWG NO.:
MB-1-03
DATE:
08/03/12
8/3/12 9:01 AM
TO: MB-1-05
GP
FROM: MB-1-02
DJ
154

NO.2 CYCLONE TO SYNGAS
REFORMER REACTOR
36,246
9,926
78,971
158
82
0
0
2,062
127,445
34.95
1,537
23
38
58,391
REFORMED SYNGAS FROM SYNGAS

REFORMER REACTOR TO SYNGAS
REFORMER REACTOR NO.1
CYCLONE
183
154
DUCT-07
DUCT-03
170,770
67,714
234,815
158
82
0
0
13,743,968
14,217,508
0.00
1,652
21
36
505,760
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
GD
180
SUPPLEMENTAL GAS FROM

OUTSIDE SOURCE TO SYNGAS
REFORMER REACTOR
134,525
38,971
6,504
0
0
0
0
0
180,000
4.07
800
23
38
48,597
206
182
180
LINE-17
SYNGAS
REFORMER
REACTOR
DUCT-13
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
FX
181
0
0
0
0
0
0
0
13,741,907
13,741,907
0.00
1,735
181
DUCT-14
170,770
48,897
85,476
158
82
0
0
2,062
307,445
16.87
1,106
23
38
106,155
BATTERY LIMITS
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
GJ
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]MB-1-04
STEAM
STEAM FROM STEAM HEADER TO

SYNGAS REFORMER REACTOR
0
18,818
149,340
0
0
0
0
0
168,157
100.00
392
174
189
7,539

DESCRIPTION
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
TOTAL GASES FROM ALL SOURCES

TO SYNGAS REFORMER REACTOR
GOLDEN, COLORADO
DATE
206
SOLIDS FROM REFORMER BED

MEDIA HEATING REACTOR NO.1
CYCLONE SOLIDS COLLECTION BIN
REV.
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
FROM: MB-1-06
BATTERY LIMITS
FR
183
DESCRIPTION
DRN
CKD
APRVD
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
PROJ NO.:
30300.00
DWG NO.:
MB-1-04
DATE:
08/03/12
8/3/12 9:01 AM
BATTERY LIMITS
HB
FROM: MB-1-04
GP

REFORMER REACTOR TO SYNGAS
CYCLONE
170,770
67,714
234,815
158
82
0
0
13,743,968
14,217,508
0.00
1,652
21
36
505,760
DUCT-08
184
183
SYNGAS
REFORMER
REACTOR NO.1
CYCLONE
DUCT-07
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
98.0%
185
LINE-10
GV
170,770
67,714
234,815
158
82
0
0
274,879
748,419
0.00
1,637
20
35
516,641
185
SOLIDS FROM SYNGAS REFORMER

REACTOR NO.1 CYCLONE TO
0
0
0
0
0
0
0
13,469,089
13,469,089
0.00
1,627
187

CYCLONE TO SYNGAS REFORMER
187
183
190
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
HH
DUCT-09
188
SYNGAS
REFORMER
REACTOR NO.2
CYCLONE
98.0%
HN

170,765
67,714
234,814
158
82
0
0
5,498
479,031
0.00
1,627
19
34
529,436
LINE-14
6
0
1
0
0
0
0
269,382
269,389
0.00
1,627
186
SYNGAS
REFORMER
REACTOR
CYCLONES
SOLIDS
COLLECTION BIN
189
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
TO: MB-1-06
HZ
6
0
1
0
0
0
0
13,738,471
13,738,478
0.00
1,627
191

GOLDEN, COLORADO
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]MB-1-05
DESCRIPTION
DRN
CKD
APRVD
191

COLLECTION BIN TO REFORMER
BED MEDIA HEATING REACTOR
LINE-15
DATE
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM

189
REV.
190
SYNGAS REFORMER CYCLONES
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PROJ NO.:
30300.00
DWG NO.:
MB-1-05
DATE:
08/03/12
8/3/12 9:01 AM
TO: MB-1-04
GD
IR
JD
FLUE GAS & SOLIDS FROM

REFORMER BED MEDIA HEATING
REACTOR TO REFORMER BED
CYCLONE
1,187 LBS/HR - CARBON
719 LBS/HR - HYDROGEN
8,872 LBS/HR - OXYGEN
22,637 LBS/HR - NITROGEN
0 LBS/HR - CHLORINE
0 LBS/HR - ASH
0.05 % MOISTURE
1,750 F
11 PSIG
26 PSIA
19,437 ACFM
206
SOLIDS FROM REFORMER BED

CYCLONE SOLIDS COLLECTION BIN
0
0
0
0
0.00000
0
0
13,741,907
13,741,907
0.00
1,735
202
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
DUCT-11
203
202
1,187
719
8,872
22,637
0.00270
0
0
280,447
313,863
2.05
1,735
10
25
20,086
REFORMER
BED MEDIA
HEATING
REACTOR NO.1
CYCLONE
DUCT-10
98.0%
JP
DUCT-12
FLUE GAS & SOLIDS FROM CHAR

CYCLONE TO REFORMER BED MEDIA
HEATING REACTOR NO.2 CYCLONE
207
BATTERY LIMITS
210
207
FLUE GAS FROM REFORMER BED

208
REFORMER
BED MEDIA
HEATING
REACTOR NO.2
CYCLONE
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
210
1,187
719
8,872
22,637
0.00270
0
0
5,609
39,025
16.47
1,725
9
24
20,839
98.0%
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
204
LINE-16
197
FROM: MB-1-05
HZ

COLLECTION BIN TO REFORMER
BED MEDIA HEATING REACTOR
6
0
1
0
0.00270
0
0
13,738,471
13,738,478
0.00
1,627
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
LINE-17
LINE-15
BATTERY LIMITS
IL
IF
201
196
SOLIDS FROM REFORMER LOOP

BED MEDIA MAKEUP BLOWER TO
REACTOR
196
0
0
6,302
22,620
0
0
0
0
28,923
0.00
800
11
26
8,807
LINE-12
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
211
REFORMER
LOOP
DEPLETED BED
MEDIA
COOLING
SCREW
CONVEYOR
NAT GAS
NATURAL GAS FROM BATTERY

LIMITS TO REFORMER BED MEDIA
HEATING REACTOR
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
1,182
398
22
17
0
0
0
0
1,619
1.11
85
11
26
379
209
DEPLETED BED MEDIA FROM

REFORMER LOOP DEPLETED BED
MEDIA COOLING SCREW CONVEYOR
0 LBS/HR - CARBON
0 LBS/HR - HYDROGEN
0 LBS/HR - OXYGEN
0 LBS/HR - NITROGEN
0 LBS/HR - CHLORINE
0 LBS/HR - ASH
0.00 % MOISTURE
1,725 F
204
BATTERY LIMITS
AIR FROM ATMOSPHERE TO

REACTOR
BATTERY LIMITS
0
321
2,547
0
0
0
0
283,883
286,751
1.00
120
IX
JJ
LINE-18
BED MEDIA FROM REFORMER BED

CYCLONE TO REFORMER BED MEDIA
HEATING REACTOR NO.1 CYCLONE
SOLIDS COLLECTION BIN
0 LBS/HR - CARBON
0 LBS/HR - HYDROGEN
0 LBS/HR - OXYGEN
0 LBS/HR - NITROGEN
0 LBS/HR - CHLORINE
0 LBS/HR - ASH
0.00 % MOISTURE
1,735 F
206
191
HT
FROM: MB-1-05
REFORMER BED
MEDIA HEATING
REACTOR NO.1
CYCLONE SOLIDS
COLLECTION BIN
REFORMER BED
MEDIA HEATING
REACTOR
191
209
205
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
BATTERY LIMITS
JV
213
DEPLETED BED MEDIA FROM

REFORMER LOOP DEPLETED BED
MEDIA COOLING SCREW CONVEYOR
TO REFORMER LOOP DEPLETED
BED MEDIA STORAGE BIN
0 LBS/H
LBS/HR
R - CARBON
0 LBS/HR - HYDROGEN
0 LBS/HR - OXYGEN
0 LBS/HR - NITROGEN
0 LBS/HR - CHLORINE
0 LBS/HR - ASH
0.00 % MOISTURE
200 F

GOLDEN, COLORADO
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]MB-1-06
DESCRIPTION
DRN
CKD
APRVD
REFORMER BED MEDIA HEATING REACTOR & CYCLONES
PROJ NO.:
30300.00
DWG NO.:
MB-1-06
DATE:
08/03/12
8/3/12 9:01 AM
APPENDIX F-2
DETAILED ESTIMATE
MASS BALANCE FLOW DIAGRAMS
BFB GASIFIER MODEL
Report 30300/01
BATTERY LIMITS
BATTERY LIMITS
AQ
AK
007
BED MEDIA FROM BATTERY LIMITS

TO GASIFIER REACTOR
0
0
3
0
0
0
0
349
353
1.00
80
438
453
-
BIOMASS STORAGE
005
NITROGEN GAS FROM BATTERY

LIMITS TO GASIFIER REACTOR
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
0
1
25
989
0
0
0
0
1,015
0.50
80
438
453
8
001
TO: MB-2-02
AW
BIOMASS FROM BIOMASS STORAGE

TO GASIFIER REACTOR
50,333
6,558
46,074
168
89
0
910
0
104,132
5.00
80
438
453
-
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
SYNGAS & ENTRAINED SOLIDS

GASIFIER CYCLONE
EQ # 103
DUCT-01
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
BU
50,333
8,889
86,126
1,197
89
0
1,219
525
149,577
15.08
1,600
438
453
4,652
012
BIOMASS, OXY, NIT, STM & BED

MEDIA IN BUBBLING FLUID BED
50,333
8,889
86,126
1,197
89
0
1,219
525
149,577
17.41
1,600
438
453
1,543
EQ # 101
GASIFIER
REACTOR
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
BC
LINE-01
BATTERY LIMITS
002
OXYGEN BLAST FROM BATTERY

LIMITS TO GASIFIER REACTOR
0
0
21,528
40
0
0
0
0
22,767
0.00
172
438
453
176
OXYGEN & STM HDR

AE
003
STEAM FROM BATTERY LIMITS TO

GASIFIER REACTOR
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
0
2,331
18,496
0
0
0
0
0
20,827
100.00
471
438
453
425
BO
0
2,331
40,024
40
0
0
0
0
43,593
47.78
315
438
453
569
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
011
CHAR, ASH & BED MEDIA FROM

BOTTOM OF GASIFIER REACTOR TO
ASH DISCHARGE SYSTEM
OXYGEN & STEAM FROM OXYGEN &

STM HDR TO GASIFIER REACTOR
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
EQ # 107
LINE-02
3,653
356
165
5
7
0
813
328
5,327
0.00
1,600
438
453
-
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
009

CYCLONE TO GASIFIER REACTOR
ASH DISCHARGE SYSTEM
004
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
3,653
356
165
5
7
0
1,121
504
5,811
0.00
1,595
437
452
-
GOLDEN, COLORADO
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
U:\30251.00\4200 Process\4215 Design Data\01 - HGI Files\Workbooks\BFB Gasifier Model\[2012-08-03 - BFB Gasifier
Model.xlsx]MB-2-01
DESCRIPTION
DRN
CKD
APRVD
GASIFIER REACTOR SYSTEM
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
REV.
####
FROM: MB-2-02
EQ # 105
BATTERY LIMITS
008
PROJ NO.:
30300.00
DWG NO.:
MB-2-01
DATE:
08/03/12
8/3/12 9:01 AM
BATTERY LIMITS
BI
FROM: MB-2-01
AW
DUCT-02

GASIFIER CYCLONE
####
50,333
8,889
86,126
1,197
89
0
1,219
525
149,577
15.08
1,600
438
453
4,652

FROM GASIFIER CYCLONE TO
BATTERY LIMITS
EQ # 106
008
EQ # 103
46,680
8,533
85,961
1,192
82
0
98
21
143,766
15.69
1,595
437
452
4,651
EQ # 104
DUCT-01
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
GASIFIER
CYCLONE
92.0%
ASH REMOVAL EFF
96.0%
BED MEDIA REMOVAL EFF
90.0%
CHAR REMOVAL EFF
010
LBS/HR - CARBON
LBS/HR - HYDROGEN
LBS/HR - OXYGEN
LBS/HR - NITROGEN
LBS/HR - SULFUR
LBS/HR - CHLORINE
LBS/HR - ASH
LBS/HR - BED MEDIA
LBS/HR - TOTAL
% MOISTURE
F
PSIG
PSIA
ACFM
TO: MB-2-01
BC
009
EQ # 105

CYCLONE TO GASIFIER REACTOR
LINE-01
3,653 LBS/HR - CARBON

356 LBS/HR - HYDROGEN
165 LBS/HR - OXYGEN
5 LBS/HR - NITROGEN
7 LBS/HR - SULFUR
0 LBS/HR - CHLORINE
1,121 LBS/HR - ASH
504
LBS/HR - BED MEDIA
0.00 % MOISTURE
1,595 F
437
PSIG
452
PSIA
-- ACFM

GOLDEN, COLORADO
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]MB-2-02
DESCRIPTION
DRN
CKD
APRVD
GASIFIER CYCLONE SYSTEM
PROJ NO.:
30300.00
DWG NO.:
MB-2-02
DATE:
08/03/12
8/3/12 9:01 AM
APPENDIX G-1
DETAILED ESTIMATE
DRAWINGS
CFB GASIFIER MODEL
Report 30300/01
DESIGN DATA
SECTION - 5
CONE TOP
HEIGHT
OD
SURFACE AREA
WEIGHT
OPEN VOLUME
5.9'
8.4' X 6.5'
140 SQFT
2,853 LBS
136 CUFT
SECTION-4
TOP CYLINDER
OPEN AREA DIA
76.00''
REFRACTORY
THICKNESS
12.00''
SECTION-4
GASIFIER VESSEL - CONSTRUCTION CODE
ASME BOILER & PRESSURE VESSEL CODE

SECTION VIII - DIVISION 1
PRESSURE VESSELS - CODE STAMPED
GASIFIER VESSEL - INTERNAL GAS PRESSURE - OPERATING
25.0 PSIG
GASIFIER VESSEL - INTERNAL GAS PRESSURE - DESIGN
40.0 PSIG
GASIFIER VESSEL - INTERNAL GAS TEMPERATURE - OPERATING
1,562.0 F
GASIFIER VESSEL - INTERNAL GAS TEMPERATURE - DESIGN
1,800.0 F
GASIFIER VESSEL - SHELL TEMPERATURE - DESIGN
300.0 F
CORROSION ALLOWANCE
0.125
REFRACTORY LINING
GUNNED INSULATING LAYER (4.7'') AND GUNNED ABRASION

LAYER (7.3'')
TOTAL SHELL SURFACE AREA
2,813 SQFT
TOTAL VESSEL WEIGHT (INCL. REFRACTORY, NOZZLES, LUGS, ETC.)
410,824 LBS
TOP CYLINDER
HEIGHT 75.0'
OD 8.4'
SURFACE AREA -1,976 SQFT
WEIGHT 40,304 LBS
OPEN VOLUME 2,363 CUFT
SHELL OD
101.00''
SHELL ID
100.00''
GASIFIER
REACTOR
SHELL
THICKNESS
1/2 "
MATERIALS OF CONSTRUCTION
SUPPORT LUGS (TYP. 4)
SECTION-3
SECTION-2
HARBISON-WALKER REFRACTORIES
STEAM DISTRIBUTOR INSERT
HGI ESTIMATE USING HIGH TEMPERATURE RESISTANT STEEL (E.G. HAYNES ALLOY 556
OR HASTELLOY)
STRUCTURAL STEEL - LUGS
ASME SA-36
NOZZLES
EXTENSION: 0''-24'' - ASME SA-106, GRADE B, SEAMLESS PIPE
BOTTOM CYLINDER
15.0'
6.1' X 8.4'
343 SQFT
6,991 LBS
320 CUFT
EXTENSION: 26''-96'' - ASME SA-516, GRADE 7, WELDED PIPE
OPEN AREA DIA

48.00''
NOZZLE SCHEDULE
REFRACTORY
THICKNESS
12.00''
DESCRIPTION
QTY
BOTTOM CYLINDER
15.0'
6.1'
287 SQFT
5,848 LBS
188 CUFT
SHELL ID
72.00''
SHELL OD
73.00''
PRESSURE
CLASS
PROTECTION
EXTENSION
LENGTH
NOZZLE
WEIGHT
150#
WATER COOLED
3''
243 LBS
150#
REFRACTORY LINED
2''
420 LBS
3''
62 LBS
REFRACTORY LINED
1''
4,284 LBS
MARK
SIZE
22''
INLET - SCREW FEEDER
30''
INLET - BED MEDIA
10''
INLET - STEAM
150#
78''
OUTLET - SYNGAS
150#
SECTION-2
HEIGHT
OD
SURFACE AREA
WEIGHT
OPEN VOLUME
ASME SA-516, GRADE 70 - CARBON STEEL
REFRACTORY LINING
FLANGE: ASME SA-387, GRADE 11 (REF-1)

HEIGHT
115.2'
SWEDGED TRANS
HEIGHT
OD
SURFACE AREA
WEIGHT
OPEN VOLUME
SHELL
44''
DRAIN / CLEANOUT
150#
REFRACTORY LINED
2''
1,019 LBS
1.5''
THERMOCOUPLE
150#
WATER COOLED
3''
5 LBS
1.5''
PRESSURE TRANSMITTER
150#
WATER COOLED
3''
5 LBS
SECTION-1
48''
MANWAY
150#
REFRACTORY LINED
2''
1,209 LBS
CONE BOTTOM
SHELL
THICKNESS
1/2 "
0.75''
INLET - COOLING WATER
20
150#
3''
2 LBS
0.75''
OUTLET - COOLING WATER
20
150#
3''
2 LBS
GOLDEN, COLORADO
EQUIPMENT DRAWING
DATE
DESCRIPTION
3,348 LBS
L
M
REV.
2,717 LBS
HEIGHT 4.3'
OD 3.7' X 6.1'
SURFACE AREA -68 SQFT
WEIGHT 1,383 LBS
OPEN VOLUME 35 CUFT
BLIND
FLANGE
WEIGHT
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-1-01
DESCRIPTION
DRN
CKD
APRVD
GASIFIER REACTOR
PROJ NO.:
30300.00
DWG NO.:
EQ-1-01
DATE:
08/03/12
8/3/12 9:47 AM
DESIGN DATA
SECTION - 3
CONE TOP
HEIGHT 7.3'
OD 10.4' X 6.5'
WEIGHT 4,093 LBS
OPEN VOLUME 243 CUFT
SECTION-2

15.0 PSIG
25.0 PSIG
1,650.0 F
1,900.0 F
300.0 F
CORROSION ALLOWANCE
0.125''
REFRACTORY LINING

LAYER (7.3'')
2,833 SQFT
379,343 LBS
SECTION-2
CYLINDER
CYLINDER
HEIGHT 75.0'
OD 10.4'
WEIGHT 50,069 LBS
OPEN AREA DIA

100.75''
CHAR
COMBUSTION
REACTOR
REFRACTORY
THICKNESS
12.00''
SHELL OD
125.00''
SHELL ID
124.75''
SHELL
THICKNESS
1/2 "
SHELL
REFRACTORY LINING
AIR DISTRIBUTOR INSERT
OR HASTELLOY)
ASME SA-36
NOZZLES
HEIGHT
89.6'
NOZZLE SCHEDULE
MARK
SIZE
DESCRIPTION
QTY
PRESSURE
CLASS
PROTECTION
EXTENSION
LENGTH
NOZZLE
WEIGHT
REFRACTORY LINED
2''
420 LBS
1''
3,168 LBS
1''
5,863 LBS
BLIND
FLANGE
WEIGHT
30''
INLET - CHAR & BED MEDIA
150#
72''
INLET - AIR
150#
94''
OUTLET - SYNGAS
150#
REFRACTORY LINED
44''
DRAIN / CLEANOUT
150#
REFRACTORY LINED
2''
1,019 LBS
1.5''
THERMOCOUPLE
150#
WATER COOLED
3''
5 LBS
1.5''
150#
WATER COOLED
3''
5 LBS
SECTION-1
48''
MANWAY
150#
REFRACTORY LINED
2''
1,209 LBS
CONE BOTTOM
AIR DISTRIBUTOR INSERT
0.75''
16
150#
3''
2 LBS
0.75''
16
150#
3''
2 LBS

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
3,348 LBS
HEIGHT 7.3'
OD 3.7' X 10.4'
WEIGHT 3,626 LBS
2,717 LBS
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-1-02
DESCRIPTION
DRN
CKD
APRVD
PROJ NO.:
30300.00
DWG NO.:
EQ-1-02
DATE:
08/03/12
8/3/12 9:47 AM
DESIGN DATA
SECTION - 3
CONE TOP
HEIGHT 14.7'
OD 21' X 6.5'
WEIGHT 14,444 LBS
SECTION-2

21.0 PSIG
35.0 PSIG
1,652.0 F
1,900.0 F
300.0 F
CORROSION ALLOWANCE
0.125''
REFRACTORY LINING

LAYER (7.3'')
4,388 SQFT
600,175 LBS
SECTION-2
CYLINDER
CYLINDER
HEIGHT 45.0'
OD 21.0'
WEIGHT 60,564 LBS
OPEN AREA DIA

227.69''
SYNGAS
REFORMER
REACTOR
REFRACTORY
THICKNESS
12.00''
SHELL ID
251.69''
SHELL OD
252.00''
SHELL
THICKNESS
1/2 "
SHELL
REFRACTORY LINING
OR HASTELLOY)
ASME SA-36
NOZZLES
HEIGHT
74.4'
NOZZLE SCHEDULE
MARK
SIZE
DESCRIPTION
QTY
PRESSURE
CLASS
PROTECTION
EXTENSION
LENGTH
NOZZLE
WEIGHT
80''
INLET - SYNGAS
150#
REFRACTORY LINED
1''
4,048 LBS
30''
INLET - BED MEDIA
150#
REFRACTORY LINED
2''
420 LBS
16''
INLET STEAM
150#
3''
155 LBS
100''
OUTLET - SYNGAS
150#
REFRACTORY LINED
1''
6,747 LBS
1.5''
THERMOCOUPLE
150#
WATER COOLED
3''
5 LBS
1.5''
150#
WATER COOLED
3''
5 LBS
SECTION-1
48''
MANWAY
150#
REFRACTORY LINED
2''
1,209 LBS
CONE BOTTOM
BLIND
FLANGE
WEIGHT
HEIGHT 14.7'
OD 6.7' X 21'
WEIGHT 14,499 LBS
0.75''
16
150#
3''
2 LBS
0.75''
16
150#
3''
2 LBS

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
3,348 LBS
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-1-03
DESCRIPTION
DRN
CKD
APRVD
PROJ NO.:
30300.00
DWG NO.:
EQ-1-03
DATE:
08/03/12
8/3/12 9:47 AM
DESIGN DATA
SECTION - 3
CONE TOP
HEIGHT 3.4'
OD 4.9' X 6.7'
WEIGHT 1,318 LBS
OPEN VOLUME 39 CUFT
SECTION-2

11.0 PSIG
20.0 PSIG
1,750.0 F
2,000.0 F
300.0 F
CORROSION ALLOWANCE
0.125''
REFRACTORY LINING

LAYER (7.3'')
2,043 SQFT
269,725 LBS
SECTION-2
CYLINDER
CYLINDER
HEIGHT 125.0'
OD 4.9'
WEIGHT 39,388 LBS
OPEN AREA DIA

34.90''
REFORMER
BED MEDIA
HEATING
REACTOR
REFRACTORY
THICKNESS
12.00''
SHELL ID
58.90''
SHELL OD
59.00''
SHELL
THICKNESS
1/2 "
SHELL
REFRACTORY LINING
NATURAL GAS / AIR BURNER INSERT
OR HASTELLOY)
ASME SA-36
NOZZLES
HEIGHT
131.9'
NOZZLE SCHEDULE
MARK
SIZE
DESCRIPTION
QTY
PRESSURE
CLASS
PROTECTION
EXTENSION
LENGTH
NOZZLE
WEIGHT
REFRACTORY LINED
2''
420 LBS
2''
918 LBS
2''
1,436 LBS
BLIND
FLANGE
WEIGHT
A
B
30''
INLET - BED MEDIA
150#
42''
INLET - AIR
150#
52''
OUTLET - SYNGAS
150#
REFRACTORY LINED
44''
DRAIN / CLEANOUT
150#
REFRACTORY LINED
2''
1,019 LBS
1.5''
THERMOCOUPLE
150#
WATER COOLED
3''
5 LBS
1.5''
150#
WATER COOLED
3''
5 LBS
SECTION-1
48''
MANWAY
150#
REFRACTORY LINED
2''
1,209 LBS
CONE BOTTOM
NATURAL GAS / AIR BURNER INSERT
0.75''
16
150#
3''
2 LBS
0.75''
16
150#
3''
2 LBS

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
3,348 LBS
HEIGHT 3.4'
OD 3.7' X 4.9'
WEIGHT 962 LBS
OPEN VOLUME 19 CUFT
2,717 LBS
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-1-04
DESCRIPTION
DRN
CKD
APRVD
PROJ NO.:
30300.00
DWG NO.:
EQ-1-04
DATE:
08/03/12
8/3/12 9:47 AM
DESIGN DATA
VESSEL - CONSTRUCTION CODE
GAS OUTLET INSERT

COLLAR

OD = 7.0
2.8'
SHELL ID
13.0'
7.6'
23.0'
5.6'
INLET
NOZZLE
OD
5.0'
9.0'
VESSEL - INTERNAL GAS PRESSURE - DESIGN
40.0 PSIG
INTERNAL GAS TEMPERATURE - OPERATING
1,547.0 F
INTERNAL GAS TEMPERATURE - DESIGN
1,800.0 F
VESSEL - SHELL TEMPERATURE - DESIGN
300.0 F
CORROSION ALLOWANCE
0.125''
REFRACTORY LINING
12.0''
1,241 SQFT
CYCLONE - TOTAL WEIGHT (READY TO SHIP)
486,741 LBS
BARREL
BARREL
SHELL OD
13.1'
OPEN SPACE ID
11.0'
REFRACTORY
THICKNESS
12.00''
SHELL
THICKNESS
3/8 "
ID
11.0'
SHELL
THICKNESS
3/8 "
OD
13.1'
45.0'
24.0 PSIG
GAS
OUTLET
INSERT
4.8'
VESSEL - INTERNAL GAS PRESSURE - OPERATING
REFRACTORY
THICKNESS
12.00''
SHELL
REFRACTORY LINING
ASME SA-36
NOZZLES

SECTION VIEW
CONE
NOZZLE SCHEDULE
22.0'
BLIND
FLANGE
WEIGHT
QTY
PRESSURE
CLASS
PROTECTION
EXTENSION
LENGTH
NOZZLE
WEIGHT
OUTLET - SYNGAS
150#
REFRACTORY LINED
1''
4,284 LBS
58''
OUTLET - BED MEDIA
150#
REFRACTORY LINED
2''
1,944 LBS
5,675 LBS
48''
MANWAY
150#
REFRACTORY LINED
2''
1,209 LBS
3,348 LBS
1.5''
THERMOCOUPLE
150#
WATER COOLED
3''
5 LBS
1.5''
150#
WATER COOLED
3''
5 LBS
0.75''
INTLET - COOLING WATER
150#
3''
2 LBS
0.75''
150#
3''
2 LBS
MARK
SIZE
78''
DESCRIPTION
G
2.8'
H
J
4.8'
K
L
ELEVATION VIEW

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-1-05
DESCRIPTION
DRN
CKD
APRVD
PROJ NO.:
30300.00
DWG NO.:
EQ-1-05
DATE:
08/03/12
8/3/12 9:47 AM
DESIGN DATA
GAS OUTLET INSERT

COLLAR

OD = 7.0
2.8'
SHELL ID
13.0'
7.6'
23.0'
5.6'
INLET
NOZZLE
OD
5.0'
9.0'
40.0 PSIG
1,537.0 F
1,800.0 F
240.0 F
CORROSION ALLOWANCE
0.125''
REFRACTORY LINING
12.0''
1,241 SQFT
479,285 LBS
BARREL
BARREL
SHELL OD
13.1'
OPEN SPACE ID
11.0'
REFRACTORY
THICKNESS
12.00''
SHELL
THICKNESS
3/8 "
ID
11.0'
SHELL
THICKNESS
3/8 "
OD
13.1'
45.0'
23.0 PSIG
GAS
OUTLET
INSERT
4.8'
REFRACTORY
THICKNESS
12.00''
SHELL
REFRACTORY LINING
ASME SA-36
NOZZLES

SECTION VIEW
CONE
NOZZLE SCHEDULE
22.0'
BLIND
FLANGE
WEIGHT
QTY
PRESSURE
CLASS
PROTECTION
EXTENSION
LENGTH
NOZZLE
WEIGHT
OUTLET - SYNGAS
150#
REFRACTORY LINED
1''
4,048 LBS
58''
OUTLET - DRAIN / CLEANOUT
150#
REFRACTORY LINED
2''
1,944 LBS
5,675 LBS
48''
MANWAY
150#
REFRACTORY LINED
2''
1,209 LBS
3,348 LBS
1.5''
THERMOCOUPLE
150#
WATER COOLED
3''
5 LBS
1.5''
150#
WATER COOLED
3''
5 LBS
0.75''
150#
3''
2 LBS
0.75''
150#
3''
2 LBS
MARK
SIZE
80''
DESCRIPTION
G
2.8'
H
J
4.8'
K
L
ELEVATION VIEW

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-1-06
DESCRIPTION
DRN
CKD
APRVD
PROJ NO.:
30300.00
DWG NO.:
EQ-1-06
DATE:
08/03/12
8/3/12 9:47 AM
DESIGN DATA
GAS OUTLET INSERT

COLLAR

OD = 8.3
3.6'
SHELL ID
16.0'
9.3'
29.0'
7.2'
INLET
NOZZLE
OD
6.3'
11.0'
25.0 PSIG
1,635.0 F
1,900.0 F
240.0 F
CORROSION ALLOWANCE
0.125''
REFRACTORY LINING
12.0''
1,955 SQFT
758,731 LBS
BARREL
BARREL
SHELL OD
16.1'
OPEN SPACE ID
14.0'
REFRACTORY
THICKNESS
12.00''
SHELL
THICKNESS
3/8 "
ID
14.0'
SHELL
THICKNESS
3/8 "
OD
16.1'
57.0'
14.0 PSIG
GAS
OUTLET
INSERT
5.7'
REFRACTORY
THICKNESS
12.00''
SHELL
REFRACTORY LINING
ASME SA-36
NOZZLES

SECTION VIEW
CONE
NOZZLE SCHEDULE
28.0'
BLIND
FLANGE
WEIGHT
QTY
PRESSURE
CLASS
PROTECTION
EXTENSION
LENGTH
NOZZLE
WEIGHT
OUTLET - SYNGAS
150#
REFRACTORY LINED
1''
5,582 LBS
68''
150#
REFRACTORY LINED
1''
2,771 LBS
8,483 LBS
48''
MANWAY
150#
REFRACTORY LINED
2''
1,209 LBS
3,348 LBS
1.5''
THERMOCOUPLE
150#
WATER COOLED
3''
5 LBS
1.5''
150#
WATER COOLED
3''
5 LBS
0.75''
150#
3''
2 LBS
0.75''
150#
3''
2 LBS
MARK
SIZE
92''
DESCRIPTION
G
3.6'
H
J
5.7'
K
L
ELEVATION VIEW

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-1-07
DESCRIPTION
DRN
CKD
APRVD
CHAR COMBUSTION REACTOR NO.1 CYCLONE
PROJ NO.:
30300.00
DWG NO.:
EQ-1-07
DATE:
08/03/12
8/3/12 9:47 AM
DESIGN DATA
GAS OUTLET INSERT

COLLAR

OD = 8.3
3.5'
SHELL ID
16.0'
9.1'
29.0'
7.0'
INLET
NOZZLE
OD
0.0'
10.8'
25.0 PSIG
1,625.0 F
1,900.0 F
240.0 F
CORROSION ALLOWANCE
0.125''
REFRACTORY LINING
12.0''
1,942 SQFT
752,354 LBS
BARREL
BARREL
SHELL OD
16.1'
OPEN SPACE ID
14.0'
REFRACTORY
THICKNESS
12.00''
SHELL
THICKNESS
3/8 "
ID
14.0'
SHELL
THICKNESS
3/8 "
OD
16.1'
57.0'
13.0 PSIG
GAS
OUTLET
INSERT
5.6'
REFRACTORY
THICKNESS
12.00''
SHELL
REFRACTORY LINING
ASME SA-36
NOZZLES

SECTION VIEW
CONE
NOZZLE SCHEDULE
28.0'
BLIND
FLANGE
WEIGHT
QTY
PRESSURE
CLASS
PROTECTION
EXTENSION
LENGTH
NOZZLE
WEIGHT
OUTLET - SYNGAS
150#
REFRACTORY LINED
1''
5,863 LBS
68''
150#
REFRACTORY LINED
1''
2,771 LBS
8,483 LBS
48''
MANWAY
150#
REFRACTORY LINED
2''
1,209 LBS
3,348 LBS
1.5''
THERMOCOUPLE
150#
WATER COOLED
3''
5 LBS
1.5''
150#
WATER COOLED
3''
5 LBS
0.75''
150#
3''
2 LBS
0.75''
150#
3''
2 LBS
MARK
SIZE
94''
DESCRIPTION
G
3.6'
H
J
5.7'
K
L
ELEVATION VIEW

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-1-08
DESCRIPTION
DRN
CKD
APRVD
CHAR COMBUSTION REACTOR NO.2 CYCLONE
PROJ NO.:
30300.00
DWG NO.:
EQ-1-08
DATE:
08/03/12
8/3/12 9:47 AM
12.0''
DESIGN DATA
INSERT

GAS OUTLET INSERT
COLLAR

OD = 9.2
3.9'
SHELL ID
18.0'
9.9'
33.0'
7.9'
INLET
NOZZLE
OD
0.0'
11.9'
30.0 PSIG
1,637.0 F
1,900.0 F
240.0 F
CORROSION ALLOWANCE
0.125''
REFRACTORY LINING
12.0''
2,494 SQFT
966,290 LBS
BARREL
BARREL
SHELL OD
18.1'
OPEN SPACE ID
16.0'
REFRACTORY
THICKNESS
12.00''
SHELL
THICKNESS
3/8 "
ID
16.0'
SHELL
THICKNESS
3/8 "
OD
18.1'
65.0'
20.0 PSIG
GAS
OUTLET
INSERT
6.0'
REFRACTORY
THICKNESS
12.00''
SHELL
REFRACTORY LINING
ASME SA-36
NOZZLES

SECTION VIEW
CONE
NOZZLE SCHEDULE
32.0'
BLIND
FLANGE
WEIGHT
QTY
PRESSURE
CLASS
PROTECTION
EXTENSION
LENGTH
NOZZLE
WEIGHT
OUTLET - SYNGAS
150#
REFRACTORY LINED
1''
6,747 LBS
74''
150#
REFRACTORY LINED
1''
3,377 LBS
10,513 LBS
48''
MANWAY
150#
REFRACTORY LINED
2''
1,209 LBS
3,348 LBS
1.5''
THERMOCOUPLE
150#
WATER COOLED
3''
5 LBS
1.5''
150#
WATER COOLED
3''
5 LBS
0.75''
150#
3''
2 LBS
0.75''
150#
3''
2 LBS
MARK
SIZE
100''
DESCRIPTION
G
4.1'
H
J
6.2'
K
L
ELEVATION VIEW

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-1-09
DESCRIPTION
DRN
CKD
APRVD
SYNGAS REFORMER REACTOR NO.1 CYCLONE
PROJ NO.:
30300.00
DWG NO.:
EQ-1-09
DATE:
08/03/12
8/3/12 9:47 AM
DESIGN DATA
INSERT

GAS OUTLET INSERT
COLLAR

OD = 9.2
3.9'
SHELL ID
18.0'
9.9'
33.0'
7.9'
INLET
NOZZLE
OD
0.0'
11.9'
30.0 PSIG
1,627.0 F
1,900.0 F
240.0 F
CORROSION ALLOWANCE
0.125''
REFRACTORY LINING
12.0''
2,494 SQFT
966,290 LBS
BARREL
BARREL
SHELL OD
18.1'
OPEN SPACE ID
16.0'
REFRACTORY
THICKNESS
12.00''
SHELL
THICKNESS
3/8 "
ID
16.0'
SHELL
THICKNESS
3/8 "
OD
18.1'
65.0'
19.0 PSIG
GAS
OUTLET
INSERT
6.0'
REFRACTORY
THICKNESS
12.00''
SHELL
REFRACTORY LINING
ASME SA-36
NOZZLES

SECTION VIEW
CONE
NOZZLE SCHEDULE
32.0'
BLIND
FLANGE
WEIGHT
QTY
PRESSURE
CLASS
PROTECTION
EXTENSION
LENGTH
NOZZLE
WEIGHT
OUTLET - SYNGAS
150#
REFRACTORY LINED
1''
6,747 LBS
74''
150#
REFRACTORY LINED
1''
3,377 LBS
10,513 LBS
48''
MANWAY
150#
REFRACTORY LINED
2''
1,209 LBS
3,348 LBS
1.5''
THERMOCOUPLE
150#
WATER COOLED
3''
5 LBS
1.5''
150#
WATER COOLED
3''
5 LBS
0.75''
150#
3''
2 LBS
0.75''
150#
3''
2 LBS
MARK
SIZE
100''
DESCRIPTION
G
4.1'
H
J
6.2'
K
L
ELEVATION VIEW

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-1-10
DESCRIPTION
DRN
CKD
APRVD
SYNGAS REFORMER REACTOR NO.2 CYCLONE
PROJ NO.:
30300.00
DWG NO.:
EQ-1-10
DATE:
08/03/12
8/3/12 9:47 AM
12.0''
DESIGN DATA
INSERT

GAS OUTLET INSERT
COLLAR

OD = 4.8
1.4'
SHELL ID
8.0'
4.9'
13.0'
2.8'
INLET
NOZZLE
OD
0.0'
5.6'
15.0 PSIG
1,735.0 F
2,000.0 F
240.0 F
CORROSION ALLOWANCE
0.125''
REFRACTORY LINING
12.0''
427 SQFT
174,580 LBS
BARREL
BARREL
SHELL OD
8.1'
OPEN SPACE ID
6.0'
REFRACTORY
THICKNESS
12.00''
SHELL
THICKNESS
3/8 "
ID
6.0'
SHELL
THICKNESS
3/8 "
OD
8.1'
25.0'
10.0 PSIG
GAS
OUTLET
INSERT
3.5'
REFRACTORY
THICKNESS
12.00''
SHELL
REFRACTORY LINING
ASME SA-36
NOZZLES

SECTION VIEW
CONE
NOZZLE SCHEDULE
12.0'
BLIND
FLANGE
WEIGHT
QTY
PRESSURE
CLASS
PROTECTION
EXTENSION
LENGTH
NOZZLE
WEIGHT
OUTLET - SYNGAS
150#
REFRACTORY LINED
2''
1,436 LBS
44''
150#
REFRACTORY LINED
2''
1,019 LBS
2,717 LBS
48''
MANWAY
150#
REFRACTORY LINED
2''
1,209 LBS
3,348 LBS
1.5''
THERMOCOUPLE
150#
WATER COOLED
3''
5 LBS
1.5''
150#
WATER COOLED
3''
5 LBS
0.75''
150#
3''
2 LBS
0.75''
150#
3''
2 LBS
MARK
SIZE
52''
DESCRIPTION
G
1.6'
H
J
3.7'
K
L
ELEVATION VIEW

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-1-11
DESCRIPTION
DRN
CKD
APRVD
REFORMER BED MEDIA HEATING REACTOR NO.1 CYCLONE
PROJ NO.:
30300.00
DWG NO.:
EQ-1-11
DATE:
08/03/12
8/3/12 9:47 AM
DESIGN DATA
INSERT

GAS OUTLET INSERT
COLLAR

OD = 4.8
1.4'
SHELL ID
8.0'
4.9'
13.0'
2.8'
INLET
NOZZLE
OD
0.0'
5.6'
15.0 PSIG
1,725.0 F
2,000.0 F
240.0 F
CORROSION ALLOWANCE
0.125''
REFRACTORY LINING
12.0''
427 SQFT
174,580 LBS
BARREL
BARREL
SHELL OD
8.1'
OPEN SPACE ID
6.0'
REFRACTORY
THICKNESS
12.00''
SHELL
THICKNESS
3/8 "
ID
6.0'
SHELL
THICKNESS
3/8 "
OD
8.1'
25.0'
9.0 PSIG
GAS
OUTLET
INSERT
3.5'
REFRACTORY
THICKNESS
12.00''
SHELL
REFRACTORY LINING
ASME SA-36
NOZZLES

SECTION VIEW
CONE
NOZZLE SCHEDULE
12.0'
BLIND
FLANGE
WEIGHT
QTY
PRESSURE
CLASS
PROTECTION
EXTENSION
LENGTH
NOZZLE
WEIGHT
OUTLET - SYNGAS
150#
REFRACTORY LINED
2''
1,436 LBS
44''
150#
REFRACTORY LINED
2''
1,019 LBS
2,717 LBS
48''
MANWAY
150#
REFRACTORY LINED
2''
1,209 LBS
3,348 LBS
1.5''
THERMOCOUPLE
150#
WATER COOLED
3''
5 LBS
1.5''
150#
WATER COOLED
3''
5 LBS
0.75''
150#
3''
2 LBS
0.75''
150#
3''
2 LBS
MARK
SIZE
52''
DESCRIPTION
G
1.6'
H
J
3.7'
K
L
ELEVATION VIEW

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-1-12
DESCRIPTION
DRN
CKD
APRVD
REFORMER BED MEDIA HEATING REACTOR NO.2 CYCLONE
PROJ NO.:
30300.00
DWG NO.:
EQ-1-12
DATE:
08/03/12
8/3/12 9:47 AM
DESIGN DATA
SECTION - 3
TOP SECTION
HEIGHT 2.5'
OD 10' X 5.7'
SURFACE AREA - 81 SQFT
WEIGHT 1,661 LBS
OPEN VOLUME 99 CUFT

15.0 PSIG
22.5 PSIG
1,546.8 F
1,800.0 F
300.0 F
CORROSION ALLOWANCE
0.125''
REFRACTORY LINING

LAYER (7.3'')
1,105 SQFT
81,940 LBS
SECTION - 2
CENTRAL SECTION
OPEN AREA DIA
109.65''
GASIFIER
REACTOR
CYCLONES
SOLIDS
COLLECTION BIN
REFRACTORY
THICKNESS
12.00''
SHELL OD
120.00''
SHELL ID
119.00''
SECTION - 2
CENTRAL SECTION
HEIGHT
OD
SURFACE AREA
WEIGHT
OPEN VOLUME
HEIGHT
35.0'
30.0'
10.0'
942 SQFT
19,227 LBS
1,967 CUFT
SHELL
REFRACTORY LINING
OR HASTELLOY)
ASME SA-36
SHELL
THICKNESS
1/2 "
NOZZLES

SECTION - 1
BOTTOM SECTION
HEIGHT
OD
SURFACE AREA
WEIGHT
OPEN VOLUME
NOZZLE SCHEDULE
2.5'
10' X 5.7'
81 SQFT
1,661 LBS
99 CUFT
MARK
SIZE
DESCRIPTION
QTY
PRESSURE
CLASS
PROTECTION
EXTENSION
LENGTH
NOZZLE
WEIGHT
BLIND
FLANGE
WEIGHT
42''
INLET - BED MEDIA
150#
REFRACTORY LINED
2''
918 LBS
36''
INLET - BED MEDIA
150#
REFRACTORY LINED
2''
664 LBS
68''
TANK TOP
150#
REFRACTORY LINED
1''
2,771 LBS
8,483 LBS
68''
BOTTOM CLEANOUT
150#
REFRACTORY LINED
1''
2,771 LBS
8,483 LBS
3,716 LBS
50''
MANWAY
150#
REFRACTORY LINED
2''
1,295 LBS
36''
OUTLET - BED MEDIA
150#
REFRACTORY LINED
2''
664 LBS
G
H
J
K
L
M
N

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-1-13
DESCRIPTION
DRN
CKD
APRVD
GASIFIER REACTOR CYCLONES SOLIDS COLLECTION BIN
PROJ NO.:
30300.00
DWG NO.:
EQ-1-13
DATE:
08/03/12
8/3/12 9:47 AM
DESIGN DATA
SECTION - 3
TOP SECTION
HEIGHT 2.5'
OD 10' X 5.7'
WEIGHT 1,661 LBS
OPEN VOLUME 99 CUFT

11.0 PSIG
16.5 PSIG
1,627.0 F
1,900.0 F
300.0 F
CORROSION ALLOWANCE
0.125''
REFRACTORY LINING

LAYER (7.3'')
1,105 SQFT
82,129 LBS
SECTION - 2
CENTRAL SECTION
OPEN AREA DIA
109.65''
SECTION - 2
SYNGAS
REFORMER
REACTOR
CYCLONES
SOLIDS
COLLECTION BIN
REFRACTORY
THICKNESS
12.00''
HEIGHT
35.0'
SHELL OD
120.00''
SHELL ID
119.00''
CENTRAL SECTION
HEIGHT 30.0'
OD 10.0'
WEIGHT 19,227 LBS
SHELL
REFRACTORY LINING
OR HASTELLOY)
ASME SA-36
SHELL
THICKNESS
1/2 "
NOZZLES

SECTION - 1
BOTTOM SECTION
NOZZLE SCHEDULE
HEIGHT 2.5'
OD 10' X 5.7'
WEIGHT 1,661 LBS
OPEN VOLUME 99 CUFT
BLIND
FLANGE
WEIGHT
QTY
PRESSURE
CLASS
PROTECTION
EXTENSION
LENGTH
NOZZLE
WEIGHT
INLET - BED MEDIA
150#
REFRACTORY LINED
2''
1,209 LBS
INLET - BED MEDIA
150#
REFRACTORY LINED
2''
562 LBS
68''
TANK TOP
150#
REFRACTORY LINED
1''
2,771 LBS
8,483 LBS
68''
BOTTOM CLEANOUT
150#
REFRACTORY LINED
1''
2,771 LBS
8,483 LBS
50''
MANWAY
150#
REFRACTORY LINED
2''
1,295 LBS
3,716 LBS
36''
OUTLET - BED MEDIA
150#
REFRACTORY LINED
2''
664 LBS
MARK
SIZE
48''
34''
DESCRIPTION
G
H
J
K
L
M
N

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-1-14
DESCRIPTION
DRN
CKD
APRVD
SYNGAS REFORMER REACTOR CYCLONES SOLIDS COLLECTION BIN
PROJ NO.:
30300.00
DWG NO.:
EQ-1-14
DATE:
08/03/12
8/3/12 9:47 AM
DESIGN DATA
SECTION - 3
TOP SECTION
HEIGHT
OD
SURFACE AREA
WEIGHT
OPEN VOLUME
2.5'
10' X 3.3'
87 SQFT
1,780 LBS
93 CUFT

0.0 PSIG
0.0 PSIG
80.0 F
100.0 F
100.0 F
CORROSION ALLOWANCE
0.125''
REFRACTORY LINING

LAYER (0.0'')
834 SQFT
22,046 LBS
A
C
SECTION - 2
CENTRAL SECTION
OPEN AREA DIA
119.00''
REFRACTORY
THICKNESS
0.00''
GASIFIER LOOP
BED MEDIA FEED
BIN
ASME SA-36
SHELL OD
120.00''
SHELL ID
119.00''
SECTION - 2
SHELL
CENTRAL SECTION
HEIGHT 20.0'
OD 10.0'
WEIGHT 12,818 LBS
HEIGHT
27.5'
SHELL
THICKNESS
1/2 "
NOZZLES

SECTION - 1
BOTTOM SECTION
NOZZLE SCHEDULE
HEIGHT 5.0'
OD 10' X 1.5'
WEIGHT 2,418 LBS
NOZZLE
WEIGHT
150#
3''
62 LBS
150#
3''
62 LBS
150#
2''
801 LBS
2,040 LBS
OUTLET - BED MEDIA
150#
3''
180 LBS
220 LBS
MANWAY
150#
2''
664 LBS
PRESSURE
CLASS
INLET - BED MEDIA
VENT
40''
TANK TOP
18''
36''
SIZE
10''
10''
BLIND
FLANGE
WEIGHT
EXTENSION
LENGTH
QTY
MARK
DESCRIPTION
PROTECTION
F
G
H
J
K
L
M
N

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-1-15
DESCRIPTION
DRN
CKD
APRVD
GASIFIER LOOP BED MEDIA FEED BIN
PROJ NO.:
30300.00
DWG NO.:
EQ-1-15
DATE:
08/03/12
8/3/12 9:47 AM
DESIGN DATA
SECTION - 3
TOP SECTION
HEIGHT
OD
SURFACE AREA
WEIGHT
OPEN VOLUME
2.5'
10' X 3.3'
87 SQFT
1,780 LBS
93 CUFT

0.0 PSIG
0.0 PSIG
80.0 F
100.0 F
100.0 F
CORROSION ALLOWANCE
0.125''
REFRACTORY LINING

LAYER (0.0'')
834 SQFT
22,046 LBS
SECTION - 2
CENTRAL SECTION
OPEN AREA DIA
119.00''
REFRACTORY
THICKNESS
0.00''
REFORMER LOOP
BED MEDIA FEED
BIN
SHELL ID
119.00''
SECTION - 2
SHELL
ASME SA-36
SHELL OD
120.00''
CENTRAL SECTION
HEIGHT 20.0'
OD 10.0'
WEIGHT 12,818 LBS
HEIGHT
35.0'
SHELL
THICKNESS
1/2 "
NOZZLES
EXTENSION: 0''-24'' - 0.546, SEAMLESS PIPE

EXTENSION: 26''-96'' - 25.25, WELDED PIPE
SECTION - 1
BOTTOM SECTION
NOZZLE SCHEDULE
HEIGHT 5.0'
OD 10' X 1.5'
WEIGHT 2,418 LBS
PRESSURE
CLASS
INLET - BED MEDIA
150#
3''
62 LBS
VENT
150#
3''
62 LBS
40''
TANK TOP
150#
2''
801 LBS
2,040 LBS
18''
MANWAY
150#
3''
180 LBS
220 LBS
36''
MANWAY
150#
2''
664 LBS
SIZE
10''
10''
DESCRIPTION
PROTECTION
EXTENSION
LENGTH
NOZZLE
WEIGHT
BLIND
FLANGE
WEIGHT
QTY
MARK
F
G
H
J
K
L
M
N

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-1-16
DESCRIPTION
DRN
CKD
APRVD
REFORMER LOOP BED MEDIA FEED BIN
PROJ NO.:
30300.00
DWG NO.:
EQ-1-16
DATE:
08/03/12
8/3/12 9:47 AM
DESIGN DATA
SECTION - 3
TOP SECTION
HEIGHT
OD
SURFACE AREA
WEIGHT
OPEN VOLUME
2.5'
10' X 5.7'
81 SQFT
1,661 LBS
99 CUFT

25.0 PSIG
37.5 PSIG
1,635.0 F
1,900.0 F
300.0 F
CORROSION ALLOWANCE
0.125''
REFRACTORY LINING

LAYER (7.3'')
1,105 SQFT
81,022 LBS
SECTION - 2
CENTRAL SECTION
OPEN AREA DIA
109.65''
CHAR
COMBUSTION
REACTOR NO.1
CYCLONE SOLIDS
COLLECTION BIN
REFRACTORY
THICKNESS
12.00''
HEIGHT
35.0'
SHELL OD
120.00''
SHELL ID
119.00''
SECTION - 2
CENTRAL SECTION
HEIGHT 30.0'
OD 10.0'
WEIGHT 19,227 LBS
SHELL
REFRACTORY LINING
OR HASTELLOY)
ASME SA-36
SHELL
THICKNESS
1/2 "
NOZZLES

SECTION - 1
BOTTOM SECTION
NOZZLE SCHEDULE
HEIGHT 2.5'
OD 10' X 5.7'
WEIGHT 1,661 LBS
OPEN VOLUME 99 CUFT
BLIND
FLANGE
WEIGHT
QTY
PRESSURE
CLASS
PROTECTION
EXTENSION
LENGTH
NOZZLE
WEIGHT
INLET - BED MEDIA
150#
REFRACTORY LINED
2''
664 LBS
68''
TANK TOP
150#
REFRACTORY LINED
1''
2,771 LBS
8,483 LBS
68''
BOTTOM CLEANOUT
150#
REFRACTORY LINED
1''
2,771 LBS
8,483 LBS
50''
MANWAY
150#
REFRACTORY LINED
2''
1,295 LBS
3,716 LBS
36''
OUTLET - BED MEDIA
150#
REFRACTORY LINED
2''
664 LBS
MARK
SIZE
36''
DESCRIPTION
B
G
H
J
K
L
M
N

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-1-17
DESCRIPTION
DRN
CKD
APRVD
CHAR COMBUSTION REACTOR NO.1 CYCLONE SOLIDS COLLECTION BIN
PROJ NO.:
30300.00
DWG NO.:
EQ-1-17
DATE:
08/03/12
8/3/12 9:47 AM
DESIGN DATA
SECTION - 3
TOP SECTION
HEIGHT
OD
SURFACE AREA
WEIGHT
OPEN VOLUME
2.5'
10' X 5.7'
81 SQFT
1,661 LBS
99 CUFT

21.0 PSIG
31.5 PSIG
1,735.0 F
2,000.0 F
300.0 F
CORROSION ALLOWANCE
0.125''
REFRACTORY LINING

LAYER (7.3'')
1,105 SQFT
81,276 LBS
SECTION - 2
CENTRAL SECTION
OPEN AREA DIA
109.65''
REFORMER BED
MEDIA HEATING
REACTOR NO.1
CYCLONE SOLIDS
COLLECTION BIN
REFRACTORY
THICKNESS
12.00''
HEIGHT
35.0'
SHELL OD
120.00''
SHELL ID
119.00''
SECTION - 2
CENTRAL SECTION
HEIGHT 30.0'
OD 10.0'
WEIGHT 19,227 LBS
SHELL
REFRACTORY LINING
OR HASTELLOY)
ASME SA-36
SHELL
THICKNESS
1/2 "
NOZZLES

SECTION - 1
BOTTOM SECTION
NOZZLE SCHEDULE
HEIGHT 2.5'
OD 10' X 5.7'
WEIGHT 1,661 LBS
OPEN VOLUME 99 CUFT
BLIND
FLANGE
WEIGHT
QTY
PRESSURE
CLASS
PROTECTION
EXTENSION
LENGTH
NOZZLE
WEIGHT
INLET - BED MEDIA
150#
REFRACTORY LINED
2''
918 LBS
68''
TANK TOP
150#
REFRACTORY LINED
1''
2,771 LBS
8,483 LBS
68''
BOTTOM CLEANOUT
150#
REFRACTORY LINED
1''
2,771 LBS
8,483 LBS
50''
MANWAY
150#
REFRACTORY LINED
2''
1,295 LBS
3,716 LBS
36''
OUTLET - BED MEDIA
150#
REFRACTORY LINED
2''
664 LBS
MARK
SIZE
42''
DESCRIPTION
B
G
H
J
K
L
M
N

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-1-18
DESCRIPTION
DRN
CKD
APRVD
REFORMER BED MEDIA HEATING REACTOR NO.1 CYCLONE SOLIDS COLLECTION BIN
PROJ NO.:
30300.00
DWG NO.:
EQ-1-18
DATE:
08/03/12
8/3/12 9:47 AM
DESIGN DATA
SECTION - 3
TOP SECTION
HEIGHT
OD
SURFACE AREA
WEIGHT
OPEN VOLUME
2.5'
10' X 3.3'
87 SQFT
1,780 LBS
93 CUFT

0.0 PSIG
0.0 PSIG
190.0 F
200.0 F
200.0 F
CORROSION ALLOWANCE
0.125''
REFRACTORY LINING

LAYER (0.0'')
834 SQFT
22,046 LBS
SECTION - 2
CENTRAL SECTION
OPEN AREA DIA
119.00''
GASIFIER LOOP
DEPLETED BED
MEDIA & ASH
STORAGE BIN
REFRACTORY
THICKNESS
0.00''
SHELL ID
119.00''
SECTION - 2
SHELL
ASME SA-36
SHELL OD
120.00''
CENTRAL SECTION
HEIGHT 20.0'
OD 10.0'
WEIGHT 12,818 LBS
HEIGHT
27.5'
SHELL
THICKNESS
1/2 "
NOZZLES
EXTENSION: 0''-24'' - 1.09, SEAMLESS PIPE

SECTION - 1
BOTTOM SECTION
NOZZLE SCHEDULE
HEIGHT 5.0'
OD 10' X 1.5'
WEIGHT 2,418 LBS
PRESSURE
CLASS
INLET - BED MEDIA
150#
3''
62 LBS
VENT
150#
3''
62 LBS
40''
TANK TOP
150#
2''
801 LBS
2,040 LBS
18''
OUTLET - BED MEDIA
150#
3''
180 LBS
220 LBS
36''
MANWAY
150#
2''
664 LBS
SIZE
10''
10''
DESCRIPTION
PROTECTION
EXTENSION
LENGTH
NOZZLE
WEIGHT
BLIND
FLANGE
WEIGHT
QTY
MARK
F
G
H
J
K
L
M
N

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-1-19
DESCRIPTION
DRN
CKD
APRVD
GASIFIER LOOP DEPLETED BED MEDIA & ASH STORAGE BIN
PROJ NO.:
30300.00
DWG NO.:
EQ-1-19
DATE:
08/03/12
8/3/12 9:47 AM
DESIGN DATA
SECTION - 3
TOP SECTION
HEIGHT
OD
SURFACE AREA
WEIGHT
OPEN VOLUME
2.5'
10' X 3.3'
87 SQFT
1,780 LBS
93 CUFT

0.0 PSIG
0.0 PSIG
190.0 F
200.0 F
200.0 F
CORROSION ALLOWANCE
0.125''
REFRACTORY LINING

LAYER (0.0'')
834 SQFT
22,046 LBS
SECTION - 2
CENTRAL SECTION
OPEN AREA DIA
119.00''
GASIFIER LOOP
DEPLETED BED
MEDIA & ASH
STORAGE BIN
REFRACTORY
THICKNESS
0.00''
SHELL ID
119.00''
SECTION - 2
SHELL
ASME SA-36
SHELL OD
120.00''
CENTRAL SECTION
HEIGHT 20.0'
OD 10.0'
WEIGHT 12,818 LBS
HEIGHT
27.5'
SHELL
THICKNESS
1/2 "
NOZZLES
EXTENSION: 0''-24'' - 3, SEAMLESS PIPE

SECTION - 1
BOTTOM SECTION
NOZZLE SCHEDULE
HEIGHT 5.0'
OD 10' X 1.5'
WEIGHT 2,418 LBS
PRESSURE
CLASS
INLET - BED MEDIA
150#
3''
62 LBS
VENT
150#
3''
62 LBS
40''
TANK TOP
150#
2''
801 LBS
2,040 LBS
18''
OUTLET - BED MEDIA
150#
3''
180 LBS
220 LBS
36''
MANWAY
150#
2''
664 LBS
SIZE
10''
10''
DESCRIPTION
PROTECTION
EXTENSION
LENGTH
NOZZLE
WEIGHT
BLIND
FLANGE
WEIGHT
QTY
MARK
F
G
H
J
K
L
M
N

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-1-20
DESCRIPTION
DRN
CKD
APRVD
REFORMER LOOP DEPLETED BED MEDIA STORAGE BIN
PROJ NO.:
30300.00
DWG NO.:
EQ-1-20
DATE:
08/03/12
8/3/12 9:47 AM
APPENDIX G-2
DETAILED ESTIMATE
DRAWINGS
BFB GASIFIER MODEL
Report 30300/01
DESIGN DATA
SECTION-5
TOP PLATE
HEIGHT
OD
SURFACE AREA
WEIGHT
OPEN VOLUME
0.1'
9.1
14 SQFT
800 LBS
-
N4
SECTION-4
UPPER CYLINDER
OPEN SPACE DIA
82.25''
REFRACTORY
THICKNESS
12.00''
SECTION-4
CONSTRUCTION CODE

PRESSURE - OPERATING
438.0 PSIG
PRESSURE - DESIGN
505.0 PSIG
TEMPERATURE - OPERATING
1,600.0 F
TEMPERATURE - DESIGN
1,800.0 F
MAXIMUM STEEL TEMPERATURE - DESIGN
300.0 F
STEEL SHELL CORROSION ALLOWANCE
0.125
TOTAL STEEL SHELL EXTERIOR SURFACE AREA
862 SQFT
TOTAL WEIGHT (READY TO SHIP)
227,776 LBS
UPPER CYLINDER
HEIGHT 14.3'
OD 9.1
WEIGHT 22,656 LBS
SHELL OD
109.00''
SHELL ID
106.25''
GASIFIER
REACTOR
SHELL
THICKNESS
1 3/8 "
HEIGHT
35.9'
SHELL
REFRACTORY - INSULATING LAYER - MATERIAL
GUNNED INSULATING LAYER (4.7'') - HARBISON-WALKER, KAST-O-LITE 20-45 G PLU

(IN 25 LB SACKS)
REFRACTORY - ABRASION LAYER - MATERIAL
GUNNED ABRASION LAYER (7.3'') - HARBISON-WALKER, WM-7214 GUN MIX

(IN 55 LB SACKS)
STEAM/OXYGEN DISTRIBUTOR INSERT
OR HASTELLOY)
SUPPORT - LUGS
ASME SA-36
SECTION-3
SECTION-2
TRANSITION CONE
HEIGHT
OD
SURFACE AREA
WEIGHT
OPEN VOLUME
EXTENSION: 0''-24'' NOZZLES - ASME SA-106, GRADE B, SEAMLESS PIPE

EXTENSION: 26''-96'' NOZZLES - ASME SA-516, GRADE 7, WELDED PIPE
LOWER CYLINDER
6.4'
6.3' X 9.1'
158 SQFT
8,706 LBS
153 CUFT
OPEN AREA DIA

49.25''
NOZZLE SCHEDULE
REFRACTORY
THICKNESS
12.00''
N1
LOWER CYLINDER
10.0'
6.3
199 SQFT
10,960 LBS
132 CUFT
N2
SHELL OD
76.00''
SHELL ID
73.25''
N9
SHELL
THICKNESS
1 3/8 "
PROTECTION
EXTENSION
LENGTH
NOZZLE
WEIGHT
900#
WATER COOLED
3''
2,133 LBS
900#
REFRACTORY LINED
2''
2,146 LBS
3''
386 LBS
REFRACTORY LINED
2''
3,655 LBS
900#
REFRACTORY LINED
2''
4,339 LBS
900#
WATER COOLED
3''
15 LBS
900#
WATER COOLED
3''
15 LBS
QTY
PRESSURE
CLASS
INLET - SCREW FEEDER
INLET - RECYCLED BED MEDIA
INLET - STEAM
900#
40''
OUTLET - SYNGAS
900#
N5
44''
OUTLET - ASH
N6
1.5''
THERMOCOUPLE
N7
1.5''
MARK
SIZE
N1
24''
N2
30''
N3
12''
N4
DESCRIPTION
N8
SECTION-2
HEIGHT
OD
SURFACE AREA
WEIGHT
OPEN VOLUME
NOZZLES
SECTION-1
N8
52''
MANWAY
900#
REFRACTORY LINED
2''
5,457 LBS
CONE BOTTOM
N9
32''
INLET - MAKEUP BED MEDIA
900#
REFRACTORY LINED
2''
2,573 LBS
STEAM/OXYGEN DISTRIBUTOR INSERT
N3
HEIGHT 5.1'
OD 3.7' X 6.3'
WEIGHT 4,511 LBS
OPEN VOLUME 33 CUFT
N11
N5
N12
0.75''
14
900#
3''
7 LBS
N13
0.75''
14
900#
3''
7 LBS
GOLDEN, COLORADO
EQUIPMENT DRAWING
DATE
DESCRIPTION
13,237 LBS
N10
REV.
BLIND
FLANGE
WEIGHT
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-2-01
DESCRIPTION
DRN
CKD
APRVD
GASIFIER REACTOR
PROJ NO.:
30300.00
DWG NO.:
EQ-2-01
DATE:
08/03/12
8/3/12 9:47 AM
DESIGN DATA
CONSTRUCTION CODE
GAS OUTLET INSERT

COLLAR
INLET
NOZZLE
OD = 3.5'
N1
0.8'
SHELL ID
62.0''
3.7'
437.0 PSIG
PRESSURE - DESIGN
505.0 PSIG
1,595.0 F
1,800.0 F
MAXIMUM STEEL TEMPERATURE - DESIGN
300.0 F
0.125''
TOTAL VESSEL EXTERIOR SURFACE AREA
166 SQFT
TOTAL WEIGHT (READY TO SHIP)
77,227 LBS
GAS
OUTLET
INSERT
OD
1.5'
1.6'
4.0'
7.3'
2.9'
N3
OPEN SPACE ID
38.0''
REFRACTORY
THICKNESS
12.00''
BARREL
SHELL
THICKNESS
1"
ID
3.2'
SHELL
THICKNESS
1"
OD
5.3'
13.7'
BARREL
SHELL OD
64.0''
REFRACTORY
THICKNESS
12.0''
SHELL
ASME SA-516,
SA-516, GRADE
GRADE 70 - CARBON STEEL
BARREL - INSULATING LAYER
GUNNED (3.8'') - HARBISON-WALKER, KAST-O-LITE 20-45 G PLU

(IN 25 LB SACKS)
BARREL - ABRASION LAYER
GUNNED (16.9'') - HARBISON-WALKER, SHOT-TECH 60

(IN 55 LB SACKS)
SUPPORT - LUGS
ASME SA-36
NOZZLES

CONE
NOZZLE SCHEDULE
6.3'
MARK
SIZE
N1
42''
N2
36''
QTY
PRESSURE
CLASS
PROTECTION
EXTENSION
LENGTH
NOZZLE
WEIGHT
TOP OUTLET - SYNGAS
900#
REFRACTORY LINED
2''
3,997 LBS
CONE OUTLET - SOLIDS
900#
REFRACTORY LINED
1''
3,427 LBS
DESCRIPTION
N3
52''
MANWAY
900#
REFRACTORY LINED
1''
5,457 LBS
N4
1.5''
THERMOCOUPLE
900#
WATER COOLED
3''
15 LBS
N5
1.5''
900#
WATER COOLED
3''
15 LBS
N12
0.75''
900#
6''
7 LBS
N13
0.75''
900#
6''
7 LBS
BLIND
FLANGE
WEIGHT
13,237 LBS
N6
N2
N7
0.9'
N8
N9
3.0'
N10
N11

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-2-02
DESCRIPTION
DRN
CKD
APRVD
GASIFIER CYCLONE
PROJ NO.:
30300.00
DWG NO.:
EQ-2-02
DATE:
08/03/12
8/3/12 11:59 AM
DESIGN DATA
SECTION - 3
CONE TOP
HEIGHT
OD
SURFACE AREA
WEIGHT
OPEN VOLUME
2.5'
11.7' X 0.8'
118 SQFT
1,799 LBS
95 CUFT
HEIGHT
2.5'
N2
N1
CONSTRUCTION CODE

PRESSURE VESSELS - NOT CODE STAMPED
0.0 PSIG
PRESSURE - DESIGN
0.0 PSIG
100.0 F
115.0 F
0.125''
STEEL SHELL EXTERIOR - TOTAL SURFACE AREA
678 SQFT
VESSEL (W/NOZZLES & SUPPORT LUGS)- TOTAL WEIGHT
15,575 LBS
SECTION - 2
CYLINDER
BED MEDIA
STORAGE BIN
SECTION - 2
HEIGHT
22.5'
CYLINDER
HEIGHT 12.0'
OD 12.0'
WEIGHT 6,824 LBS
SHELL OD
140.69''
SHELL ID
139.94''
SHELL
SUPPORT - LUGS
ASME SA-36
NOZZLES
N4
SHELL
THICKNESS
3/8 "
N5
SECTION - 1
CONE BOTTOM
NOZZLE SCHEDULE
HEIGHT
8.0'
MARK
HEIGHT 8.0'
OD 11.7' X 0.7'
WEIGHT 1,642 LBS
N3
SIZE
DESCRIPTION
QTY
PRESSURE
CLASS
PROTECTION
EXTENSION
LENGTH
NOZZLE
WEIGHT
N1
12''
INLET - BED MEDIA
150#
3''
98 LBS
N2
10''
TOP VENT
150#
3''
62 LBS
N3
8''
OUTLET - BOTTOM DISCHARGE
150#
3''
48 LBS
N4
36''
MANWAY
150#
2''
664 LBS
N5
2''
LEVEL SWITCH
150#
3''
7 LBS
BLIND
FLANGE
WEIGHT
1,676 LBS
N6
N7
N8
N9
N10
N11
N12
N13

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-2-03
DESCRIPTION
DRN
CKD
APRVD
BED MEDIA STORAGE BIN
PROJ NO.:
30300.00
DWG NO.:
EQ-2-03
DATE:
08/03/12
8/3/12 11:59 AM
DESIGN DATA
SECTION - 3
CONE TOP
HEIGHT 2.5'
OD 5.4' X 0.7'
WEIGHT 1,780 LBS
OPEN VOLUME 19 CUFT
HEIGHT
2.5'
N2
N1
CONSTRUCTION CODE

438.0 PSIG
PRESSURE - DESIGN
505.0 PSIG
100.0 F
115.0 F
0.125''
172 SQFT
14,200 LBS
SECTION - 2
CYLINDER
BED MEDIA
NITROGEN TANK
SECTION - 2
HEIGHT
11.0'
CYLINDER
HEIGHT 6.0'
OD 6.0'
WEIGHT 5,917 LBS
SHELL ID
62.28''
SHELL OD
65.03''
SHELL
SUPPORT - LUGS
ASME SA-36
NOZZLES
N4
EXTENSION: 26'-96'' NOZZLES - ASME SA-516, GRADE 7, WELDED PIPE
SHELL
THICKNESS
1 3/8 "
N5
N3
SECTION - 1
HEIGHT
2.5'
NOZZLE SCHEDULE
CONE BOTTOM
HEIGHT 2.5'
OD 5.4' X 0.7'
WEIGHT 1,417 LBS
OPEN VOLUME 19 CUFT
MARK
SIZE
DESCRIPTION
QTY
PRESSURE
CLASS
PROTECTION
EXTENSION
LENGTH
NOZZLE
WEIGHT
N1
4''
INLET - NITROGEN
900#
3''
57 LBS
N2
6''
PRESSURE RELIEF
900#
3''
117 LBS
N3
8''
OUTLET - BOTTOM DRAIN
900#
3''
196 LBS
N4
30''
MANWAY
900#
2''
2,146 LBS
N5
1.5''
LEVEL TRANSMITTER
900#
3''
15 LBS
N6
1.5''
HIGH LEVEL SWITCH
900#
3''
15 LBS
N7
1''
PRESSUREL TRANSMITTER
900#
3''
9 LBS
BLIND
FLANGE
WEIGHT
N8
N9
N10
N11
N12
N13

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-2-04
DESCRIPTION
DRN
CKD
APRVD
BED MEDIA NITROGEN TANK
PROJ NO.:
30300.00
DWG NO.:
EQ-2-04
DATE:
08/03/12
8/3/12 11:59 AM
DESIGN DATA
SECTION - 3
CONE TOP
HEIGHT 2.5'
OD 8.3' X 2'
WEIGHT 3,882 LBS
OPEN VOLUME 52 CUFT
HEIGHT
2.5'
N1
CONSTRUCTION CODE

438.0 PSIG
PRESSURE - DESIGN
505.0 PSIG
300.0 F
345.0 F
0.125''
381 SQFT
27,288 LBS
SECTION - 2
CYLINDER
ASH DISCHARGE
HOPPER
SECTION - 2
HEIGHT
19.5'
CYLINDER
HEIGHT 9.0'
OD 9.0'
WEIGHT 14,712 LBS
SHELL OD
100.06''
SHELL ID
96.06''
SHELL
SUPPORT - LUGS
ASME SA-36
NOZZLES
N4
SHELL
THICKNESS
2"
N5
N3
SECTION - 1
CONE BOTTOM
NOZZLE SCHEDULE
HEIGHT
8.0'
HEIGHT 8.0'
OD 8.3' X 2'
WEIGHT 3,604 LBS
N2
QTY
PRESSURE
CLASS
INLET - ASH
OUTLET - ASH
8''
PRESSURE EQUALIZATION
N4
2''
N5
2''
MARK
SIZE
N1
24''
N2
24''
N3
EXTENSION
LENGTH
NOZZLE
WEIGHT
900#
3''
2,133 LBS
900#
3''
2,133 LBS
900#
3''
196 LBS
MANWAY
900#
3''
25 LBS
INSTRUMENTS
900#
3''
25 LBS
DESCRIPTION
PROTECTION
BLIND
FLANGE
WEIGHT
25 LBS
N6
N7
N8
N9
N10
N11
N12
N13

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-2-05
DESCRIPTION
DRN
CKD
APRVD
ASH DISCHARGE HOPPER
PROJ NO.:
30300.00
DWG NO.:
EQ-2-05
DATE:
08/03/12
8/3/12 11:59 AM
DESIGN DATA
SECTION - 3
CONE TOP
HEIGHT 2.5'
OD 8.3' X 2'
WEIGHT 3,906 LBS
OPEN VOLUME 54 CUFT
HEIGHT
2.5'
N1
CONSTRUCTION CODE

438.0 PSIG
PRESSURE - DESIGN
505.0 PSIG
300.0 F
345.0 F
0.125''
378 SQFT
27,208 LBS
SECTION - 2
CYLINDER
ASH LOCK
HOPPER
SECTION - 2
HEIGHT
19.5'
CYLINDER
HEIGHT 9.0'
OD 9.0'
WEIGHT 14,766 LBS
SHELL OD
100.06''
SHELL ID
96.81''
SHELL
SUPPORT - LUGS
ASME SA-36
NOZZLES
N4
SHELL
THICKNESS
1 5/8 "
N5
N3
SECTION - 1
CONE BOTTOM
NOZZLE SCHEDULE
HEIGHT
8.0'
HEIGHT 8.0'
OD 8.3' X 2'
WEIGHT 3,447 LBS
N2
QTY
PRESSURE
CLASS
INLET - ASH
OUTLET - ASH
8''
PRESSURE EQUALIZATION
N4
2''
N5
2''
MARK
SIZE
N1
24''
N2
24''
N3
EXTENSION
LENGTH
NOZZLE
WEIGHT
900#
3''
2,133 LBS
900#
3''
2,133 LBS
900#
3''
196 LBS
MANWAY
900#
3''
25 LBS
INSTRUMENTS
900#
3''
25 LBS
DESCRIPTION
PROTECTION
BLIND
FLANGE
WEIGHT
25 LBS
N6
N7
N8
N9
N10
N11
N12
N13

GOLDEN, COLORADO
EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
DATE
Model.xlsx]EQ-2-06
DESCRIPTION
DRN
CKD
APRVD
ASH LOCK HOPPER
PROJ NO.:
30300.00
DWG NO.:
EQ-2-06
DATE:
08/03/12
8/3/12 11:59 AM
APPENDIX G-3
DETAILED ESTIMATE
DRAWINGS
HP BIOMASS FEED SYSTEM MODEL
Report 30300/01
DESIGN DATA
CONE TOP
HEIGHT 2.5'
OD 14' X 2'
WEIGHT 2,490 LBS
HEIGHT
2.5'
N1
N2
CONSTRUCTION CODE

300.0 PSIG
PRESSURE - DESIGN
345.0 PSIG
250.0 F
288.0 F
0.125''
1,546 SQFT
VESSEL (W/NOZZLES & SUPPORT LUGS) - TOTAL WEIGHT
38,413 LBS
N4
WOOD CHIP
DENSITY
38.44 lb/ft3
CYLINDER
BIOMASS LOCK
HOPPER
CYLINDER
HEIGHT 28.0'
OD 14.0
WEIGHT 18,800 LBS
SHELL
FLANGE: ASME SA-36

NOZZLES
HEIGHT
31.0'

SHELL ID
13.94''
SHELL ID
13.94'
SHELL OD
14.00''
N6
NOZZLE SCHEDULE
SHELL
THICKNESS
3/8 "
TYP. 3
MARK
N5
ROTATING
SCREW
CONE BOTTOM
HEIGHT 0.5'
OD 14' X 2'
WEIGHT 2,304 LBS
OPEN VOLUME 29 CUFT
N3
HEIGHT
0.5'
SIZE
DESCRIPTION
QTY
PRESSURE
CLASS
PROTECTION
LENGTH
NOZZLE
WEIGHT
N1
24''
TOP BIOMASS INLET
900#
14''
2,143 LBS
N2
12''
TOP VENT
900#
10''
390 LBS
N3
24''
BOTTOM BIOMASS DISCH
900#
14''
2,143 LBS
N4
8''
PRESS EQUALIZATION
900#
9''
196 LBS
N5
2''
LEVEL SWITCH
900#
7''
25 LBS
N6
30''
MANWAY
900#
14''
2,146 LBS
BLIND
FLANGE
WEIGHT
3,758 LBS
N7
N8
N9
N10
N11
N12
N13
N14

GOLDEN, COLORADO
HP BIOMASS FEED SYSTEM - EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
U:\30251.00\4200 Process\4215 Design Data\01 - HGI Files\Workbooks\HP Biomass Feed Model\[2012-08-03 - HP

Biomass Feed Model.xlsx]EQ-3-01
DATE
DESCRIPTION
DRN
CKD
APRVD
BIOMASS LOCK HOPPER
PROJ NO.:
30300.00
DWG NO.:
EQ-3-01
DATE:
08/03/12
8/3/12 11:59 AM
DESIGN DATA
CONE TOP
HEIGHT 2.5'
OD 15' X 2'
WEIGHT 2,835 LBS
HEIGHT
2.5'
N1
N4
CONSTRUCTION CODE

300.0 PSIG
PRESSURE - DESIGN
345.0 PSIG
250.0 F
288.0 F
0.125''
1,774 SQFT
41,501 LBS
WOOD CHIP
DENSITY
38.44 lb/ft3
SHELL
CYLINDER
BIOMASS
METERING BIN
CYLINDER
HEIGHT 30.0'
OD 15.0
WEIGHT 21,585 LBS
FLANGE: ASME SA-36

FLANGE: 0.84
NOZZLES
HEIGHT
33.0'

SHELL ID
14.94''
SHELL ID
14.94'
SHELL OD
15.00''
N6
NOZZLE SCHEDULE
SHELL
THICKNESS
3/8 "
TYP. 3
N5
ROTATING
SCREW
PRESSURE
CLASS
TOP BIOMASS INLET
24''
SIZE
N1
24''
N3
DESCRIPTION
LENGTH
NOZZLE
WEIGHT
900#
14''
2,143 LBS
900#
14''
2,143 LBS
PROTECTION
BLIND
FLANGE
WEIGHT
N2
CONE BOTTOM
HEIGHT 0.5'
OD 15' X 2'
WEIGHT 2,651 LBS
OPEN VOLUME 33 CUFT
QTY
MARK
N3
HEIGHT
0.5'
N4
8''
PRESS EQUALIZATION
900#
9''
196 LBS
N5
2''
LEVEL SWITCH
900#
7''
25 LBS
N6
30''
MANWAY
900#
14''
2,146 LBS
3,758 LBS
N7
N8
N9
N10
N11
N12
N13
N14

GOLDEN, COLORADO
HP BIOMASS FEED SYSTEM - EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
U:\30251.00\4200 Process\4215 Design Data\01 - HGI Files\Workbooks\HP Biomass Feed Model\[2012-08-03 - HP

DATE
DESCRIPTION
DRN
CKD
APRVD
BIOMASS METERING BIN
PROJ NO.:
30300.00
DWG NO.:
EQ-3-02
DATE:
08/03/12
8/3/12 1:15 PM
APPENDIX G-4
DETAILED ESTIMATE
DRAWINGS
Report 30300/01
DESIGN DATA
CONE TOP
HEIGHT - 2.5'
OD - 15' X 2'
WEIGHT - 2,835 LBS
OPEN VOLUME - 167 CUFT
HEIGHT
2.5'
N1
N4
CONSTRUCTION CODE

25.0 PSIG
PRESSURE - DESIGN
30.0 PSIG
250.0 F
288.0 F
0.125''
1,774 SQFT
41,305 LBS
WOOD CHIP
DENSITY
38.44 lb/ft3
SHELL
CYLINDER
BIOMASS
METERING BIN
CYLINDER
HEIGHT - 30.0'
OD - 15.0
WEIGHT - 21,585 LBS
OPEN VOLUME - 5,257 CUFT
FLANGE: ASME SA-36

FLANGE: 0.84
NOZZLES
HEIGHT
33.0'

SHELL ID
14.94''
SHELL ID
14.94'
SHELL OD
15.00''
N6
NOZZLE SCHEDULE
SHELL
THICKNESS
3/8 "
TYP. 3
N5
ROTATING
SCREW
QTY
PRESSURE
CLASS
TOP BIOMASS INLET
24''
N5
2''
N6
30''
MARK
SIZE
N1
24''
LENGTH
NOZZLE
WEIGHT
900#
14''
2,143 LBS
900#
14''
2,143 LBS
LEVEL SWITCH
900#
7''
25 LBS
MANWAY
900#
14''
2,146 LBS
DESCRIPTION
PROTECTION
BLIND
FLANGE
WEIGHT
N2
N3
N4
CONE BOTTOM
HEIGHT - 0.5'
OD - 15' X 2'
WEIGHT - 2,651 LBS
OPEN VOLUME - 33 CUFT
N3
HEIGHT
33.0'
3,758 LBS
N7
N8
N9
N10
N11
N12
N13
N14

GOLDEN, COLORADO
LP BIOMASS FEED SYSTEM - EQUIPMENT DRAWING
REV.
DATE
DESCRIPTION
DRN
CKD
APRVD
REV.
U:\30251.00\4200 Process\4215 Design Data\01 - HGI Files\Workbooks\LP Biomass Feed Model\[2012-08-03 - LP

DATE
DESCRIPTION
DRN
CKD
APRVD
BIOMASS METERING BIN
PROJ NO.:
30300.00
DWG NO.:
EQ-4-01
DATE:
08/03/12
8/3/12 1:16 PM
APPENDIX H-1
DETAILED ESTIMATE
CFB GASIFIER MODEL
Report 30300/01
CAPITAL COST ESTIMATE

CFB GASIFICATION MODEL
GOLDEN, COLORADO
DATE: 08/03/2012
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
Category
Row
EQUIPMENT AND MATERIAL
1
2b
2e
3
4
5
6
7
8
DESCRIPTION
SUMMARY BY WORK CATEGORY
Civil / Earthwork
Buildings
Equipment Foundations / Supports
Piping
Electrical
Instrumentation
Equipment
Demolition
Total Direct Cost (TDC)
Contractor Premium Pay
Contractor's Indirects as % of labor
Contractor's markup as % of matls & subs
Total Construction Cost (TCC)
Owner Engineering
Pre-Project Cost
Other Outside Engineering Services/Construction Mngnt
Capitalized Spares
Sales Taxes
Construction Insurance
Freight
Total Indirect Cost (TIC)
Total Direct and Indirect Costs (TD&IC)
Contingency
Escalation
Working Capital
Operator Training and Start-up
Grand Total
QTY
% of TDC
2.7%
18.9%
0.1%
0.6%
1.0%
3.00%
0.1%
73.6%
0.0%
% of TCC
10.0%
2.0%
0.5%
2.0%
1.0%
3.0%
3.5%
0.0%
3.0%
25.0%
UNIT
CONTRACTOR LABOR
OWNER
CONTR. FURN
UNIT PRICE
FURN. TOTAL
TOTAL
0
0
0
0
0
0
0
0
0
0
683,100
4,652,500
12,900
131,400
111,200
1,304,500
13,500
28,844,800
0
35,753,900
35,753,900
% of TD&IC
15.0%
% of TD&IC
0%
0%
0%
0%
2%
[Range: Lower -15% = $54,054,000; Upper +30% = $82,671,000]
L.H.
UNIT
LABOR
HOURS
3,920
38,461
390
1,490
1,087
582
36,950
82,881
82,881
RATE
85.02
85.00
85.09
84.96
85.06
TOTAL
84.80
333,300
3,269,100
33,200
126,600
92,500
0
31,000
3,142,900
0
7,028,600
84.80
0
0
0
7,028,600
53.23
85.06
SUBCONTR
TOTAL
(Lab & Mat)
GRAND
TOTAL
150,000
300,000
0
0
250,000
0
0
0
0
700,000
1,166,400
8,221,600
46,100
258,000
453,700
1,304,500
44,500
31,987,700
0
43,482,500
700,000
0
0
0
43,482,500
4,348,300
869,700
217,400
869,700
434,800
1,304,500
1,521,900
0
1,304,500
10,870,800
54,353,300
8,153,000
62,506,300
0
0
0
0
1,087,100
63,593,400
Category
Row

DESCRIPTION
QTY
UNIT
UNIT
QTY
UNIT PRICE
CONTRACTOR LABOR
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
LABOR
HOURS
RATE
TOTAL
SUBCONTR
TOTAL
(Lab & Mat)
GRAND
TOTAL
TOTAL
LABOR
HOURS
LABOR
RATE
TOTAL
LABOR
COST
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
50
ESTIMATE INPUTS/ASSUMPTIONS
51
52
53
Rounding Factor (Round values to this many places)
--
-2
54
Grand Total Lower Range Multiplier
--
0.85
55
Grand Total Upper Range Multiplier
--
1.3
56
Labor Rate
$ / hr
85.00
UNIT
QTY
UNIT PRICE
57
CIVIL/EARTHWORK (GASIFIER SITE ONLY)
58
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
59
Site Clearing - Clear & Grub
acre
1.00
3,020.00
3,000
92.571
93
85.00
7,900
10,900
60
Site Grading - Fill & Compaction
yd3
4,440
1.46
6,500
0.018
80
85.00
6,800
13,300
61
Site - Width
ft
200
62
Site - Length
ft
200
63
Site Clearing - Cut Depth
ft
3.0
64
65
Foundation Preparation - Excavation
yd3
797
1.50
1,200
0.150
120
85.00
10,200
11,400
66
Foundation Preparation - Backfill
yd3
199
20.00
4,000
0.060
12
85.00
1,000
5,000
67
Excavation - Depth
ft
2.60
68
Backfill - Depth
ft
0.65
69
Bay-1 - Qty
each
70
Bay-1 - Width
ft
35
71
Bay-1 - Length
ft
40
72
Bay-2 - Qty
each
11
73
Bay-2 - Width
ft
25
Row
Category
74
75
76
77
78
Piles (16" Diameter)
79
Piles - Equipment Rental
80
Pile - Density
pile / ft2
0.034
81
Pile - Length
ft
60
82
Casing
83
84
85
86
DESCRIPTION
Bay-2 - Length
Site Grading & Foundation Preparation - Equipment Rental
QTY
UNIT
UNIT PRICE
ft
25
lot
each
281
2,340.00
lot
50,000.00
CONTRACTOR LABOR
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
LABOR
HOURS
RATE
TOTAL
100,000.00
SUBCONTR
TOTAL
(Lab & Mat)
100,000
658,400
12.000
3376
85.00
287,000
GRAND
TOTAL
100,000
945,400
50,000
50,000
included
Concrete - Miscellaneous
yd
20.0
Roads
lot
0.00
87
Paving
lot
0.00
88
Retention Ponds
lot
0.00
89
Ditches / Culverts
lot
0.00
90
Containment Berms
lot
0.00
91
Sumps
lot
0.00
92
Hydrants
lot
0.00
93
UNIT
QTY
UNIT PRICE
yd3
766
250.00
in
30
BUILDINGS
94
95
2b
96
2b
97
2b
Concrete Slab - Pile Cap / Foundation

Concrete Slab - Thickness
500.00
10,000
12.000
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
191,600
6.000
240
TOTAL
LABOR
HOURS
4597
85.00
LABOR
RATE
85.00
20,400
TOTAL
LABOR
COST
390,800
30,400
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
582,400

Row
Category
CONTRACTOR LABOR
98
2b
Concrete Slab - Elevated - Bay-1
yd3
26
99
2b
in
100
2b
101
2b
Steel - Structural Steel
short ton
841
3,180.00
2,675,700
21.000
102
2b
Steel - Miscellaneous
short ton
59
4,740.00
279,200
103
2b
Steel - Grating & Guardrail
short ton
280
4,740.00
104
2b
Steel - Access Stairs
short ton
35
4,740.00
105
2b
Total Weight of Equipment in Building
short ton
6,097
106
2b
Ratio of Building Structural Steel Wt to Equip Wt
--
0.138
107
2b
Ratio of Misc Steel Wt to Building Structural Steel Wt
DESCRIPTION
108
2b
Ratio of Grating & Guardrail Steel Wt to Bldg Structural Steel

Wt
109
2b
Ratio of Access Stairs Steel Wt to Bldg Structural Steel Wt
110
2b
Galvanized coating
111
2b
112
2b
113
2b
114
QTY
UNIT
--
0.070
--
0.333
--
0.042
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
400.00
10,400
10.000
LABOR
HOURS
259
RATE
TOTAL
SUBCONTR
TOTAL
(Lab & Mat)
GRAND
TOTAL
85.00
22,000
32,400
17,670
85.00
1,501,900
4,177,600
68.000
4,005
85.00
340,400
619,600
1,328,100
34.000
9,526
85.00
809,700
2,137,800
167,500
68.000
2,403
85.00
204,300
371,800
included
Steel Handling - Equipment Rental
lot
300,000.00
300,000
300,000
2b
Masonry, Carpentry, Paint
lot
0.00
115
2b
Sprinklers
lot
0.00
116
2b
Roofing
lot
0.00
117
2b
Siding
lot
0.00
118
2b
UNIT
QTY
UNIT PRICE
yd3
42.0
307
each
EQUIPMENT FOUNDATIONS/SUPPORTS
119
120
2e
Large Equipment Pedistals
121
2b
Combustion Air Blowers
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
12,900
9.290
TOTAL
LABOR
HOURS
390
LABOR
RATE
85.00
TOTAL
LABOR
COST
33,200
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
46,100
Row
Category
122
2b
Bed Media Makeup Blowers
each
123
2b
Bed Media Feeders
each
124
2e
Large Equipment Pedistal Length
ft
8.0
125
2e
Large Equipment Pedistal Width
ft
8.0
126
2e
Large Equipment Pedistal Thickness
in
36.0
127
2e
UNIT
QTY
DESCRIPTION
PIPING INCLUDING FITTINGS (NATURAL GAS,

PROCESS WATER, COOLING WATER, INERT GAS,
PROCESS AIR, AND STEAM)
128
QTY
UNIT
UNIT PRICE
UNIT PRICE
CONTRACTOR LABOR
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
LABOR
HOURS
RATE
TOTAL
SUBCONTR
TOTAL
(Lab & Mat)
GRAND
TOTAL
TOTAL
LABOR
HOURS
LABOR
RATE
TOTAL
LABOR
COST
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
129
Isolation Valves per 100 Linear Feet of Pipe
each
130
Check Valves per 100 Linear Feet of Pipe
each
131
ft
500
7.01
3,500
0.445
223
85.00
18,900
22,400
1" Piping
Carbon Steel
Standard Weight
w/Fittings
No Valves
1" Valves
Carbon Steel
150#
Wedge Gate
each
20
710
14,200
0.860
17
85.00
1,500
15,700
134
1" Valves
Carbon Steel
150#
Check
each
10
660
6,600
0.860
85.00
700
7,300
135
ft
200
9.38
1,900
0.726
145
85.00
12,300
14,200
each
710
5,700
0.860
85.00
600
6,300
132
133
136
2" Piping
Carbon Steel
Standard Weight
w/Fittings
No Valves
137
2" Valves
Carbon Steel
150#
Wedge Gate
Row
Category
138
139
DESCRIPTION
2" Valves
Carbon Steel
150#
Check
CONTRACTOR LABOR
660
2,600
0.860
85.00
300
2,900
200
12.03
2,400
0.821
164
85.00
14,000
16,400
each
ft
LABOR
HOURS
GRAND
TOTAL
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
UNIT
L.H.
UNIT
SUBCONTR
TOTAL
(Lab & Mat)
UNIT PRICE
QTY
RATE
TOTAL
3" Piping
Carbon Steel
Standard Weight
w/Fittings
No Valves
3" Valves
Carbon Steel
150#
Wedge Gate
each
1,000
8,000
1.250
10
85.00
900
8,900
142
3" Valves
Carbon Steel
150#
Check
each
780
3,100
1.250
85.00
400
3,500
143
ft
200
15.82
3,200
0.907
181
85.00
15,400
18,600
140
141
144
4" Piping
Carbon Steel
Standard Weight
w/Fittings
No Valves
145
4" Valves
Carbon Steel
150#
Wedge Gate
each
1,250
10,000
1.530
12
85.00
1,000
11,000
146
4" Valves
Carbon Steel
150#
Check
each
1,125
4,500
1.530
85.00
500
5,000
147
ft
450
24.06
10,800
1.302
586
85.00
49,800
60,600
each
18
1,850
33,300
2.000
36
85.00
3,100
36,400
148
6" Piping
Carbon Steel
Standard Weight
w/Fittings
No Valves
149
6" Valves
Carbon Steel
150#
Wedge Gate
CONTRACTOR LABOR
Row
Category
SUBCONTR
TOTAL
(Lab & Mat)
150
151
152
Eye Wash / Shower Stations
each
1,150
3,500
13.500
41
85.00
3,400
6,900
153
Hose Stations
each
1,150
2,300
13.500
27
85.00
2,300
4,600
154
Fire Water Piping
lot
85.00
155
DESCRIPTION
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
1,750
15,800
2.000
18
85.00
1,500
17,300
UNIT
6" Valves
Carbon Steel
150#
Check
each
L.H.
UNIT
LABOR
HOURS
GRAND
TOTAL
UNIT PRICE
QTY
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
TOTAL
LABOR
HOURS
RATE
LABOR
RATE
TOTAL
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
LABOR
COST
156
ELECTRICAL
UNIT
QTY
157
5 HP Motor Wiring
200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
3,780
7,600
50.460
101
85.00
8,600
16,200
10 HP Motor Wiring
200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
3,929
7,900
52.230
104
85.00
8,900
16,800
25 HP Motor Wiring
200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
5,762
17,300
64.170
193
85.00
16,400
33,700
50 HP Motor Wiring
200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
8,421
33,700
88.770
355
85.00
30,200
63,900
100 HP Motor Wiring

200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
11,906
127.770
85.00
200 HP Motor Wiring

200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
22,350
44,700
167.220
334
85.00
28,400
73,100
158
159
160
161
162
UNIT PRICE
TOTAL
Category
Row

DESCRIPTION
250 HP Motor Wiring
200 ft of Wire
Medium Voltage
1C Conduit
Wire Terminations
CONTRACTOR LABOR
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
32,313
QTY
UNIT
each
L.H.
UNIT
160.890
LABOR
HOURS
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
85.00
GRAND
TOTAL
163
164
165
Control Cabling, Terminations, Conduit
lot
100,000
100,000
100,000
166
Lighting
lot
100,000
100,000
100,000
167
Control System UPS
lot
25,000
25,000
25,000
168
Lightning Protection
lot
25,000
25,000
25,000
169
Motors
170
Medium/High Voltage Feeder
lot
171
Unit Substation(s)
lot
172
Power Distribution To MCC Room
lot
173
Power Distribution To Control Rack Room
lot
174
UNIT
QTY
lot
INSTRUMENTATION
175
176
177
Actuated Valve Hook Up
included
178
Controls Software & Hardware (PLC Ctrl System w/HMI)
included
179
I/O Racks
included
180
Remote Termination
included
181
PROCESS INSULATION / PAINTING
182
183
Field Instruments, Installation & Wiring
included
Cal Sil, 1-1/2" Wall, 4" Ips Al Jkt (Steam Piping Only) (Assume
Only Steam Piping Is Insulated)
UNIT PRICE
1,304,474
UNIT
QTY
UNIT PRICE
linear ft
200
7.3
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
TOTAL
LABOR
HOURS
LABOR
RATE
TOTAL
LABOR
COST
SUBCONTR
TOTAL
(Lab & Mat)
1,304,500
1,304,500
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
1,500
TOTAL
0.343
TOTAL
LABOR
HOURS
69
LABOR
RATE
85.00
TOTAL
LABOR
COST
5,800
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
7,300
Row
Category
184
Paint Finish Coat

Temperature Indicating Paint
For use on Reactors, Duct & Cyclones
ft2
57,084
0.210
185
Equipment Insulation
lot
0.00
186
UNIT
QTY
DESCRIPTION
EQUIPMENT
187
Equipment Installation Labor Hours As a Function of

Equipment Weight
QTY
UNIT
hrs / ston
188
189
190
191
192
193
194
195
CONTRACTOR LABOR
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
12,000
UNIT PRICE
L.H.
UNIT
0.009
LABOR
HOURS
514
RATE
49.00
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
25,200
GRAND
TOTAL
37,200
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
TOTAL
LABOR
HOURS
LABOR
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
LABOR
COST
TOTAL
6.0
210,000
210,000
240
240
85.00
20,400
230,400
INCL
85.00
INCL
85.00
INCL
85.00
INCL
85.00
196
INCL
85.00
197
75,000
75,000
85.00
5,100
80,100
198
INCL
85.00
199
INCL
85.00
200
120,000
120,000
120
120
85.00
10,200
130,200
201
Biomass Line-1 - Pressurized Metering Bin Live Bottom Screws
INCL
85.00
202

Motor
INCL
85.00
203
17,000
17,000
85.00
4,300
21,300
204
85.00
205
34,000
34,000
85.00
5,100
39,100
206
85.00
207
INCL
INCL
60
60
50
-
50
-
60
-
60
-
Row
Category
208
209
INCL
210
INCL
211
212
213
214
DESCRIPTION
QTY
UNIT
CONTRACTOR LABOR
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
210,000
210,000
L.H.
UNIT
LABOR
HOURS
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
GRAND
TOTAL
240
240
85.00
20,400
230,400
85.00
85.00
INCL
85.00
INCL
85.00
INCL
85.00
75,000
75,000
85.00
5,100
80,100
215
INCL
85.00
216
INCL
85.00
217
120,000
120,000
120
120
85.00
10,200
130,200
218
INCL
85.00
219

Motor
INCL
85.00
220
17,000
17,000
85.00
4,300
21,300
221
85.00
222
34,000
34,000
85.00
5,100
39,100
223
224
225
210,000
210,000
226
INCL
227
INCL
228
229
230
231
232
INCL
INCL
60
60
50
-
50
-
60
60
85.00
240
240
85.00
20,400
230,400
85.00
85.00
INCL
85.00
INCL
85.00
INCL
85.00
75,000
75,000
85.00
5,100
80,100
85.00
INCL
60
-
60
-
Row
Category
233
234
235
INCL
236

Motor
INCL
237
238
239
240
241
242
243
244
245
246
DESCRIPTION
QTY
UNIT
INCL
CONTRACTOR LABOR
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
120,000
120,000
L.H.
UNIT
LABOR
HOURS
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
GRAND
TOTAL
85.00
120
120
85.00
10,200
130,200
85.00
85.00
17,000
17,000
85.00
4,300
21,300
85.00
34,000
34,000
85.00
5,100
39,100
210,000
210,000
INCL
INCL
247
248
INCL
INCL
50
-
50
-
60
60
85.00
240
240
85.00
20,400
230,400
85.00
85.00
INCL
85.00
INCL
85.00
INCL
85.00
75,000
75,000
85.00
5,100
80,100
249
INCL
85.00
250
INCL
85.00
251
120,000
120,000
120
120
85.00
10,200
130,200
252
INCL
85.00
253

Motor
INCL
85.00
254
17,000
17,000
85.00
4,300
21,300
255
85.00
256
34,000
34,000
85.00
5,100
39,100
257
85.00
INCL
INCL
60
60
50
-
50
-
60
-
60
-
CONTRACTOR LABOR
Row
Category
SUBCONTR
TOTAL
(Lab & Mat)
258
GASIFIER REACTOR & CYCLONES
259
Gasifier Reactor
821,963
822,000
1,240
1,240
85.00
105,400
927,400
260
50,000
50,000
30
30
85.00
2,600
52,600
261
Duct-01 - From Gasifier Reactor To Gasifier Reactor No.1

Cyclone
649,975
650,000
510
510
85.00
43,400
693,400
262
511,015
511,000
1,470
1,470
85.00
125,000
636,000
263
Line-01 - From Gasifier Reactor No.1 Cyclone To Gasifier

Reactor Cyclones Solids Collection Bin
124,188
124,200
100
100
85.00
8,500
132,700
264
496,632
496,600
250
250
85.00
21,300
517,900
265
Duct-02 - From Gasifier Reactor No.1 Cyclone To Gasifier

Reactor No.2 Cyclone
562,066
562,100
430
430
85.00
36,600
598,700
266
504,655
504,700
1,440
1,440
85.00
122,400
627,100
267
200,579
200,600
190
190
85.00
16,200
216,800
268
1,235,358
1,235,400
1,460
1,460
85.00
124,100
1,359,500
269
279,658
279,700
330
330
85.00
28,100
307,800
270
306,772
306,800
680
680
85.00
57,800
364,600
271
GASIFIER LOOP BED MEDIA MAKEUP SYSTEM
272
Gasifier Loop Bed Media Truck Unloading Station
5,000
5,000
10
10
85.00
900
5,900
273
Line-02 - From Gasifier Loop Bed Media Truck Unloading

Station To Gasifier Loop Bed Media Feed Bin
31,196
31,200
50
50
85.00
4,300
35,500
274
Gasifier Loop Bed Media Feed Bin
109,246
109,200
70
70
85.00
6,000
115,200
275
Gasifier Loop Bed Media Makeup Blower
35,000
35,000
10
10
85.00
900
35,900
276
Gasifier Loop Bed Media Makeup Blower Motor
85.00
277
Line-03 - From Gasifier Loop Bed Media Makeup Blower To

41,937
41,900
70
70
85.00
6,000
47,900
278
279
896,893
896,900
1,140
1,140
85.00
96,900
993,800
280
Char Combustion Reactor Air Heater
159,000
159,000
80
80
85.00
6,800
165,800
281
Char Conbustion Reactor Air Blower
262,500
262,500
60
60
85.00
5,100
267,600
282
Char Conbustion Reactor Air Blower Motor
85.00
DESCRIPTION
Line-05 - From Gasifier Reactor No.2 Cyclone To Gasifier

Reactor Cyclones Solids Collection Bin
Duct-03 - From Gasifier Reactor No.2 Cyclone To Duct-14 From Duct-03 & Duct-13 To Syngas Reformer Reactor
Line-06 - From Gasifier Reactor Cyclones Solids Collection Bin
To Char Combustion Reactor
Duct-17 - From Duct-15 - From Char Conbustion Reactor Air
Blower To Char Combustion Reactor Startup Burner To
QTY
UNIT
INCL
INCL
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
LABOR
HOURS
RATE
TOTAL
GRAND
TOTAL
CONTRACTOR LABOR
Row
Category
SUBCONTR
TOTAL
(Lab & Mat)
283
50,000
50,000
30
30
85.00
2,600
52,600
284
Duct-15 - From Char Conbustion Reactor Air Blower To Char

Combustion Reactor Startup Burner
484,442
484,400
360
360
85.00
30,600
515,000
285
CHAR COMBUSTION CYCLONES
286
Duct-04 - From Char Combustion Reactor To Char

Combustion Reactor No.1 Cyclone
768,435
768,400
540
540
85.00
45,900
814,300
287
785,028
785,000
2,280
2,280
85.00
193,800
978,800
288
Line-07 - From Char Combustion Reactor No.1 Cyclone To

Char Combustion Reactor No.1 Cyclone Solids Collection Bin
246,648
246,600
230
230
85.00
19,600
266,200
289
Char Combustion Reactor No.1 Cyclone Solids Collection Bin
490,073
490,100
250
250
85.00
21,300
511,400
290
279,658
279,700
330
330
85.00
28,100
307,800
291
718,530
718,500
490
490
85.00
41,700
760,200
292
780,928
780,900
2,260
2,260
85.00
192,100
973,000
189,828
189,800
210
210
85.00
17,900
207,700
644,279
644,300
440
440
85.00
37,400
681,700
20,000
20,000
20
20
85.00
1,700
21,700
85.00
7,000
7,000
85.00
900
7,900
85.00
14,367
14,400
10
10
85.00
900
15,300
109,246
109,200
70
70
85.00
6,000
115,200
541,728
541,700
400
400
85.00
34,000
575,700
702,848
702,800
490
490
85.00
41,700
744,500
DESCRIPTION
Line-08 - From Char Combustion Reactor No.1 Cyclone Solids

Collection Bin To Gasifier Reactor
Duct-05 - From Char Combustion Reactor No.1 Cyclone To
Line-09 - From Char Combustion Reactor No.2 Cyclone To
Char Combustion Loop Depleted Bed Media & Ash Cooling
Duct-06 - From Char Combustion Reactor No.2 Cyclone To
Battery Limit (Flue Gas)
QTY
UNIT
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
LABOR
HOURS
RATE
TOTAL
GRAND
TOTAL
293
294
295
296
297
298
299
300
301
Gasifier Loop Depleted Bed Media & Ash Storage Bin
302
SYNGAS REFORMER & CYCLONES
303
304
305
1,522,654
1,522,700
1,810
1,810
85.00
153,900
1,676,600
306
Duct-07 - From Syngas Reformer Reactor To Syngas Reformer

Reactor No.1 Cyclone
1,199,771
1,199,800
1,060
1,060
85.00
90,100
1,289,900
307
992,813
992,800
2,900
2,900
85.00
246,500
1,239,300
CHAR COMBUSTION BED MEDIA & ASH DISPOSAL

Screw Conveyor
Screw Conveyor Motor
Screw Conveyor Outlet Pocket Feeder
Screw Conveyor Outlet Pocket Feeder Motor
Line-19 - From Char Combustion Loop Depleted Bed Media &
Ash Cooling Screw Conveyor To Gasifier Loop Depleted Bed
Duct-13 - From Supplemental Gas Battery Limits To Syngas

Reformer Reactor
Duct-14 - From Duct-03 & Duct-13 To Syngas Reformer
Reactor
INCL
1
1
INCL
10
10
-
Row
Category
308
309
DESCRIPTION
QTY
UNIT
CONTRACTOR LABOR
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
LABOR
HOURS
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
GRAND
TOTAL
Line-10 - From Syngas Reformer Reactor No.1 Cyclone To

Syngas Reformer Reactor Cyclones Solids Collection Bin
179,003
179,000
130
130
85.00
11,100
190,100
498,006
498,000
250
250
85.00
21,300
519,300
310
Duct-08 - From Syngas Reformer Reactor No.1 Cyclone To

1,199,771
1,199,800
1,060
1,060
85.00
90,100
1,289,900
311
992,813
992,800
2,900
2,900
85.00
246,500
1,239,300
183,783
183,800
180
180
85.00
15,300
199,100
1,199,771
1,199,800
1,060
1,060
85.00
90,100
1,289,900
326,966
327,000
380
380
85.00
32,300
359,300
Line-14 - From Syngas Reformer Reactor No.2 Cyclone To

Duct-09 - From Syngas Reformer Reactor No.2 Cyclone To
Battery Limit (Reformed Syngas)
Line-15 - From Syngas Reformer Reactor Cyclones Solids
Collection Bin To Reformer Bed Media Heating Reactor
312
313
314
315
REFORMER LOOP BED MEDIA MAKEUP SYSTEM
316
Reformer Loop Bed Media Truck Unloading Station
5,000
5,000
10
10
85.00
900
5,900
317
Line-11 - From Reformer Loop Bed Media Truck Unloading

Station To Reformer Loop Bed Media Feed Bin
33,835
33,800
50
50
85.00
4,300
38,100
318
Reformer Loop Bed Media Feed Bin
109,246
109,200
70
70
85.00
6,000
115,200
319
Reformer Loop Bed Media Makeup Blower
35,000
35,000
10
10
85.00
900
35,900
320
Reformer Loop Bed Media Makeup Blower Motor
85.00
321
Line-12 - From Reformer Loop Bed Media Makeup Blower To

44,576
44,600
70
70
85.00
6,000
50,600
322
323
593,440
593,400
810
810
85.00
68,900
662,300
324
159,000
159,000
80
80
85.00
6,800
165,800
325
262,500
262,500
60
60
85.00
5,100
267,600
326
85.00
327
75,000
75,000
30
30
85.00
2,600
77,600
328
Duct-16 - From Reformer Bed Media Heating Reactor Air

Heater To Reformer Bed Media Heating Reactor
208,339
208,300
180
180
85.00
15,300
223,600
329
REFORMER BED MEDIA HEATING CYCLONES
330
Duct-10 - From Reformer Bed Media Heating Reactor To

438,507
438,500
480
480
85.00
40,800
479,300
331
193,670
193,700
530
530
85.00
45,100
238,800
Line-16 - From Reformer Bed Media Heating Reactor No.1

Cyclone To Reformer Bed Media Heating Reactor No.1
183,783
183,800
180
180
85.00
15,300
199,100
332
INCL
INCL
Row
Category
333
334
335
336
337
338
339
340
DESCRIPTION
Reformer Bed Media Heating Reactor No.1 Cyclone Solids
Collection Bin
Cyclone Solids Collection Bin To Syngas Reformer Reactor
Duct-11 - From Reformer Bed Media Heating Reactor No.1
Cyclone To Reformer Bed Media Heating Reactor No.2
Cyclone To Reformer Loop Depleted Bed Media Cooling Screw
Duct-12 - From Reformer Bed Media Heating Reactor No.2
Cyclone To Battery Limit (Flue Gas)
CONTRACTOR LABOR
LABOR
HOURS
GRAND
TOTAL
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
491,894
491,900
250
250
85.00
21,300
513,200
326,966
327,000
380
380
85.00
32,300
359,300
438,507
438,500
480
480
85.00
40,800
479,300
193,670
193,700
530
530
85.00
45,100
238,800
218,098
218,100
260
260
85.00
22,100
240,200
438,507
438,500
480
480
85.00
40,800
479,300
20,000
20,000
20
20
85.00
1,700
21,700
85.00
7,000
7,000
85.00
900
7,900
85.00
17,006
17,000
10
10
85.00
900
17,900
109,246
109,200
70
70
85.00
6,000
115,200
6,000
6,000
10
10
85.00
900
6,900
UNIT
L.H.
UNIT
SUBCONTR
TOTAL
(Lab & Mat)
UNIT PRICE
QTY
RATE
TOTAL
REFORMER HEATER BED MEDIA & ASH DISPOSAL

Reformer Loop Depleted Bed Media Cooling Screw Conveyor
Screw Conveyor Motor
Screw Conveyor Outlet Pocket Feeder
Screw Conveyor Outlet Pocket Feeder Motor
Line-20 - From Reformer Loop Depleted Bed Media Cooling
Screw Conveyor To Reformer Loop Depleted Bed Media
INCL
341
342
343
344
345
Reformer Loop Depleted Bed Media Storage Bin
346
FLARE SYSTEM
347
Stack Flare Burner
348
349
350
351
352
353
Inert Gas System
lot
0.00
354
Flue Gas ID Fans (Including Drives)
lot
0.00
355
Flue Gas Scrubbers (Including Scrubber, Separator, Pump,

Piping)
lot
0.00
356
Stack
lot
0.00
357
Cooling Tower/Cooling System
lot
0.00
1
1
INCL
10
-
10
-
Row
Category
358
DEMOLITION
359
360
DESCRIPTION
Demolition
QTY
UNIT
UNIT PRICE
UNIT
QTY
UNIT PRICE
lot
CONTRACTOR LABOR
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
LABOR
HOURS
RATE
TOTAL
SUBCONTR
TOTAL
(Lab & Mat)
GRAND
TOTAL
TOTAL
LABOR
HOURS
LABOR
RATE
TOTAL
LABOR
COST
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
0.00
700,000
43,482,500
361
U:\30251.00\4200 Process\4215 Design Data\01 - HGI Files\Workbooks\CFB Gasifier Model\[2012-08-03 - CFB Gasifier Model.xlsx]03-Cost Est
35,753,900
82,881
84.80
7,028,600
8/2/12 5:55 PM
APPENDIX H-2
DETAILED ESTIMATE
BFB GASIFIER MODEL
Report 30300/01

BFB BIOMASS GASIFICATION SYSTEM
GOLDEN, COLORADO
DATE: 08/03/2012
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
Category
Row
1
2b
2e
3
4
5
6
7
8
DESCRIPTION
Civil / Earthwork
Buildings
Piping
Electrical
Instrumentation
Equipment
Demolition
Owner Engineering
Pre-Project Cost
Capitalized Spares
Sales Taxes
Freight
Contingency
Escalation
Working Capital
Grand Total
QTY
% of TDC
8.6%
14.6%
0.2%
1.0%
6.1%
3.0%
0.2%
66.2%
0.0%
% of TCC
10.0%
2.0%
0.5%
2.0%
1.0%
3.0%
3.5%
0.0%
3.0%
25.0%
UNIT
CONTRACTOR LABOR
OWNER
CONTR. FURN
UNIT PRICE
FURN. TOTAL
TOTAL
0
0
0
0
0
0
0
0
0
0
% of TD&IC
15.0%
% of TD&IC
0%
0%
0%
0%
2%
222,200
269,600
2,100
24,000
14,200
135,700
2,100
2,842,200
0
3,512,100
3,512,100
L.H.
UNIT
LABOR
HOURS
1,276
3,064
65
275
153
95
1,810
6,738
6,738
RATE
84.95
84.99
84.58
85.08
85.00
TOTAL
84.95
108,400
260,400
5,500
23,400
13,000
0
7,100
154,600
0
572,400
84.95
0
0
0
572,400
74.40
85.41
SUBCONTR
TOTAL
(Lab & Mat)
GRAND
TOTAL
60,000
130,000
0
0
250,000
0
0
0
0
440,000
390,600
660,000
7,600
47,400
277,200
135,700
9,200
2,996,800
0
4,524,500
440,000
0
0
0
4,524,500
452,500
90,500
22,600
90,500
45,200
135,700
158,400
0
135,700
1,131,100
5,655,600
848,300
6,503,900
0
0
0
0
113,100
6,617,000
Category
Row

DESCRIPTION
QTY
UNIT
UNIT
QTY
UNIT PRICE
CONTRACTOR LABOR
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
LABOR
HOURS
RATE
TOTAL
SUBCONTR
TOTAL
(Lab & Mat)
GRAND
TOTAL
TOTAL
LABOR
HOURS
LABOR
RATE
TOTAL
LABOR
COST
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
50
51
52
53
--
-2
54
--
0.85
55
--
1.3
56
Labor Rate
$ / hr
85.00
UNIT
QTY
UNIT PRICE
57
58
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
59
acre
0.06
3,020.00
200
92.571
85.00
500
700
60
yd3
310
1.46
500
0.018
85.00
500
1,000
61
Site - Width
ft
31
62
Site - Length
ft
91
63
ft
3.0
64
65
yd3
260
1.50
400
0.150
39
85.00
3,300
3,700
66
yd3
65
20.00
1,300
0.060
85.00
300
1,600
67
Excavation - Depth
ft
2.60
68
Backfill - Depth
ft
0.65
69
Bay-1 - Qty
each
70
Bay-1 - Width
ft
30
71
Bay-1 - Length
ft
30
72
Bay-2 - Qty
each
73
Bay-2 - Width
ft
Row
Category
74
75
76
77
78
79
80
Pile - Density
pile / ft2
0.034
81
Pile - Length
ft
60
82
Casing
83
84
85
86
DESCRIPTION
Bay-2 - Length
QTY
UNIT
UNIT PRICE
ft
lot
40,000.00
each
92
2,340.00
lot
20,000.00
CONTRACTOR LABOR
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
LABOR
HOURS
RATE
TOTAL
SUBCONTR
TOTAL
(Lab & Mat)
40,000
214,800
12.000
1102
85.00
93,600
GRAND
TOTAL
40,000
308,400
20,000
20,000
included
yd
10.0
Roads
lot
0.00
87
Paving
lot
0.00
88
Retention Ponds
lot
0.00
89
Ditches / Culverts
lot
0.00
90
Containment Berms
lot
0.00
91
Sumps
lot
0.00
92
Hydrants
lot
0.00
93
UNIT
QTY
UNIT PRICE
yd3
250
250.00
in
30
BUILDINGS
94
95
2b
96
2b
97
2b

500.00
5,000
12.000
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
62,500
6.000
120
TOTAL
LABOR
HOURS
1500
85.00
LABOR
RATE
85.00
10,200
TOTAL
LABOR
COST
127,500
15,200
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
190,000

Row
Category
CONTRACTOR LABOR
98
2b
qty
99
2b
yd3
100
2b
in
101
2b
102
2b
short ton
39
3,180.00
124,500
21.000
103
2b
short ton
4,740.00
13,000
104
2b
short ton
13
4,740.00
105
2b
short ton
4,740.00
106
2b
short ton
284
107
2b
--
0.138
108
2b
--
0.070
109
2b

Wt
--
0.333
110
2b
--
0.042
111
2b
Galvanized coating
112
2b
113
2b
114
2b
115
DESCRIPTION
QTY
UNIT
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
400.00
10.000
LABOR
HOURS
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
GRAND
TOTAL
85.00
822
85.00
69,900
194,400
68.000
186
85.00
15,800
28,800
61,800
34.000
443
85.00
37,700
99,500
7,800
68.000
112
85.00
9,500
17,300
included
lot
130,000.00
130,000
130,000
2b
lot
0.00
116
2b
Sprinklers
lot
0.00
117
2b
Roofing
lot
0.00
118
2b
Siding
lot
0.00
119
2b
UNIT
QTY
UNIT PRICE
yd3
7.0
307
120
121
2e
LABOR
CONTRACTOR
OWNER
HOURS /
FURNISHED
FURNISHED
UNIT
2,100
9.290
TOTAL
LABOR
HOURS
65
LABOR
RATE
85.00
TOTAL
LABOR
COST
5,500
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
7,600
Row
Category
122
2b
Bed Media Transporter
each
123
2b
Not Used
each
124
2b
Not Used
each
125
2e
ft
8.0
126
2e
ft
8.0
127
2e
in
36.0
128
2e
UNIT
QTY
DESCRIPTION

129
QTY
UNIT
UNIT PRICE
UNIT PRICE
CONTRACTOR LABOR
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
LABOR
HOURS
RATE
TOTAL
SUBCONTR
TOTAL
(Lab & Mat)
GRAND
TOTAL
TOTAL
LABOR
HOURS
LABOR
RATE
TOTAL
LABOR
COST
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
130
each
131
each
132
ft
150
7.01
1,100
0.445
67
85.00
5,700
6,800
133
1" Piping
Carbon Steel
Standard Weight
w/Fittings
No Valves
134
1" Valves
Carbon Steel
150#
Wedge Gate
each
710
4,300
0.860
85.00
400
4,700
135
1" Valves
Carbon Steel
150#
Check
each
660
2,000
0.860
85.00
200
2,200
136
ft
60
9.38
600
0.726
44
85.00
3,700
4,300
each
2.4
710
1,700
0.860
85.00
200
1,900
137
2" Piping
Carbon Steel
Standard Weight
w/Fittings
No Valves
138
2" Valves
Carbon Steel
150#
Wedge Gate
Row
Category
139
140
DESCRIPTION
2" Valves
Carbon Steel
150#
Check
CONTRACTOR LABOR
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
660
800
0.860
12.03
0.821
QTY
UNIT
each
1.2
ft
L.H.
UNIT
LABOR
HOURS
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
GRAND
TOTAL
85.00
100
900
85.00
3" Piping
Carbon Steel
Standard Weight
w/Fittings
No Valves
3" Valves
Carbon Steel
150#
Wedge Gate
each
1,000
1.250
85.00
143
3" Valves
Carbon Steel
150#
Check
each
780
1.250
85.00
144
ft
100
15.82
1,600
0.907
91
85.00
7,700
9,300
141
142
145
4" Piping
Carbon Steel
Standard Weight
w/Fittings
No Valves
146
4" Valves
Carbon Steel
150#
Wedge Gate
each
1,250
5,000
1.530
85.00
500
5,500
147
4" Valves
Carbon Steel
150#
Check
each
1,125
2,300
1.530
85.00
300
2,600
148
ft
24.06
1.302
85.00
each
1,850
2.000
85.00
149
6" Piping
Carbon Steel
Standard Weight
w/Fittings
No Valves
150
6" Valves
Carbon Steel
150#
Wedge Gate

Row
Category
CONTRACTOR LABOR
151
152
153
each
1,150
2,300
13.500
154
Hose Stations
each
1,150
2,300
13.500
155
Fire Water Piping
lot
156
DESCRIPTION
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
1,750
2.000
QTY
UNIT
6" Valves
Carbon Steel
150#
Check
each
L.H.
UNIT
LABOR
HOURS
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
GRAND
TOTAL
85.00
27
85.00
2,300
4,600
27
85.00
2,300
4,600
85.00
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
RATE
TOTAL
LABOR
HOURS
LABOR
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
LABOR
COST
157
ELECTRICAL
UNIT
QTY
158
5 HP Motor Wiring
200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
3,780
50.460
85.00
10 HP Motor Wiring
200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
3,929
52.230
85.00
25 HP Motor Wiring
200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
5,762
5,800
64.170
64
85.00
5,500
11,300
50-70 HP Motor Wiring

200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
8,421
8,400
88.770
89
85.00
7,500
15,900
100 HP Motor Wiring

200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
11,906
127.770
85.00
200 HP Motor Wiring

200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
22,350
167.220
85.00
159
160
161
162
163
UNIT PRICE
TOTAL
Category
Row

DESCRIPTION
250 HP Motor Wiring
200 ft of Wire
Medium Voltage
1C Conduit
Wire Terminations
CONTRACTOR LABOR
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
32,313
QTY
UNIT
each
L.H.
UNIT
160.890
LABOR
HOURS
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
85.00
GRAND
TOTAL
164
165
166
lot
100,000
100,000
100,000
167
Lighting
lot
100,000
100,000
100,000
168
Control System UPS
lot
25,000
25,000
25,000
169
lot
25,000
25,000
25,000
170
Motors
171
lot
172
Unit Substation(s)
lot
173
lot
174
lot
175
UNIT
QTY
lot
INSTRUMENTATION
176
177
178
included
179
included
180
I/O Racks
included
181
Remote Termination
included
182
183
184
included
UNIT PRICE
135,736
UNIT
QTY
UNIT PRICE
linear ft
200
7.3
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
TOTAL
LABOR
HOURS
LABOR
RATE
TOTAL
LABOR
COST
SUBCONTR
TOTAL
(Lab & Mat)
135,700
135,700
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
1,500
TOTAL
0.343
TOTAL
LABOR
HOURS
69
LABOR
RATE
85.00
TOTAL
LABOR
COST
5,800
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
7,300
Row
Category
185
Paint Finish Coat

ft2
2,979
0.210
186
lot
0.00
187
UNIT
QTY
DESCRIPTION
EQUIPMENT
188

Equipment Weight
CONTRACTOR LABOR
QTY
UNIT
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
600
hrs / ston
UNIT PRICE
L.H.
UNIT
LABOR
HOURS
0.009
27
RATE
49.00
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
1,300
GRAND
TOTAL
1,900
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
TOTAL
LABOR
HOURS
LABOR
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
LABOR
COST
TOTAL
6.0
189
190
191
GASIFIER REACTOR & CYCLONE
192
Gasifier Reactor
546,361
546,400
690
690
85.00
58,700
605,100
193
150,000
150,000
10
10
85.00
900
150,900
194
Duct-01 (Refractory Lined) - From Gasifier Reactor To Gasifier

Cyclone
161,893
161,900
60
60
85.00
5,100
167,000
195
Gasifier Cyclone
160,924
160,900
240
240
85.00
20,400
181,300
191,879
191,900
140
140
85.00
11,900
203,800
201,035
201,000
100
100
85.00
8,500
209,500
130,945
130,900
60
60
85.00
5,100
136,000
8,500
8,500
10
10
85.00
900
9,400
85.00
Line-01 (Refractory Lined) - From Gasifier Cyclone To Gasifier

Reactor
Duct-02 (Refractory Lined) - From Gasifier Cyclone To Battery
Limit
Line-02 (Refractory Lined) - From Gasifier Reactor To Ash
196
197
198
199
BED MEDIA MAKEUP SYSTEM
200
Bed Media Truck Unloading Station
201
Piping - From Bed Media Truck Unloading Station To Bed

Media Storage Bin
202
105,819
105,800
50
50
85.00
4,300
110,100
203
Bed Media Nitrogen Tank
83,111
83,100
50
50
85.00
4,300
87,400
204
Piping - From Bed Media Nitrogen Tank To Bed Media

Pneumatic Transporter
2,500
2,500
10
10
85.00
900
3,400
205
Bed Media Pneumatic Transporter
250,000
250,000
10
10
85.00
900
250,900
206
Piping - From Bed Media Pneumatic Transporter To Gasifier

Reactor
85.00
207
ASH REMOVAL SYSTEM
208
159,497
159,500
85.00
4,300
163,800
INCL
INCL
50
50

Row
Category
CONTRACTOR LABOR
209
Ash Cooling Screw Conveyor Motor
210
Piping - From Ash Cooling Screw Conveyor To Ash Discharge

Hopper
5,000
5,000
10
211
Ash Discharge Hopper
165,732
165,700
212
Ash Lock Hopper Inlet Block Valve
15,000
213
Piping - From Ash Discharge Hopper To Ash Lock Hopper
214
Ash Lock Hopper
215
216
DESCRIPTION
QTY
UNIT
INCL
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
GRAND
TOTAL
85.00
10
85.00
900
5,900
90
90
85.00
7,700
173,400
15,000
10
10
85.00
900
15,900
5,000
5,000
10
10
85.00
900
5,900
165,185
165,200
90
90
85.00
7,700
172,900
Ash Lock Hopper Discharge Screw Conveyor
310,935
310,900
100
100
85.00
8,500
319,400
Ash Lock Hopper Discharge Screw Conveyor Motor
85.00
217
Ash Lock Hopper Outlet Block Valve
15,000
15,000
10
10
85.00
900
15,900
218
Piping - From Ash Lock Hopper To Battery Limit
8,000
8,000
10
10
85.00
900
8,900
219
220
221
222
223
224
225
226
227
228
229
230
Inert Gas System
lot
0.00
231
lot
0.00
232

Piping)
lot
0.00
233
Stack
lot
0.00
INCL
LABOR
HOURS
Row
Category
234
235
DEMOLITION
236
237
DESCRIPTION
Demolition
QTY
UNIT
lot
UNIT
QTY
lot
UNIT PRICE
CONTRACTOR LABOR
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
LABOR
HOURS
RATE
TOTAL
0.00
UNIT PRICE
SUBCONTR
TOTAL
(Lab & Mat)
GRAND
TOTAL
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
TOTAL
LABOR
HOURS
LABOR
RATE
TOTAL
LABOR
COST
0.00
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
440,000
4,524,500
238
U:\30251.00\4200 Process\4215 Design Data\01 - HGI Files\Workbooks\BFB Gasifier Model\[2012-08-03 - BFB Gasifier Model.xlsx]03-Cost Est
3,512,100
6,738
84.95
572,400
8/2/12 5:55 PM
APPENDIX H-3
DETAILED ESTIMATE
HP BIOMASS FEED SYSTEM MODEL MODEL
Report 30300/01

HP BIOMASS FEED SYSTEM - SINGLE LINE
GOLDEN, COLORADO
DATE: 08/03/2012
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
Category
Row
1
2b
2e
3
4
5
6
7
8
DESCRIPTION
Civil / Earthwork
Buildings
Piping
Electrical
Instrumentation
Equipment
Demolition
Owner Engineering
Pre-Project Cost
Capitalized Spares
Sales Taxes
Freight
Contingency
Escalation
Working Capital
Grand Total
QTY
% of TDC
0.0%
0.0%
0.0%
1.9%
2.5%
3.0%
0.0%
92.6%
0.0%
% of TCC
10.0%
2.0%
0.5%
2.0%
1.0%
3.0%
3.5%
0.0%
3.0%
25.0%
UNIT
CONTRACTOR LABOR
OWNER
CONTR. FURN
UNIT PRICE
FURN. TOTAL
TOTAL
0
0
0
0
0
0
0
0
0
0
% of TD&IC
15.0%
% of TD&IC
0%
0%
0%
0%
2%
0
0
0
25,200
9,700
81,800
0
2,455,000
0
2,571,700
2,571,700
L.H.
UNIT
LABOR
HOURS
317
116
800
1,233
1,233
RATE
TOTAL
85.47
0
0
0
27,000
9,900
0
0
68,500
0
105,400
85.47
0
0
0
105,400
85.23
85.05
85.63
SUBCONTR
TOTAL
(Lab & Mat)
GRAND
TOTAL
0
0
0
0
49,000
0
0
0
0
49,000
0
0
0
52,200
68,600
81,800
0
2,523,500
0
2,726,100
49,000
0
0
0
2,726,100
272,600
54,500
13,600
54,500
27,300
81,800
95,400
0
81,800
681,500
3,407,600
511,100
3,918,700
0
0
0
0
68,200
3,986,900
Category
Row

DESCRIPTION
QTY
UNIT
UNIT
QTY
UNIT PRICE
CONTRACTOR LABOR
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
LABOR
HOURS
RATE
TOTAL
SUBCONTR
TOTAL
(Lab & Mat)
GRAND
TOTAL
TOTAL
LABOR
HOURS
LABOR
RATE
TOTAL
LABOR
COST
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
50
51
52
53
--
-2
54
--
0.85
55
--
1.3
56
Labor Rate
$ / hr
85.00
UNIT
QTY
UNIT PRICE
3,020.00
92.571
85.00
1.46
0.018
85.00
57
58
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
59
acre
0.00
60
yd3
61
Site - Width
ft
62
Site - Length
ft
63
ft
0.0
64
65
yd3
1.50
0.150
85.00
66
yd3
20.00
0.060
85.00
67
Excavation - Depth
ft
0.00
68
Backfill - Depth
ft
0.00
69
Bay-1 - Qty
each
70
Bay-1 - Width
ft
71
Bay-1 - Length
ft
72
Bay-2 - Qty
each
73
Bay-2 - Width
ft
Row
Category
74
75
76
77
78
79
80
Pile - Density
pile / ft2
0.034
81
Pile - Length
ft
82
Casing
83
84
85
86
DESCRIPTION
Bay-2 - Length
QTY
UNIT
UNIT PRICE
ft
lot
40,000.00
each
2,340.00
lot
20,000.00
CONTRACTOR LABOR
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
LABOR
HOURS
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
GRAND
TOTAL
12.000
85.00
0
0
included
yd
0.0
Roads
lot
0.00
87
Paving
lot
0.00
88
Retention Ponds
lot
0.00
89
Ditches / Culverts
lot
0.00
90
Containment Berms
lot
0.00
91
Sumps
lot
0.00
92
Hydrants
lot
0.00
93
UNIT
QTY
yd3
in
BUILDINGS
94
95
2b
96
2b
97
2b

500.00
UNIT PRICE
250.00
12.000
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
0
6.000
TOTAL
LABOR
HOURS
85.00
LABOR
RATE
0
85.00
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
LABOR
COST
0
TOTAL

Row
Category
CONTRACTOR LABOR
98
2b
yd3
99
2b
in
100
2b
101
2b
short ton
3,180.00
21.000
102
2b
short ton
4,740.00
103
2b
short ton
4,740.00
104
2b
short ton
4,740.00
105
2b
short ton
106
2b
--
0.138
107
2b
DESCRIPTION
108
2b

Wt
109
2b
110
2b
Galvanized coating
111
2b
112
2b
113
2b
114
QTY
UNIT
--
0.070
--
0.333
--
0.042
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
400.00
10.000
LABOR
HOURS
0
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
GRAND
TOTAL
85.00
85.00
68.000
85.00
34.000
85.00
68.000
85.00
included
lot
130,000.00
2b
lot
0.00
115
2b
Sprinklers
lot
0.00
116
2b
Roofing
lot
0.00
117
2b
Siding
lot
0.00
118
2b
UNIT
QTY
UNIT PRICE
307
119
120
2e
yd3
0.0
121
2b
each
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
0
9.290
TOTAL
LABOR
HOURS
-
LABOR
RATE
85.00
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
LABOR
COST
0
TOTAL
Row
Category
122
2b
Not Used
each
123
2b
Not Used
each
124
2e
ft
8.0
125
2e
ft
8.0
126
2e
in
36.0
127
2e
UNIT
QTY
DESCRIPTION

128
QTY
UNIT
UNIT PRICE
UNIT PRICE
CONTRACTOR LABOR
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
LABOR
HOURS
RATE
TOTAL
SUBCONTR
TOTAL
(Lab & Mat)
GRAND
TOTAL
TOTAL
LABOR
HOURS
LABOR
RATE
TOTAL
LABOR
COST
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
129
each
130
each
131
ft
7.01
0.445
85.00
1" Piping
Carbon Steel
Standard Weight
w/Fittings
No Valves
1" Valves
Carbon Steel
150#
Wedge Gate
each
710
0.860
85.00
134
1" Valves
Carbon Steel
150#
Check
each
660
0.860
85.00
135
ft
9.38
0.726
85.00
each
710
0.860
85.00
132
133
136
2" Piping
Carbon Steel
Standard Weight
w/Fittings
No Valves
137
2" Valves
Carbon Steel
150#
Wedge Gate
Row
Category
138
139
DESCRIPTION
2" Valves
Carbon Steel
150#
Check
CONTRACTOR LABOR
660
0.860
85.00
ft
12.03
0.821
85.00
each
LABOR
HOURS
GRAND
TOTAL
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
UNIT
L.H.
UNIT
SUBCONTR
TOTAL
(Lab & Mat)
UNIT PRICE
QTY
RATE
TOTAL
3" Piping
Carbon Steel
Standard Weight
w/Fittings
No Valves
3" Valves
Carbon Steel
150#
Wedge Gate
each
1,000
1.250
85.00
142
3" Valves
Carbon Steel
150#
Check
each
780
1.250
85.00
143
ft
250
15.82
4,000
0.907
227
85.00
19,300
23,300
140
141
144
4" Piping
Carbon Steel
Standard Weight
w/Fittings
No Valves
145
4" Valves
Carbon Steel
150#
Wedge Gate
each
10
1,250
12,500
1.530
15
85.00
1,300
13,800
146
4" Valves
Carbon Steel
150#
Check
each
1,125
5,600
1.530
85.00
700
6,300
147
ft
24.06
1.302
85.00
each
1,850
2.000
85.00
148
6" Piping
Carbon Steel
Standard Weight
w/Fittings
No Valves
149
6" Valves
Carbon Steel
150#
Wedge Gate
Row
Category
150
151
DESCRIPTION
6" Valves
Carbon Steel
150#
Check
CONTRACTOR LABOR
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
1,750
2.000
ft
50
24.06
1,200
1.302
QTY
UNIT
each
L.H.
UNIT
LABOR
HOURS
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
GRAND
TOTAL
85.00
65
85.00
5,500
6,700
85.00
200
2,100
8" Piping
Carbon Steel
Standard Weight
w/Fittings
No Valves
8" Valves
Carbon Steel
150#
Wedge Gate
each
1,850
1,900
2.000
154
8" Valves
Carbon Steel
150#
Check
each
1,750
2.000
85.00
155
156
each
1,150
13.500
85.00
157
Hose Stations
each
1,150
13.500
85.00
158
Fire Water Piping
lot
85.00
159
152
153
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
160
ELECTRICAL
UNIT
QTY
161
5 HP Motor Wiring
200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
3,780
50.460
10 HP Motor Wiring
200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
3,929
3,900
52.230
15 HP Motor Wiring
200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
5,762
55.000
162
163
UNIT PRICE
TOTAL
LABOR
HOURS
52
LABOR
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
LABOR
COST
TOTAL
85.00
85.00
4,400
8,300
85.00
Category
CONTRACTOR LABOR
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
5,762
60.000
each
5,762
5,800
64.170
30 HP Motor Wiring
200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
5,762
72.000
50 HP Motor Wiring
200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
8,421
75 HP Motor Wiring
200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
8,421
100 HP Motor Wiring

200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
200 HP Motor Wiring

200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
171
250 HP Motor Wiring

200 ft of Wire
Medium Voltage
1C Conduit
Wire Terminations
172
173
174
175
Row
UNIT PRICE
164
165
166
167
168
169
170
DESCRIPTION
QTY
UNIT
20 HP Motor Wiring
200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
25 HP Motor Wiring
200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
L.H.
UNIT
LABOR
HOURS
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
GRAND
TOTAL
85.00
85.00
5,500
11,300
85.00
78.000
85.00
88.770
85.00
11,906
127.770
85.00
22,350
167.220
85.00
each
32,313
160.890
85.00
each
12,000
24,000
24,000
Lighting
lot
100,000
Control System UPS
lot
25,000
64
CONTRACTOR LABOR
Row
Category
SUBCONTR
TOTAL
(Lab & Mat)
176
177
Motors
178
lot
179
Unit Substation(s)
lot
180
lot
181
lot
182
UNIT
QTY
lot
DESCRIPTION
INSTRUMENTATION
183
25,000
included
included
186
included
187
I/O Racks
included
188
Remote Termination
included
189
UNIT PRICE
81,782
UNIT PRICE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
LABOR
COST
81,800
TOTAL
81,800
LABOR
CONTRACTOR
OWNER
HOURS /
FURNISHED
FURNISHED
UNIT
TOTAL
LABOR
HOURS
LABOR
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
LABOR
COST
7.3
0.343
85.00
0.009
49.00
192
Paint Finish Coat

ft2
0.210
193
lot
0.00
194
UNIT
QTY
LABOR
RATE
linear ft
197
TOTAL
LABOR
HOURS
QTY

Equipment Weight
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
UNIT
191
GRAND
TOTAL
25,000
196
TOTAL
25,000
EQUIPMENT
RATE
185
195
LABOR
HOURS
lot
L.H.
UNIT
UNIT
184
190
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
QTY
hrs / ston
6.0
UNIT PRICE
TOTAL
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
TOTAL
LABOR
HOURS
LABOR
RATE
TOTAL
LABOR
COST
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL

Row
Category
CONTRACTOR LABOR
198
BIOMASS FEED LINE
199
Biomass Lock Hopper Feed Equipment
250,000
250,000
200
Biomass Lock Hopper Feed Chute
15,000
15,000
10
201
Biomass Lock Hopper Inlet Block Valve
75,000
75,000
202
Biomass Lock Hopper
176,400
203
Biomass Lock Hopper Bottom Reclaimer
204
Biomass Lock Hopper Rotating Dischrage Screw Motor
205
Biomass Lock Hopper Outlet Block Valve
206
207
DESCRIPTION
QTY
UNIT
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
GRAND
TOTAL
250,000
10
85.00
900
15,900
10
10
85.00
900
75,900
176,400
120
120
85.00
10,200
186,600
232,100
232,100
80
80
85.00
6,800
238,900
85.00
75,000
75,000
10
10
85.00
900
75,900
Biomass Lock Hopper Vent Filter
15,000
15,000
10
10
85.00
900
15,900
Biomass Lock Hopper Vent Filter Valve
15,000
15,000
10
10
85.00
900
15,900
208
197,100
197,100
130
130
85.00
11,100
208,200
209
Biomass Metering Bin Rotating Dischrage Screw
248,300
248,300
80
80
85.00
6,800
255,100
210
Biomass Metering Bin Rotating Dischrage Screw Motor
211
764,300
764,300
212
213
Biomass Transfer Screw Conveyor Discharge Expansion Joint
57,500
57,500
10
214
15,000
15,000
215
Biomass Transfer Screw Conveyor Discharge Chute Block

Valve
75,000
216
217
218
219
220
221
222
INCL
INCL
INCL
RATE
85.00
INCL
LABOR
HOURS
85.00
230
230
85.00
19,600
783,900
85.00
10
85.00
900
58,400
10
10
85.00
900
15,900
75,000
10
10
85.00
900
75,900
244,300
244,300
80
80
85.00
6,800
251,100
85.00

Category
SUBCONTR
TOTAL
(Lab & Mat)
Row
CONTRACTOR LABOR
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
Inert Gas System
lot
0.00
239
lot
0.00
240

Piping)
lot
0.00
241
Stack
lot
0.00
242
lot
0.00
243
UNIT
QTY
lot
DEMOLITION
244
245
DESCRIPTION
Demolition
QTY
UNIT
UNIT PRICE
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
LABOR
HOURS
TOTAL
LABOR
HOURS
RATE
LABOR
RATE
TOTAL
TOTAL
LABOR
COST
0.00
SUBCONTR
TOTAL
(Lab & Mat)
GRAND
TOTAL
TOTAL
49,000
2,726,100
246
2,571,700
1,233
85.47
105,400
Category
Row

DESCRIPTION
QTY
UNIT
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
U:\30251.00\4200 Process\4215 Design Data\01 - HGI Files\Workbooks\HP Biomass Feed Model\[2012-08-03 - HP Biomass Feed Model.xlsx]03-Cost Est
CONTRACTOR LABOR
L.H.
UNIT
LABOR
HOURS
RATE
TOTAL
SUBCONTR
TOTAL
(Lab & Mat)
GRAND
TOTAL
8/2/12 5:55 PM
APPENDIX H-4
DETAILED ESTIMATE
Report 30300/01

LP BIOMASS FEED SYSTEM - SINGLE LINE
GOLDEN, COLORADO
DATE: 08/03/2012
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
Category
Row
1
2b
2e
3
4
5
6
7
8
DESCRIPTION
Civil / Earthwork
Buildings
Piping
Electrical
Instrumentation
Equipment
Demolition
Owner Engineering
Pre-Project Cost
Capitalized Spares
Sales Taxes
Freight
Contingency
Escalation
Working Capital
Grand Total
QTY
% of TDC
0.0%
0.0%
0.0%
2.4%
3.2%
3.0%
0.0%
91.4%
0.0%
% of TCC
10.0%
2.0%
0.5%
2.0%
1.0%
3.0%
3.5%
0.0%
3.0%
25.0%
UNIT
CONTRACTOR LABOR
OWNER
CONTR. FURN
UNIT PRICE
FURN. TOTAL
TOTAL
0
0
0
0
0
0
0
0
0
0
% of TD&IC
15.0%
% of TD&IC
0%
0%
0%
0%
2%
0
0
0
25,200
9,700
64,300
0
1,911,100
0
2,010,300
2,010,300
L.H.
UNIT
LABOR
HOURS
317
116
560
993
993
RATE
TOTAL
85.38
0
0
0
27,000
9,900
0
0
47,900
0
84,800
85.38
0
0
0
84,800
85.23
85.05
85.54
SUBCONTR
TOTAL
(Lab & Mat)
GRAND
TOTAL
0
0
0
0
49,000
0
0
0
0
49,000
0
0
0
52,200
68,600
64,300
0
1,959,000
0
2,144,100
49,000
0
0
0
2,144,100
214,400
42,900
10,700
42,900
21,400
64,300
75,000
0
64,300
535,900
2,680,000
402,000
3,082,000
0
0
0
0
53,600
3,135,600
Category
Row

DESCRIPTION
QTY
UNIT
UNIT
QTY
UNIT PRICE
CONTRACTOR LABOR
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
LABOR
HOURS
RATE
TOTAL
SUBCONTR
TOTAL
(Lab & Mat)
GRAND
TOTAL
TOTAL
LABOR
HOURS
LABOR
RATE
TOTAL
LABOR
COST
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
50
51
52
53
--
-2
54
--
0.85
55
--
1.3
56
Labor Rate
$ / hr
85.00
UNIT
QTY
UNIT PRICE
3,020.00
92.571
85.00
1.46
0.018
85.00
57
58
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
59
acre
0.00
60
yd3
61
Site - Width
ft
62
Site - Length
ft
63
ft
0.0
64
65
yd3
1.50
0.150
85.00
66
yd3
20.00
0.060
85.00
67
Excavation - Depth
ft
0.00
68
Backfill - Depth
ft
0.00
69
Bay-1 - Qty
each
70
Bay-1 - Width
ft
71
Bay-1 - Length
ft
72
Bay-2 - Qty
each
73
Bay-2 - Width
ft
Row
Category
74
75
76
77
78
79
80
Pile - Density
pile / ft2
0.034
81
Pile - Length
ft
82
Casing
83
84
85
86
DESCRIPTION
Bay-2 - Length
QTY
UNIT
UNIT PRICE
ft
lot
40,000.00
each
2,340.00
lot
20,000.00
CONTRACTOR LABOR
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
LABOR
HOURS
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
GRAND
TOTAL
12.000
85.00
0
0
included
yd
0.0
Roads
lot
0.00
87
Paving
lot
0.00
88
Retention Ponds
lot
0.00
89
Ditches / Culverts
lot
0.00
90
Containment Berms
lot
0.00
91
Sumps
lot
0.00
92
Hydrants
lot
0.00
93
UNIT
QTY
yd3
in
BUILDINGS
94
95
2b
96
2b
97
2b

500.00
UNIT PRICE
250.00
12.000
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
0
6.000
TOTAL
LABOR
HOURS
85.00
LABOR
RATE
0
85.00
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
LABOR
COST
0
TOTAL

Row
Category
CONTRACTOR LABOR
98
2b
yd3
99
2b
in
100
2b
101
2b
short ton
3,180.00
21.000
102
2b
short ton
4,740.00
103
2b
short ton
4,740.00
104
2b
short ton
4,740.00
105
2b
short ton
106
2b
--
0.138
107
2b
DESCRIPTION
108
2b

Wt
109
2b
110
2b
Galvanized coating
111
2b
112
2b
113
2b
114
QTY
UNIT
--
0.070
--
0.333
--
0.042
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
400.00
10.000
LABOR
HOURS
0
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
GRAND
TOTAL
85.00
85.00
68.000
85.00
34.000
85.00
68.000
85.00
included
lot
130,000.00
2b
lot
0.00
115
2b
Sprinklers
lot
0.00
116
2b
Roofing
lot
0.00
117
2b
Siding
lot
0.00
118
2b
UNIT
QTY
UNIT PRICE
307
119
120
2e
yd3
0.0
121
2b
each
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
0
9.290
TOTAL
LABOR
HOURS
-
LABOR
RATE
85.00
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
LABOR
COST
0
TOTAL
Row
Category
122
2b
Not Used
each
123
2b
Not Used
each
124
2e
ft
8.0
125
2e
ft
8.0
126
2e
in
36.0
127
2e
UNIT
QTY
DESCRIPTION

128
QTY
UNIT
UNIT PRICE
UNIT PRICE
CONTRACTOR LABOR
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
LABOR
HOURS
RATE
TOTAL
SUBCONTR
TOTAL
(Lab & Mat)
GRAND
TOTAL
TOTAL
LABOR
HOURS
LABOR
RATE
TOTAL
LABOR
COST
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
129
each
130
each
131
ft
7.01
0.445
85.00
1" Piping
Carbon Steel
Standard Weight
w/Fittings
No Valves
1" Valves
Carbon Steel
150#
Wedge Gate
each
710
0.860
85.00
134
1" Valves
Carbon Steel
150#
Check
each
660
0.860
85.00
135
ft
9.38
0.726
85.00
each
710
0.860
85.00
132
133
136
2" Piping
Carbon Steel
Standard Weight
w/Fittings
No Valves
137
2" Valves
Carbon Steel
150#
Wedge Gate
Row
Category
138
139
DESCRIPTION
2" Valves
Carbon Steel
150#
Check
CONTRACTOR LABOR
660
0.860
85.00
ft
12.03
0.821
85.00
each
LABOR
HOURS
GRAND
TOTAL
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
UNIT
L.H.
UNIT
SUBCONTR
TOTAL
(Lab & Mat)
UNIT PRICE
QTY
RATE
TOTAL
3" Piping
Carbon Steel
Standard Weight
w/Fittings
No Valves
3" Valves
Carbon Steel
150#
Wedge Gate
each
1,000
1.250
85.00
142
3" Valves
Carbon Steel
150#
Check
each
780
1.250
85.00
143
ft
250
15.82
4,000
0.907
227
85.00
19,300
23,300
140
141
144
4" Piping
Carbon Steel
Standard Weight
w/Fittings
No Valves
145
4" Valves
Carbon Steel
150#
Wedge Gate
each
10
1,250
12,500
1.530
15
85.00
1,300
13,800
146
4" Valves
Carbon Steel
150#
Check
each
1,125
5,600
1.530
85.00
700
6,300
147
ft
24.06
1.302
85.00
each
1,850
2.000
85.00
148
6" Piping
Carbon Steel
Standard Weight
w/Fittings
No Valves
149
6" Valves
Carbon Steel
150#
Wedge Gate
Row
Category
150
151
DESCRIPTION
6" Valves
Carbon Steel
150#
Check
CONTRACTOR LABOR
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
1,750
2.000
ft
50
24.06
1,200
1.302
QTY
UNIT
each
L.H.
UNIT
LABOR
HOURS
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
GRAND
TOTAL
85.00
65
85.00
5,500
6,700
85.00
200
2,100
8" Piping
Carbon Steel
Standard Weight
w/Fittings
No Valves
8" Valves
Carbon Steel
150#
Wedge Gate
each
1,850
1,900
2.000
154
8" Valves
Carbon Steel
150#
Check
each
1,750
2.000
85.00
155
156
each
1,150
13.500
85.00
157
Hose Stations
each
1,150
13.500
85.00
158
Fire Water Piping
lot
85.00
159
152
153
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
160
ELECTRICAL
UNIT
QTY
161
5 HP Motor Wiring
200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
3,780
50.460
10 HP Motor Wiring
200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
3,929
3,900
52.230
15 HP Motor Wiring
200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
5,762
55.000
162
163
UNIT PRICE
TOTAL
LABOR
HOURS
52
LABOR
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
LABOR
COST
TOTAL
85.00
85.00
4,400
8,300
85.00
Category
CONTRACTOR LABOR
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
5,762
60.000
each
5,762
5,800
64.170
30 HP Motor Wiring
200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
5,762
72.000
50 HP Motor Wiring
200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
8,421
75 HP Motor Wiring
200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
8,421
100 HP Motor Wiring

200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
200 HP Motor Wiring

200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
171
250 HP Motor Wiring

200 ft of Wire
Medium Voltage
1C Conduit
Wire Terminations
172
173
174
175
Row
UNIT PRICE
164
165
166
167
168
169
170
DESCRIPTION
QTY
UNIT
20 HP Motor Wiring
200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
each
25 HP Motor Wiring
200 ft of Wire
Low Voltage
1C Conduit
Wire Terminations
L.H.
UNIT
LABOR
HOURS
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
GRAND
TOTAL
85.00
85.00
5,500
11,300
85.00
78.000
85.00
88.770
85.00
11,906
127.770
85.00
22,350
167.220
85.00
each
32,313
160.890
85.00
each
12,000
24,000
24,000
Lighting
lot
100,000
Control System UPS
lot
25,000
64
CONTRACTOR LABOR
Row
Category
SUBCONTR
TOTAL
(Lab & Mat)
176
177
Motors
178
lot
179
Unit Substation(s)
lot
180
lot
181
lot
182
UNIT
QTY
lot
DESCRIPTION
INSTRUMENTATION
183
25,000
included
included
186
included
187
I/O Racks
included
188
Remote Termination
included
189
UNIT PRICE
64,324
UNIT PRICE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
LABOR
COST
64,300
TOTAL
64,300
LABOR
CONTRACTOR
OWNER
HOURS /
FURNISHED
FURNISHED
UNIT
TOTAL
LABOR
HOURS
LABOR
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
LABOR
COST
7.3
0.343
85.00
0.009
49.00
192
Paint Finish Coat

ft2
0.210
193
lot
0.00
194
UNIT
QTY
LABOR
RATE
linear ft
197
TOTAL
LABOR
HOURS
QTY

Equipment Weight
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
UNIT
191
GRAND
TOTAL
25,000
196
TOTAL
25,000
EQUIPMENT
RATE
185
195
LABOR
HOURS
lot
L.H.
UNIT
UNIT
184
190
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
QTY
hrs / ston
6.0
UNIT PRICE
TOTAL
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
TOTAL
LABOR
HOURS
LABOR
RATE
TOTAL
LABOR
COST
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL

Row
Category
CONTRACTOR LABOR
198
BIOMASS FEED LINE
199
Biomass Metering Bin Distributor
250,000
250,000
200
Biomass Metering Bin Feed Chute
15,000
15,000
10
201
196,700
196,700
202
Biomass Metering Bin Reclaim Screw
248,300
248,300
203
Biomass Metering Bin Reclaim Screw Motor
204
764,300
764,300
205
206
Biomass Transfer Chute Expansion Joint
57,500
57,500
10
207
Biomass Transfer Chute
15,000
15,000
208
Biomass Transfer Chute Rotary Valve
120,000
209
210
211
212
213
214
215
216
217
218
219
220
221
222
DESCRIPTION
QTY
UNIT
INCL
INCL
INCL
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
LABOR
HOURS
RATE
SUBCONTR
TOTAL
(Lab & Mat)
TOTAL
GRAND
TOTAL
85.00
250,000
10
85.00
900
15,900
130
130
85.00
11,100
207,800
80
80
85.00
6,800
255,100
85.00
230
230
85.00
19,600
783,900
85.00
10
85.00
900
58,400
10
10
85.00
900
15,900
120,000
10
10
85.00
900
120,900
244,300
244,300
80
80
85.00
6,800
251,100
85.00

Category
SUBCONTR
TOTAL
(Lab & Mat)
Row
CONTRACTOR LABOR
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
Inert Gas System
lot
0.00
239
lot
0.00
240

Piping)
lot
0.00
241
Stack
lot
0.00
242
lot
0.00
243
UNIT
QTY
lot
DEMOLITION
244
245
DESCRIPTION
Demolition
QTY
UNIT
UNIT PRICE
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
L.H.
UNIT
LABOR
OWNER
CONTRACTOR
HOURS /
FURNISHED
FURNISHED
UNIT
LABOR
HOURS
TOTAL
LABOR
HOURS
RATE
LABOR
RATE
TOTAL
TOTAL
LABOR
COST
0.00
SUBCONTR
TOTAL
(Lab & Mat)
GRAND
TOTAL
TOTAL
49,000
2,144,100
246
2,010,300
993
85.38
84,800
Category
Row

DESCRIPTION
QTY
UNIT
UNIT PRICE
OWNER
CONTR. FURN
FURN. TOTAL
TOTAL
U:\30251.00\4200 Process\4215 Design Data\01 - HGI Files\Workbooks\LP Biomass Feed Model\[2012-08-03 - LP Biomass Feed Model.xlsx]03-Cost Est
CONTRACTOR LABOR
L.H.
UNIT
LABOR
HOURS
RATE
TOTAL
SUBCONTR
TOTAL
(Lab & Mat)
GRAND
TOTAL
8/2/12 5:55 PM
APPENDIX I
CAPITAL COST COMPARISON TABLE
Report 30300/01
NREL COST COMPARISONS

PROJECT NAME: GASIFIER MODELS
DATE: 11/02/2012
CFB
1
ROW
EQUIPMENT DESCRIPTION
BFB
2
15
Biomass Delivery Equipment
16
Biomass Delivery Equipment Motor
17
Biomass Distirbution Equipment
18
Biomass Distirbution Equipment Motor
19
20
Biomass Line-1 - Weigh Bin - Inlet Distribution Spreader
21
Biomass Line-1 - Weigh Bin - Inlet Distribution Spreader Motor
Biomass Bucket Elevator
Biomass Rotating Chute System
Rotating spreader in top of bin
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU*)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
Not Incl
Not Incl
Not Incl
Not Incl
Not Incl
Not Incl
Not Incl
Not Incl
Not Incl
Not Incl
Not Incl
Not Incl
Not Incl
Not Incl
Not Incl
Not Incl
Not Incl
Not Incl
Not Incl
$750,000
$250,000
Not Incl
Not Incl
Not Incl
Not Incl
Not Incl
Not Incl
Incl
--
--
Incl
--
--
--
--
--
--
Incl
--
--
--
--
$408,348
$210,000
Incl
--
--
--
--
--
--
Incl
--
--
--
--
EQUIPMENT DETAILS
14
FEED
22
23
Weighing hopper
Atmospheric vessel
24
Biomass Line-1 - Weigh Bin - Bottom Reclaimer
Reclaimer with single rotating screw, which pivets around

bottom of bin to move biomass to a center discharge chute.
25
Biomass Line-1 - Weigh Bin - Bottom Reclaimer - Screw Motor
--
--
Incl
--
--
--
--
26
Biomass Line-1 - Weigh Bin - Bottom Reclaimer - Pivet Motor
--
--
Incl
--
--
--
--
27
Biomass Line-1 - Weigh Bin - Outfeed Splitting Transfer Screw
--
--
Incl
--
--
--
--
28
Biomass Line-1 - Weigh Bin - Outfeed Splitting Transfer Screw Motor
--
--
Incl
--
--
--
--
29
Biomass Line-1 - Weigh Bin - Live Bottom Discharger
Reclaimer with multiple screws, which discharge to a single

screw conveyor
Incl
--
--
--
--
--
--
30
Biomass Line-1 - Weigh Bin - Live Bottom Discharger Screws Motor
Single motor and drive mechanism used to drive multiple

screws
Incl
--
--
--
--
--
--
31
Biomass Line-1 - Weigh Bin - Rotary Discharger
Rotary pocket feeder discharge device
Incl
--
--
--
--
--
--
32
Biomass Line-1 - Weigh Bin - Discharge Screw Conveyor

screw conveyor
--
Incl
--
--
--
--
--
33
Biomass Line-1 - Weigh Bin - Discharge Screw Conveyor Motor

screws
--
Incl
--
--
--
--
--
34
Biomass Line-1 - Weigh Bin - Vent Filter
Fabric filter
Incl
Incl
Incl
--
--
--
--
* ASU: Air Separation Unit
Reversible screw conveyor to split feed to two lock hoppers

DATE: 11/02/2012
CFB
1
ROW
BFB
2
FEED
5
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
--
--
--
--
--
$15,000
$15,000
--
Incl
Incl
--
--
$75,000
$75,000
Incl
$75,000
Incl
--
--
$198,100
$198,100
EQUIPMENT DETAILS
35
36
Biomass Line-1 - Lock Hopper No.1 - Feed Chute
37
Biomass Line-1 - Lock Hopper No.1 - Inlet Valve
Inlet pneumatic slide gate
38
Pressure vessel
39
Biomass Line-1 - Lock Hopper No.1 - Outlet Valve
Outlet pneumatic slide gate
--
--
Incl
--
--
--
--
40
Biomass Line-1 - Lock Hopper No.1 - Bottom Reclaimer

--
--
--
--
--
$245,400
$245,400
41
Biomass Line-1 - Lock Hopper No.1 - Bottom Reclaimer Screw Motor
--
--
--
--
--
Incl
Incl
42
Biomass Line-1 - Lock Hopper No.1 - Bottom Reclaimer - Pivet Motor
--
--
--
--
--
Incl
Incl
43
--
--
Incl
--
--
--
--
44
Pressure vessel
--
--
Incl
--
--
--
--
45
--
--
Incl
--
--
--
--
46
Biomass Line-1 - Lock Hopper - Discharge Conveyor
Pressurized
Reversible screw conveyor to receive discharge from two
lock hoppers
--
--
Incl
--
--
--
--
47
Biomass Line-1 - Lock Hopper - Discharge Conveyor Motor
--
--
Incl
--
--
--
--
48
Biomass Line-1 - Lock Hopper - Rotary Discharger
Incl
--
--
--
--
--
--
49
Biomass Line-1 - Lock Hopper - Rotary Discharger Motor
Incl
--
--
--
--
--
--
50
Biomass Line-1 - Lock Hopper - Vent Filter
--
--
--
--
--
$15,000
$15,000
51
Biomass Line-1 - Lock Hopper - Vent Filter Valve
--
--
--
--
--
$15,000
$15,000
Fabric filter
52
53
Biomass Line-1 - Lock Hopper Weigh Bin - Inlet Valve
--
--
--
Incl
--
--
--
54
Pressure vessel
Pressurized with nitrogen
--
--
--
Incl
--
--
--

DATE: 11/02/2012
CFB
1
ROW
55
Biomass Line-1 - Lock Hopper Weigh Bin - Discharge Screw

Conveyor
56

Conveyor Motor
BFB
2
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
--
--
--
Incl
--
--
--
--
--
--
Incl
--
--
--
EQUIPMENT DETAILS
Pressure vessel
FEED
57
58
Biomass Line-1 - Metering Bin - Inlet Valve
Incl
Incl
Incl
Incl
--
$75,000
$75,000
59
Pressure vessel
Incl
$120,000
Incl
Incl
--
$197,100
$197,100
60
Biomass Line-1 - Metering Bin - Outlet Valve
Incl
--
Incl
--
--
--
--
61
Biomass Line-1 - Metering Bin - Live Bottom Discharger

screw conveyor
Incl
--
Incl
--
--
--
--
62
Biomass Line-1 - Metering Bin - Live Bottom Discharger Motor

screws
Incl
--
Incl
--
--
--
--
63
Biomass Line-1 - Metering Bin - Bottom Reclaimer

--
--
--
--
--
$245,400
$245,400
64
Biomass Line-1 - Metering Bin - Bottom Reclaimer Screw Motor
--
--
--
--
--
Incl
Incl
65
Biomass Line-1 - Metering Bin - Bottom Reclaimer - Pivet Motor
--
--
--
--
--
Incl
Incl
66
Biomass Line-1 - Metering Bin - Discharge Screw Conveyor
--
Incl
Incl
Incl
--
--
--
67
Biomass Line-1 - Metering Bin - Discharge Screw Conveyor Motor
--
Incl
--
Incl
--
--
--
68
Biomass Line-1 - Metering Bin - Transfer Screw Conveyor
--
$17,000
Incl
Incl
--
$761,700
$761,700
69
Biomass Line-1 - Metering Bin - Transfer Screw Conveyor Motor
--
Incl
--
Incl
--
Incl
Incl
70
Biomass Line-1 - Metering Bin - Transfer Screw Conveyor Discharge

Expansion Joint
--
--
--
--
--
$57,500
$57,500
71
Biomass Line-1 - Metering Bin - Transfer Screw Outlet Chute
--
--
--
--
--
$15,000
$15,000
72
Biomass Line-1 - Metering Bin - Transfer Screw Outlet Valve
Pneumatic slide gate
--
--
--
--
--
$75,000
$75,000
Screw conveyor
Pressurized
Water cooled
Incl
$34,000
Incl
Incl
--
$243,400
$243,400
Screw conveyor
Pressurized
73
74

DATE: 11/02/2012
CFB
1
ROW
75
76
77
78
BFB
2
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
Incl
Incl
Incl
Incl
--
Incl
Incl
--
--
Incl
--
--
--
--
--
--
Incl
--
--
--
--
$408,348
$210,000
Incl
--
--
--
--
--
--
Incl
--
--
--
--
EQUIPMENT DETAILS
FEED
79
80
Weighing hopper
Atmospheric vessel
81

82
--
--
Incl
--
--
--
--
83
--
--
Incl
--
--
--
--
84
--
--
Incl
--
--
--
--
85
--
--
Incl
--
--
--
--
86

screw conveyor
Incl
--
--
--
--
--
--
87

screws
Incl
--
--
--
--
--
--
88
Incl
--
--
--
--
--
--
89

screw conveyor
--
Incl
--
--
--
--
--
90

screws
--
Incl
--
--
--
--
--
91
Fabric filter
Incl
Incl
Incl
--
--
--
--
--
--
--
--
--
$15,000
--
--
Incl
Incl
--
--
$75,000
--
Incl
$75,000
Incl
--
--
$198,100
--
92
93
94
95
Pressure vessel

DATE: 11/02/2012
CFB
1
ROW
BFB
2
FEED
5
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
EQUIPMENT DETAILS
96
--
--
Incl
--
--
--
--
97

--
--
--
--
--
$245,400
--
98
--
--
--
--
--
Incl
--
99
--
--
--
--
--
Incl
--
100
--
--
Incl
--
--
--
--
101
Pressure vessel
--
--
Incl
--
--
--
--
102
--
--
Incl
--
--
--
--
103
Pressurized
lock hoppers
--
--
Incl
--
--
--
--
104
--
--
Incl
--
--
--
--
105
Incl
--
--
--
--
--
--
106
Incl
--
--
--
--
--
--
107
--
--
--
--
--
$15,000
--
108
--
--
--
--
--
$15,000
--
Fabric filter
109
110
--
--
--
Incl
--
--
--
111
Pressure vessel
--
--
--
Incl
--
--
--
112

Conveyor
Pressure vessel
--
--
--
Incl
--
--
--
113

Conveyor Motor
--
--
--
Incl
--
--
--
Incl
Incl
Incl
Incl
--
$75,000
--
114
115

DATE: 11/02/2012
CFB
1
ROW
BFB
2
FEED
5
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
EQUIPMENT DETAILS
116
Pressure vessel
Incl
$120,000
Incl
Incl
--
$197,100
--
117
Incl
--
Incl
--
--
--
--
118

screw conveyor
Incl
--
Incl
--
--
--
--
119

screws
Incl
--
Incl
--
--
--
--
120

--
--
--
--
--
$245,400
--
121
--
--
--
--
--
Incl
--
122
--
--
--
--
--
Incl
--
123
--
Incl
Incl
Incl
--
--
--
124
--
Incl
--
Incl
--
--
--
125
--
$17,000
Incl
Incl
--
$761,700
--
126
--
Incl
--
Incl
--
Incl
--
127

Expansion Joint
--
--
--
--
--
$57,500
--
128
--
--
--
--
--
$15,000
--
129
--
--
--
--
--
$75,000
--
131
Screw conveyor
Pressurized
Water cooled
Incl
$34,000
Incl
Incl
--
$243,400
--
132
Incl
Incl
Incl
Incl
--
Incl
--
133
134
--
--
Incl
--
--
--
--
135
--
--
Incl
--
--
--
--
Screw conveyor
Pressurized
130

DATE: 11/02/2012
CFB
1
ROW
BFB
2
FEED
5
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
$408,348
$210,000
Incl
--
--
--
--
--
--
Incl
--
--
--
--
EQUIPMENT DETAILS
136
137
Weighing hopper
Atmospheric vessel
138

139
--
--
Incl
--
--
--
--
140
--
--
Incl
--
--
--
--
141
--
--
Incl
--
--
--
--
142
--
--
Incl
--
--
--
--
143

screw conveyor
Incl
--
--
--
--
--
--
144

screws
Incl
--
--
--
--
--
--
145
Incl
--
--
--
--
--
--
146

screw conveyor
--
Incl
--
--
--
--
--
147

screws
--
Incl
--
--
--
--
--
148
Fabric filter
Incl
Incl
Incl
--
--
--
--
--
--
--
--
--
$15,000
--
--
Incl
Incl
--
--
$75,000
--
Incl
$75,000
Incl
--
--
$198,100
--
149
150
151
152
Pressure vessel
153
--
--
Incl
--
--
--
--
154

--
--
--
--
--
$245,400
--
155
--
--
--
--
--
Incl
--
156
--
--
--
--
--
Incl
--

DATE: 11/02/2012
CFB
1
ROW
BFB
2
FEED
5
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
EQUIPMENT DETAILS
157
--
--
Incl
--
--
--
--
158
Pressure vessel
--
--
Incl
--
--
--
--
159
--
--
Incl
--
--
--
--
160
Pressurized
lock hoppers
--
--
Incl
--
--
--
--
161
--
--
Incl
--
--
--
--
162
Incl
--
--
--
--
--
--
163
Incl
--
--
--
--
--
--
164
--
--
--
--
--
$15,000
--
165
--
--
--
--
--
$15,000
--
Fabric filter
166
167
--
--
--
Incl
--
--
--
168
Pressure vessel
--
--
--
Incl
--
--
--
169

Conveyor
Pressure vessel
--
--
--
Incl
--
--
--
170

Conveyor Motor
--
--
--
Incl
--
--
--
171
172
Incl
Incl
Incl
Incl
--
$75,000
--
173
Pressure vessel
Incl
$120,000
Incl
Incl
--
$197,100
--
174
Incl
--
Incl
--
--
--
--
175

screw conveyor
Incl
--
Incl
--
--
--
--
176

screws
Incl
--
Incl
--
--
--
--

DATE: 11/02/2012
CFB
1
ROW
BFB
2
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
--
--
--
--
--
$245,400
--
EQUIPMENT DETAILS

FEED
177
178
--
--
--
--
--
Incl
--
179
--
--
--
--
--
Incl
--
180
--
Incl
Incl
Incl
--
--
--
181
--
Incl
--
Incl
--
--
--
182
--
$17,000
Incl
Incl
--
$761,700
--
183
--
Incl
--
Incl
--
Incl
--
184

Expansion Joint
--
--
--
--
--
$57,500
--
185
--
--
--
--
--
$15,000
--
186
--
--
--
--
--
$75,000
--
188
Screw conveyor
Pressurized
Water cooled
Incl
$34,000
Incl
Incl
--
$243,400
--
189
Incl
Incl
Incl
Incl
--
Incl
--
190
191
--
--
Incl
--
--
--
--
192
--
--
Incl
--
--
--
--
$408,348
$210,000
Incl
--
--
--
--
--
--
Incl
--
--
--
--
--
--
Incl
--
--
--
--
Screw conveyor
Pressurized
187
193
194
Weighing hopper
Atmospheric vessel
195

196

DATE: 11/02/2012
CFB
1
ROW
BFB
2
FEED
5
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
--
--
Incl
--
--
--
--
--
--
Incl
--
--
--
--
--
--
Incl
--
--
--
--
EQUIPMENT DETAILS
197
198
199
200

screw conveyor
Incl
--
--
--
--
--
--
201

screws
Incl
--
--
--
--
--
--
202
Incl
--
--
--
--
--
--
203

screw conveyor
--
Incl
--
--
--
--
--
204

screws
--
Incl
--
--
--
--
--
205
Fabric filter
Incl
Incl
Incl
--
--
--
--
--
--
--
--
--
$15,000
--
--
Incl
Incl
--
--
$75,000
--
Incl
$75,000
Incl
--
--
$198,100
--
206
207
208
209
Pressure vessel
210
--
--
Incl
--
--
--
--
211

--
--
--
--
--
$245,400
--
212
--
--
--
--
--
Incl
--
213
--
--
--
--
--
Incl
--
214
--
--
Incl
--
--
--
--
215
Pressure vessel
--
--
Incl
--
--
--
--
216
--
--
Incl
--
--
--
--

DATE: 11/02/2012
CFB
1
ROW
217
218
219
220
221
222
BFB
2
Fabric filter
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
--
--
Incl
--
--
--
--
--
--
Incl
--
--
--
--
Incl
--
--
--
--
--
--
Incl
--
--
--
--
--
--
--
--
--
--
--
$15,000
--
--
--
--
--
--
$15,000
--
EQUIPMENT DETAILS
Pressurized
lock hoppers
FEED
223
224
--
--
--
Incl
--
--
--
225
Pressure vessel
--
--
--
Incl
--
--
--
226

Conveyor
Pressure vessel
--
--
--
Incl
--
--
--
227

Conveyor Motor
--
--
--
Incl
--
--
--
228
229
Incl
Incl
Incl
Incl
--
$75,000
--
230
Pressure vessel
Incl
$120,000
Incl
Incl
--
$197,100
--
231
Incl
--
Incl
--
--
--
--
232

screw conveyor
Incl
--
Incl
--
--
--
--
233

screws
Incl
--
Incl
--
--
--
--
234

--
--
--
--
--
$245,400
--
235
--
--
--
--
--
Incl
--
236
--
--
--
--
--
Incl
--

DATE: 11/02/2012
CFB
1
ROW
BFB
2
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
--
Incl
Incl
Incl
--
--
--
EQUIPMENT DETAILS
Screw conveyor
Pressurized
FEED
237
238
--
Incl
--
Incl
--
--
--
239
--
$17,000
Incl
Incl
--
$761,700
--
240
--
Incl
--
Incl
--
Incl
--
241

Expansion Joint
--
--
--
--
--
$57,500
--
242
--
--
--
--
--
$15,000
--
243
--
--
--
--
--
$75,000
--
245
Screw conveyor
Pressurized
Water cooled
Incl
$34,000
Incl
Incl
--
$243,400
--
246
Incl
Incl
Incl
Incl
--
Incl
--
247
248
Pressure vessel
Inlet and outlet pneumatic slide gates
--
--
--
Incl
--
--
--
249
Biomass Line-5 - Lock Hopper Weigh Bin Live Bottom Discharge

Device
Proprietary
conveyor
--
--
--
Incl
--
--
--
250

Device Motor

screws
--
--
--
Incl
--
--
--
251
Biomass Line-5 - Lock Hopper Weigh Bin Discharge Screw Conveyor
Screw conveyor
--
--
--
Incl
--
--
--
252

Motor
--
--
--
Incl
--
--
--
253
Pressure vessel
--
--
--
Incl
--
--
--
254
Biomass Line-5 - Metering Bin Live Bottom Discharge Device
Proprietary
conveyor
--
--
--
Incl
--
--
--
255
Biomass Line-5 - Metering Bin Live Bottom Discharge Device Motor

screws
--
--
--
Incl
--
--
--
244

DATE: 11/02/2012
CFB
1
ROW
BFB
2
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
--
--
--
Incl
--
--
--
--
--
--
Incl
--
--
--
--
--
--
Incl
--
--
--
--
--
--
Incl
--
--
--
--
--
--
Incl
--
--
--
--
--
--
Incl
--
--
--
EQUIPMENT DETAILS
Screw conveyor
FEED
256
Biomass Line-5 - Metering Bin Discharge Screw Conveyor
257
Biomass Line-5 - Metering Bin Discharge Screw Conveyor Motor
258
259
260
261
262
263
Pressure vessel
--
--
--
Incl
--
--
--
264

Device
Proprietary
conveyor
--
--
--
Incl
--
--
--
265

Device Motor

screws
--
--
--
Incl
--
--
--
266
Screw conveyor
--
--
--
Incl
--
--
--
267

Motor
--
--
--
Incl
--
--
--
268
Pressure vessel
--
--
--
Incl
--
--
--
269
Biomass Line-6 - Metering Bin Live Bottom Discharge Device
Proprietary
conveyor
--
--
--
Incl
--
--
--
270
Biomass Line-6 - Metering Bin Live Bottom Discharge Device Motor

screws
--
--
--
Incl
--
--
--
271
Biomass Line-6 - Metering Bin Discharge Screw Conveyor
Screw conveyor
--
--
--
Incl
--
--
--
272
Biomass Line-6 - Metering Bin Discharge Screw Conveyor Motor
--
--
--
Incl
--
--
--
273
--
--
--
Incl
--
--
--
274
--
--
--
Incl
--
--
--
Screw conveyor
Screw conveyor
Water cooled
Screw conveyor

DATE: 11/02/2012
CFB
1
ROW
BFB
2
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
--
--
--
Incl
--
--
--
--
--
--
Incl
--
--
--
$38,800
$5,000
$38,800
$38,800
$8,500
$8,500
--
EQUIPMENT DETAILS
Screw conveyor
Water cooled
FEED
275
276
277
GASIFIER BED MEDIA STORAGE & HANDLING
278
Gasifier Bed Media - Unloading Station
Truck unloading station

Dolomite or silica material
279
Gasifier Bed Media - Unloading Transfer Line
Bed Media From Unloading Station To Storage Silo

Pressurized air is the motive power source
Incl
$1,500
Incl
Incl
Incl
Incl
--
280
Gasifier Bed Media - Storage Silo
Atmospheric vessel
Bottom discharge
Incl
$109,425
Incl
$116,300
$105,819
$105,819
--
281
Gasifier Bed Media - Storage Silo Vent Filter
Fabric filter
Incl
--
Incl
Incl
--
--
--
282
Gasifier Bed Media - Pneumatic Transporter
Rotary feeder
Pressurized air or nitrogen gas is the motive power source
Incl
--
--
--
$250,000
$250,000
--
283
Gasifier Bed Media - Pneumatic Transporter Motor
Incl
--
--
--
Incl
Incl
--
284
Gasifier Bed Media - Nitrogen Gas Tank
Dedicated tank to supply nitrogen to bed media transporter

Pressurized tank
--
--
--
--
$83,111
$83,111
--
285
Gasifier Bed Media - Nitrogen Gas Line
Dedicated line to supply nitrogen to bed media transporter
Incl
--
--
--
$2,500
$2,500
--
286
Gasifier Bed Media - Makeup Air Blower
--
$35,000
--
--
--
--
--
287
Gasifier Bed Media - Makeup Air Blower Motor
--
Incl
--
--
--
--
--
288
Gasifier Bed Media - Transfer Screw Conveyor
--
--
--
Incl
--
--
--
289
Gasifier Bed Media - Transfer Screw Conveyor Motor
--
--
--
Incl
--
--
--
290
Gasifier Bed Media - Recycled Media Mixing Hopper
Atmospheric vessel
Bottom discharge
--
--
--
Incl
--
--
--
291
Gasifier Bed Media - Dense Phase Conveyor Bin
Pressure vessel
--
--
--
Incl
--
--
--
292
Gasifier Bed Media - Pneumatic Metering Conveyor
Bed material and recycled char

Pressurized nitrogen is the motive power source
--
--
--
Incl
--
--
--
293
Gasifier Bed Media - Weigh Hopper
Atmospheric vessel
Bottom discharge fluidizing air system
--
--
Incl
--
--
--
--
294
Gasifier Bed Media - Lock Hopper
Pressure vessel
Inlet shutoff valve
Outlet shutoff valve
--
--
Incl
--
--
--
--
Metering screw conveyor

Pressurized

DATE: 11/02/2012
CFB
1
ROW
BFB
2
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
--
--
Incl
--
--
--
--
--
--
Incl
--
--
--
--
EQUIPMENT DETAILS

Pressurized
Outlet shutoff valve
FEED
295
Gasifier Bed Media - Lock Hopper Discharge Conveyor
296
Gasifier Bed Media - Lock Hopper Discharge Conveyor Motor
297
GASIFIER SORBENT MEDIA STORAGE & HANDLING
298
Gasifier Sorbent Media - Recieving Station
Truck unloading station

Typically limestone for removal of chlorine and sulfur
--
--
--
$58,750
--
--
--
299
Gasifier Sorbent Media - Pneumatic Unloading Conveyor
--
--
--
Incl
--
--
--
300
Gasifier Sorbent Media - Storage Silo
Atmospheric vessel
Bottom discharge
--
--
--
$176,250
--
--
--
Gasifier Sorbent Media - Storage Silo Vent Filter
Fabric filter
--
--
--
Incl
--
--
--
302
Gasifier Sorbent Media - Transfer Conveyor

Pressurized
--
--
--
Incl
--
--
--
303
Gasifier Sorbent Media - Transfer Conveyor Motor
--
--
--
Incl
--
--
--
304
Gasifier Sorbent Media - Dense Phase Conveyor Bin
Pressure vessel
--
--
--
Incl
--
--
--
305
Gasifier Sorbent Media - Pneumatic Metering Conveyor
Pressurized nitrogen is the motive power source
--
--
--
Incl
--
--
--
306
GASIFIER
Gasifier (BFB)
--
--
$14,528,047
$14,248,916
$546,361
$546,361
--
308
Gasification (CFB)
Circulating fluidized bed allothermal gasifier

Low pressure vessel
Refractory lined
Fluidized bed composed of biomass, externally heated bed
material & medium pressure steam
$14,330,003
$822,204
--
--
--
--
--
309
Horizontal pressure vessel fire box

Natural gas or light fuel oil burner
Refractory lined
--
$50,000
Incl
Incl
$150,000
$150,000
--
310
Gasifier - Startup Burner - Light Fuel Oil Booster Pump
Oil pump
--
--
Incl
--
--
--
--
311
Gasifier - Startup Burner - Light Fuel Oil Booster Pump Motor
--
--
Incl
--
--
--
--
307
Bubbling fluid bed auto thermal gasifier

Pressure vessel
Refractory lined
Fired with biomass, oxygen & steam
Fluidized bed composed of bed media, & biomass

DATE: 11/02/2012
CFB
1
ROW
BFB
2
FEED
5
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
EQUIPMENT DETAILS
312
Gasifier - Startup Burner - Air Compressor
Screw compressor
Air cooled
Oil free operation
--
--
Incl
Incl
--
--
--
313
Gasifier - Startup Burner - Air Compressor Motor
Variable frequency drive
--
--
Incl
Incl
--
--
--
314
Gasifier - Startup Burner - Air Receiver
Pressure vessel
--
--
Incl
--
--
--
--
315
GASIFIER CYCLONES
316
Pressure vessel
Refractory lined
Cone shaped bottom
Incl
$511,015
Incl
Incl
$160,924
$160,924
--
317
Gasification Reactor - Cyclone No.1 - Rotary Discharger

Pressurized
Incl
--
Incl
Incl
--
--
--
318
Gasification Reactor - Cyclone No.1 - Rotary Discharger Motor
Incl
--
Incl
Incl
--
--
--
319
Gasification Reactor - Heated Bed Material Surge Vessel
Cone shaped bottom
Incl
--
--
--
--
--
--
320
Cone shaped bottom
Incl
$504,655
--
--
--
--
--
321
Gasification Reactor - Cyclone No.2 - Rotary Discharger
Incl
--
--
--
--
--
--
322
Gasification Reactor - Cyclone No.2 - Rotary Discharger Motor
Incl
--
--
--
--
--
--
323
Gasification Reactor - Ash Surge Vessel
Incl
--
--
--
--
--
--
324
--
$491,545
--
--
--
--
--
325
GASIFIER BOTTOM ASH REMOVAL SYSTEM
326
Gasifier Ash Removal - Screw Conveyor
--
--
Incl
Incl
$159,497
$159,497
--
327
Gasifier Ash Removal - Screw Conveyor Motor
--
--
Incl
Incl
Incl
Incl
--
328
Gasifier Ash Removal - Dischrage Hopper
--
--
--
--
$165,732
$165,732
--
329
Gasifier Ash Removal - Lock Hopper No.1 Inlet Valve
--
--
--
--
$15,000
$15,000
--
330
Gasifier Ash Removal - Lock Hopper No.1
Pressure vessel
--
--
Incl
Incl
$165,185
$165,185
--
331
Gasifier Ash Removal - Lock Hopper No.1 Discharge Screw Conveyor
Screw conveyor
Pressurized
--
--
--
Incl
$310,935
$310,935
--
Screw conveyor
Pressurized
Water cooled
Pressure vessel

DATE: 11/02/2012
CFB
1
ROW
BFB
2
FEED
5
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
EQUIPMENT DETAILS
332
Gasifier Ash Removal - Lock Hopper No.1 Discharge Screw Conveyor

Motor
--
--
--
Incl
--
--
--
333
Gasifier Ash Removal - Lock Hopper No.1 Inlet Valve
--
--
--
--
$15,000
$15,000
--
334
Gasifier Ash Removal - Lock Hopper No.2
Pressure vessel
--
--
--
Incl
--
--
--
335
Gasifier Ash Removal - Screen
Atmospheric
--
--
--
Incl
--
--
--
336
Gasifier Ash Removal - Scree Rejects Conveyor
Atmospheric
--
--
--
Incl
--
--
--
337
Gasifier Ash Removal - Scree Rejects Conveyor Motor
--
--
--
Incl
--
--
--
338
Gasifier Ash Removal - Conveyor Hopper
Atmospheric vessel
Nitrogen gas pneumatic discharge
--
--
Incl
--
--
--
--
339
Gasifier Ash Removal - Pneumatic Conveyor
Pressurized nitrogen gas motive power source
--
--
Incl
--
--
--
--
340
Gasifier Ash Removal - Ash Storage Silo
Atmospheric vessel
--
$109,425
Incl
--
--
--
--
341
Screw conveyor
--
--
$40,000
--
--
--
--
342
Gasifier Ash Removal - Ash Transfer Conveyor Motor
--
--
Incl
--
--
--
--
343
COMBUSTION REACTOR
Incl
$896,891
--
--
--
--
--
Circulating fluidized bed combustion reactor

Fluidized bed composed of externally heated bed material &
clean gasifier syngas
Atmospheric vessel
Refractory lined
344
Combustion Reactor - Vessel
345
Combustion Reactor - Flue Gas Fan
Incl
--
--
--
--
--
--
346
Combustion Reactor - Flue Gas Fan Motor
Incl
--
--
--
--
--
--
347
Combustion Reactor - Startup Burner

Refractory lined
Natural gas burner
Incl
$50,000
--
--
--
--
--
348
Combustion Reactor - Air Heater
Screw conveyor
Water cooled
Incl
$159,000
--
--
--
--
--
349
Combustion Reactor - Air Fan
Incl
$262,500
--
--
--
--
--
350
Combustion Reactor - Air Fan Motor
Incl
Incl
--
--
--
--
--

DATE: 11/02/2012
CFB
1
ROW
BFB
2
FEED
5
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
EQUIPMENT DETAILS
351
COMBUSTION REACTOR CYCLONES
352
Combustion Reactor - No.1 Cyclone
Pressure vessel
Refractory lined
Cone shaped bottom
Incl
$785,028
--
--
--
--
--
353
Combustion Reactor - No.1 Cyclone - Rotary Discharger
Incl
--
--
--
--
--
--
354
Combustion Reactor - No.1 Cyclone - Rotary Discharger Motor
Incl
--
--
--
--
--
--
355
Combustion Reactor - No.1 Cyclone Solids Collection Bin
--
$488,556
--
--
--
--
--
356
Combustion Reactor - No.2 Cyclone
--
$780,928
--
--
--
--
--
357
Combustion Reactor - Transfer Screw Conveyor
Incl
--
--
--
--
--
--
358
Combustion Reactor - Transfer Screw Conveyor Motor
Incl
--
--
--
--
--
--
359
COMBUSTION REACTOR ASH DISPOSAL
360
Combustion Reactor - Ash Storage Bin
Atmospheric vessel
Incl
--
--
--
--
--
--
361
Combustion Reactor - Ash Storage Bin Discharge Screw Conveyor
Screw conveyor
Process water added to supress dust
Ash discharged as a moist solid suitable for soil
ammendment
Incl
--
--
--
--
--
--
362
Combustion Reactor - Ash Storage Bin DischargeScrew Conveyor

Motor
Incl
--
--
--
--
--
--
363
Combustion Reactor - Ash/Bed Material Disposal - Screw Conveyor
Incl
$20,000
--
--
--
--
--
364
Combustion Reactor - Ash/Bed Material Disposal - Screw Conveyor

Motor
Incl
Incl
--
--
--
--
--
365
Combustion Reactor - Ash/Bed Media Screw Conveyor Outlet Pocket

Feeder
--
$7,000
--
--
--
--
--
366
Combustion Reactor - Ash/Bed Media Screw Conveyor Outlet Pocket

Feeder Motor
--
Incl
--
--
--
--
--
367
SYNGAS TAR REFORMER BED MEDIA STORAGE & HANDLING
368
Syngas Tar Reformer Bed Media Truck Unloading Station
--
$5,000
--
--
--
--
--
369
Syngas Tar Reformer Bed Media Feed Bin
--
$109,425
--
--
--
--
--
Screw conveyor
Water cooled
Screw conveyor
Water cooled

DATE: 11/02/2012
CFB
1
ROW
BFB
2
FEED
5
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
EQUIPMENT DETAILS
370
Syngas Tar Reformer Bed Media Makeup Blower
--
$35,000
--
--
--
--
--
371
Syngas Tar Reformer Bed Media Makeup Blower Motor
--
Incl
--
--
--
--
--
372
SYNGAS TAR REFORMER
--
$1,522,654
Incl
Incl
--
$2,138,600
--
Syngas Tar Reformer
374
Syngas Tar Reformer - Conditioning Reactor
Circulating fluidized bed tar reformer

Fluidized bed composed of externally heated bed material &
clean gasifier syngas
Atmospheric vessel
Refractory lined
Incl
--
--
--
--
--
--
375
Syngas Tar Reformer - Pulse Tank
Pressure vessel
Steam receiver tank for periodic back flow pulsing of catalyst
blocks to clean catalyst
--
--
Incl
--
--
--
--
376
Syngas Tar Reformer - Burner

Natural gas or light fuel oil burner
Refractory lined
--
--
Incl
--
--
--
--
377
SYNGAS TAR REFORMER CYCLONES
378
Syngas Tar Reformer- No.1 Cyclone
--
$992,814
--
--
--
--
--
379
Syngas Tar Reformer - No.2 Cyclone
--
$992,813
--
--
--
--
--
380
Syngas Tar Reformer - Cyclones Solids Collection Bin
--
$491,545
--
--
--
--
--
381
382
--
$593,441
--
--
--
--
--
383
--
$159,000
--
--
--
--
--
384
--
$262,500
--
--
--
--
--
385
--
Incl
--
--
--
--
--
386
--
$75,000
--
--
--
--
--
387
REFORMER BED MEDIA HEATING REACTOR CYCLONES
373
Pressure vessel
Refractory lined
Internal catalyst support trays
Packed with catalyst blocks

DATE: 11/02/2012
CFB
1
ROW
BFB
2
FEED
5
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
EQUIPMENT DETAILS
388
--
$193,670
--
--
--
Incl
--
389
--
$193,670
--
--
--
--
--
390
Reformer Bed Media Heating Reactor No.1 Cyclone Solids Collection

Bin
--
$488,556
--
--
--
--
--
391
REFORMER BED MEDIA HEATING REACTOR - ASH DISPOSAL
392
Reformer Bed Media Heating Reactor - Ash Cooling Screw Conveyor
--
$20,000
--
--
--
--
--
393

Motor
--
Incl
--
--
--
--
--
394

Outlet Pocket Feeder
--
$7,000
--
--
--
--
--
395

Outlet Pocket Feeder Motor
--
Incl
--
--
--
--
--
396
Reformer Bed Media Heating Reactor - Ash Storage Bin
--
$109,425
--
--
--
--
--
397
PROCESS AIR SYSTEM
398
Screw compressor
Air cooled
Oil free operation
$50,000
--
$50,000
$50,000
--
$50,000
--
399
Variable frequeny drive
Incl
--
Incl
Incl
--
Incl
--
400
Process Air - Dryer
Incl
--
Incl
Incl
--
Incl
--
401
Incl
--
Incl
Incl
--
Incl
--
402
403
Air Separation Plant - Oxygen / Nitrogen Separator
Screw compressor
Oil free operation
$784,539
--
$7,198,807
$7,186,112
--
$7,186,112
--
404
Pressure vessel
--
--
Incl
Incl
--
Incl
--
405
Air Separation Plant - Nitrogen Gas Receiver Tank
Pressure vessel
Incl
--
Incl
Incl
--
Incl
--
406
OXYGEN SYSTEM
407
--
--
$50,000
$50,000
--
$50,000
--
Pressure vessel
Screw compressor
Air cooled
Oil free operation

DATE: 11/02/2012
CFB
1
ROW
BFB
2
FEED
5
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
EQUIPMENT DETAILS
408
--
--
Incl
Incl
--
Incl
--
409
Pressure vessel
Oxygen supply for gasifier & tar remover combustion
--
--
Incl
Incl
--
Incl
--
410
Oxygen System - Oxygen Heater
Indirect heat supplied by medium pressure steam
--
--
Incl
--
--
--
--
411
NITROGEN SYSTEM
412
Nitrogen System - Instrument Nitrogen Gas Supply Tank
Pressure vessel
Nitrogen supply for instrumentation operation
Incl
--
Incl
$75,000
--
$75,000
--
413
Screw compressor
Air cooled
Oil free operation
Incl
--
Incl
Incl
--
Incl
--
414
Incl
--
Incl
Incl
--
Incl
--
Nitrogen System - Process Nitrogen Gas Supply Tank No.1
Pressure vessel
High pressure nitrogen
Nitrogen supply for biomass feed system, gasifier,tar
reformer pressurization & purge requirements
Incl
--
Incl
Incl
--
Incl
--
416
Nitrogen System - Process Nitrogen Gas Supply Tank No.2
Pressure vessel
Low pressure nitrogen
Nitrogen supply for biomass feed system, gasifier,tar
reformer pressurization & purge requirements
--
--
Incl
--
--
--
--
417
Nitrogen System - Emergency Booster Compressor
Screw compressor
Air cooled
Oil free operation
--
--
Incl
--
--
--
--
418
Nitrogen System - Emergeny Booster Compressor Motor
--
--
Incl
--
--
--
--
419
Nitrogen System - Emergency Nitrogen Gas Storage Tank
Pressure vessel
High pressure nitrogen
Nitrogen supply for emergency shutdowns to prevent fires
and explosions
--
--
Incl
--
--
--
--
420
FLARE STACK
421
Syngas Flare Stack
Incl
$6,000
$25,000
Incl
--
$25,000
--
422
COMBUSTION REACTOR EXHAUST STACK
423
Exhaust Stack
Incl
--
--
--
--
--
--
424
ASH SCREW COOLING WATER SYSTEM
415

DATE: 11/02/2012
CFB
1
ROW
BFB
2
FEED
5
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
--
--
Incl
--
--
--
--
EQUIPMENT DETAILS
425
Ash Screw Cooling Water - Storage Tank
426
Indirect heat exchanger with clean ash screw cooling water

on one side being cooled by cold mill water on the other side
--
--
Incl
Incl
--
--
--
427
Centrifugal pump
--
--
Incl
--
--
--
--
428
--
--
Incl
--
--
--
--
429
--
--
Incl
--
--
--
--
430
--
--
Incl
--
--
--
--
431
SEAL WATER SYSTEM
432
Seal Water - Storage Tank
--
--
Incl
--
--
--
--
433
Seal Water - Heat Exchanger
Indirect heat exchanger with clean seal water on one side

being cooled by cold mill water on the other side
--
--
Incl
--
--
--
--
434
Centrifugal pump
--
--
Incl
--
--
--
--
435
--
--
Incl
--
--
--
--
436
--
--
Incl
--
--
--
--
437
--
--
Incl
--
--
--
--
438
DUCTS & PIPING
439
Line
From Bed Media Pneumatic Transporter
To Gasifier
Refractory lined
--
$136,902
--
--
Incl
Incl
--
440
Line
From Gasifier Reactor Cyclone No.1
To Gasifier
Refractory lined
--
--
--
--
$191,879
$191,879
--
441
Line
To Gasifier Reactor Cyclones Collection bin
Refractory lined
--
$104,572
--
--
--
--
--
442
Line
From Gasifier
To Gasifier Ash Cooling Screw Conveyor
Refractory lined
--
--
--
--
$130,945
$130,945
--
443
Line
From Ash Cooling Screw Conveyor
To Ash Discharge Hopper
Refractory lined
--
--
--
--
$5,000
$5,000
--
Centrifugal pump
Centrifugal pump

DATE: 11/02/2012
CFB
1
ROW
BFB
2
FEED
5
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
EQUIPMENT DETAILS
444
Line
From Ash Discharge Hopper
To Ash Lock Hopper
Refractory lined
--
--
--
--
$5,000
$5,000
--
445
Line
From Gasifier Reactor No.2 Cyclone
To Gasifier Reactor Cyclones Solids Collection Bin
Refractory lined
--
$103,072
--
--
--
--
--
446
Line
From Gasifier Reactor Cyclones Solids Collection Bin
To Char Combustion Reactor
Refractory lined
--
$129,986
--
--
--
--
--
447
Line
From Char Combustion Reactor No.1 Cyclone
To Char Combustion Reactor No.1 Cyclone Solids Collection Bin
Refractory lined
--
$103,072
--
--
--
--
--
448
Line
From Char Combustion Reactor No.1 Cyclone Solids Collection Bin Refractory lined
To Gasifier Reactor
--
$129,986
--
--
--
--
--
449
Line
To Char Combustion Loop Depleted Bed Media & Ash Cooling
Screw Conveyor
Refractory lined
--
$103,351
--
--
--
--
--
450
Line
From Syngas Reformer Reactor No.1 Cyclone
To Syngas Reformer Reactor Cyclones Solids Collection Bin
Refractory lined
--
$63,399
--
--
--
--
--
451
Line
From Reformer Loop Bed Media Truck Unloading Station
To Reformer Loop Bed Media Feed Bin
Refractory lined
--
$100,151
--
--
--
--
--
452
Line
From Reformer Loop Bed Media Makeup Blower
To Reformer Bed Media Heating Reactor
Refractory lined
--
$136,902
--
--
--
--
--
453
Line
To Syngas Reformer Reactor Cyclones Solids Collection Bin
Refractory lined
--
$103,072
--
--
--
--
--
454
Line
From Syngas Reformer Reactor Cyclones Solids Collection Bin
Refractory lined
--
$174,599
--
--
--
--
--
455
Line
From Reformer Bed Media Heating Reactor No.1 Cyclone
To Reformer Bed Media Heating Reactor No.1 Cyclone Solids
Collection Bin
Refractory lined
--
$103,072
--
--
--
--
--
456
Line
From Reformer Bed Media Heating Reactor Cyclone No.1 Solids
Collection Bin
To
Refractory lined
--
$174,599
--
--
--
--
--

DATE: 11/02/2012
CFB
1
ROW
BFB
2
FEED
5
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
EQUIPMENT DETAILS
457
Line
To Reformer Loop Depleted Bed Media Cooling Screw Conveyor
Refractory lined
--
$129,986
--
--
--
--
--
458
Line
From Char Combustion Loop Depleted Bed Media & Ash Cooling
Screw Conveyor
To Gasifier Loop Depleted Bed Media & Ash Storage Bin
Refractory lined
--
$43,423
--
--
--
--
--
459
Line
From Reformer Loop Depleted Bed Media Cooling Screw Conveyor Refractory lined
To Reformer Loop Depleted Bed Media Storage Bin
--
$43,423
--
--
--
--
--
460
Line
From Gasifier Ash Removal - Lock Hopper No.1
To Battery Limit
--
$43,423
--
--
$8,000
$8,000
--
461
Duct
From Gasifier Reactor
To Gasifier Reactor Cyclone No.1
Refractory lined
--
$651,112
--
--
$161,893
$161,893
--
462
Duct
To Gasifier Reactor Cyclone No.2
Refractory lined
--
$566,281
--
--
--
--
--
463
Duct
To Battery limit
Refractory lined
--
--
--
--
$201,035
$201,035
--
464
Duct
To Syngas Reformer Reactor
Refractory lined
--
$1,179,581
--
--
--
--
--
465
Duct
From Char Combustion Reactor
To Char Combustion Reactor No.1 Cyclone
Refractory lined
--
$769,578
--
--
--
--
--
466
Duct
To Char Combustion Reactor No.2 Cyclone
Refractory lined
--
$721,797
--
--
--
--
--
467
Duct
To Battery Limit (Flue Gas)
Refractory lined
--
$648,346
--
--
--
--
--
468
Duct
From Syngas Reformer Reactor
To Syngas Reformer Reactor No.1 Cyclone
Refractory lined
--
$1,175,795
--
--
--
--
--
469
Duct
From Syngas Tar Reformer Cyclone No.1
To Syngas Tar Reformer Cyclone No.2
Refractory lined
--
$1,175,795
--
--
--
--
--

DATE: 11/02/2012
CFB
1
ROW
BFB
2
FEED
5
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
EQUIPMENT DETAILS
470
Duct
To Battery Limit (Reformed Syngas)
Refractory lined
--
$1,175,795
--
--
--
--
--
471
Duct
From Reformer Bed Media Heating Reactor
To Reformer Bed Media Heating Reactor Cyclone No.1
Refractory lined
--
$436,706
--
--
--
--
--
472
Duct
To Reformer Bed Media Heating Reactor No.2 Cyclone
Refractory lined
--
$436,706
--
--
--
--
--
473
Duct
To Battery Limit (Flue Gas)
Refractory lined
--
$436,706
--
--
--
--
--
474
Duct
From Supplemental Gas Battery Limits
Refractory lined
--
$545,714
--
--
--
--
--
475
Duct
From Duct-03 & Duct-13
Refractory lined
--
$706,251
--
--
--
--
--
476
Duct
From Char Conbustion Reactor Air Blower
To Char Combustion Reactor Startup Burner
Refractory lined
--
$490,004
--
--
--
--
--
477
Duct
From Reformer Bed Media Heating Reactor Air Heater
Refractory lined
--
$215,977
--
--
--
--
--
478
Duct
From Char Conbustion Reactor Air Blower
To Char Combustion Reactor Startup Burner & Gasifier Reactor
Startup Burner
Refractory lined
--
$378,234
--
--
--
--
--

DATE: 11/02/2012
CFB
1
ROW
BFB
2
FEED
5
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
EQUIPMENT DETAILS
479
TOTAL COST
480
Civil / Earthwork
$354,400
$683,100
$487,300
$487,300
$222,200
$489,984
$0
481
Buildings
$460,000
$4,569,300
$460,000
$460,000
$269,600
$462,534
$0
482
$2,556,000
$12,900
$3,124,000
$3,124,000
$2,100
$3,141,208
$0
483
Piping & Ducts - Individually Identified
$0
$13,637,400
$0
$0
$703,800
$703,800
$0
484
Piping & Ducts - Miscellaneous
$2,010,000
$131,400
$2,010,000
$2,010,000
$24,000
$2,021,072
$25,200
485
Electrical
$1,792,000
$111,200
$2,116,700
$2,120,400
$14,200
$2,128,359
$21,100
486
Instrumentation
$995,600
$1,268,100
$1,175,900
$1,178,000
$135,700
$1,182,377
$84,100
487
Process Insulation / painting
$398,200
$13,100
$470,400
$471,200
$2,100
$472,991
$0
488
Equipment
$16,836,700
$14,171,200
$21,930,700
$22,000,100
$2,138,600
$21,347,700
$2,483,600
489
Total Equipment & Materials
$25,402,900
$34,597,700
$31,775,000
$31,851,000
$3,512,300
$31,950,025
$2,614,000
490
General Contractor Labor Cost
$13,698,900
$6,915,700
$14,467,500
$14,474,100
$572,400
$14,547,191
$115,600
491
Sub-Contractor Material & Labor Cost
$720,400
$700,000
$795,200
$795,200
$440,000
$799,580
$73,000
492
Total Direct Cost (Total Installed Cost)
$39,822,200
$42,213,400
$47,037,700
$47,120,300
$4,524,700
$47,296,796
$2,802,600
493
% Indirect Costs
25.00
25.00
25.00
25.00
25.00
25.00
25.00
494
Total Indirect Costs (Engineering, Taxes, Freight, etc.)
$9,955,600
$10,553,400
$11,759,400
$11,780,100
$1,131,200
$11,824,200
$700,700
495
Total Direct & Indirect Costs
$49,777,800
$52,766,800
$58,797,100
$58,900,400
$5,655,900
$59,120,996
$3,503,300
496
% Contingency
20.00
15.00
20.00
20.00
15.00
15.00
15.00
497
Contingency
$9,955,600
$7,915,000
$11,759,400
$11,780,100
$848,400
$8,868,100
$525,500
498
% Startup & Training
2.00
2.00
2.00
2.00
2.00
2.00
2.00
499
Startup & Training
$796,400
$844,300
$940,800
$942,400
$90,500
$945,900
$56,100

DATE: 11/02/2012
CFB
1
ROW
500
Total Project Investment
BFB
2
FEED
5
TECHNOLOGY #2
EXCEL MODEL
TECHNOLOGY #1
TECHNOLOGY #3
EXCEL MODEL
COMPOSITE SYSTEM
EXCEL MODEL
CFB
CFB
BFB
OXYGEN BLOWN
BFB
OXYGEN BLOWN
BFB WITHOUT AIR

SEPARATION,
REFORMER OR
BIOMASS FEED
SYSTEMS
BFB WITH AIR

SEPARATION,
REFORMER AND (4)
HP BIOMASS FEED
SYSTEMS
SINGLE LINE HIGH

PRESSURE
BIOMASS FEED
SYSTEM
ORDER OF
MAGNITUDE
BUDGETARY
ORDER OF
MAGNITUDE
ORDER OF
MAGNITUDE
BUDGETARY
BUDGETARY
(EXCEPT ASU)
BUDGETARY
COST
COST
COST
COST
COST
COST
COST
$60,529,800
$61,526,100
$71,497,300
$71,622,900
$6,594,800
$68,934,996
$4,084,900
EQUIPMENT DETAILS
APPENDIX J
GASIFICATION VENDOR COMPARISON MATRIX
Report 30300/01
REV
G
B
C
D
E
F
REV
Technology
G
Suppliers
PROJECT:
DATE:
Basic process
Indicates an IBR Project,

http://www1.eere.energy.gov/biomass/integrated_biorefineries.html
PROJECT NAME:
Press.
(psig)
Heat Source
Tar production
auto
PRM Energy
updraft airblown gasifier using a

bed agitator
auto
B&W Volund
updraft air blown gasifier with wet

ash removal system; bed agitated
at top
auto
high
Primenergy
updraft airblown gasifier using a

bed agitator (copied PRME
systems)
auto
high
auto
use hydraulic cylinders to push
feedstock into gasifier, air as
oxidant, hydraulic cylinders to pull
ash out; modular gasifiers in
12,000BTU/hr units
Tars methodology
HHV
Technology status:
keep gases hot,

technology to convert tars
high - 85BTU/cuft, tar
commercialized on
~150 BTU/cuft
to lighter gaseous
dewpoint 625F
limited basis
hydrocarbons in
development
developing in coordination
10-21g/Nm3, tar
with Dahlman OLGA
syngas 147
nemerous rice hull units
dewpoint 420F
system; considering
BTU/cuft
plasma arc
air blown updraft gasifier, moving

ash grate in bottom of vessel
MaxWest
Environmental
Mechanically
Agitated Bed
Temp
BY
MWW
MWW
MWW
MWW
MWW
MWW
Nexterra
Heat Transfer Intl HTI
Fixed Bed Updraft
6/14/2011
DATE
6/14/2011
11/15/2010
2/3/2011
2/28/2011
3/17/2011
5/12/2011
tried metallic catalysts,

tried water scrubbing, then
settled on gas cooling with
post wet ESP to catch
aerosols; tars stored for
industrial oil
Biomass sites:
Advantages
Disadvantages
Comments
Tolko, Kamloops, BC and

USC
have experience with 24/7

gasifiers
vendor will guarantee fossil fuel

displacement of only 65%
unless feedstock is dried to
under 10% moisture, moving
ash grate inside vessel
IBR Link
Website
too small and only making power,

although they have started looking at
syngas
Stugart, AR, Italy,

Moissannes, FR
many operating units
mechanically agitated bed and 1. rice hull gasifier design not optimized
primary air supply not good in for wood 2. internal moving parts 3. only
wood service
air blown so far
http://www.prmenergy.com/
1. only one demonstrable plant at

very limited number and size of 3.5MW 2. internal moving parts 3. only
small scale power so far 3. using
applications to date
Jenbacher genset
http://www.volund.dk/technologies_
products/gasification/the_gasificatio
n_process
http://www.nexterra.ca/
probably 150
BTU/cuft
limited to one 3.5MW

site with a lot of
experience
Harboore Denmark CHP

plant, new plant in Japan
93% availabililty and

generating power at
Harboore for several years
syngas
147BTU/cuft
numerous rice hull units
Little Falls, MN and others
none
customer support is an issue,

technology is a copy of PRME
1. potential lack of technical expertise

and customer support 2. rice hull
gasifier that is not optimized for wood
usage 3. internal moving parts
commercialized and
operating several
medical waste
incineration facilities
none
have gasification experience

more than some
no single focus area for this

company, no biomass
experience
not demonstratable in biomass,

variation on Nexterra
http://www.heatxfer.com/
just starting up horse

manure unit in Ocala
area
2 Florida units
no large scale experience
not demonstrable on large scale
http://www.maxwestenergy.com/how
_it_works.html
http://www.primenergy.com/
Andritz / Carbona
Nat gas
burners/allotherm
al
Nat gas
burners/allotherm
al
Thermoselect
O2-blown, bottom ram-fed,

upflow
Interstate Waste
Technologies
O2-blown, bottom ram-fed,

upflow
Krann Energy
Systems
Fixed bed up draft
Innovative Energy Inc
pressurized updraft
Lurgi (Air Liquide)
aka dry-ash moving bed. It's

really just an updraft fixed bed
coal gasifier
auto
not srue if this is the current technology

that they market. I think the entrained
flow is the current technology
http://www.netl.doe.gov/technologie
s/coalpower/gasification/gasifipedia/
4-gasifiers/4-1-1-1_lurgi.html
Linde
Licensors Engineering
Contractors for a major portion of
the Sasol, Fixed Bed Dry
Bottom (FBDB) Gasification
Technology for an initial term of
10 years.
auto
worked on Choren project
http://www.the-lindegroup.com/en/corporate_responsibil
ity/engineering_division/biomass/bio
fuels/gasification_of_biomass.html
Entech
looks like maybe a reciprocating

grate or similar furnace design
auto
EnviroArc
Dual vessel, first vessesl is fixed

bed slagging with plasma tourch
on second vessel for tar
reforming
auto
Phoenix BioEnergy
LLC. License to ICM
Auger gasifier
ICM
has license w/ Phoenix for

transportaiton fuels pathway
Range Fuels (IBR

Project)
Series of externally heated

augers followed by an externally
heated suspension pyrolysis loop
Used by Interstate Waste Technologies

on a number of commercial sites??
6 or 7 sites in Japan on
industrial waste and MSW
http://www.iwtonline.com/aboutus/faqs.html
same as Thermoselect??
http://krann.ca/index.htm
web site says nothing of technology
http://innovativeenergyinc.com/
http://www.entech-res.com/wtgas/
Licensed to ICM who has pilot

plant in Newton, KS
http://phoenixbioenergyusa.com/ind
ex.php
ICM has license for transportation fuels
http://www.icminc.com/services/gasi
fiers/
out of business?
http://www1.eere
.energy.gov/biom
ass/pdfs/ibr_com
mercial_rangefu
els.pdf
REV
G
B
C
D
E
F
REV
Technology
G
Suppliers
Basic process
Renet
closest thing to a downdraft

gasifier found so far (biomass
inserted at top, air inserted on
sides at upper and lower levels,
syngas pulled off side)
PHG Energy
Downdraft Gasifier is a
sequential, co-current flow,
gravity-assisted
Community Power
Corp
fixed bed down draft
Fixed Bed Downdraft
Plasma Arc
PROJECT:
DATE:
6/14/2011
Temp
BY
MWW
MWW
MWW
MWW
MWW
MWW

PROJECT NAME:
Press.
(psig)
Heat Source
auto
Tar production
Tars methodology
HHV
syngas passes through hot

oxidation zone where tars
lower tar levels than
are cracked; rape methyl
updraft gasifiers, but
esther (RME) is used to
still a challenge
further scrub tars
afterward
Technology status:
Biomass sites:
small scale pilot
Wiener Neustadt pilot plant
Advantages
Disadvantages
Comments
very little experience, still

struggling with addressing tars
in syngas
not demonstrable
IBR Link
Website
http://www.renet.at/english/sites/wr.
neustadt/technology.php
http://www.phgenergy.com/?page_i
d=2
auto
small modular units up to about 2

tons/day of dry feedstock, not scalable
Alter NRG (was

westinghouse)
less feedstock sizing required but

still need drying, gasify with
Westinghouse plasma torches,
inert slag comes out bottom;
three stdd sizes: 75/150/500tpd;
water used on lower unit for
cooling; air added at torches as
well as sec/ter air zones above
allo
near zero
not needed; higher

temperature gasification
breaks tars
Utashinai, Japan
150mmBTU/cuft
280tpdMSW, Defiance,OH
on air,
in use at steel and
(GM foundry) Quebec (Alcan feedstock size/moisture can
250mmBTU/cuft
torch power consumes 3-10% of plasma assisted O2 gasification, might
aluminum foundries,
vary; most forgiving design
Aluminum) pilot plant in
be an option by subtracting out the
on O2 (gasifier
input BTU rate; torches last
hazmat facilities, MSW Madison,PA; Tallahassee and for blending knots/shives or
plasma portion?
processes more
3000hrs and take 1hr to change
GPS signed contract to
processers
other wastes
wood on O2
process 1000tpdMSW and
also)
make 35MW in 2010
MPM Technologies
three electrodes produce electric

arc to gasify biomass
allo
near zero
not needed; higher

breaks all tars
InEnTec (S4 Energy

DC plasma arc with an AC glass
is partnership w/
melter
waste mngmnt)
allo
Solena Group
medium/high?
everything shut down

now
pilot site in Libby, MT,

120tpd in Italy
feedstock moisture can vary

up to 55% with no difficulty
substantial parasitic power

consumption
Dow Cornings silicone-based

manufacturing facility in
Midland, Mic
Plasco Energy Group
std technology is two-stage

gasification. 2nd stage is
plasma.
allo
Princeton
plasma torch gasification done in

sequenced batches to smooth out
syngas production
allo
http://www.gocpc.com/
http://www.alternrg.ca/gasification/in
dex.html
not demonstrable
commercialization of INL? Fulcrum is
using this technology
allo
Europlasma
Electrode/Electri
c Arc
DATE
6/14/2011
11/15/2010
2/3/2011
2/28/2011
3/17/2011
5/12/2011
http://www.inentec.com/
http://www.solenagroup.com/
near zero
not needed; higher

breaks all tars
medium/high?
Commercial
5 tonne/day R&D in Spain,

planned sites = 100 tonne/day
Demo in Ottawa, 200 tpd
Commercial MSW & ICI in
Red Deer, Canada
used mostly for

hazardous wastes
SE Asia
very little info
substantial parasitic power

consumption
2 or 3 other commercial sites in the

works, Drives IC enginers. Claim > 1
MW-hr / tonne of waste. Designs based
on standard 100 tpd
http://www.plascoenergygroup.com/
1. units are small 2. parasitic power

consumption can be high
http://www.princetonenvironmental.c
om/plasma.html
allo
AdaptiveARC, Inc.
"low temp" cool plasma
allo
http://www.adaptivearc.com/
MPM Technologies,
Inc. Skygas
zero O2 or air used, similar to

smelting
allo
http://www.mpmtech.com/gasificatio
n.html
GTI Renugas
Pressurized fluid bed air/ocygen

835C (1535F)
blown
333 max
Andritz / Carbona
(IBR Project w/
Haldor Topsoe)
circulating and bubling fluidized

bed (Renugas license) air and/or
O2 blown gasifier
range (100150)
Frontline Bioenergy
bubbling fluidized bed air blown

60psi gasifier, single vessel
atm+
Enerkem (IBR
Project)
auto
auto
.03BTU/cuft (after
catalyst?)
nickel catalyst at Skive,

Denmark
auto
5-21g/Nm3, tar
dewpoint 450F
keep gases hot
bubbling fuidized bed air blown

single vessel; company focus is
on creating cellulosic ethanol by
catalysis
auto
high
catalytic and tar reinjection to reactor
Radian Bioenergy
(was Emery Energy)
air blown gasifier, technology

unclear
auto
Synthesis Energy
fluidized bed gasifier (air blown?)
auto
Bubbling Fluid
Bed
used 60pulse/sec syngas burners

TRI (previous name provide heat to aluminum oxide
was MTCI) (2 IBR
bed; fluidizing steam is
Projects)
introduced evenly spaced across
vessel
allo
Carbona has license, Still need field

verification; fully demonstrated at 12
tpd, it has been scaled up to 100 tpd at
air-blown mode
270 Btu/cuft
Carbona/Ahlstom/Andrit
z have lime kiln
~150 BTU/cuft
experience since mid
1980s
~150 BTU/cuft
probably 150
BTU/cuft
likely to be moderate
none
not needed
first commercial gasifier

is in commissioning
demo and pilot plants

only
commericialized and
operating several large
units on coal
commercial site on
black liqr; working on
syngas medium
issue of other
BTU value
biomasses plugging
vessel
Skive, Denmark with ties to

Wisaforst, Finland
Norrsundet, Sweden
more experience than most some ash and carbon carryover

Carbona has probably most experience
in syngas with all CFB units,
companies; Skive gasifier
making true syngas in pilot plant, using
although this is supposed to
has worked well so far, but
Jenbacher gensets after removing dust,
is still doing plant
increased radiative heat transfer
alkali, and water
commissioning
at kiln burner
Recently found European investor...dust
is filtered, some alkalis condensed out,
but adequate for power gen?
http://www.gastechnology.org/webro
ot/app/xn/xd.aspx?it=enweb&xd=4re
portspubs\4_8focus\biomassgasifica
tionformultipleapplications.xml
http://www1.eere
.energy.gov/biom
ass/pdfs/ibr_arra http://www.andritz.com/iss_17.pdf
_haldortopsoe.p
df
Chippewa Valley Ethanol
CFB technology generally

works well with biomass
Sherbrooke, Quebec pilot

plant; Westbury, Quebec
cellulosic ethanol plant
starting up fall08
gasifier picture looks a lot

like a Carbona unit
building first plant
25tpd plant, Salt Lake City?
have engineered a 100tpd

modular gasifier system
very limited info, no large

gasifier experience
1. not demonstrable beyond test/pilot

plants
http://www.radianbioenergy.com/ind
ex.html
none?
CFB technology generally

works well with biomass
coal experience only
not demonstrable in biomass
http://www.synthesisenergy.com/IG
CC.html
Norampac Trenton, ON (1/7

of 3RB capacity)
the pulse heaters are in their

3rd generation design; fully
operating pilot plant
91.5% availability in 2005,

87.2% in 2006; many types of
biomass will plug the gasifier
vessel
http://www.frontlinebioenergy.com/
Limited information as Enerkem is not http://www1.eere

interested in selling the gasification
.energy.gov/biom http://www.enerkem.com/en/home.ht
technology, rather they manufacture, ass/pdfs/ibr_arra ml
own and operate the plants
_enerkem.pdf
http://www1.eere
.energy.gov/biom
http://www1.eere.energy.gov/biomass/p
ass/pdfs/ibr_de http://www.tri-inc.net/index.html
dfs/ibr_demonstration_flambeau.pdf
monstration_new
page.pdf
REV
G
B
C
D
E
F
REV
Technology
Suppliers
TPS Termiska
Processer
Metso (formerly
Kvaerner,
Gotaverken)
Circulating Fluid
Bed
PROJECT:
DATE:
6/14/2011
Basic process
CFB air blown dual vessel
Temp
859-900C
(1562-1652F)
DATE
6/14/2011
11/15/2010
2/3/2011
2/28/2011
3/17/2011
5/12/2011
BY
MWW
MWW
MWW
MWW
MWW
MWW
PROJECT NAME:
Press.
(psig)
21
circulating fluidized bed air blown

gasifier
Heat Source
auto
auto
Tar production
Tars methodology
medium
second gasifier runs at

higher temp for tar
cracking; wet scrubbing
afterward
moderate
HHV
syngas 153
BTU/cuft (107188)
Varo Sodra Cell pulp mill

feeding lime kiln, also
affiliated with Wisa Forest
Finland gasifier on lime kiln
and others
operating a number of
fluidized bed
gasifiers/boilers for
years on various
feedstocks
supplied several lime
kilns with CFB gasifiers
back in 1980s
atm?
auto
moderate
keep gases hot
Foster Wheeler
circulating fluidized bed air blown

950-1000C
gasifier, some (all?) at high
(1742-1832F)
pressure
262
auto
moderate
keep gases hot
~150 BTU/cuft
(142-169)
Andritz/Carbona
apparently Carbona also offers a

CFB, although the BFB seems to
be the main design
auto
EERC
CFB
auto
Rentech/SilvaGas
Corp (FERCO,
Battelle)
(IBR
Project - ClearFuels)
CFB, dual vessel, steam to first

vessel, air to second vessel
Biomass Gas and

Electric
variation on silvagas
Repotec

vessel, air to second vessel
allo
Milena (ECN)
double reactor with gasif occuring

in riser tube; hot sand from char
combustion drives gasif
allo
FICFB
CFB
allo
Taylor Biomass
Energy

vessel, air to second vessel,
syngas sent to gas conditioning
vessel
allo
Lurgi (by itself)
originally had a low press CFB
allo
Choren
2 stage , pyro-gas / might

consider an entrained flow design
allo
Red Lion Bioenergy

(IBR Project)
Dual vessel pyrolysis followed by

reforming
allo
allo
ARBRE project at North

Yorkshire, UK (now shut
down due to liquidation)
operating on lime kiln

since 1987
~150 BTU/cuft
(100-200)
Biomass sites:
first syngas to TG in
2002
~150 BTU/cuft
circulating fluidized bed air blown 540-980C

gasifier, single vessel
(1004-1796F)
atm?
Technology status:
keep gases hot
Energy Products of
Idaho
830C (1526F

Advantages
ARBRE is second only to
Varnamo site to perform
biomass IGCC
Disadvantages
Comments
limited time on gas turbine due

to liquidation of plant
1. not demonstrable - only one wood

project that never finished startup 2.
more equipment - higher capital 3. out
of business
21yrs experience, the

lots of carryover of ash,
gasifier sticky pluggages
carbon/char, and bed material if
and tar buildups have been
no de-duster is added to system
resolved, simple setup
lots of experience in CFB

boiler and gasifier projects
Electrabel, Belgium
Varnamo, Sweden
Lahti,
Finland
affiliated with lime kilns

using CFB gasifiers back in
1980s; running 97%
availability at Lahti
this company has to date been

non-responsive
IBR Link
Website
http://www.tps.se/
only repower and CHP so far
http://www.metso.com/pulpandpape
r/recovery_boiler_prod.nsf/WebWID
/WTB-090521-22575A40B0?OpenDocument&mid=7CC3
252B3979EB4BC22575BD0057742
C
fully scalable, would need to modify if

other then CHP
http://www.energyproducts.com/EPI
Technology.htm
fully scalable, no reponse, lack of

interest?, moved HQ to switzerland,
maybe track down costs through
existing Swedish project
http://www.fwc.com/GlobalPowerGr
oup/EnvironmentalProducts/Biomas
sGCS.cfm
http://www.undeerc.org/equipment/g
asification.aspx
0.001lb/cuft (1215BTU/cuft)
proprietary DN34 catalyst

breaks ~90% of
condensibles
syngas 450500BTU/cuft
(410-464)
500wettpd ran 24/7 for

yrs
demo:McNeil Power Station

Burlington, VT (shut down
now) - permit for BG&E in
Tallahassee applied for
%moisture doesn't affect

gas BTU value, only the
volume produced
no operating units at this time
fully scalable, not demonstrable
has Silva gas license and working on

three projects
allo
"low"
scrubbed out; this stream

is then made into steam to
be injected into first vessel
for driving gasification
process
syngas
322BTU/cuft
planning to use Dahlman

OLGA system
developmental
Gussing, Austria
8MW/26mmBTU/hr (studying
341mmBTU/hr syngas site for
Goteborg to put natgas to
header)
higher BTU value syngas,

better for liquid fuels
generation later
smaller scale systems

experience only
prob too small
none?
none
no operating units at this time
not demonstrable, too small right now,

variation on slivagas and repotec
This is the Repotec technology

low; gas can be
tar converted to syngas in
cooled to 300F before
conditioning reactor
any condensation
syngas
400BTU/cuft
no demonstration site at this

time
not demonstrable, only marketing

smaller 500 tpd units
http://www1.eere
.energy.gov/biom
ass/pdfs/ibr_arra http://www.silvagas.com/index.htm
_clearfuelstechn
ology.pdf
http://www.biggreenenergy.com/
http://www.repotec.at/
http://www.biosng.com/experimentalline-up/gasification-technology/
http://www.ficfb.at/
http://www.taylorbiomassenergy.co
m/TBE%20Technology.htm
NO INFO FOUND ON THIS AT THIS

TIME
non-detect
more complicated process, lots

of capital, limited
demonstratability
syngas "high"
1. very complex, high pressure system

2. lots of equipment to maintain 3.
higher capital cost
http://www.choren.com/en/biomass_
to_energy/advantages_of_carbo-v/
Hybid
GE/Texaco
Lurgi (Air Liquide)

MPG
Shell
pulverize fuel, inject in slurry

form, entrained flow, use O2,
produce high pressure steam and
medium BTU syngas (singlestage, downward-feed, entrainedflow)
dry fuel put into refractory-wall
gasifier using steam and O2 at
high 25+bar; produce hp steam
and medium BTU syngas
dry fuel put into membrane-wall
gasifier using O2 at high
pressure; produce hp steam and
medium BTU syngas
DOE project, renewable energy

institute, Ohio
auto
medium/high
commercialized in coal
gasification, but not
biomass
auto
tar levels?
medium/high
gasification, but only
one biomass unit
auto
tar levels?
medium/high
gasification, firing 30%
biomass at one site
none?
http://www1.eere
.energy.gov/biom
http://www.redlionbio-energy.com/
ass/pdfs/ibr_arra
_reii.pdf
no biomass experience,
biomass would be pulverized to
dust to work in entrained flow
configuration, higher capital
1. entrained flow is not good approach

for biomass gasification - too much
pulverizing required to get necessary
reaction time 2. higher capital
http://www.gepower.com/prod_serv/
products/gasification/en/overview.ht
m
a Lurgi rep expressed lack of

interest

http://www.lurgi.com/website/index.
php?id=19&L=1

http://www.shell.com/home/content/
globalsolutionsen/industries/gas_and_lng/tech_pap
ers/coal_gasification_300805.html#0
little biomass experience,

many coal sites; Buggenum, higher BTU value syngas;
Netherlands is processing
membrane-wall gasifier dust to work in entrained flow
30%wt biomass also
high reliability in coal service
REV
G
B
C
D
E
F
REV
Technology
G
Suppliers
PROJECT:
DATE:
6/14/2011
Basic process
Temp
DATE
6/14/2011
11/15/2010
2/3/2011
2/28/2011
3/17/2011
5/12/2011
Press.
(psig)
Heat Source
Pearson
allo/indirect
Brightstar
entrained flow
allo/indirect
Future Energy
entrained flow
allo
MHI
entrained flow
Uhde
Prenflo process; looks much like

the Shell process; runs at 40+bar
Dynamotive
pyrolize biomass at coolest

gasification temperature to
produce black oil
Entrained Flow
Siemens
auto
Tar production
Tars methodology
tar levels?
HHV
medium/high
Technology status:
biomass (??)
Biomass sites:
none?
Advantages
Disadvantages
Comments

IBR Link
Website
http://www.conocophillips.com/Tech/
downstream/E-Gas/index.htm
4-gasifiers/4-1-2-4_siemens.html
auto
focused on municipal solid

waste (MSW)
not demonstrable, company exists on

paper only?, clear fuels
variation on Choren?
tar levels?
most are condensed to

liquids by design
medium/high
biomass (??)
two commercial scale

bio oil
plants currently selling
~80,000BTU/gal
bio-oil
use hot turbulent sand to pyrolize

Ensyn (IBR Project,
biomass at 500C/930F; in their
Envergent is a
RTP process, vapor is quickly
UOP/Ensyn
cooled to generate liquid in under
partnership)
2 seconds

liquids by design
bio oil
~80,000BTU/gal
has operated
commercially since
1989, starting in WI;
currently run 7
commercial plants
BTG
pyrolize biomass using hot sand

for heat exchange, produce black
oil

liquids by design
bio oil
Malaysia plant has run

on palm residues for
2yrs
GTI (IBR Project w/

CRI/Criterion Inc.)
Integrated Hydropyrolysis and

Hydroconversion (IH2)
technology
Lurgi (Air Liquide)
limited info
Pyrolysis

PROJECT NAME:
pulverize fuel, inject in slurry

form, use O2, produce high
pressure steam and medium
BTU syngas
dry-feed, pressurized, entrainedflow reactor, with the internal
gasifier chamber enclosed by a
cooling screen/wall
entrained flow
Conoco Phillips
BY
MWW
MWW
MWW
MWW
MWW
MWW
http://gasifiers.bioenergylists.org/tax
onomy/term/406
http://www.seas.columbia.edu/earth/
wtert/sofos/nawtec/nawtec10/nawtec
10-1012.pdf
http://www.future-energy.de/energyunlimited/
4-gasifiers/4-1-2-5_mhi.html
none?

http://www.uhde.biz/cgibin/byteserver.pl/archive/upload/uhd
e_brochures_pdf_en_11.00.pdf
commerical plants at West

Lorne, Ontario and Guelph,
Ontario
testing for use as kiln fuel

and limited usage as gas
TG fuel has been done
bark must be removed
operating gas turbine on bio-oil at West

Lorne
http://www.dynamotive.com
long commercial success;

plants tend to be smaller - a
1. multiple processes required to utilize
still growing; pushing toward
larger one is 31mmBTU/hr,
http://www1.eere
largest site is 200dt/day
all of feedstock 2. process is limited to
starting up at Renfrew, ON for more chemical products; bio- char/carbon residue rate is high
.energy.gov/biom
http://www.ensyn.com/
an industrial oil replacement - doesn't
liquid fuel, polymers, power,
oil has been fired as
ass/pdfs/ibr_arra
at 12%, a syngas is also
lend itself to future process of
chemicals
industrial fuel replacement in
_uop.pdf
produced using 13% of
transportation fuels generation options
multiple systems
feedstock
Malaysia plant
limited info, only operating

1. not demonstrable except on palm
several years of commercial
commercially on palm residues residues 2. not impressed by company
oil production experience
(?)
technical personnel
http://www.btgworld.com
http://www.gastechnology.org/webro
http://www1.eere
ot/app/xn/xd.aspx?it=enweb&xd=1R
.energy.gov/biom
esearchCap/1_8GasificationandGas
ass/pdfs/ibr_arra
Processing/MajCurrentProj/Biomass_gti.pdf
to-Diesel.xml

liquids by design
bio oil
developmental
KIT, organisaton doing the

pyrolysis, pilot plant in
Karlsruhe
limited info; Lurgi handles

nearly 3/4 of world's coal
gasification
limited info
not demonstrable
http://www.lurgi.com/website/index.
php?L=1
REV
G
B
C
D
E
F
REV
Technology
Black Liquor
Gasification
Molten Metals
G
Suppliers
PROJECT:
DATE:
Basic process
used 60pulse/sec syngas burners

provide heat to aluminum oxide
TRI (previous name bed and gasify black liqr at 60%
was MTCI)
solids; fluidizing steam is
introduced evenly spaced across
vessel
spray black liquor into gasifier,
either pressurizedusing O2 or
non-pressurized using air,
Chemrec
quench syngas to make green
liquor
Clean Earth Energy
use molten sodium to gasify

wood to CO and H2
ze-gen
O2 blown liquid metal gasifier
Diversified Energy /
Alchemix
uses 2400F molten tin/iron and

steam to create H2 and CO gas;
FeO is generated by stripping O
off of H20, then feedstock C strips
O from FeO to make CO
6/14/2011
Temp
DATE
6/14/2011
11/15/2010
2/3/2011
2/28/2011
3/17/2011
5/12/2011
BY
MWW
MWW
MWW
MWW
MWW
MWW

PROJECT NAME:
Press.
(psig)
Heat Source
Tar production
Tars methodology
HHV
Technology status:
Biomass sites:
Advantages
Disadvantages
Comments
commercial site on
black liqr; working on
issue of other
biomasses plugging
vessel
Norampac Trenton, ON (1/7

of 3RB capacity)
the pulse heaters are in their

3rd generation design; fully
operating pilot plant
91.5% availability in 2005,

87.2% in 2006; many types of
biomass will plug the gasifier
vessel
company is focusing on biomass now
commercial at low
pressure; delopment
plant for O2/hi press
Weyerhaeuser New Bern

330tonBLS/day commercial
plant; pilot plant in Pitea,
Sweden
limited info
~91% uptime after numerous

issues; refractory is now good
for 2yrs
BFB/autothermal
none
not needed
syngas medium
BTU value
entrained
flow/autothermal
none
not needed
syngas medium
BTU value
near zero
not needed; higher

premium syngas
one commercial plant
due to high H2%
breaks all tars
Idaho
demo plant at New Bedford,

Mass
near zero
not needed; higher

breaks all tars
lab testing
lab
energy intensive, no projects
Website
http://www.tri-inc.net/index.html
http://www.chemrec.se/Technology.
aspx
higher capital; very complex

operation; kill process with
1. complexity 2. capital cost 3. safety
vinegar deluge, have to chill
high BTU value gas
hazards
vessel walls and prevent sodium
escape which uses parasitic
power
tars are not an issue similar
appears to be designing/offering
to plazma due to the high
modular units for sorted MSW/RDF
heat
gasification
at this high temp, nearly

everything put in is gasified
IBR Link
1. not demonstrable 2. capital cost 3.

safety hazards
http://cleanearthenergytech.com/co
mpany.html
http://www.ze-gen.com/#home
http://www.diversifiedenergy.com/index.cfm?s_webAction
=hydromax

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Biomass Gasification

NREL Technical Monitor: Abhijit Dutta

NREL is a national laboratory of the U.S. Department of Energy, Office of Energy

NREL Technical Monitor: Abhijit Dutta

NREL is a national laboratory of the U.S. Department of Energy, Office of Energy

National Renewable Energy Laboratory

This publication was reproduced from the best available copy

submitted by the subcontractor and received minimal editorial review at NREL.

GASIFIER TECHNOLOGY DESCRIPTIONS ...............................................

GASIFIER OPERATION AND PERFORMANCE...........................................

ORDER OF MAGNITUDE CAPITAL COST ESTIMATES............................

DETAILED CAPITAL COST ESTIMATE CFB GASIFIER..........................

DETAILED CAPITAL COST ESTIMATE BFB GASIFIER ..........................

DETAILED CAPITAL COST ESTIMATE HP BIOMASS FEED.................

DETAILED CAPITAL COST ESTIMATE LP BIOMASS FEED..................

GASIFICATION COST COMPARISONS.........................................................

Order of Magnitude Estimates Flow Diagrams

oxidation) bubbling fluidized bed design.

o Total Project Investment Cost - $ 70,590,000 (2011 dollars).

composed of wood chips and bark, using allothermal (indirect heating)

circulating fluidized bed design. Heating of bed media occurs in a separate

combustor by combustion of char with air.

o Tar Reformer allothermal bubbling fluidized bed design.

oxidation) bubbling fluidized bed design.

o Tar Reformer - unknown technology.

Gasifier - direct or autothermal bubbling fluidized bed design.

Tar Reformer - solid (blocks) catalyst filled reactor design.

Gasifier - indirect or allothermal circulating fluidized bed design.

Tar Reformer - bubbling fluidized bed design.

Gasifier - direct or autothermal bubbling fluidized bed design.

Tar Reformer design not revealed by vendor.

impacts on the process. First, consumption of energy for drying (vaporization

Air Verses Oxygen Blown Gasifier Operation

MODELING AND DETAILED CAPITAL COST ESTIMATES

CFB Gasifier Model

BFB Gasifier Model

High Pressure Biomass Feed Model

Low Pressure Biomass Feed Model

Material Balance (Excel)

Material Balance Flow Diagrams (Excel)

Equipment List (Excel)

CAPITAL COST COMPARISONS

GASIFIER ISLAND TECHNOLOGY #1

A flow diagram depicting the system is located in Appendix A.

Biomass Storage and Metering System

Bed Media Storage and Metering System

Air Separation Plant

Oxygen Gas Supply System

Inert Gas (Nitrogen) Supply System

Steam Supply System

Cooling Water Supply System

Ash/Char Discharge System

Gasifier and Tar Reformer Startup Burners

Dust Collection Cyclone

Gasifier Control System

Seal Water System