25-landfill-recycle-center

Valuation

Generous asset valuation: $12,000,000,000. The listed price is the platform maximum; acquisition at valuation is handled by direct enquiry.

Project 25: Landfill Recycle Center

Project 25: Landfill Recycle Center

Stationary Landfill Mining and Resource Recovery Facility

• Price: $50,000,000
• Status: Complete Engineering Package
• Author: Christopher Gabriel Brown
• Date: March 2026
• Patent Portfolio: Consolidated utility application 19/540,453 (filed 02/13/2026)

What This Is

A fixed-site industrial facility that mines closed or active landfills, separates materials into saleable commodities, recovers energy from non-recyclables, and produces clean water. Unlike Project 15 (mobile truck), this is a permanent processing center with full-scale industrial equipment, no weight constraints, and 10-50x the throughput.

Why a Center, Not a Truck

Project 15 proposed a mobile truck. The truck concept has fundamental limitations:

The center is the right architecture. Trucks can haul material TO the center from multiple landfill sites within a 50-mile radius.

Core Technology — All Proven, All Commercial

Every processing stage uses equipment that is manufactured today and operating at existing facilities worldwide:

1. Excavation & Hauling — Standard earthmoving equipment (CAT, Komatsu). Material trucked to center.

2. Trommel Screening — Rotating drum screens. Separates by size. Commercial units from Terex, McCloskey.

3. Magnetic Separation — Overhead belt magnets and drum magnets. Pulls ferrous metals. Eriez, Bunting.

4. Eddy Current Separation — Repels non-ferrous metals (aluminum, copper, brass). Eriez, SGM Magnetics.

5. Density Separation — Air classifiers and sink-float tanks. Separates plastics, organics, inerts. Westeria, Nihot.

6. Optical/NIR Sorting — Near-infrared cameras identify plastic types for sorting. TOMRA, Steinert, Pellenc ST.

7. Thermal Processing — Waste-to-energy for non-recyclables. Proven gasification or incineration with heat recovery. Covanta, Babcock & Wilcox.

Facility Specifications

Revenue Model (Conservative)

Based on actual commodity prices and existing landfill mining operations (references: SWANA, EPA data):

Payback period: 5-8 years (conservative) | 3-5 years (optimistic)

5-year ROI: 20-60%

What's in This Package

25-landfill-recycle-center/
  README.md                          — This file
  specs/
    TECHNICAL_SPECIFICATIONS.md      — Full engineering specs with calculations
  blueprints/
    FACILITY_DESIGN.md               — Building layout, material flow, site plan
    PROCESSING_STAGES.md             — 7-stage pipeline, equipment specs per stage
    EQUIPMENT_BOM.md                 — Bill of materials with vendors and costs
    ENERGY_RECOVERY.md               — Thermal unit specs and energy math
  financials/
    BUSINESS_PLAN.md                 — Full financial model with sensitivity analysis
    REGULATORY_PATHWAY.md            — Permitting timeline and compliance requirements
  software/
    control_system.py                — SCADA/PLC monitoring and control logic
    dashboard.py                     — Web-based facility monitoring dashboard
  drawings/
    site_layout.svg                  — Facility site plan
    process_flow.svg                 — Material flow diagram

Heritage from Project 15

This project inherits the viable concepts from Project 15:

• Universal Recycling Container (URC) system for standardized material handling
• Multi-stage separation philosophy
• Thermal energy recovery concept
• Revenue diversification strategy

What it discards:

• Mobile truck constraint (replaced with stationary facility)
• Unproven element separation claims (replaced with commercial sorting tech)
• Overstated recovery rates (replaced with industry-validated 45-65%)
• Fictional electricity generation methods (replaced with proven waste-to-energy)

Contact

Christopher Gabriel Brown

1341 Wellington Cove

Lawrenceville, GA 30043-5255

Email:: crioneaka@outlook.com

Email: crioneaka@outlook.com

Web: www.chrisgbrown.co

25 - Landfill Recycle Center

25 - Landfill Recycle Center

> Internal playbook -- not for public eyes.

> Last scaffolded: 2026-05-11

1. Identity

2. One-liner

> A fixed-site industrial facility that mines closed or active landfills, separates materials into saleable commodities, recovers energy from non-recyclables, and produces clean water. Unlike Project 15 (mobile truck), this is a permanent processing center with full-scale industrial equipment, no weight constraints, and 10-50x the throughput.

*(Edit this once. It becomes the single sentence you reuse in replies,

on the catalog page, and at the top of any future write-up.)*

3. What's actually in the folder

• blueprints/ (5 entries)
• drawings/ (0 entries)
• financials/ (2 entries)
• sales-pitches/ (3 entries)
• software/ (2 entries)
• specs/ (1 entries)
• / (1 entries)
• CHANGELOG.md
• CONTACT_INFO.txt
• MANIFEST.json
• PLAYBOOK.md
• README.md

4. README at a glance

Top sections found in README.md:

• What This Is
• Why a Center, Not a Truck
• Core Technology — All Proven, All Commercial
• Facility Specifications
• Revenue Model (Conservative)
• What's in This Package
• Heritage from Project 15
• Contact

(Full text: D:\special\25-landfill-recycle-center\README.md)

5. Hook lines (pick the one that fits the reader)

• (default) A fixed-site industrial facility that mines closed or active landfills, separates materials into saleable commodities, recovers energy from non-recyclables, and produces clean water. Unlike Project 15 (mobile truck), this is a permanent processing center with full-scale industrial equipment, no weight constraints, and 10-50x the throughput.
• (skeptic / 'what is this really?') TODO -- one honest sentence about

what's solved here that wasn't before.

• (buyer's-finance angle) TODO -- pricing/risk framing (zero-upfront,

4-step credit-forward, revenue share if applicable).

• (competitor question) TODO -- the one comparable product or approach

this most often gets confused with, and the one-sentence delta.

6. Reply patterns

When inbound lands, fall back to the cross-portfolio patterns in

D:\special\manager\emails\PLAYBOOK_software_for_data.md (sections 5

and 8 are reusable across every project) and adapt the specifics.

The product-specific bits to fill in here (TODO):

• One objection unique to this project + the honest answer
• One pricing anchor unique to this project
• One reason to walk away that's worth saying out loud

7. Status & gaps

• Vault: EMPTY -- no archive (must create before 'Send Vault' works)
• Catalog presence: TODO -- search cri-one.com/store for this product

and paste the live URL here.

• PoF readiness: TODO -- is there a working demo / sample / proof a

prospect could run in under an hour?

• NDA-gated technical brief: TODO -- written? not written? where?
• Critical missing piece before this can close: TODO.

8. Quick links

• Folder: D:\special\25-landfill-recycle-center\
• Catalog (cri-one.com): TODO
• Related projects in portfolio: TODO (cross-reference here once mapped)

*This scaffold was auto-generated. Replace TODOs as you learn each project

better. Search across all playbooks: grep -ri "<term>" D:\special\\PLAYBOOK.md

Autonomous Operations Architecture

Autonomous Operations Architecture

Project 25 — Landfill Recycle Center

Author: Christopher Gabriel Brown

Date: March 2026

Design Philosophy

This facility is designed to operate with minimal human intervention. Every processing stage is automated. Humans supervise, maintain, and handle exceptions — they do not sort, separate, or feed material. The target is 90%+ autonomous operation with a staff of 12-15 people running a 1,000 ton/day facility.

Traditional recycling facilities employ 40-60 manual sorters per shift standing on picking lines. This facility replaces them entirely with machine vision, robotic arms, and sensor-driven conveyor routing.

Staffing Model (Autonomous)

Compare: A conventional MRF (Materials Recovery Facility) of similar capacity employs 45-60 people, with 20-30 of those being manual sorters.

Annual labor cost: 14 staff × $65,000 avg (wages + benefits) = $910,000/year

Autonomous Systems by Processing Stage

Stage 1: Receiving & Feed Control

Automation:

• Truck arrives → drives onto weigh bridge → RFID tag auto-identifies hauler and waste stream
• Tipping floor: truck dumps → wheel loader (human-operated) pushes material into feed hopper
• Feed hopper has ultrasonic level sensor (Siemens SITRANS LU240) monitoring fill level
• Variable-speed apron feeder (0-80 tons/hour) controlled by SCADA based on downstream throughput
• If any downstream stage signals backup → feed rate automatically reduces
• If thermal unit needs more fuel → feed rate to residuals conveyor increases

Sensors:

• 2x ultrasonic level sensors on feed hopper (redundant)
• Belt scale (Thermo Scientific Ramsey 60-12) on main infeed conveyor — continuous mass flow measurement
• Metal detector on infeed (Eriez Metalarm) — triggers alarm if large ferrous object could damage trommel

Human involvement: Wheel loader operator only. Everything downstream is automatic.

Stage 2: Trommel Screening

Automation:

• Trommel runs at fixed speed (8-12 RPM) set during commissioning
• Automatic spray bars (water) activate on timer to prevent screen blinding
• Three output conveyors (fines <25mm, mid 25-150mm, oversize >150mm) run continuously
• Oversize conveyor has a slow-speed shredder (SSI Dual-Shear M85) that auto-feeds oversized items back into the trommel for a second pass
• Vibration sensor (SKF CMSS 2200) on trommel bearings detects bearing wear
• Automatic shutdown if vibration exceeds threshold (7.1 mm/s RMS per ISO 10816)

Sensors:

• 2x vibration sensors (drive end, non-drive end)
• 1x trommel motor current monitor (overload detection)
• 1x spray water flow meter
• Belt scales on all 3 output conveyors

Human involvement: None during normal operation. Maintenance tech clears jams if alarm triggers.

Stage 3: Magnetic Separation

Automation:

• Overhead suspended electromagnet (Eriez SE-7 series, 48" wide) runs continuously over main conveyor
• Captured ferrous drops onto cross-belt conveyor to ferrous collection bin
• Drum magnet (Eriez RE7) downstream as secondary capture
• Both magnets are passive/continuous — no control logic needed beyond on/off
• Ferrous bin has ultrasonic level sensor — when full, triggers alert to swap bin

Sensors:

• Ferrous bin level sensor
• Magnet coil temperature sensor (RTD)
• Belt alignment sensors on cross-belt

Human involvement: None. Forklift swaps bins when full (could be automated with AGV in future).

Stage 4: Eddy Current Separation

Automation:

• Eriez RevX-E eddy current separator runs at fixed rotor speed (1,500-3,000 RPM)
• Non-ferrous metals (aluminum, copper, brass) are repelled into separate chute
• Splitter plate position set during commissioning for optimal separation
• Rotor speed adjustable via VFD — can be tuned by control room operator if material mix changes
• Non-ferrous collection bin with level sensor

Sensors:

• Rotor speed encoder
• Motor temperature (RTD)
• Motor current (overload)
• Output bin level sensor
• Inductive proximity sensor downstream to verify non-ferrous capture rate

Human involvement: None. Control room operator may adjust rotor speed seasonally.

Stage 5: Density Separation

Automation:

• Air classifier (Westeria Recuwind or Nihot SDS) — variable airflow via VFD-driven fan
• Light fraction (film plastic, paper, textiles) blown up and over into separate conveyor
• Heavy fraction (rigid plastics, glass, stones, ceramics) falls through
• Airflow auto-adjusts based on material density feedback from downstream belt scale
• Sink-float tank: water density maintained at SG 1.0 by automated polymer dosing pump
• Float fraction (light plastics) skimmed off by paddle conveyor
• Sink fraction (heavy plastics, glass) conveyed out by drag conveyor

Sensors:

• Air classifier: fan speed, differential pressure across classifier, belt scale on light/heavy fractions
• Sink-float tank: SG sensor (Endress+Hauser Liquiphant FTL31), water temperature, water level
• pH sensor on tank water (for contamination monitoring)

Human involvement: None. Tank water quality checked weekly by lab tech.

Stage 6: Optical/NIR Sorting (Replaces Manual Picking Line)

This is the key autonomy stage. Traditional facilities use 20-30 humans here. We use robots and cameras.

Primary System: TOMRA AUTOSORT (3 units in series)

Each unit:

• Near-infrared (NIR) spectrometer identifies polymer type at 320 scan lines/second
• Visual (VIS) camera identifies color
• Material passes on high-speed belt (3 m/s)
• Compressed air nozzle array (256 nozzles, 6 bar) ejects targeted material
• Unit 1: Ejects PET
• Unit 2: Ejects HDPE
• Unit 3: Ejects PP/PS mix
• Remaining: mixed residuals to thermal unit

Specifications per unit:

• Belt width: 2,000 mm
• Throughput: 8-10 tons/hour
• Detection accuracy: 95%+ (manufacturer spec)
• Ejection accuracy: 90-95% purity per stream
• Power: 15 kW per unit
• Compressed air: 6 bar, 3,000 L/min per unit
• Self-cleaning: automatic belt tracking, air nozzle purge cycle every 4 hours

Secondary System: AMP Robotics Cortex (2 units)

Robotic arms positioned after optical sorters for final quality control:

• AI vision system identifies contaminants in sorted streams
• Delta robot arm performs 80 picks/minute
• Removes non-target materials missed by optical sorters
• Self-learning: accuracy improves over time with operation data
• Power: 5 kW per unit
• No compressed air needed (mechanical grippers)

Combined system replaces: 20-30 manual sorters

Combined power: 55 kW (3 optical + 2 robotic)

Combined throughput: 25-30 tons/hour (more than enough for facility feed rate)

Sensors:

• NIR spectrometer (built into TOMRA)
• Visual cameras (built into TOMRA and AMP)
• Belt speed encoders
• Compressed air pressure sensors
• Air compressor monitoring (oil temp, discharge pressure, hours)

Human involvement: None during operation. Maintenance tech cleans cameras weekly.

Stage 7: Thermal Processing

Automation:

• Residuals fed automatically from Stage 6 reject conveyor
• Feed rate controlled by combustion air damper position and steam drum pressure
• Moving grate speed auto-adjusts to maintain bed depth
• Combustion air (primary under-grate + secondary over-fire) controlled by O2 trim
• Target O2: 6-8% in flue gas (Lambda sensor)
• Steam turbine: auto-synchronized to grid, load-following
• Flue gas treatment: all automated
• Baghouse: differential pressure monitoring, auto bag cleaning (reverse pulse)
• Activated carbon injection: screw feeder, rate set by mercury CEMS reading
• SCR: ammonia injection rate controlled by NOx CEMS reading
• Spray dryer: lime slurry pump speed controlled by HCl/SO2 CEMS reading

Continuous Emissions Monitoring System (CEMS):

• O2, CO, CO2, NOx, SO2, HCl, mercury, particulate
• Data logged every 15 minutes per EPA 40 CFR Part 60 requirements
• Auto-reports to state environmental agency
• If any parameter exceeds permit limit → automatic feed reduction → if still exceeded → automatic shutdown

Sensors (partial list):

• 4x thermocouples in combustion chamber
• 2x O2 analyzers (flue gas)
• Steam drum level, pressure, temperature
• Turbine RPM, vibration, bearing temperature
• Stack opacity monitor
• Full CEMS suite (7+ analyzers)
• Baghouse differential pressure (per compartment)
• Ash hopper level sensors

Human involvement: Control room operator monitors. System runs itself.

Central Control System

Hardware

Network Architecture

[SCADA Servers] ←→ [Core Switch] ←→ [Main PLC]
                                    ├── [Stage 1 Remote I/O]
                                    ├── [Stage 2 Remote I/O]
                                    ├── [Stage 3 Remote I/O]
                                    ├── [Stage 4 Remote I/O]
                                    ├── [Stage 5 Remote I/O]
                                    ├── [Stage 6 Remote I/O] ←→ [TOMRA x3] [AMP x2]
                                    ├── [Stage 7 Remote I/O] ←→ [CEMS]
                                    └── [Utilities I/O] (compressors, water, fire)

• EtherNet/IP for PLC-to-I/O communication (1 Gbps industrial Ethernet)
• OPC-UA for SCADA-to-PLC communication
• TOMRA and AMP units have native Ethernet interfaces, integrated via OPC-UA
• CEMS has dedicated data link to SCADA for regulatory logging
• Remote access via VPN for off-site monitoring (plant manager can view from phone)

Control Philosophy

Normal Operation:

1. Control room operator presses START on SCADA

2. System performs pre-start checks (all conveyors clear, all drives ready, thermal unit at temperature)

3. Stages start in reverse order: thermal → optical → density → eddy current → magnet → trommel → feed

4. Feed rate ramps from 0 to setpoint over 15 minutes

5. System runs autonomously — SCADA displays status, alarms, production totals

6. At end of shift: operator presses STOP → feed stops → conveyors run until empty → stages stop in forward order

Fault Handling:

• Minor fault (sensor out of range, motor overtemp warning): alarm on SCADA, operator investigates
• Major fault (conveyor jam, fire detected, CEMS exceedance): automatic stage shutdown, upstream stages reduce feed, alarm + horn + strobe
• Emergency stop: all stages stop immediately, fire suppression activates if applicable

Auto-Recovery:

• After minor fault clearance, operator presses RESET and RESTART on affected stage
• System verifies fault is cleared before allowing restart
• No auto-restart after major fault — requires operator acknowledgment

Remote Monitoring & Fleet Readiness

The SCADA system (Ignition) supports:

• Web-based dashboards accessible from any browser
• Mobile app with push notifications for alarms
• Multi-site support — if CRI builds additional centers, all can be monitored from a central operations room
• Data historian with 10+ years of storage for regulatory compliance
• Automated reports: daily production, monthly emissions, annual compliance

This architecture is designed so that ONE control room operator can eventually monitor 2-3 facilities simultaneously from a central location, further reducing staffing needs as the business scales.

Autonomy Metrics

Future Autonomy Upgrades (Phase 2)

Once the facility is operational and baseline data is collected:

1. Autonomous wheel loader — Volvo LX04 or Caterpillar autonomous loader for tipping floor. Removes last human from the process floor.

2. AGV bin transport — Automated guided vehicles swap full material bins, eliminating forklift operators.

3. Predictive maintenance — Machine learning on vibration/temperature data to predict bearing failures 2-4 weeks in advance (existing SCADA data feeds the model).

4. Dynamic sort recipes — TOMRA units auto-adjust sort parameters based on real-time commodity pricing feeds (sort more PET when PET price is high, let it pass to thermal when price is low).

5. Autonomous excavation — At the landfill site itself, autonomous excavators (Built Robotics) load haul trucks without human operators.

These upgrades are not required for initial operation but represent the roadmap to 95%+ autonomy within 3-5 years of commissioning.

Energy Recovery Specifications — Thermal Processing Unit

Energy Recovery Specifications — Thermal Processing Unit

Landfill Resource Recovery Center

Author: Christopher Gabriel Brown

Date: March 2026

Document: ENERGY_RECOVERY.md

1. Thermal Unit Design

1.1 Combustion Technology

1.2 Feed Characteristics

1.3 Waste Composition and Heating Value

Note: Moisture content of 20–30% reduces effective heating value. Applying a 15% moisture penalty:

LHV_effective = LHV_dry × (1 - moisture_fraction) - (moisture_fraction × h_fg)

Where:
  LHV_dry     = 16.10 MJ/kg (from table above)
  moisture    = 0.25 (25% average)
  h_fg        = 2.44 MJ/kg (latent heat of vaporization at 1 atm)

LHV_effective = 16.10 × (1 - 0.25) - (0.25 × 2.44)
              = 16.10 × 0.75 - 0.61
              = 12.075 - 0.61
              = 11.47 MJ/kg

Working design value: ~12 MJ/kg (accounting for conservative margin on composition variability; range 11–15 MJ/kg depending on seasonal mix).

1.4 Thermal Energy Calculation

Q_thermal = m_dot × LHV

Where:
  m_dot  = feed rate (kg/s)
  LHV    = lower heating value (MJ/kg)

At nominal 300 tons/day:
  m_dot  = 300,000 kg/day ÷ 86,400 s/day = 3.472 kg/s

  Q_thermal = 3.472 kg/s × 12 MJ/kg = 41.67 MW_thermal

Range:
  At 200 t/d: Q = 2.315 kg/s × 12 MJ/kg = 27.78 MW_th
  At 400 t/d: Q = 4.630 kg/s × 12 MJ/kg = 55.56 MW_th

2. Heat Recovery

2.1 HRSG (Heat Recovery Steam Generator)

2.2 Steam Conditions

2.3 Steam Production Rate

Q_boiler = Q_thermal × η_boiler

At nominal:
  Q_boiler = 41.67 MW × 0.82 = 34.17 MW_th recovered

Steam mass flow:
  m_steam = Q_boiler / (h_steam - h_fw)
          = 34,170 kW / (3,214 - 440) kJ/kg
          = 34,170 / 2,774
          = 12.32 kg/s
          = 44.3 tonnes/hour

2.4 Steam Turbine

Turbine power calculation:

  Ideal (isentropic) enthalpy drop:
    Δh_ideal = h_steam - h_cond_ideal
             = 3,214 - 2,160 kJ/kg  (isentropic expansion to 0.1 bar)
             = 1,054 kJ/kg

  Actual enthalpy drop:
    Δh_actual = Δh_ideal × η_is = 1,054 × 0.78 = 822 kJ/kg

  Gross electrical power:
    P_gross = m_steam × Δh_actual × η_mech × η_gen
            = 12.32 kg/s × 822 kJ/kg × 0.98 × 0.96
            = 12.32 × 822 × 0.9408
            = 9,528 kW (≈ 9.53 MW)

Note: The calculation above yields a theoretical maximum. In practice, the turbine is sized for 2.5–3.5 MW gross because:

• Not all thermal energy reaches the steam cycle (radiation losses, incomplete combustion ~5–8%)
• Boiler fouling reduces effective heat transfer
• Part-load operation reduces efficiency
• Conservative design margin

Design gross output: 3.0 MW_e (with turbine capable of 3.5 MW peak)

2.5 Parasitic Loads

Range: 0.5–1.0 MW depending on operating mode.

2.6 Net Export Power

P_net = P_gross - P_parasitic
      = 3.0 MW - 0.7 MW
      = 2.3 MW net export

Overall electrical efficiency:
  η_electrical = P_net / Q_thermal
               = 2.3 / 41.67
               = 5.5%

  (Typical for small-scale WtE: 15–25% gross, but with high parasitic fraction
   at this scale. Actual gross efficiency = 3.0/41.67 = 7.2%)

2.7 Annual Electricity Production

E_annual = P_net × operating_hours
         = 2.3 MW × 7,500 hours/year
         = 17,250 MWh/year

Revenue at $0.06/kWh:
  Revenue = 17,250 MWh × 1,000 kWh/MWh × $0.06/kWh
          = $1,035,000 / year

With renewable energy credits (RECs) or tipping fee offsets,
effective rate may reach $0.08–0.12/kWh:
  High estimate: 17,250 × 1,000 × $0.10 = $1,725,000 / year

3. Emissions Control

3.1 Air Pollution Control Device (APCD) Train

The flue gas treatment system is arranged in the following sequence:

Furnace → HRSG → Spray Dryer Absorber → Activated Carbon Injection
  → Baghouse → SCR Reactor → ID Fan → Stack

3.2 Component Specifications

3.2.1 Baghouse (Fabric Filter)

3.2.2 Activated Carbon Injection (ACI)

3.2.3 Selective Catalytic Reduction (SCR)

3.2.4 Spray Dryer Absorber (SDA)

3.3 Continuous Emissions Monitoring System (CEMS)

CEMS data is reported quarterly to the state agency and annually to EPA per 40 CFR Part 60, Subpart Eb (Large MWC) or Subpart CCCC (Commercial/Industrial SW Incinerators).

3.4 EPA MACT Compliance Summary

All values corrected to 7% O2, dry basis, standard conditions (0°C, 1 atm).

4. Ash Management

4.1 Bottom Ash

Bottom ash production:
  m_bottom = feed_rate × ash_fraction
           = 300 t/d × 0.22
           = 66 tons/day
           = 2.75 tons/hour

4.1.1 Metals Recovery from Bottom Ash

Ferrous recovery estimate:
  = 66 t/d × 0.04 = 2.64 tons/day ferrous
  Revenue at $150/ton: $396/day = ~$145,000/year

Non-ferrous recovery:
  = 66 t/d × 0.01 = 0.66 tons/day non-ferrous
  Revenue at $800/ton: $528/day = ~$193,000/year

4.2 Fly Ash and Air Pollution Control Residue (APCr)

Fly ash / APCr production:
  m_fly = feed_rate × fly_fraction
        = 300 t/d × 0.03
        = 9 tons/day

5. Energy Balance

5.1 Facility-Wide Power Consumption by Stage

5.2 Power Generation

Gross generation:
  P_gross = 3.0 MW × 24 hours = 72,000 kWh/day

Thermal unit parasitic (already counted above):
  P_parasitic = 700 kW × 24 hours = 16,800 kWh/day

Net generation:
  P_net = 72,000 - 16,800 = 55,200 kWh/day

5.3 Net Energy Position

Net facility energy = Generation - Total consumption
                    = 72,000 - 35,080
                    = +36,920 kWh/day net surplus

Alternatively (excluding thermal parasitic from both sides):
  Non-thermal consumption = 35,080 - 16,800 = 18,280 kWh/day
  Net export to grid = 72,000 - 35,080 = 36,920 kWh/day

The facility is ENERGY-POSITIVE, generating approximately 2.05× the total energy it consumes.

Annual net export:
  = 36,920 kWh/day × 365 days × 0.856 availability
  = 11,536,000 kWh/year
  = 11,536 MWh/year

Revenue from net export at $0.06/kWh:
  = $692,160/year

Combined energy value (self-consumption offset + export):
  Self-consumption offset: (35,080 - 16,800) × 365 × 0.856 × $0.10/kWh
                         = 5,713,000 kWh × $0.10 = $571,300/year
  Grid export revenue: 11,536,000 × $0.06 = $692,160/year
  Total energy value: ~$1,263,460/year

5.4 Thermodynamic Summary

Sankey Diagram (energy flow, nominal 300 t/d):

  Waste Chemical Energy:     41.67 MW_th (100%)
    │
    ├─ Radiation / incomplete combustion losses: 4.17 MW (10%)
    │
    ├─ Boiler heat recovery: 34.17 MW_th (82%)
    │     │
    │     ├─ Steam turbine gross power: 3.0 MW_e (7.2%)
    │     │     │
    │     │     ├─ Parasitic loads: 0.7 MW_e
    │     │     └─ Net export: 2.3 MW_e (5.5%)
    │     │
    │     └─ Condenser reject heat: 31.17 MW_th (74.8%)
    │           (potential for district heating if demand exists)
    │
    └─ Stack losses (sensible heat in flue gas): 3.33 MW (8.0%)

Overall electrical efficiency (Carnot comparison):
  η_Carnot = 1 - T_cold/T_hot = 1 - 313/1073 = 70.8% (theoretical max)
  η_actual = 5.5% (typical for small-scale WtE without CHP)
  η_actual_gross = 7.2%

  If combined heat and power (CHP) with district heating:
    η_CHP = (P_net + Q_district) / Q_thermal
           = (2.3 + 15) / 41.67 = 41.5% (potential)

Appendix A: Key Thermodynamic Formulas

First Law (energy balance):

Q_in = W_out + Q_rejected + Q_losses
41.67 = 3.0 + 31.17 + 3.33 + 4.17  (MW, checks within rounding)

Boiler efficiency:

η_boiler = (m_steam × (h_steam - h_fw)) / Q_thermal
         = (12.32 × 2774) / 41,670
         = 34,170 / 41,670 = 0.82 = 82%

Rankine cycle thermal efficiency:

η_Rankine = (h_steam - h_exhaust) / (h_steam - h_fw)
          = (3214 - 2392) / (3214 - 440)
          = 822 / 2774
          = 29.6% (ideal with isentropic turbine losses)

Net plant heat rate:

Heat rate = Q_thermal / P_net
          = 41.67 MW_th / 2.3 MW_e
          = 18.1 MJ/kWh
          = 17,160 BTU/kWh
          (Compare: modern coal plant ~9,000 BTU/kWh)

End of Energy Recovery Specifications

Equipment Bill of Materials

Equipment Bill of Materials

Stationary Landfill Mining & Resource Recovery Center

Author: Christopher Gabriel Brown

Date: March 2026

Revision: 1.0

Project Budget Target: $35,000,000 - $40,000,000

Table of Contents

1. Screening Equipment

2. Separation Systems

3. Conveyor Systems

4. Thermal / Waste-to-Energy

5. Material Handling Equipment

6. Baling & Compaction

7. Water Treatment Systems

8. Controls & SCADA

9. Safety & Fire Protection

10. Weigh Bridges

11. Dust Control Systems

12. Buildings & Structures

13. Cost Summary

1. Screening Equipment

Screening Subtotal: $1,980,000

2. Separation Systems

2A. Magnetic Separation

2B. Eddy Current Separation

2C. Density Separation

2D. Optical / Sensor-Based Separation

Separation Subtotal: $4,502,000

3. Conveyor Systems

Conveyor Subtotal: $2,094,000

4. Thermal / Waste-to-Energy

Thermal/WTE Subtotal: $12,655,000

5. Material Handling Equipment

Material Handling Subtotal: $1,907,000

6. Baling & Compaction

Baling Subtotal: $1,315,000

7. Water Treatment Systems

Water Treatment Subtotal: $1,762,000

8. Controls & SCADA

Controls & SCADA Subtotal: $1,570,200

9. Safety & Fire Protection

Safety & Fire Subtotal: $869,200

10. Weigh Bridges

Weigh Bridge Subtotal: $456,000

11. Dust Control Systems

Dust Control Subtotal: $892,000

12. Buildings & Structures

Buildings & Structures Subtotal: $6,840,000

13. Cost Summary

Additional Project Costs (Not in BOM)

Notes

1. All prices are budgetary estimates (Q1 2026, USD) and subject to formal quotation from manufacturers. Prices are FOB manufacturer and do not include freight, installation, or applicable taxes unless noted.

2. Lead times are typical manufacturer lead times from order confirmation. Site delivery adds 1-4 weeks depending on origin.

3. Maintenance intervals are manufacturer-recommended minimums. Actual intervals may vary based on operating conditions, feedstock abrasiveness, and climate.

4. Specifications reflect standard configurations. Final selections will be confirmed during detailed engineering based on site-specific feedstock characterization.

5. Electrical supply assumes 13.8 kV primary / 480V secondary, 60 Hz, 3-phase. Total connected load approximately 3,500 kW (excluding WTE turbine output).

6. WTE system sized for 150 TPD refused-derived fuel fraction; net export power approximately 6 MW after parasitic loads.

Document prepared by Christopher Gabriel Brown, March 2026.

This document is for planning purposes only and does not constitute a binding quotation.

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