pyrolytic heat recovery with enhanced gasification sustainable value recovery solutions for your...
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Pyrolytic Heat Recovery with Pyrolytic Heat Recovery with Enhanced GasificationEnhanced Gasification
Sustainable Value Recovery Sustainable Value Recovery Solutions for Your Organic WasteSolutions for Your Organic Waste
Value Recovery Solutions for Value Recovery Solutions for Organic Waste DisposalOrganic Waste Disposal
Pyrolytic Gasification yields a high quality Synthesis Gas from Waste Pyrolytic Gasification yields a high quality Synthesis Gas from Waste Materials such as:Materials such as:
– Municipal Solid Waste (Landfill after resource recovery at $25 -$150/ton)Municipal Solid Waste (Landfill after resource recovery at $25 -$150/ton)– Biomass and Agricultural Wastes (Burn on Site – emissions problems)Biomass and Agricultural Wastes (Burn on Site – emissions problems)– Sewer Plant Sludge (Limited landfill availability - Landfill at $50 -$150/ton)Sewer Plant Sludge (Limited landfill availability - Landfill at $50 -$150/ton)– Medical & Hospital Waste (Hazardous Landfill at $250 - $500/ton)Medical & Hospital Waste (Hazardous Landfill at $250 - $500/ton)– Refinery & Oil Processing Wastes (Hazardous Landfill at $250- $1500/ton)Refinery & Oil Processing Wastes (Hazardous Landfill at $250- $1500/ton)– Used Tires (Hazardous Landfill, Local Nuisance, Fire Danger – equiv fuel Used Tires (Hazardous Landfill, Local Nuisance, Fire Danger – equiv fuel
to coal)to coal)– Food, Beverage, & Cosmetic Manufacturing Waste (Very High BOD to Food, Beverage, & Cosmetic Manufacturing Waste (Very High BOD to
Sewer, Landfill Disposal at $25 - $150/ton)Sewer, Landfill Disposal at $25 - $150/ton)– Construction & Demolition Wastes (Landfill after resource recovery at $25 - Construction & Demolition Wastes (Landfill after resource recovery at $25 -
$150/ton)$150/ton)
If it contains organics…it’s a fuel to us and a disposal problem solved for If it contains organics…it’s a fuel to us and a disposal problem solved for you !you !
Why Pyrolysis ?Why Pyrolysis ? Incineration inherently emits oxidized hazardous pollutants (NOx, SOx, ClOx, Incineration inherently emits oxidized hazardous pollutants (NOx, SOx, ClOx,
FlOx, dioxins, furans, aldehydes, ketones, others) promoted by direct FlOx, dioxins, furans, aldehydes, ketones, others) promoted by direct combustion of waste materialcombustion of waste material
Pyrolysis in PHREG unit occurs in a reducing atmosphere. Pyrolysis in PHREG unit occurs in a reducing atmosphere. Hazardous components of off-gas are NHHazardous components of off-gas are NH33, H, H22S, HCl, HF, HCN, amines, etc.S, HCl, HF, HCN, amines, etc.easily and economically scrubbed with existing technology.easily and economically scrubbed with existing technology.Cleanup equipment capital costs are 20-40% less for PHREG than for Cleanup equipment capital costs are 20-40% less for PHREG than for incineration processes. incineration processes.
PHREG process avoids conditions favorable to the production of dioxins via the PHREG process avoids conditions favorable to the production of dioxins via the deNovo synthesis reaction.deNovo synthesis reaction.
Low nitrogen in Syngas Product reduces NOx formation tendencies during Low nitrogen in Syngas Product reduces NOx formation tendencies during combustion. Air combustion of waste makes NOx formation a recurring combustion. Air combustion of waste makes NOx formation a recurring problem for incinerators. Impossible to make a true low NOx solids burner. problem for incinerators. Impossible to make a true low NOx solids burner.
Why Pyrolysis ?Why Pyrolysis ? Incineration is pretty much limited to Combined Cycle CoGen units. PHREG Incineration is pretty much limited to Combined Cycle CoGen units. PHREG
product gas can be used in a number of ways. product gas can be used in a number of ways.
Incinerators generate large amounts of ash Incinerators generate large amounts of ash difficult to handle difficult to handle typically must be treated and disposed of as a hazardous waste. typically must be treated and disposed of as a hazardous waste.
Greater flue gas and ash cleanupGreater flue gas and ash cleanupInherently higher cost of a steam power systemInherently higher cost of a steam power system
net cost per ton of equivalent feed is 20-25% greater than pyrolysisnet cost per ton of equivalent feed is 20-25% greater than pyrolysis
Grate efficiency of burn is at best 30% - more likely below 25%.Grate efficiency of burn is at best 30% - more likely below 25%.PHREG net efficiency is 22% of feed LHV PHREG net efficiency is 22% of feed LHV
capital cost 20% below that of “Trash burn “ plant capital cost 20% below that of “Trash burn “ plant eliminates ash disposal headaches.eliminates ash disposal headaches.
Organic FeedSolutions
for Scrubbing
Particulate Solids / Liquids RemovalAux.
Boiler(Optional)
Scrubber Soln.
Regeneration
Air
Acid
Gas
Absorber
Oxygen Plant
(Optional)
Slag Collection
Disposal/Recycle
Scrubber Salt
To DisposalBurner (Typ. 4-8)Fresh Fuel
(As Needed)
Steam &
Condensor ProductGas
Recycle Fuel
Dirty Gas
O2 (As Needed)
Water
Clean Pyrogas
Pyrolysis/ Gasification Reactor W/Jacketing
PHREG PYRO & GASIFICATION PROCESS DETAILSPHREG PYRO & GASIFICATION PROCESS DETAILS
Water Recycle
Process Units:Process Units:Individually Proven – New Application!Individually Proven – New Application!
Waste ReceivingWaste Receiving– SortingSorting– Surge PilesSurge Piles
Waste Pre-ProcessingWaste Pre-Processing Feed ConveyingFeed Conveying PHREG ReactorPHREG Reactor Overhead Gas Cleaning & RecoveryOverhead Gas Cleaning & Recovery SynGas product utilization SynGas product utilization
Equipment NeededEquipment Needed Receiving PadReceiving Pad Sorting TableSorting Table ShredderShredder Pan conveyorsPan conveyors AirlockAirlock Solids/Droplets RemovalSolids/Droplets Removal Acid Gas Treatment Acid Gas Treatment Oxygen SupplyOxygen Supply Sulfur Recovery Unit Sulfur Recovery Unit
– tire / refinery waste disposal onlytire / refinery waste disposal only
Waste Sorting & ConveyingWaste Sorting & Conveying
One Supplier’s solution for recycling and One Supplier’s solution for recycling and destruction of solid wastesdestruction of solid wastes
Shredder with Feed ConveyorShredder with Feed Conveyor
A commercially available unitA commercially available unit for shredding tiresfor shredding tires
Shredder OptionsShredder Options
Other commercially available solutionsOther commercially available solutions
Airlock FeederAirlock Feeder
Commercially available from multiple Commercially available from multiple supplierssuppliers
Dual Flap-valve construction is less Dual Flap-valve construction is less likely to experience damaged seals – likely to experience damaged seals – easier to clean and repair than rotary easier to clean and repair than rotary valvesvalves
CLOSE(OPEN)
OPEN(CLOSE)
Segmental Flange
Injector/Burner Ring
Wet Feed Solids Hopper
Solids Pyrolysis Zone II
Solids Drying Zone I
Char Gasification Zone III
Ash/Slag Liquefaction Zone IV
Slag / Glass/ Metals Collection Pit
Pyrogas & Steam Vent
Air Lock Feeder
Reactor Fuel
Air/O2/SteamTo each burner
PyroliquidsRecycle(optional)
Liquid OrganicFeed (optional)
Slag/Glass recovery
Metals recovery
100- 120 C
350- 400 C
850- 900 C
1200- 1600 C
1700- 2000 C
Insulation &/or Jacketing
Feed Flow Controller
Figure 2PyroliquidsDraw (optional)
PHREG REACTORPHREG REACTOR CONCEPTCONCEPT
PHREG ReactorPHREG Reactor Derived from Blast Furnace Technology Derived from Blast Furnace Technology
– more than 800 years of technological history! more than 800 years of technological history! – High Temp, Low Pressure, Cost Effective designHigh Temp, Low Pressure, Cost Effective design– Chemical Engineers call this a “counter-current falling bed reactor”Chemical Engineers call this a “counter-current falling bed reactor”
Gas injection is through Tuyeres Gas injection is through Tuyeres – No elemental oxygen in contact with feed materialNo elemental oxygen in contact with feed material– Complete flow and temperature control of driver gas outside of reaction Complete flow and temperature control of driver gas outside of reaction
zonezone Slag collection is from the hearthSlag collection is from the hearth
– No char handling !No char handling ! Air Separation Unit needed for max Syngas ProductionAir Separation Unit needed for max Syngas Production
– 95% purity membrane or PSA95% purity membrane or PSA Use Natural gas to start, switch to completely autothermal recycle ops Use Natural gas to start, switch to completely autothermal recycle ops
in minimal timein minimal time Net SynGas product proportional to organic content in feedNet SynGas product proportional to organic content in feed Cold Gas Efficiency of 75-80% on feed LHVCold Gas Efficiency of 75-80% on feed LHV
Exhaust Gas TreatmentExhaust Gas Treatment
Separate out dust and condensable mistsSeparate out dust and condensable mists CondenserCondenser CycloneCyclone ScrubberScrubber Dryer / DesiccatorDryer / Desiccator Salt Recovery & RemovalSalt Recovery & Removal Sulfur Recovery Unit Sulfur Recovery Unit
– tires/refinery waste onlytires/refinery waste only
Dust / Mist CollectorsDust / Mist CollectorsWet Scrubber useful for Acid Gas removal as wellWet Scrubber useful for Acid Gas removal as well
SynGas UtilizationSynGas UtilizationSeveral commercially viable options availableSeveral commercially viable options available
Clean SynGas Clean SynGas
Power From Power From Gas Turbine Gas Turbine
GeneratorGenerator
Power & Steam from Power & Steam from Combined cycle Combined cycle
Cogen UnitCogen Unit
Alt Fuels &Alt Fuels &ChemicalsChemicals
(H(H22, CH, CH33OH,OH,
CHCH44, Hydrocarbons), Hydrocarbons)
What’s Left to Dispose of ?What’s Left to Dispose of ?Maybe Nothing !!Maybe Nothing !!
Scrubber Salts (which may be recyclable to chemical Scrubber Salts (which may be recyclable to chemical manufacturer) – 0.2-1.0% of original feed wtmanufacturer) – 0.2-1.0% of original feed wt
Non-hazardous Vitreous slag ( which may be used as Non-hazardous Vitreous slag ( which may be used as construction fill or primary material ) – 0.5-2.5 % of original construction fill or primary material ) – 0.5-2.5 % of original
feed weightfeed weight
The rest is all revenue streams - $$$$The rest is all revenue streams - $$$$
1. Lowest capital, quickest implementation1. Lowest capital, quickest implementation2. Lots of equipment “optimized” for low-Btu 2. Lots of equipment “optimized” for low-Btu gas feed to GTGgas feed to GTG3. Net Feed Gas Efficiency of 33-45%3. Net Feed Gas Efficiency of 33-45%4. Baseload operations with waste feed4. Baseload operations with waste feed5. Support peaker ops with supplemental 5. Support peaker ops with supplemental import gas for minimal extra (5-10%) capital import gas for minimal extra (5-10%) capital costcost
SynGas Utilization Option 1SynGas Utilization Option 1Power from Gas Turbine-Generator SetPower from Gas Turbine-Generator Set
FEED LHV FEED RATE NET POWER CAPITAL COST CAPITAL RECOVERY REMARKSFEED LHV FEED RATE NET POWER CAPITAL COST CAPITAL RECOVERY REMARKS BTU/LB TONS/DAY GEN MW APPROX $MM APPROX YRS BTU/LB TONS/DAY GEN MW APPROX $MM APPROX YRS
4500 500 0 50 6 MSW MINIMUM 4500 500 0 50 6 MSW MINIMUM SELF SUSTAINING SELF SUSTAINING
8500 500 20 75 7 BASELOAD MSW 8500 500 20 75 7 BASELOAD MSW
8500 2500 100 250 5 BASELOAD MSW 8500 2500 100 250 5 BASELOAD MSW
12500 50 4 15 2 MED WASTE TYP 12500 50 4 15 2 MED WASTE TYP
15000 100 11 28 24 OLD TIRES TYP. 15000 100 11 28 24 OLD TIRES TYP.
15000 500 55 85 5 OLD TIRES TYP. 15000 500 55 85 5 OLD TIRES TYP.
BASIS: GIVEN TONS/DAY OF TRASH @ LHV 7500 HRS/YR UTILIZATIONBASIS: GIVEN TONS/DAY OF TRASH @ LHV 7500 HRS/YR UTILIZATION ANNUAL OP COSTS @ 10% OF CAPITAL ANNUAL OP COSTS @ 10% OF CAPITAL BASELOAD POWER REVENUE @ $200/MWH BASELOAD POWER REVENUE @ $200/MWH FEED TIPPING FEE AT $ 100 /TON MSW FEED TIPPING FEE AT $ 100 /TON MSW AT $ 500 /TON MED WASTE AT $ 500 /TON MED WASTE AT $ 100 /TON TIRES AT $ 100 /TON TIRES
SynGas Utilization Option 1SynGas Utilization Option 1Power from Gas Turbine-Generator Power from Gas Turbine-Generator
SetSet