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Pyrolytic Heat Recovery with Enhanced Gasification

Pyrolytic Heat Recovery with Enhanced Gasification. Sustainable Value Recovery Solutions for Your Organic Waste. Value Recovery Solutions for Organic Waste Disposal. Pyrolytic Gasification yields a high quality Synthesis Gas from Waste Materials such as:

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Pyrolytic Heat Recovery with Enhanced Gasification

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  1. Pyrolytic Heat Recovery with Enhanced Gasification Sustainable Value Recovery Solutions for Your Organic Waste

  2. Value Recovery Solutions for Organic Waste Disposal Pyrolytic Gasification yields a high quality Synthesis Gas from Waste Materials such as: • Municipal Solid Waste (Landfill after resource recovery at $25 -$150/ton) • Biomass and Agricultural Wastes (Burn on Site – emissions problems) • Sewer Plant Sludge (Limited landfill availability - Landfill at $50 -$150/ton) • Medical & Hospital Waste (Hazardous Landfill at $250 - $500/ton) • Refinery & Oil Processing Wastes (Hazardous Landfill at $250- $1500/ton) • Used Tires (Hazardous Landfill, Local Nuisance, Fire Danger – equiv fuel to coal) • Food, Beverage, & Cosmetic Manufacturing Waste (Very High BOD to Sewer, Landfill Disposal at $25 - $150/ton) • Construction & Demolition Wastes (Landfill after resource recovery at $25 - $150/ton) If it contains organics…it’s a fuel to us and a disposal problem solved for you !

  3. Why Pyrolysis ? Incineration inherently emits oxidized hazardous pollutants (NOx, SOx, ClOx, FlOx, dioxins, furans, aldehydes, ketones, others) promoted by direct combustion of waste material Pyrolysis in PHREG unit occurs in a reducing atmosphere. Hazardous components of off-gas are NH3, H2S, HCl, HF, HCN, amines, etc. easily and economically scrubbed with existing technology. Cleanup equipment capital costs are 20-40% less for PHREG than for incineration processes. PHREG process avoids conditions favorable to the production of dioxins via the deNovo synthesis reaction. Low nitrogen in Syngas Product reduces NOx formation tendencies during combustion. Air combustion of waste makes NOx formation a recurring problem for incinerators. Impossible to make a true low NOx solids burner.

  4. Why Pyrolysis ? Incineration is pretty much limited to Combined Cycle CoGen units. PHREG product gas can be used in a number of ways. Incinerators generate large amounts of ash difficult to handle typically must be treated and disposed of as a hazardous waste. Greater flue gas and ash cleanup Inherently higher cost of a steam power system net cost per ton of equivalent feed is 20-25% greater than pyrolysis Grate efficiency of burn is at best 30% - more likely below 25%. PHREG net efficiency is 22% of feed LHV capital cost 20% below that of “Trash burn “ plant eliminates ash disposal headaches.

  5. PHREG PYRO & GASIFICATION PROCESS DETAILS Product Gas Condensor Clean Pyrogas Organic Feed Solutions for Scrubbing Water Recycle Acid Gas Absorber Steam & Recycle Fuel Particulate Solids / Liquids Removal Aux. Boiler (Optional) Scrubber Soln. Regeneration Dirty Gas Pyrolysis/ Gasification Reactor W/ Jacketing Water Scrubber Salt To Disposal Burner (Typ. 4-8) Fresh Fuel (As Needed) Air Slag Collection Disposal/Recycle O2 (As Needed) Oxygen Plant (Optional)

  6. Process Units:Individually Proven – New Application! • Waste Receiving • Sorting • Surge Piles • Waste Pre-Processing • Feed Conveying • PHREG Reactor • Overhead Gas Cleaning & Recovery • SynGas product utilization

  7. Equipment Needed • Receiving Pad • Sorting Table • Shredder • Pan conveyors • Airlock • Solids/Droplets Removal • Acid Gas Treatment • Oxygen Supply • Sulfur Recovery Unit • tire / refinery waste disposal only

  8. Waste Sorting & Conveying One Supplier’s solution for recycling and destruction of solid wastes

  9. Shredder with Feed Conveyor A commercially available unit for shredding tires

  10. Shredder Options Other commercially available solutions

  11. Airlock Feeder Commercially available from multiple suppliers Dual Flap-valve construction is less likely to experience damaged seals – easier to clean and repair than rotary valves

  12. PHREG REACTORCONCEPT Wet Feed Solids Hopper Feed Flow Controller CLOSE (OPEN) Air Lock Feeder OPEN (CLOSE) Pyrogas & Steam Vent 100- 120 C Solids Drying Zone I Liquid Organic Feed (optional) Figure 2 Pyroliquids Draw (optional) Pyroliquids Recycle(optional) 350- 400 C Solids Pyrolysis Zone II 850- 900 C Char Gasification Zone III Air/O2/Steam To each burner 1200- 1600 C Ash/Slag Liquefaction Zone IV 1700- 2000 C Reactor Fuel Slag/Glass recovery Slag / Glass/ Metals Collection Pit Insulation &/or Jacketing Metals recovery Segmental Flange Injector/Burner Ring

  13. PHREG Reactor • Derived from Blast Furnace Technology • more than 800 years of technological history! • High Temp, Low Pressure, Cost Effective design • Chemical Engineers call this a “counter-current falling bed reactor” • Gas injection is through Tuyeres • No elemental oxygen in contact with feed material • Complete flow and temperature control of driver gas outside of reaction zone • Slag collection is from the hearth • No char handling ! • Air Separation Unit needed for max Syngas Production • 95% purity membrane or PSA • Use Natural gas to start, switch to completely autothermal recycle ops in minimal time • Net SynGas product proportional to organic content in feed • Cold Gas Efficiency of 75-80% on feed LHV

  14. Exhaust Gas Treatment • Separate out dust and condensable mists • Condenser • Cyclone • Scrubber • Dryer / Desiccator • Salt Recovery & Removal • Sulfur Recovery Unit • tires/refinery waste only

  15. Dust / Mist CollectorsWet Scrubber useful for Acid Gas removal as well

  16. SynGas UtilizationSeveral commercially viable options available

  17. What’s Left to Dispose of ?Maybe Nothing !!Scrubber Salts (which may be recyclable to chemical manufacturer) – 0.2-1.0% of original feed wtNon-hazardous Vitreous slag ( which may be used as construction fill or primary material ) – 0.5-2.5 % of original feed weightThe rest is all revenue streams - $$$$

  18. SynGas Utilization Option 1Power from Gas Turbine-Generator Set 1. Lowest capital, quickest implementation2. Lots of equipment “optimized” for low-Btu gas feed to GTG3. Net Feed Gas Efficiency of 33-45%4. Baseload operations with waste feed5. Support peaker ops with supplemental import gas for minimal extra (5-10%) capital cost

  19. SynGas Utilization Option 1Power from Gas Turbine-Generator Set FEED LHV FEED RATE NET POWER CAPITAL COST CAPITAL RECOVERY REMARKS BTU/LB TONS/DAY GEN MW APPROX $MM APPROX YRS 4500 500 0 50 6 MSW MINIMUM SELF SUSTAINING 8500 500 20 75 7 BASELOAD MSW 8500 2500 100 250 5 BASELOAD MSW 12500 50 4 15 2 MED WASTE TYP 15000 100 11 28 24 OLD TIRES TYP. 15000 500 55 85 5 OLD TIRES TYP.BASIS: GIVEN TONS/DAY OF TRASH @ LHV 7500 HRS/YR UTILIZATION ANNUAL OP COSTS @ 10% OF CAPITAL BASELOAD POWER REVENUE @ $200/MWH FEED TIPPING FEE AT $ 100 /TON MSW AT $ 500 /TON MED WASTE AT $ 100 /TON TIRES

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