THE TREATMENT OF RESIDUES BY PLASMA, DREAM OR REALITY?

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Problematic of the residues:

Increase in number and complexity of the residues. Need of a sustainable management of the residues. Order of preference: reduction, reuse, recycling, energetic use and landfill. Need to guarantee the certain elimination of dangerous waste. Increase of legal requirements for the waste management due to the sanitary and environmental problems that generate the processing facilities. Social rejection facilities. to the processing

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Solution: Plasma Converter System

The technology of plasma is known and widely used. INNOVATIVE: his application to the treatment of resides. Plasma Converter System generates an intense field of radiant energy that induce molecular dissociation of solid, liquids and gases. To more than 5.000 C the organic molecules desintegrate giving rise to a mixture of H2 and CO and inorganic vitrified matter. Therefore ashes are not formed. Obtained products:
Synthesis gas: From organic matter, contains mixture of H2 and CO, with traces of other elements. Crystal of silicate: From inorganic matter, material inert and vitrified.

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Comparison between technologies

Deposit on a landfill Identified and classified residues that fulfill the requirements of every type of landfill. It needs a big area with specific geological characteristics. Only for residues in which there isnt another alternative. Environmental problems. Great social rejection. Incineration Identified and classified residues to prevent toxic emission to atmosphere. It generates ashes, classified often as dangerous waste. Method of energetic assessment if it is connected to recovery of energy system. Environmental problems. Great social rejection. Plasma Converter System Effective even though the residues to treat change or exact composition is unknown. Sure and irreversible elimination of dangerous residues. Low atmospheric emission. It has formed an inert material: silicate. Method of energetic assessment that generates goods of value. It fulfills environmental requirements more strict than the legal ones.
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Energy available vs Temperature in the Plasma Converter System

The energy available in the Plasma Converter System does not reduce at the temperature fall unlike other technologies.

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Incineration vs Plasma Converter

OPPOSITE PROCESS
Exothermic Its characterized for energy production. Endothermic Its characterized for energy absorption.

Its generate energy Heat

It consumes electricity

Process of incineration
Spontane chain reaction. Difficult to control Residue limited and clasiffied. Ashes and contaminated particles emission It generates heat

Plasma Converter System

Induced reaction. Easy to control. Dont exist limitation in the type of residues, dont need to classify them. Obtaining of vitrified residue with industrial applications. It produces syngas

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How does the Plasma Converter System work?

The intensity of the plasma excites and breaks the residual bonds, producing to him the " molecular dissociation. " It recycles residues, turning them commodities: synthesis gas, metals and silicate. Obtains important volumetric reductions of the residues, of the order from 300 to 1. It exceeds in several magnitude orders the current environmental and safety requirements.

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Plasma Converter System Process of five steps

Process of five (5) steps
Feedstock material in Plasma Feed System Silicate Vessel Synthesis gas (PCG) Final cleaning Heat Recovery Boiler Particle filter

Clean gas

Stage 1 Supply

Stage 2 Dissociate

Stage 3 Cool

Stage 5 Stage 4 Neutralize and Filter final cleaning

Stage 1
Supply Solid Liquid Gas

Stage 2

Stage 3

Stage 4
Filter

Stage 5
Neutralize and final cleaning

Dissociation Cooling Plasma is used to destroy material into molecular level in a total and irreversible manner.

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Supply
Liquid feed system:
- Supply from barrels or tanks. - Pump with pipeline of transfer to the vessel. - Measurement of the injection flow in the vessel.

Solid feed system:

- Pneumatic piston. - Crushing mashine. - A conveyor belt. - Solid screw .

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Vessel of Plasma Converter System

Feed system Atmosphere Pressure Materials based in carbon, separated and gasificated

22.000 C Plasma zone (3.000 9.000 C) P C G P C G

Metals, Glass and others combined chemically in an inert silicate. Not toxic silicate and without escapes

Melt silicate: Metals (FE, AL, CU, ...) Glass (Sodium Silicate) Others (Silice, SiO2 , ... )

PCG (Synthesis gas)

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Construction of the vessel

Vessel
Vessel is outfited with a refractory liner system. Sealed. Negative pressure in the operation. Only one exit to the PCG and vitrified silicate.

Exit of vitrified silicate

Extraction continues in a car cooled by water. Extraction for inclination.

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Types of plasma torch

TWIN TORCH Non transferred and transferred operation

SINGLE TORCH Non transferred and transferred operation

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Control System
The primary process control is based in PLCs. The program control and communication with the remote I/O. The control centralized. station is

Computer system based in human interface. Monitoring of the process and recording video in real time .

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Analysis of the PCG in real time

Synthesis gas monitoring is realized continuously to assure his composition.

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More energy produced than consumed

Waste, like MSW, medical waste, and industrial waste; dangerous and not dangerous, that are rich in hydrogen and carbon turn into components of a fuel called Synthesis Gas.

For every unit of energy consumed by PCS for the processing of waste, energy value contained in the Synthesis Gas produced is four times higher.

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Energy balance Fuel derived from Waste

(Per Tonne)
MSW in 18,6 billion BTU 5,450 MWh

Clean Syngas 16,2 billion BTU 4,746 MWh

Electrical energy in 3,6 billionBTU 1,055 MWh

PLASMA CONVERTER SYSTEM

Sensible heat out 6 millions BTU (~60% recoverable)

PCG energy out = 4,5 Electrical energy in

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PCG energy out Total energy in

Treatment of MSW 2000 TPD

=87%

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Balance Graph
FM (kmol)

oC

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PCG constant composition

The composition of the synthesis gas remains practically constant independently of the type of organic residue treated.

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Energy and volume of PCG

The volume of synthesis gas produced increases with the fraction of organic matter of the residue treated.

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Products of the process Synthesis gas and vitrified silicate

Supply materials: Solids, Liquids & Gases Hazardous and Inerts

CHEMICAL PRODUCTS

Synthesis gas

P C G

ELECTRIC ENERGY

Vitrified silicate

HYDROGEN PRODUCTION

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Gas to Liquid process

Gas to Liquid GTL process turns synthesis gas into ultraclean liquid fuels. With broad experience from the World War II. Two types of products:
LIQUID HYDROCARBON

DIESEL NAFTA KEROSENO METHANOL ETHANOL DME

OXIGENATED

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Gas to Liquid Stage of the process

FINAL USE

PURIFICATON

PURIFICATON

PCG

ADJUST SYNGAS COMPOSITION

SYNTHESIS REACTOR

FINISHED PRODUCT

Adjust syngas composition Synthesis reactor Adjustment of the syngas composition to the ideal conditions for the reaction. Catalytic reaction admits multiple configurations for the reactor, pressure and temparture.

Purification It increases the purity of the product obtained up to the needed level.

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Adjust syngas composition

SYNTHESIS GAS

Adjust the ideal H2/CO/CO2 ratio for the synthesis by means:

Enrichment in H2 : supply H2 or steam. CO2. Removal system.

shift-conversion reactor

STEAM

Stripper

SYNTHE SIS GAS

AMINE SOLUTION

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Chemical synthesis
Previous adjust of the pressure and temperature. Catalytic reactions: Catalyst with metals as active ingredient Fe/Cu/Co/Ni Reactions:
(2n) H2 + nCO CnH2n+1 OH + (n-1) H2O (alcohol production) CnH2n+2 + n H2O (2n+1) H2 + nCO (paraffin production) (2n) H2 + nCO CnH2n + n H2O (oleffin production)

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Improvement the product

Oxigenated hydrocarbons.

Purification of the product by means of distillation columns.

Liquid hydrocarbons.
Improvement the product characteristics e.g. hydrocraking

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Closed system of recycling

CH2HC

CH2 CH CH CH2 CH CH2 CH m CH2 CH

m

CH2 HC CH

CH

CH

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Obtaining Hydrogen from Synthesis Gas

The ceramic membrane is a technology for the separation and purification of hydrogen. The synthesis gas enters by a supply pipe, pushing the hydrogen through the ceramic membrane. Then the hydrogen leaves by a exit port, while the rest of the synthesis gas leaves by another.

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Hydrogen Filters
The ceramic membrane is a systematic and multifacete technology for the separation and purification of the hydrogen. It is a ultrafine coats with nanoporos supported in a ceramic membrane on a low cost. It works, obtaining a very high performance to temperatures of 200C and pressures of 10 bar. The design ensures a defect-free manufacturing. Chemically steady. High hydrothermal stability
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FILTERS HAS BEEN TESTED IN MULTIPLE OPERATING CONDITIONS SATISFACTORY

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Obtaining Energy from Synthesis Gas

The synthesis gas is fed to the engine where it is produced electric power. The heat available from the engine exhaust will be recovered through the cooling system in the form of steam. The steam is transformed into electrical energy in cogeneration unit.
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Economical benefits
Lower construction and operation costs than other plants with comparable technologies. Reduction of recurring operational costs .
It reduces direct cost and generates benefits as electricity. Reduction responsibility for emission to atmosphere, spillages to water or production dangerous residues.

New source of income from material that before was representing operational expense.
The process produces several materials: gas of syntheses, hydrogen and silicate, which can be commercialized.

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Enviromental benefits
Sure and virtually closed systems, without negative impact in the environment. It is designed to eliminate possible emissions or unnecessary unloads.. System is formed in closed cycle. According to volume and composition of materials to process, the operation can be formed to produce: Clean fuels as synthesis gas or hydrogen, based on renewable resources. Chemical products like methanol, diesel It contributes to the sustainable development: there are obtained energy and useful products (synthesis gas and silicate) from renewable resources as the residues. Gas purification system is atmospheric pollutants. exemplary: Low emissions of

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Conclusion
Nowadays, it is necessary to rely on a technology that contribute to the sustainable development to be able to correct the increasing problems of the residues. The Plasma Converter System appears as a solution to the problem, since it is capable of obtaining energy and useful products (synthesis gas and silicate) from renewable resources as the residues, respecting the environment and being an impulse for the alternative energies as well as an example of ecological sustainability.

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Experience list

Japan & Asia BAOSTEEL BHK CHINA STEEL DAIDO STEEL EBARA K-PLANT JFE KOBELCO ECO SOLUTIONS (KES) KURIMOTO NIPPON STEEL America ENERSOL TECHNOLOGIES GE GLOBAL RESEARCH PLASCO ENERGY GROUP PPG INDUSTRIES STARTECH ENVIRONMENTAL U.S. ARMY U.S. NAVY Europe BELLWETHER GASIFICATION CHEMOPROJEKT

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In construction
PLANT IN MADRID (SPAIN)
Plant capacity : 50 TPD Residues: RDF (residues derived fuel) Valuation of synthesis gas: obtaining methanol Start operating: In construction

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Questions:

?
Contact us:
Paseo de la Castellana 268, 1 28046 Madrid (Spain) Phone.: (+34) 913 14 17 78 Fax: (+34) 913 14 77 30

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