© StarPower Italia - 2005 Plasma Special Waste Treatment Tetronics / StarPower Italia experience...

© StarPower Italia - 2005

Plasma Special Waste Treatment

Tetronics / StarPower Italia experience

Technology for a cleaner environment

© StarPower Italia - 2005

Overview

• Who we areMMG/CDC

• The Markets CDC

• Environmental Drivers CDC

• Tetronics Environmental Plasma System (TEPS) CDC

• Cost Analysis MMG

• Waste Management in the production cycle MMG

• Conclusion MMG

© StarPower Italia - 2005

• StarPower Italia s.r.l. is a limited liability company actively

engaged in promoting and marketing innovative waste

management technology in Italy since 2002.

• StarPower Italia is the Tetronics ltd agent in Italy.

Starpower Italia s.r.l. - who we are

© StarPower Italia - 2005

Tetronics Limited – who we are

• World Leader in thermal plasma applications

• >30 years experience

• Proven, established technology

• International and credible customer base

• 33 environmental solutions engineered to date (upto 35,000 tonnes per year, 9MW)

• Key Environmental Sectors

• Inorganic waste treatment (Haz waste)

• Organic waste treatment (Haz + Non Haz)

• Commercial operations and plant supply

Advanced Rand D facilities >1MW Power, 6 operating stations

© StarPower Italia - 2005

Tetronics: The Markets 1

• Clean Heat

• Market leader in heating of steel in continuous casting process,

• 25 systems predominantly in the far East

• Customers include Posco, NSC, NKK, Sumitomo, Kobe

• Advanced Materials

• Prime opportunity is in the synthesis of powders

• Strategic alliance with QinetiQ for nanotechnology

• Most advanced processing facility in UK for thermal production of nanopowders

• Opportunities in micron powders and glass melting

© StarPower Italia - 2005

Tetronics: The Markets 2

• Environmental Market

• Inorganic wastes

• Extensive commercial experience:

• Recovery of precious metals from autocats (US, South Korea)

• Treatment of steel plant dusts (Italy, US)

• Vitrification of incinerator ashes (Japan)

• Organic wastes

• Major opportunity in treatment of hazardous organic and mixed wastes

• Oily sludges and solvents

• Food, meat and other agro-wastes

• Clinical and pharmaceutical wastes

• LLRW

© StarPower Italia - 2005

ENVIRONMENTAL FACTORS

-More severe regulations

-Landfill of certain wastes restricted

-Avoidance of leaching of toxins

-Prevention of dioxins and toxic gases

POLITICAL FACTORS

-Targets for reduction in landfill

-Recycling/utilization

-Energy recovery

-Sustainable, clean solutions

-Support of clean technologies

ECONOMIC AND SOCIAL

-Limited landfill and landfill tax

-Increased cost of disposal

-Tax incentive schemes

-Recovery of energy by CHP

-Poor perception of incineration

PLASMA TREATMENT OF WASTES

ENVIRONMENTAL BENEFITS

- Efficient destruction of organics

- Vitrification of wastes

- Meets most severe standards

- Non-toxic slag

ECONOMIC & SOCIAL BENEFITS

- Revenues from electrical generation

- Cost savings from avoidance of landfill

- Saleable by-product

TECHNICAL BENEFITS

- High energy efficiency

- Robust, reliable, simple and flexible

- Easy to automate

- Proven in wide range of applications

- Clean

Environmental Drivers: Hazardous Wastes

© StarPower Italia - 2005

TEPS: Solution to Hazardous wastes

• Strong regulatory and economic drivers

• Clean process solution

• Robust and proven DC Plasma arc technology

• Simple to operate and maintain

• High destruction efficiency of persistent organics

• Stable vitrified slag, with good utilization potential

• Minimisation of waste by-products

• Recycling of valuable metals

• Economic

• Strong position within the waste management hierarchy

© StarPower Italia - 2005

PLASMA ZONE > 10,000 K

High Temperature Destruction of Organics

Metallic Phase Recovery of Metal

Value

High Intensity UV Catalysis of Photo-Chemical Reaction

Environmentally Stable Slag Repository for

Heavy Metals

Furnace Off Gas Combustible Gases and

Volatile Species

TEPS: Typical Plasma Reactor

© StarPower Italia - 2005

TEPS: Inorganic / Organic Haz Waste Treatment

Metallurgical residues, contaminated soils, incinerator ashes, asbestos

LLRW, contaminated meat, oil sludges, solvents, POPS, clinical,

No oxidant added to furnaceAir, water or oxygen added to furnace

Raw material < 5% carbon. Furnace off gas has no significant calorific value

Raw material > 5% carbon. Furnace off gas has calorific value (CO and H2)

INORGANIC (vitrification/smelting)

ORGANIC (gasification)

© StarPower Italia - 2005

PYROLYSIS22H

mnCHC mn

2 mH2nCOOHC mn

22 HCOOHC

COOC 22

1

INPUTS OUTPUTS

FEED

OXIDANT

GAS

SLAG

METAL

CO, H2, CO2, H2O, HCL, Zn, Pb, Hg etc

MeO (e.g. SiO2, CaO, Al2O3, P2O5, Cr2O3, FeO etc)

Me (Fe, Cu, etc)

CnHm …..MeO, Me, O, S, Cl, P etc

H2O, O2, Air

GASIFICATION

FEATURES

• High destruction efficiency

• High UV and temperature

• Metal recovery

• Non leachable slag

TEPS: Process Mechanism

© StarPower Italia - 2005

WASTE MATERIALS

FLUXES

PLASMA

CONVERTOR

PLASMA POWER

SLAG PRODUCT

SECONDARY OXIDATION,

COMBUSTION

GAS CLEANING

SECONDARY USES,

RECYCLING, SAFE

DISPOSAL

HEAT RECOVERY

PROCESS PREHEATING

HOT WATER / STEAM

ELECTRICITY GENERATION

OXIDANT (AIR,

WATER)

Organic waste only

METAL PRODUCT

TEPS: Key Stages

© StarPower Italia - 2005

TEPS: Process Flow Sheet

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FEED RECEIVER

GAS DISCHARGE

GAS CLEANING

THERMAL OXIDISER

PLASMA REACTOR

PRODUCT DELIVERY

SHREDDER

TEPS: Layout of a Plasma Waste Treatment Plant

© StarPower Italia - 2005

TEPS Product Utilization Cycle

PLASMA

TREATMENT

WASTE

MATERIAL

CHP

PLANT

STEAM/

ELECTRICAL

Vitrified Product

Export of electricity

Production of chemicals, hydrogen

© StarPower Italia - 2005

TEPS:Typical composition and impurities of Syn-gas

Gas Species Volume %

H2 20-40

CO 20-30

CO2 <5

N2 <20

CnHm <1

Pollutant mg/Nm3

SOx <10

HCl <5

CO <20

NOx <20

Heavy Metals <1

Syn-gas quality Syn-gas Pollutants

© StarPower Italia - 2005

Plasma Convertor

PRIMARY ASH ~ 50ng TEQ/g

SLAG<0.001 ng TEQ/g SECONDARY FLY ASH

Gas Handling

<0.005 ng TEQ/g

TEPS: Plasma Destruction of Dioxins

GAS EMMISSION < 0.05ng TEQ/M3

© StarPower Italia - 2005

5

1

2.5

5 5

0.04 0.02 0.06 0.14 0.040

2

4

6

PPM

Arsenic Cadmium Cr 6+ Lead Silver

Toxic Leachate Species

Slag TCLP Limits

TEPS: Leachate Test results (steel dust)

© StarPower Italia - 2005

Cost Analysis

• Tetronics can provide custom-made solutions optimized to address

specific waste problems • Capital costs are dependant on the type and quantity of waste to be

treated• When the waste chemical composition is known StarPower Italia

can employ its financial analysis model to forecast costs of

disposal and Return of Investment rates

© StarPower Italia - 2005

Cost Analysis

• Case study – 50 tpd plant / pharmaceutical waste / 348dx24h /

tipping fee 0.41 €/kg• 1.6MwH torch• 0.09 €/kWh power costs• Labour rates per year:

• Plant Manager 88,000 euro• Shift Supervisor 26,000 euro• System Operator 26,000 euro• Assistant x 3 26,000 euro• Other (secretary) 23,000 euro

© StarPower Italia - 2005

• Break even point for plant in operation after 9 months

from start of project without considering revenues from

system by-products

Cost Analysis

© StarPower Italia - 2005

Cost Analysis

© StarPower Italia - 2005

• The TEPSTM can be easily integrated into companies existing production cycle to treat their waste streams

• Reduce waste management costs in the balance sheet

• Generates by-products and energy that could be fed in the production cycle

• Guarantees the compliance with all current and future environmental regulations

• Produce valuable products from “GARBAGE”

Waste Management in the Production Cycle

© StarPower Italia - 2005

Conclusion

• TEPSTM is as an effective and versatile solution for the treatment of hazardous waste streams

• The products arising are readily recycled, reused or disposed of in a safe manner

• The slag products are stable and non-leachable

• Potential savings by diverting vitrified slag product away from landfill

• Technical risk minimised by industrial track record

• Economic risk stabilised against future regulatory drivers

© StarPower Italia - 2005

StarPower Italia s.r.l. Tetronics Ltd:

www.star-power.it www.tetronics.com

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