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© 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
© StarPower Italia - 2005
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
For more information: