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