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THE TREATMENT OFRESIDUES 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 to the processing
facilities.
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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 vitrifiedmatter. 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
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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 fallunlike other
technologies.
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Incineration vs Plasma Converter
OPPOSITE PROCESS
Process of incineration Plasma Converter System
Spontane chain reaction. Difficult to control
Residue limited and clasiffied. Ashes and contaminated particles
emission It generates heat
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
ExothermicIts characterized for energy production.
Its generate energy
Heat
EndothermicIts characterized for energy absorption.
It consumes
electricity
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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 currentenvironmental and safety requirements.
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Plasma Converter System
Process of five steps
Supply
SolidLiquidGas
Dissociation
Plasma is usedto destroymaterial intomolecular level in
a total andirreversiblemanner.
Neutralize and
final cleaning Cooling Filter
Stage 1
Supply
Stage 2
Dissociate
Stage 3
Cool
Stage 5
Neutralize and
final cleaning
Stage 4
Filter
Process of five (5) stepsFeedstockmaterial in
Synthesisgas(PCG)
Feed
System
Plasma
Vessel
Particlefilter
Silicate
Final
cl
eaning
Clean gasHeatRecoveryBoiler
Stage 1 Stage 2 Stage 5Stage 3 Stage 4
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Supply
Liquid feed system:
- Supply from barrels or
tanks.
-
Pump with pipeline oftransfer 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
PCG
PCG
PCG(Synthesis gas)
Metals, Glass and others
combined chemically in an inertsilicate. Not toxic silicate andwithout escapes
Atmosphere
Pressure
Materials basedin carbon,
separated andgasificated
Melt silicate:Metals (FE, AL, CU, ...)Glass (Sodium Silicate)Others (Silice, SiO2 , ... )
22.000 C
Plasma zone
(3.000 9.000 C)
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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 andtransferred operation
SINGLE TORCH
Non transferred andtransferred operation
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Control System
The primary process control
is based in PLCs.
The program control andcommunication with the
remote I/O.
The control station is
centralized.
Computer system based in
human interface.
Monitoring of the processand recording video in real
time .
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Analysis of the PCG in real time
Synthesis gas
monitoring is
realized
continuously toassure 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 BTU5,450 MWh
Clean Syngas16,2 billion BTU
4,746 MWh
Sensible heat out6 millions BTU(~60% recoverable)
Electrical energy in3,6 billionBTU1,055 MWh
PLASMA
CONVERTER
SYSTEM
PCG energy out
= 4,5Electrical energy in Total energy in
PCG energy out
=87%
Treatment of MSW 2000 TPD Materiales Renovados, SL The content may not be
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Balance Graph
F M ( k m o l)
oC
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PCG constant composition
The composition of the synthesis gas remains practicallyconstant 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 thefraction of organic matter of the residue treated.
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Products of the process
Synthesis gas and vitrified silicate
Supply materials:
Solids, Liquids & GasesHazardous and Inerts
P
CG
Vitrifiedsilicate
Synthesis
gasELECTRICENERGY
HYDROGENPRODUCTION
CHEMICAL
PRODUCTS
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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
OXIGENATED
DIESEL
NAFTA
KEROSENO
METHANOL
ETHANOL
DME
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Gas to Liquid
Stage of the process
ADJUSTSYNGAS
COMPOSITION
SYNTHESISREACTOR
PURIFICATON
P
URIFICATON
FINALUSE
PCG
FINISHEDPRODUCT
Adjust syngas composition Synthesis reactor Purification
Adjustment of the
syngas composition tothe ideal conditions forthe reaction.
Catalytic reaction admits
multiple configurations forthe reactor, pressure andtemparture.
It increases the purityof the product
obtained up to theneeded level.
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Adjust syngas composition
Adjust the ideal
H2/CO/CO2 ratio for
the synthesis by
means:
Enrichment in H2 :supply H2 or
steam.
CO2. Removalsystem.
SYNTHESISGAS
STEAM
SYNTHESIS GAS
AMINESOLUTION
shift-conversion reactor
Stripper
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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)
(2n+1) H2 + nCO CnH2n+2 + n H2O(paraffin production)
(2n) H2 + nCO CnH2n + n H2O(oleffin production)
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Improvement the product
Oxigenated hydrocarbons.
Purification of the product bymeans of distillation columns.
Liquid hydrocarbons.
Improvement the productcharacteristics
e.g. hydrocraking
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Closed system of recycling
CH2 CH CH CH2 CH CH
HC
CH2
n
CH2
CH
CH m
H
C
CH2
n
CH2CH
CH
m
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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 asystematic and multifacetetechnology for the separation andpurification of the hydrogen.
It is a ultrafine coats with nanoporossupported in a ceramic membraneon a low cost.
It works, obtaining a very highperformance to temperatures of200C and pressures of 10 bar.
The design ensures a defect-freemanufacturing.
Chemically steady.
High hydrothermal stability
FILTERS HAS BEENTESTED IN MULTIPLE
OPERATING CONDITIONS
SATISFACTORY
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Obtaining Energy from
Synthesis Gas
The synthesis gas is fed to the engine where it isproduced electric power.
The heat available from the engine exhaust will berecovered through the cooling system in the form ofsteam. The steam is transformed into electricalenergy 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 exemplary: Low emissions of
atmospheric pollutants.
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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
BAOSTEELBHK
CHINA STEELDAIDO STEEL
EBARAK-PLANT
JFEKOBELCO ECO SOLUTIONS (KES)
KURIMOTO
NIPPON STEELAmerica
ENERSOL TECHNOLOGIESGE GLOBAL RESEARCH
PLASCO ENERGY GROUPPPG INDUSTRIES
STARTECH ENVIRONMENTAL
U.S. ARMYU.S. NAVY
Europe
BELLWETHER GASIFICATIONCHEMOPROJEKT
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I t ti
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In construction
PLANT IN MADRID (SPAIN)
Plant capacity : 50 TPDResidues: RDF (residues derived fuel)Valuation of synthesis gas: obtaining methanolStart operating: In construction
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Questions:
Contact us:
Paseo de la Castellana 268, 128046 Madrid (Spain)
Phone.: (+34) 913 14 17 78Fax: (+34) 913 14 77 30
?
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