innovative technology for processing of carbonaceous wastes · 2019-02-07 · the plant for...

The plant for processing of carbonaceous wastes with recovery of high-heating synthetic gas and optional production of thermal and electric energy, synthetic liquid fuel, propane

butane fraction gas, ethers or spirits

INNOVATIVE TECHNOLOGYFOR PROCESSING OF CARBONACEOUS WASTES

2019

INNOVATION OF PROJECT

The innovation of project provides:

• The recovery of high-heating synthetic gas with calorific capacity of 6000 to9000 kcal/m3 from carbonaceous solid and liquid wastes by means of thermaldestruction;

• The application of technological know-how for recovery of synthetic liquid fuel,propane butane fraction gas, ethers and spirits from generated high-heatingsynthetic gas including one with no catalysts used;

• The manufacture of mobile plant for processing of carbonaceous wastes toproduce up to 7 types of energy products in compliance with environmentalstandards;

• The plant’s power self-sufficiency with no need to provide the external sourcesof thermal and electric energy for its operation

The innovative technological solutions used in the plant’s operationalcircuit enable for

• excluding the formation of dioxins, furans , benzenes, phenols;

• possibility of substantial reduction of costs with regard to gas-cleaning andenergy equipment;

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SCOPE OF APPLICATION

Our technology enables for recovery of energy and fuel while processingany carbonaceous wastes, e.g. solid (pre-crushed to small-sized pieces),liquid (black oil and heavy oil) or gaseous (associated petroleum gases,coke gas) ones, including:

• oil sludge from oil storage tanks; oil-polluted soil, waste products of oilrefineries

• waste products of wood-processing, pulp and paper or timber industry(sawdust, wood chips, bark, lignin, etc);

• various sludge from effluent treatment facilities, drain fields or methanetanks during biological treatment, etc;

• solid household wastes;

• medical wastes;

• waste products of livestock breeding, poultry farming, plant growing as wellas all kinds of raw materials with an organic origin (peat, coal and other)

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With a view to experimental background available, a newconstruction of turbo-jet thermal destruction reactor which uses thetechnology of heat exchange in a vortex flow, which allows processing largevolumes of organic raw materials, was developed and manufactured in 2017.The technology for heat exchange arrangement in vortex flow applied in itenables for processing of greater amounts of organic raw stock.

The new reactor is characterized by small dimensions, which allowthe plant for processing of carbonaceous wastes to be implemented as amodular construction.

This reactor was tried out for such feedstock as waste water sludge,sawdust, peat, straw, chicken dung with sawdust , brown coal, lignite.

All performed tests provided good results with regard to the qualityof high-heating synthetic gas.

The respective modules are manufactured as transportablecontainers with a complete set of equipment inside.

PRACTICAL RESULTS OBTAINED

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The plant for processing of carbonaceous wastes in the city of Rybinsk, Yaroslavl region, Russia

General view


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Raw stock feed-in conveyor

Ash residue collector

Stockpiling, refinement and drying section

Pre-treated feedstock piling bin


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Turbo-jet thermal destruction reactor

High-heating synthetic gas after leaving the plant


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TRADITIONAL TECHNOLOGY INNOVATIVE TECHNOLOGY

PROCESSING PROCEDURE

Slow (auger or retort) pyrolysis, plasma processing

Turbo-jet thermal destruction reactor

PRE-TREATMENT OF WASTES TO BE PROCESSED

Sorting, withdrawal of non-organic components, crushing to medium-sized

pieces, drying

Sorting, withdrawal of non-organic components, crushing to small-sized pieces,

drying

PRIMARY PROCESSING PRODUCTS

Low-heating pyrolysis gas (up to 2000 – 3500 kcal/m3), synthetic liquid fuel, ash residue

High-heating synthetic gas (6000-9000 kcal/m3), ash residue

ENERGY PRODUCTS

Electric power, heat energy, synthetic liquid fuel

High-heating synthetic gas, electric power, heat, synthetic liquid fuel, ethers, spirits,

propane butane fraction gas, coal dust fuel

COMPARATIVE DATA

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COMPARATIVE DATA

TRADITIONAL TECHNOLOGY INNOVATIVE TECHNOLOGY

HEAT-GENERATING EFFECT

None This effect is available, which enables for generation of additional amounts of heat and

reduction of power inputs

AUXILIARY POWER CONSUMPTION

The usage of gas produced on-site to heat the reactor is no less than 30-50% of its total

yield rate

The usage of gas produced on-site to heat the reactor is no more than 10% of its total

yield rate

CONTROL OF PRODUCED GAS COMPOSITION

None Technological procedures of gasification in the process enable to control a mass yield of

light and heavy hydrocarbon components

MOBILITY

None or limited mobility High mobility of plant due to its modular construction

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OVERVIEW OF PLANT FOR PROCESSING OF CARBONACEOUS WASTES

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CONTAINER-TYPE PLANT

FOR PROCESSING OF

CARBONACEOUS WASTES

Main characteristics of CPWC-2

Pre-treated waste processing performance, kg/h ............................... up to 2000

Initial raw stock moisture, % .................... up to 75

Temperature of gasification,°С ….............700 - 900

Pressure in the reactor, kg/сm‘.............- 0,1 - + 0,1

Period of gasification, sec ……………………….…1 - 3

High-heating synthetic gas yield, kg/h …….……………… up to 1500

Gas combustion heat, kcal/mЗ ………. 6000 - 9000

Self-supply electric power, kW/h …………up to 175

Total electric power productionusing synthetic gas, mW/h ………….......... up to 3,5

The period of reactor’s initial heating to reach its operational temperature, min ………... up to 30

The container’s dimensions, m ………. 6 x 2,4 x 2,6

Initial heat energy source………………………….… gas

Waste feed-in to the reactor……………..continuous

Maintenance staff, operator/shift ………..……...2/1

Raw stock feed-in

conveyor

Stockpiling, refinement and drying section

Gas burner

Turbo-jet thermal destruction

reactor

Ash residue collector

Pre-treated stock piling bin

Gas cleaning and cooling-down

system

TECHNICAL CHARACTERISTICS OF CONTAINER-TYPEFOR PROCESSING OF CARBONACEOUS WASTES PLANT

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TECHNOLOGICAL SCHEME FOR PROCESSING OF CARBONACEOUS WASTES

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CPPCPP

Stage 1RAW STOCK FEED-IN SECTION• Pre-treatment of raw materials to be processed (withdrawal of large-sized waste)SORTING AND CRUSHING LINE• Manual sorting (withdrawal of metal inclusions, stones and other non-organic

materials)• Crushing – preliminary refinement of wastes to medium-sized pieces• Magnetic separation – withdrawal of metal inclusions from waste flow

Stage 2DRYING, REFINEMENT AND PRE-HEATING• Pre-treated organic mass of sorted wastes is subjected to drying up to their

dampness rate of < 20% and is refined to the pieces of < 3 mm in size• Before being fed to turbo-jet thermal destruction reactor, dried and refined waste

in continuous flow is heated to 130-150 ºС

THERMOCHEMICAL PROCESSING BY THERMAL DESTRUCTION• With no access for oxygen at 700-900oС in the reactor, organic substances are

subjected to thermal destruction and they transform to gaseous state while non-organic substances deposit as an ash residue

• The period for gasification of organic substances is no more than 3 seconds


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Stage 3CLEANING AND COOLING-DOWN OF GASES• After leaving the turbo-jet thermal destruction reactor, gases undergo a

multistep cleaning to prevent the formation of dioxins, furans, phenols andbenzenes

• Cooling-down and separation of gases produce the condensate, which is runoff for its further treatment

Stage 4COLLECTION OF ASH RESIDUE• The ash residue consists of non-organic elements and carbon. It represents a

powder mass, which is not contaminated by hazardous substances and issuitable for its further application (building materials, dyes, absorbents )

Stage 5RECOVERY OF GAS FROM ENERGY PRODUCTSThe generated high-heating synthetic gas can be used for• production of electric power• production of heat energy• production of synthetic liquid fuel• production of ethers, spirits• production of propane butane fraction gas


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The usage of waste incineration technology obliterates valuablecomponents of carbonaceous raw stock. It also provides a large amount ofhazardous combustion gases, including an ample quantity of dust-like and gaseousemissions, calling for major technological solutions to clean them, which result inconsiderable financial expenditures on their development and furthermaintenance. Thus, the incineration of 1 ton of wastes requires 10 000 - 15 000m3 of air and subsequent cleaning of total amount of combustion gases.

During thermal destruction of the same mass of wastes the respectiveamount of emitted hazardous gases to be processed after separation of gases ismerely 30-50 m3. That is 300 times less than the amount of combustion gasesformed after incineration of wastes.

Thermal destruction results in generation of high-heating synthetic gas,which can be used for production of electric power, heat, synthetic liquid fuel,ethers, spirits or propane-butane fraction gas.

Ash residue with a high content of metal oxides formed as a result ofthermal destruction can be used in metallurgy, coating plants as an absorbent orplastic filler.

ADVANTAGES OF TURBO-JET THERMAL DESTRUCTION REACTOR TECHNOLOGY OVER WASTE INCINERATION

TECHNOLOGY

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CONCLUSIONS

1. The proposed technology for processing of carbonaceous wastes excels itsworld-wide analogues with regard to their profitability and it is based mainlyon cost-efficient equipment

2. The plant enables for production of energy products from organiccomponents of wastes in compliance with the strictest environmentalstandards

3. Production of power energy and heat from wastes provides self-containedoperation of equipment with low power consumption

4. The plant’s modular construction enables for processing of carbonaceouswastes within a wide range of its daily capacity (20 – 300 tons of wastes)

5. The plant’s equipment enables for production of alternative energy products(high-heating synthetic gas, electric power, heat, synthetic liquid fuel, ethers,spirits, propane butane fraction gas) from wastes.

6. The short period of construction (9-10 months) and payback (1-3 years)

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Alexander Vladimirovich Katlovskiy - General DirectorGrigory Leonidovich Rassokhin - Adviser, Project ManagerE-mail: [email protected], tel: +7 (910) 665-22-44

In scientific and technical association with

“Rythm”, production company, Rybinsk, Russia

“Novaya energiya”, Rybinsk, Russia

“YarLes - 2012”, Rybinsk, Russia

“RUSINPRO”, Moscow, Russia

Lomonosov Moscow State University of Fine Chemical Technologies, Moscow, Russia

Topchiev Institute of Petrochemical Synthesis, RAS, Moscow, Russia

Gubkin Russian State University of Oil and Gas (National Research University), Moscow, Russia

Kirov Saint-Petersburg State University of Forestry Engineering, Saint-Petersburg, Russia

Soloviev Rybinsk State Technical University of Aviation, Rybinsk, Russia

Institute of Combustible Minerals – Technical Scientific Center for Complex Processing of SolidCombustible Minerals, Moscow, Russia

“Sevmash” Production Association, Severodvinsk, Russia

Bezhetsk ASO plant, Bezhetsk, Russia

“Bezhetskselmash”plant, Bezhetsk, Russia

PARTICIPANTS AND PARTNERS OF PROJECT

www.nt-yar.ru

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THANK YOU!

innovative technology for processing of carbonaceous wastes · 2019-02-07 · the plant for...

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