thermolyzer™ - today's waste tomorrow's energy

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CHZ Technologies, LLC 5547 Mahoning Ave Suite 340 Austintown, OH 44515 USA Ernest Zavoral, Sr. 330 286 7076 office 330 233 0498 mobile 330 799 4515 fax [email protected] The Future of De-carbonization in Waste -to - E nergy Technology THERMOLYZER™ 1

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Page 1: THERMOLYZER™ - Today's Waste Tomorrow's Energy

CHZ Technologies, LLC 5547 Mahoning Ave Suite 340 Austintown, OH 44515 USA Ernest Zavoral, Sr. 330 286 7076 office 330 233 0498 mobile 330 799 4515 fax [email protected]

The Future of De-carbonization in

Waste-to-Energy Technology

THERMOLYZER™

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< A 44 tons/day (TPD) Plant 2

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Table of Contents

• A CIRCULAR ECONOMY SOLUTION TO WASTEMATERIALS............................................................................. 4

• OBJECTIVE ..................................................................... 4

• TECHNOLOGY ................................................................... 4

• BOARD REVIEW ............................................................... 5

• LANDFILL DEVELOPMENT .................................................. 5

• ALTERNATIVE TECHNOLOGIES ................................................. 6

• EMISSIONS ...................................................................................... 6

• MICRO-UTILITY ..................................................................... 6

• MODULE SIZES ..................................................................... 6

• FEEDSTOCK CONDITIONING .................................................... 6

• FEEDSTOCK OPTIONS ......................................................... 6

• USABLE BYPRODUCTS ......................................................... 7

• THERMOLYZER SYSTEM ........................................................ 8

• BENEFITS OF THE THERMOLYZER SYSTEM .............................. 8

• COST COMPARISONS .......................................................... 9

• SYSTEM RETURN ON INVESTMENT ......................................... 10

• SYSTEM MAINTENANCE ........................................................ 10

• OPERATIONAL REVIEW ........................................................ 10

• THERMOLYSIS …................................................................. 10

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Thermolyzer™

• COMPARISON OF GASIFICATION TYPES…........................... 11

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• A CIRCULAR ECONOMY SOLUTION TO WASTE MATERIALSAliquippa Holdings, LLC, and its subsidiary CHZ Technologies, LLC, are addressing the globalsustainability, economic and climate change challenges of communities, businesses, governments,municipalities, industry, military, medical facilities, and landfill operators to find transformative non-incineration technologies to address the waste material crisis and produce clean, renewable energy andreusable byproducts.

• OBJECTIVETo advance the circular economy and enable global sustainability through the conversion of waste materialssuch as mixed 1-7 plastics, tires, e-waste, auto shredder residue, municipal solid waste (MSW), carpet,biomass, and other hydrocarbon-containing feedstocks for the production of renewable energy and usefulbiochar.

Recycling waste materials into clean energy reduces GHG emissions, use of fossil fuels and simultaneouly reduce requirements for landfill development.

• TECHNOLOGYThe company has manufactured three generations of 4 tons/day (TPD) pilot plants and one 44 TPD commercialdemonstration plant to prove technology scale-up in Germany. All future systems will be built in the USA.

The patented thermolysis gasifier includes three cascading internal reactors, scrubbers, and a tar/oil cracker. Feedstock is indirectly heated in an Oxygen-Free environment using the system’s own synthesis gas called “Thermolgas™ to maintain reactor temperature. The system uses only 18-30% of the Thermolgas to maintain the thermolysis reaction. The cracked tar and oils are recirculated to make more Thermol gas and increase efficiency, reduce maintenance and increase economic returns.

Char exits secondary reactor on the 4 TPD pilot plant.

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Jean
Highlight
biochar?
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• INDEPENDENT REVIEWThe Thermolyzer system has been reviewed and vetted by R.W. Beck, HDI Gerling and Munich RE Insurance. Additionally, Siemens AG and Caterpillar Division MWM, have approved the direct injection of Thermolgas™ into its turbines and gas engines with full warranty. This direct use of Thermolgas allows users to install gas turbines that make the system significantly more efficient than heating a boiler to make steam to operate a steam turbine.

• LANDFILL DEVELOPMENTThe Thermolyzer system aids in the reduction of landfills. In the U.S., 237 million tons of waste goes to landfills annually. Landfill methane (CH4) GHG emissions have a global warming potential (GWP) that is 23 times worse than carbon dioxide (CO2) emissions. Landfills can capture up to 70% of the methane generation but 30% still enters the atmosphere.

New U.S. landfills costs run about $2,00,000 per acre. Plus, many landfills are required to spend significant amounts for water and soil reclamation due to seepage problems.

Unfortunately, many large U.S. cities transport its waste hundreds of miles to distant landfills increasing transportation GHG emissions. In emerging countries, landfills create significant health and environmental issues due to open landfills.

• ALTERNATIVE TECHNOLOGIESThere are several environmentally and economically inferior alternative technologies available for waste disposal.

• Incineration – 2,200°+: This option has been used most often. It has a history of emission issues and is expensive due to the need to handle toxic emissions and molten metals. It has high parasitic loads and the military and others are moving away from incineration.

• Plasma arc – 3,000°+: Uses high voltage and high temperature to break down waste into gaseous form. It also has high parasitic loads.

• Gasification – 1,200°+: Process temperature is lower than incineration and plasma arc. Uses a controlled amount of oxygen. Control of combustion rate and temperature is difficult. It has lower emissions than the previous as well as lower parasitic loads.

• Thermolysis gasification – 1,000°+: It has the lowest temperature and lowest pressure and operates in an oxygen-free environment preventing harmful emission of chemicals and off-gassing into the atmosphere.

• Solar – uses solar panels to create electric energy directly. They generally have a capacity factor of about 17% and therefore do not provide base load power. They are a complementary source of power.

• Wind – uses wind turbines that turn and generate power. They generally have a capacity factor of 32% in high wind areas and therefore do not provide base load power. They are a complementary source of power.

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Jean
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unfortunately
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Emission Type Standard Units

Particulates < 20 ppm

SO2 < 35 ppm

Organics < 10 ppm

Chlorides < 20 ppm

Mercury < 0.03 ppm

Cadmium <0.05 ppm

Dioxins/Furans < 0.00001 ppb

• MICRO-UTILITYThe micro-utility business model allows users to solve waste management issues and produce electricity by using small, modular plants in the 1.5 MW to 12 MW size range with municipal solid waste. High-BTU feedstock such as tires and plastics provide up to 50% more output. The modules may also be chained together for larger system requirements and improved economics.

The modular design also allows for units to be placed around cities to be near to feedstock sources and thereby reduce costs of transporting the waste materials. The Thermolyzer system operates 24/7 thereby providing continuous power output.

• MODULE SIZESThere are five module sizes: 10 TPD, 22 TPD, 44 TPD, 88 TPD and 176 TPD.

• FEEDSTOCK CONDITIONINGFor maximum energy efficiency, metals (e.g. aluminum and ferrous materials) and glass are pre-sorted for recycling. The Thermolyzer units can accept maximum moisture content of 20% and particle sizes of 2 inches or smaller. The system shredder can reduce feedstock moisture by up to 50% and waste heat is use for additional drying. Tires may be shredded and used as fuel with no requirement for removing the steel prior to gasification.

• FEEDSTOCK OPTIONSThe system can use any hydrocarbon-based feedstock (waste) including tires, all plastics, carpet, rubber, auto shredder residue, e-waste, municipal solid waste, and biomass. Dried sludge cakes and animal wastes are acceptable. These options allow developers to use locally-derived feedstock. Patents issued for carpet, plastics, tires and electronic waste.

For maximum efficiency, developers send one ton of material to be tested in the pilot plant. The produced gas analysis is used to size the system for maximum performance.

• EMISSIONSThermolyzer stack emissions meet California and German air quality standards. Compared to incineration and reduced oxygen gasification systems, the Thermolyzer emits near zero hazardous gases (similar to natural gas engine emissions).

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as

is

carbon• USABLE BYPRODUCTSUsable byproducts depend on the feedstock.

§ MSW produces a charcoal that can be used afuel for heating.

§ Biomass produces “bio-char” thatsequestered carbon. It may be used as fertilizerand potentially may be used to earn credits.

§ Plastics create a synthetic coke used

steel-

making steel and industrial applications.§ Tires create carbon black and steel.§ E-waste processing yields valuable

gold,

silver, palladium, and electronic metals (Cu).

FEEDSTOCK 22 TONS/DAY

THERMOLGAS BTU/FT3 POWER

MW CHAR

TONS/DAY STEEL

TONS/DAY

TIRES 1000 2.25 4.6 Carbon Black 1.4

PLASTIC 650 1.95 1.85 Coke -

Thermolyzer Model 44 TPD

Thermolyzer Model 88 TPD

Thermolyzer Model 176 TPD

Thermolyzer Model 22 TPD

TPD 500 1.7 4.6 Charcoal -

600 1.5 - 1

MSW

FEEDSTOCK 22 TONS/DAY

THERMOLGAS BTU/FT3 POWER

MW CHAR

TONS/DAY STEEL

TONS/DAY 1000 4.5 9.2 Carbon Black 2.8 TIRES

PLASTIC 650 3.85 3.7 Coke -

WOOD 500 3.25 9.1 Charcoal

600 3 - 2

MSW

-

MSW

FEEDSTOCK 88 TONS/DAY

THERMOLGAS BTU/FT3 POWER

MW CHAR

TONS/DAY STEEL

TONS/DAY TIRES

PLASTIC

WOOD

5.6

-

-

4

7.4 Coke

-

18.2 Charcoal

18.4 Carbon Black9

7.7

6.5

6

1000

650

500

600

MSW

FEEDSTOCK 176 TONS/DAY

THERMOLGAS BTU/FT3 POWER

MW CHAR

TONS/DAY STEEL

TONS/DAY TIRES

PLASTIC

WOOD

1000

650

500

600

18

15.4

13

12

36.8 Carbon Black

14.8 Coke

36.4 Charcoal

-

11.2

-

-

8

7

Jean
Highlight
S needs to be moved up
Jean
Highlight
S needs moved up
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• THERMOLYZER SYSTEM

• BENEFITS OF THE THERMOLYZER SYSTEMThe Thermolyzer provides:

• Low air emissions that meet California and German air quality standards• Reduces CO2 emissions• Small system footprint (System 25’ x 125’)• Low temperature / low pressure – 600 °C / 50 millibar• Feedstock flexibility• Operation efficiency / safety – no molten material handling• 3rd party independent engineering review• 24/7 operation for base load electric energy production• Valuable byproduct production• Direct injection of the Thermolgas™ into a gas turbine• Modules may be combined for larger systems• 20-year design life• May be combined with carbon dioxide to use stack emissions for plant fertilizer• System can eliminate up to 97% of landfill requirements vs. 70-80% for incinerators• System can produce electricity, syngasor liquid fuels as primary products• Engineering liability insurance• Residual heat may be used to purify drinking water• High carbon conversion: >98%• Provides extra benefit via carbon credit sales• Short start-up times• Creates green energy jobs

The complete system includes a sorting area, shredder, patented gasifier, gas scrubbers, char processor, gas engine or gas turbine, electric generator, waste heat boiler, steam turbine for combined cycle operation and a grid substation. Liquid transportation fuels will require the addition of a gas-to-liquid reactor and storage component and are under development.

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• COST COMPARISONSCompeting system costs and qualities can vary greatly around the globe. In the U.S., the price of a completeMSW Thermolyzer system is similar to the cost per megawatt of a coal-fired power plant. By comparison,an incinerator can cost 50 to 100% more than a Thermolyzer system. System cost depends upon a detailedengineering study to meet customer needs.

Operationally, Thermolyzer costs are significantly lower than an incinerator. The system has far lower parasitic loads for operation – 18-30% vs. 40-50% for an incinerator. The Thermolyzer also provides added revenues from byproduct sales.

.

A view of a section of a 44 TPD Plant

Views of a second generation 4 TPD pilot plant and an industrial plant

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Jean
Highlight
Don't need above?
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Compared to other systems, the Thermolyzer provides more revenue streams: § Clean Thermolgas§ Electricity§ Transportation fuel (under development)§ Presorted steel and glass§ Tipping fees§ Precious metals from e-scrap waste§ Industrial gases: e.g. hydrogen, methane§ Carbon black and steel from tires§ Biochar as fertilizer§ Charcoal§ Synthetic coke

System returns may also benefit from carbon credit sales and local renewable incentives. System returns vary by country and region and feedstock.

• SYSTEM MAINTENANCEThe system operates 344 days per year. It requiresadditional maintenance every third year. A detailedmaintenance schedule is provided with systemtraining.

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• OPERATIONAL REVIEWSystem sensors are monitored 24/7 via the internet to provide additional supervision.

• THERMOLYSISThermolysis (a third generation pyrolysis system) gasification is a fully-developed and validatedtechnology. The pyrolyis process drives the thermal decomposition of organic materials creating asynthesis gas leaving carbon char as a residue. Pyrolysis has been used since ancient times for turningwood into charcoal. It is also commonly used today in the chemicals industry.

The patented Thermolyzer system converts any hydrocarbon-based material into Thermolgas and char. The Thermolyzer system also converts the unavoidable tars and oils into additional Thermolgas to create more energy. The process solves maintenance and disposal issues by handling the tars and oils that often plague other system designs and is a major benefit of this technology.

The use of a proprietary scrubber systems creates Thermolgas that is comparable to natural gas in both cleanliness and energy content. The Thermolgas has low nitrogen content and the emissions similar to natural gas when it is burned.

• SYSTEM RETURN ON INVESTMENT

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The high quality Thermolgas allows for direct injection into gas engines or turbines or for a boiler system and thereby achieving higher efficiencies of electric power production. .

Gasification with Air Plasma GasificationVolume % Volume % Vol. % MSW Vol. % ASR Vol. % Tires Vol. % PET

CO Carbon monoxide 23.1 19.7 11.3 22.6 7.0 31.1CO2 Carbon dioxide 9.8 7.9 10.8 10.4 5.6 21.9

H2 Hydrogen 16.6 21.7 29.4 24.0 16.2 21.6

O2 Oxygen 0 0 0 0 0 0

N2 Nitrogen 48.5 46.7 0 0 0 0

CH4 Methane 2 2 30.1 24.8 36.0 18.7

C2H6 Ethane 0 2 3.6 3.0 7.5 1.2

C3H8 Propane 0 0 0.1 2.2 6.0 0

C4H10 i-Butane 0 0 0 0 1.3 0

C4H10 n-Butane 0 0 0 0 0.4 0

C5H12 n-Pentane 0 0 0 0 0 0

C6H14 n-Hexane 0 0 0 0 0 0

C3H6 Propene 0 0 2.1 4.0 10.0 0.6

C4H8 iso- Butene 0 0 0 0 0 0

C6H12 Cyclohexane 0 0 0 0 0 0

C2H4 Ethylene 0 0 12.6 9.0 10.0 4.9Total 100 100 100 100 100 100Gas Value BTU/ft3 138 174 672 692 1090 438Wobbe Index 5.53 7.2 31.91 29.98 45.15 18

Gas ComponentsThermolyzer

Comparison of Gasification Types

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CHZ Technologies, LLC 5547 Mahoning Ave Suite 340 Austintown, OH 44515 USA Ernest J. Zavoral, Sr. 330 286 7076 office 330 233 0498 mobile 330 799 4515 fax [email protected]

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HERMOLYZER™

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