Time to flourish or perish ? There should be nothing like waste - - PowerPoint PPT Presentation

Time to flourish or perish ? There should be nothing like waste anymore to dump on Mother earth ?

Innovative Technologies from Integrated Waste Management . Gasification and Industrial solutions

Movers India Pvt Ltd, Bangalore, India BESI-W2E Technologies—USA.

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Input Process Output

BIOMASS

MSW with

Mositure up to 20%

INDUSTL AGRI

PETROLEUM TurnW2E TM GASIFICATION PROCESS

FLUE GAS FLUE GAS CLEAN UP & HEAT RECOVERY CLEAN GAS

DIRECT HEAT APPLICATION ASH

CONTROLLED AIR

SCIENTIFIC LANDFILL / SALE

FISCHER-TROPSCH SYNTHESIS METHNAE HYDROGEN CHEMICALS ELECTRICITY MECHANICAL EFFECT EVOPRORATOR STEAM ABSORPTION CHILLING

INDUSTRIAL COMMERCIAL AGRICULTURAL, & MUNICIPAL WASTE TURNW2E TM GASIFICATION PROCESS ALTERNATIVE ENERGY & WASTE OUTPUTS

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Calorific Values of Different Waste Materials

Types of Wastes Calorific Value Biomedical Waste 2500 Kcal/kg Biomass Materials 3500 - 4000 Kcal/kg e-Waste 7300 Kcal/kg Farm Waste 3700 Kcal/kg Low-Quality Coal 5000 Kcal/kg Municipal Solid Waste (MSW) 1200 Kcal/kg Pharmaceutical Waste 2700 Kcal/kg Plastic Waste 5000 - 6000 Kcal/kg Sludge & Oil Waste 8000 -9000 Kcal/kg Used Tyres 8000 -9000 Kcal/kg

BASICS OF W2E TECHNOLOGY

• Waste is treated with air/oxygen under substoichiometric conditions at elevated temperature
• Solid waste transforms into gaseous fuel - Syngas - containing mainly CO and H2 as

combustible components

• Syngas is cleaned to remove particulates, chlorine compounds, sulfur compounds and

nitrogen compounds when present.

• Syngas contains energy in the range of 900 to 2700 kCal/Nm3 (100 to 300 BTU/SCF)
• Syngas can be utilized to generate heat, for air conditioning or cooling and to generate

electricity and any other special applications like ZLD

• Syngas burns as clean or cleaner than natural gas

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STEAM ELECTRICITY

FEED HANDLING SYSTEM GASIFIER GAS CLEANUP SYSTEM

FISCHER-TROPSCH SYNTHESIS

FLOW DIAGRAM

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ENERGY RECOVERY POTENTIAL- EXAMPLES

Waste Feed Waste Wood Mixed Plastic Waste Tyre Waste oil & Sludge Composite MSW Capacity, kg/hr 80.00 80.00 80.00 80.00 80.00 Capacity, TPD 2.00 2.00 2.00 2.00 2.00 Feed HHV, kCal/kg (wet) 4000.00 5100.00 6200.00 7600.00 3200.00 Syngas Production, Nm3/hr 280.00 317.33 347.20 354.67 256.00 Syngas HHV, kCal/Nm3 800.00 900.00 1000.00 1200.00 700.00 Thermal Energy Output, kWth 260.00 330.00 400.00 490.00 200.00

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Incineration W2E Gasification(Rotary) Typically Large volumes/Tonnage of waste-power generation. Can be as low as 0.5TPD to 100TPD per Kiln(transportation cost can be nil)—can be any application incl Power. No predrying of waste –up to 25% Moi Mostly Total Oxidation to maximise the heat out- put-large excess air-high temp 1300/1400degC Controlled Combustion air—mostly near stochiometric or even reducing atmosphere—not more than 900degC Treated flue gas can contain dioxins and furans Cleaned syn gas can be like Natural gas-no generation of dioxins and furans— manageable flue gas exit suphur has to exit the stack as SOX Recovery of elemental sulphur is possible (waste composition )— thereby reduce SOX emission Bottom ash and flyash collected and disposed as waste Same ---except as above for sulphur or any other. Necessary to understand relative merits in Technologies-(confusion galore)

Plasma / Pyrolysis Vs. Rotary Advanced Gasification

Plasma / Pyrolysis Rotary Advanced Gasification High Water Requirement Low Water requirement High Capital Cost Lower Capital Cost Solid Discharge in batch manner Continuous Solid discharge High Operating Cost Lower Operating Cost Limitation on plant capacity due to the torch size No limitation in Plant Capacity(per kiln approach) Higher Operating temperatures & hence higher maintenance cost Moderate Operating temperature and hence lower maintenance cost More land requirement Less land requirement compared to plasma Gasification(1.5 acre per 100TPD)

GAS CLEANUP

• Clean and cool the Syngas exiting the Gasifier at 900 0C
• All impurities like particulates, Sulphur, Chlorine, heavy metals are removed when

present.

• Systems employed in cleanup

Cyclone – Particulate Removal Quencher / Waste Heat Boiler – Gas Cooling Scrubber and/or Lime Bed – Sulphur and Chlorine Carbon Filter - Heavy Metal Removal

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EMISSIONS DATA FROM W2E SYSTEM

POLLUTANT EMISSION IN W2E SYSTEM INDIA PCB STANDARDS FOR CONTROLLED COMBUSTION Mercury, mg/Nm3 0.001 0.05 HCl, mg/Nm3 Less than 1.00 50.00 Dioxin, mg/Nm3 Less than 0.01 0.10 NOx, mg/Nm3 25.00-30.00 100.00 SO2, mg/Nm3 10.00-15.00 200.00 CO, mg/Nm3 10.00-20.00 100.00 Particulate Matter, mg/Nm3 10.00-15.00 50.00

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FOOTPRINT W2E Plants are designed for low footprint Capacity Area Required 2 TPD Plant 0.10 Acres 10 TPD 0.50 Acre 25 TPD 0.75 Acres 50 TPD 1.00 Acres 100 TPD 1.50 Acres

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Preferred Size for TurnW2Etm Systems

RATIONALE FOR SMALL SIZE  Affordability  Custom design  Allows for distributed waste management and power generation  Reduces long distance waste hauling  Small footprint  Easier permit process  Easier integration into industrial processing

• 30 kW to 5MW electrical output
• 2 TPD to 100 TPD waste capacity
• Modular max. 100 TPD capacity trains

PLANT BUILT AND ERECTED IN BANGALORE, for US Airforce , Hawaii TEAM who built this plant for US Army.

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TEXTILE Waste gasification system

 Turn W2E Gasifier System  400 kg/hr Shredded textile waste

gasifier

 Integrated with Effluent treatment

system

 Syngas utilization

 Direct Hot Air Generator  Generate Steam to be used in

Multiple Effect Evaporator

COAL REPLACEMENT

Syngas pipeline into DHAG

Syngas burning in DHAG

 Syngas combustion in Coal DHAG

with minimum modifications

 Up to 70 % coal replacement.

Syn gas/Coal based hot air generator with spray dryer

Heat Output – 100,000 kcal/hr Primary Fuel: Pulverized Coal Type : Fluidized Bed Exit Temperature: 540 deg C Spray dryer Evaporation capacity: 1000 lph

Multiple Effect Evaporation System

 Evaporation of Effluent with steam

generated from syngas boiler

 Evaporation of effluent to increase the

concentration

 Three effect forced circulation system

 Feed rate – 2000 kg/hr

 Single effect Forced Circulation System

 Feed rate - 700 kg/hr

 Three effect forced circulation system

 Feed rate – 2000 kg/hr

COAL BASED DHAG

Capacity 56 TPD Spray Dryer Evaporation capacity 8000 Kg/hr Thermal Energy from HAG 80,00,000 kcal/hr CV of coal 3,500 kcal/kg

Integrated Waste Management Solution

Coal : Syngas 25:75 Ratio Amount of Coal required 583 kg/hr Amount of energy from Coal 22,19,203 kcal/hr Amount of Energy from Syngas 57,80,797 kcal/hr CV of Waste 5,000 kcal/kg TurnW2ETM Plant capacity required (Waste CV 5000 kcal/kg) 35 TPD

• Multiple Effect Evaporator

MEE is a system used to efficiently use steam to evaporate water. It consists multiple vessels in series each maintained at a lower pressure than the last. Since the boiling point of water decreases with pressure, vapour boiled off from one vessel can be used evaporate water from next. Live steam is required only at the first

• vessel. This live steam can be produced in a boiler by combusting syngas along with coal or any other

secondary fuel.

Three Effect Falling Film System Effluent Feed rate 2000 kg/hr Input TDS 7 % Output TDS 20 % Live Steam required @ 6 barg 370 kg/hr Single Effect forced Circulation Effluent Feed rate 700 kg/hr Input TDS 20 % Output TDS 40 % Live Steam required @ 8 barg 220 kg/hr Live Steam from Process Application 500 kg/hr Total Steam Required 1090 kg/hr TurnW2Er Plant Capacity Required 5 TPD

Integrated Waste Management solution for Zero Liquid Discharge Spray dryer system is an important section of zero liquid discharge system. It is the last stage of the effluent treatment process where concentrate from multiple effect evaporator into dry powder. Direct Hot Air Generator is used to produce hot air to be used in spray dryer for effluent evaporation. Coal is generally used as fuel for DHAG.

Spray Dryer—Dye Output