Time to flourish or perish ? There should be nothing like waste anymore to dump on Mother earth ?
Integrated Waste Management . Gasification and Industrial solutions Innovative Technologies from Movers India Pvt Ltd , Bangalore, India BESI-W2E Technologies — USA . 2
Input Process Output FISCHER-TROPSCH SYNTHESIS BIOMASS METHNAE MSW with HYDROGEN Mositure up to 20% FLUE GAS FLUE GAS CLEAN GAS CHEMICALS INDUSTL CLEAN UP & HEAT ELECTRICITY RECOVERY AGRI MECHANICAL EFFECT EVOPRORATOR PETROLEUM TurnW2E TM STEAM DIRECT HEAT GASIFICATION APPLICATION PROCESS ABSORPTION CHILLING CONTROLLED AIR SCIENTIFIC LANDFILL / SALE ASH INDUSTRIAL TURNW2E TM ALTERNATIVE ENERGY COMMERCIAL GASIFICATION & AGRICULTURAL, & PROCESS WASTE OUTPUTS MUNICIPAL WASTE
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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 5
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 H 2 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/Nm 3 (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 6
FLOW DIAGRAM STEAM ELECTRICITY FEED HANDLING SYSTEM GASIFIER GAS CLEANUP SYSTEM FISCHER-TROPSCH SYNTHESIS 7
ENERGY RECOVERY POTENTIAL- EXAMPLES Waste Mixed Waste Tyre Waste oil & Waste Feed Composite MSW Wood Plastic Sludge 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, Nm 3 /hr 280.00 317.33 347.20 354.67 256.00 Syngas HHV, kCal/Nm 3 800.00 900.00 1000.00 1200.00 700.00 Thermal Energy Output, kW th 260.00 330.00 400.00 490.00 200.00 8
Necessary to understand relative merits in Technologies- (confusion galore) Incineration W2E Gasification(Rotary) Typically Large Can be as low as 0.5TPD to 100TPD volumes/Tonnage of per Kiln(transportation cost can be waste-power generation. nil) — can be any application incl Power. No predrying of waste – up to 25% Moi Mostly Total Oxidation to Controlled Combustion air — mostly maximise the heat out- near stochiometric or even reducing put-large excess air-high atmosphere — not more than 900degC temp 1300/1400degC Treated flue gas can Cleaned syn gas can be like Natural contain dioxins and gas-no generation of dioxins and furans furans — manageable flue gas exit suphur has to exit the Recovery of elemental sulphur is stack as SOX possible (waste composition ) — thereby reduce SOX emission Bottom ash and flyash Same ---except as above for sulphur or collected and disposed as any other. waste
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 No limitation in Plant Capacity(per kiln torch size approach) Higher Operating temperatures & hence Moderate Operating temperature and higher maintenance cost 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 0 C 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 11
EMISSIONS DATA FROM W2E SYSTEM EMISSION IN INDIA PCB STANDARDS FOR POLLUTANT W2E SYSTEM 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 SO 2 , 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 12
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 13
Preferred Size for TurnW2E tm Systems 30 kW to 5MW electrical output • 2 TPD to 100 TPD waste capacity • Modular max. 100 TPD capacity trains • 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
PLANT BUILT AND ERECTED IN BANGALORE, for US Airforce , Hawaii TEAM who built this plant for US Army. 15
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 combustion in Coal DHAG with minimum modifications Up to 70 % coal replacement. Syngas pipeline into DHAG Syngas burning in DHAG
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 80,00,000 kcal/hr Thermal Energy from HAG 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 TurnW2E TM Plant capacity required 35 TPD (Waste CV 5000 kcal/kg)
• 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 TurnW2E r 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
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