CONTINUOUS PYROLYSIS EQUIPMENT COMPLEX WASTE TO ENERGY SOLUTION

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1 CONTINUOUS PYROLYSIS EQUIPMENT COMPLEX WASTE TO ENERGY SOLUTION

2 Pyrolysis is an innovative environmental solution of various waste treatment based on commercially effective technology. Continuous Pyrolysis Technology leads to the new life without landfills and energy deficit.

3 TWO PROBLEMS, ONE SOLUTION The waste management problem became one of the most important environmental issues after the artificial materials became widely distributed, as the waste remain dumped for tens and hundreds of years poisoning soil, water and air. Inappropriate placement of toxic materials causes the infectious diseases in developing countries. The situation gravity is compounded by the landfills conflagration because of the high temperature in the hot seasons. Therefore, the waste management attracts the worldwide interest. The Polvax-Ukraine continuous pyrolysis technology of waste recycling contributes not to only solving the environmental issues but also to solving the energy deficit problem, increased proportionally to natural resources limitation. Continuous pyrolysis complex unit is compared to a small oil refining facility, however virtually worthless raw materials (municipal and industrial waste) are used instead of expensive oil. The equipment allows producing biooil and biogas, heat and electric power, reusing of industrial waste and also eliminating the necessity to use landfills and dumps for unsorted MSW (municipal solid waste).

4 LOW-TEMPERATURE PYROLYSIS WASTE RECYCLING PYROLYSIS project has been started in early Polvax-Ukraine, well-known initiator of environmental projects and innovations investigation, has presented a unique low-temperature pyrolysis technology of waste recycling with power generation. Owing to the efforts of experienced engineers, designers and technicians, waste processing equipment has been modernized to increase the pyrolysis products efficiency and to recycle different types of waste materials. The continuous pyrolysis equipment complexes are successfully functioning in Ukraine, Bulgaria, Australia etc. Waste management project PYROLYSIS is aimed at: design, production and installation of complex pyrolysis equipment for treatment of different types of waste; development of innovative eco-friendly waste recycling technologies; commercially effective production of biofuel, heat and electric energy; research and production of the effective biochar

5 MULTIPURPOSE SOLUTION The waste recycling equipment complex allows solving a number of problems: full waste reprocessing (pre-sorting systems are included into the complex; no solid residues, which require dumping and further storage); fuel production (synthetic oil, boiler fuel, diesel fuel etc.) that meets the requirements for the green tariff power and heat generation; generation of pure heat or electric energy (no toxic emissions during the whole recycling process); fast cost-recovery (near 3,5 years, IRR 30%); low operational costs due to self-operated control system, reusing of own resources and waste heat; ensured stable investments in the sector; high productivity and economic efficiency (utilization of one ton of MSW is equal to m3 of natural gas).

6 The pyrolysis equipment has demonstrated completely satisfactory results in accordance with EU and US standards by wide margins. This fact helps reducing risks of the equipment compatibility in the future, in case of international environmental norms will be tightened up. Based on the sanitary epidemiological examination results dated 09/09/2015, the Continuous pyrolysis equipment complex for thermal waste treatment met the existing requirements of Ukrainian Sanitary Regulations.

7 Continuous pyrolysis technology allows to recycle almost all types of waste, except building materials. Low-temperature pyrolysis units treat unsorted MSW, sewage sludge, agricultural waste (biomass) and other types of raw materials. Type of waste Municipal solid waste (without pre-sorting) Car tire casings (and other rubber products) Medical waste Wood waste and agricultural waste Sewage sludge All types of plastic Oil sludge Hard coal, brown coal, peat

8 COMPLEX EQUIPMENT MODIFICATIONS The relevant range of continuous pyrolysis complex units consists of 2 models: CPCom-1.5 (input capacity 1.5 t per hour); CPCom-2.5 (input capacity 2.5 t per hour). Every equipment complex is designed individually regarding the required parameters (output products, raw material characteristics etc.).

9 CONDITIONS AND REQUIREMENTS Pyrolysis units need electric power and water supply for proper functioning. The average electric power consumption is 60 kw/hour (maximum consumption is 210 kw/ hour). The inquired staff consists of 9 engineers and operators (3 day shifts). The footprint of the pyrolysis plant is ha. The period of the equipment preparation and transportation is 180 working days. The period of setting equipment into operation is about 1 month.

10 TECHNOLOGICAL CHARACTERISATION The technological advantage of continuous pyrolysis equipment complex is eco-friendly technology of waste destruction at low temperature ( ⁰C). The pyrolysis process is going inside the closed reactor chamber protected from oxygen access. It provides full dioxins and furans decomposition and ensures clean output carbon residues. CONTROL AND MONITOR SYSTEM The complex pyrolysis unit is equipped with temperature and pressure sensors to monitor the exhausts. The control system of the burner is automatic. The screw driver of the reactor block is equipped with frequency converters to adjust the screw rotational speed. Therefore, the technology of continuous pyrolysis waste utilization eliminates the emission of toxic substances, ensuring operational and environmental safety. The automatic control system keeps track of all extraordinary situations and signals to the operator, the protection system is activated at emergency higher limits. Pyrolysis process goes continuously 24/7 that ensures high capacity for utilization, less operation cost and technological stability. The raw materials change into liquid fuel, biogas and pyrocarbon during the lowthermal pyrolysis destruction. Waste heat, generated during the process, is usually used for space heating. All the control devices are placed in the separate control panel. The control panel is equipped with ground connection system and the emergency stop button.

11 MAIN EQUIPMENT ELEMENTS (CONTINUOUS PYROLYSIS UNIT FOR UNSORTED MSW RECYCLING) Denomination Notice Denomination Notice 11 Separator-demister (gob deflector) For gas fine purification from liquid 1 Rotor shredder The size of the separate particles shall not exceed the dimension of the shredder charging bay 170х100х250 mm 12 Regulating station 2 Screw conveyer For raw materials supplying into the receiving bin 13 Air cooling radiator 3 Receiving bin 14 Load frame 4 Continuous pyrolysis reactor Efficiency more than 1 t/day 15 Slag exhausting device 5 Coarse filter (Cyclone) To purify the gas-vapor mixture from heavy particles 16 Flue dust collector 6 Bag filter To purify the gas-vapor mixture from medium particles 17 Air-lock system 7 Zeolite filter To purify the gas-vapor mixture from sulfur, small particles etc. 18 Burner 8 Condenser I (initial) To cool down the gas-vapor mixture 19 Gas-vapor mixture output from the reactor 9 Condenser II (derived) For gas-vapor mixture condensation 20 Reactor Drives Liquid fuel container To receive liquid fuel from the capacitors 21 The pipeline of gas supply to the gas burner and/or to the consumer 10 To cool down the rotational mechanism Protects the system from air entering

12 WASTE TO ENERGY PROCESS The additional units of the equipment (turbines and boilers) may provide pyrolysis products recycling into the electric power. During this process the warm steam goes through the turbine, than the heat energy of the warmed gas is transformed into mechanic spinning energy. The turbine shaft is connected to the rotor of turbogenerator and spins it. The rotational energy turns into electric power. The generated electricity supplies electrical circuit.

13 Average output of the pyrolysis products from 1 t of MSW: pyrogas t or 425 m3 (caloric value kcal/m3); fuel for boilers 0.3 t (caloric value kcal/kg); pyrocarbon t (caloric value kcal/kg). The pyrolysis products may be transformed into the electric or heat energy, using additional equipment elements. The quality and the quantity of the products depend on the type of raw materials.

14 PYROGAS (Analysis results of pyrolysis gas composition) Gas mixture components К. No 1, % volume Pellets, ion. activated К. No 2, % volume Pellets, ion. disabled К. No 3, % volume Wood chips H O N CH CO CO C2H C2H C3H C3H ic4h nc4h neoc5 traces traces traces ic5 traces traces traces C2H5OH Common

15 PYROCARBON (solid carbon residue) Results Parameter Wood chips Pellets Total moisture (drying at T 60 oc), % Ash content (dry matter), % Volatile matters (dry matter), % Sulfur content (dry matter), % Carbon content (dry matter), % Net calorific value (active state), kcal/kg Gross calorific value (active state), kcal/kg Net calorific value (dry matter), kcal/kg Gross calorific value (dry matter), kcal/kg Absorption activity by iodine, % Iodine number, mg/g Particle size distribution, wt.-% > 2.50 mm 0, ,60 mm 0,0 1,60-1,00 mm 1,0 1,00-0,50 mm 23,8 0,50-0,25 mm 28,8 < 0.25 mm 46,4

16 WHAT IS BIOCHAR? PROPERTIES OF ВIOCHAR Biochar (biological charcoal) is the product of biological waste utilization using continuous pyrolysis technology. The biochar main component is carbon, which accumulates in biomass (wood, sunflower husk, coffee husk and other clean agricultural waste). porosity (biochar remains nutrient and moisture balance of the soil, stimulates the development of mycorrhiza (symbiotic association composed of a fungus and roots, found to have a protective role for plants, rooted in soils). Porosity increases the volume of the product and decreases of the material consumption for fertilizing (1x50 values of volume)); chemical inactivity (materials don t degrade over thousands of years); high-capacity adsorption and resistance to toxicity (biochar eliminates excess substances, which slow down root system development; absorbs aluminum oxides for soil stabilization); stability in transportation and storage. It is also used as a feed supplement for domestic animals (cattle and poultry). The clean biochar improves animals immunity to virus and bacterial infections, and increases hen s egg producing ability.

17 PYROLYSIS PRODUCTS APPLICATION SYNTHETIC OIL and PYROGAS: PYROCARBON: as a boiler fuel (to warm the water for space heating); coal-water fuel production; for hot water supply service; waste-water treatment; for electric power production (using turbines and other special equipment). plastic and plastic dyes manufacture. Pyrolysis output materials are commercially successful products that reduce essentially the cost recovery period.

18 ENVIRONMENTAL SECURITY Therefore, the continuous pyrolysis technology minimizes the emission of toxic substances, ensuring operational and environmental safety of the recycling process. The Polvax-Ukraine engineers have developed modern filtration system for biooil and biogases cleaning from CO2, CH, Carbon monoxide and solids. Thus, the facilities can be located in proximity from residential districts and have no negative environmental effect. Analysis results of gas-dust stream from continuous pyrolysis plant dated 13/03/2017 (temperature: 194,7 ос, speed: 1,382 m/sec, volumetric flow rate: 0,1181 m3/s, Oxygen content: 15,5%) Mass concentration of EP Environmental standards* converted into O2 mg/m3 Mass concentration mg/m3 Nitrogen oxide (converted into dioxide) 111, ,0048 < 1,39 Carbon oxide 158, ,0067 < 1,39 Sulfur dioxide 30, ,0013 < 1,39 Hydrogen fluoride 1,023 5,0 0, ,0139 Oil aerosol 50,0 0,0000 Suspended particulate matter 40,36 50,0 0,0017 < 0,139 Chromium (VI) compounds 0,185 5,0 0, Silicon dioxide 2,359 n/a 0,0001 n/a Manganese compounds 0,355 5,0 0, Ferrum and iron compounds 2,370 n/a 0,0001 n/a Copper compounds 0,772 5,0 0,0003 < Plumbum 0,330 5,0 0, Hydrogen chloride 30,0 0,0000 < Types of environmental pollutants (EP) Mass flow rate of EP emission g/sec Environmental standards* Mass flow rate of EP emission g/sec

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