The Cleaner World
Through Pyro Thermic Reaction
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Introduction
Time Lapse
Technology Comparisons
New Era
Treatment Zones
Power Process
Maintenance
Process Flow Diagram
Desalination
Operator Controls
Construction
Plant List
Mobile Plant
Contact Details
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INTRODUCTION TO WACS
Waste Away Consultancy Services have been formed as a
“One Stop Shop” to deal with waste from creation to
final destruction and disposal, avoiding landfill and
contamination to the environment.
The process of turning waste materials into energy
through the Pyro-Thermic Reactor (PTR) is
environmentally effective. What WAS the vision of using
the Ultra High Temperature Reactor to extract virtually
all of the calorific value from unwanted waste material
and turning it into energy is NOW reality.
This system is not only capable of providing the safe
disposal of large variety of waste including more
problematic materials, it is capable of simultaneously
generating high volumes of electricity for resale or for
the client’s own use.
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INTRODUCTION TO WACS
We use the Ultra High Temperature Reactor
to extract virtually all of the calorific value
from unwanted waste material.
This process allows the waste to be
transformed into energy, as well as allowing
the waste itself to become the provider of
energy release.
The process is so efficient that it destroys an
amazing 97% of the waste material.
Due to the residue’s inert
nature, the potential exists
for the re-sale as a
construction industry raw
material.
municipal waste
industrial waste
clinical waste
asbestos waste
tyres, rubber, plastics
oil waste
nuclear waste
chemical waste
pharmaceutical waste
offal waste
sewage sludge
contaminated water
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INTRODUCTION TO WACS
The reactor is able to treat the waste in one
process. This is because the reactor
temperature is 1700°C using direct-fired
burners of oil or gas combined with
compressed air.
The concept of thermal conversion began
nearly 30 years ago, and is a proven
technology
with
over
25
plants
commissioned throughout the world.
By combining the properties of a rotary
thermal treatment process with a refractory
lined lower chamber, various key stages of
thermal action are created and achieved
within this same item of equipment. Known
as the Pyro Thermic Reactor.
Nontoxic
Nonporous
Contaminant-free
Mineral composition
Dust-free
Sterile
Vitrified bead-like structure
Totally inert
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TIME LAPSE, A WACS HISTORY
Designed by our Principals, the Pyro
Thermic Reactor has multiple installations
throughout the world.
Focus was then moved to United Kingdom
and European sales, but complex
regulations regarding waste treatment in
these areas hampered efforts.
Now, however the marketplace is changing
with the arrival of the new Global Green
Agenda, and WACS has refocused and
renewed its efforts to take advantage of
shifting opinions on renewable energy and
waste disposal.
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TECHNOLOGY COMPARISONS
TEMPERATURE
800° TO 850°C
1700°C
WASTE CONTROL
uncontrolled, uncontained
100% contained
PERCENT RESIDUE
30% to 40%
3%
POWER OUTPUT
250-300 KWH/T
1000 KWH/T
There are many
pyrolysis systems
in use but they have
significant problems in
conforming to WID, EPA
and EU directives. We would
emphasise that the Pyro
Thermic Reactor is not a
pyrolysis system but also
incorporates gasification
as a combined function.
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NEW ERA: THE MODEL PROCESS
STEP 1
SHREDDING
Unsorted waste is shredded down
to 50 mm, transported via screw
conveyor into the reactor.
The only preparation required is the
inclusion in the system of a multishafted shredder to reduce the
feedstock to a standard size for ease
of feeding to the reactor.
The top of the screw conveyor
compresses waste material, which
forms a gas tight seal at the reactor
entry point.
STEP 2
DRYING AND
DEGASIFICATION
Compressed waste passes into the
reactor where the drying process
begins. Released gases are drawn
through the reactor. The top section
of the reactor is supplied with
pressurised returning heat from the
latter end of the thermal process to
accelerate this action through the
gasification stage.
Gasification breaks down waste
hydrocarbons and also leads to the
production of syngas. This is the first
fuel stage for the waste material to
pass through and it is similar to the
effect widely used in the past of
heating coal to produce a fuel called
town gas.
STEP 3
PYROTHERMIC
Pyrothermic Reaction is a
thermal chemical decomposition of organic
material at elevated
temperatures without
the participation of
oxygen. It involves the
simultaneous change of
chemical composition
and physical phase and is
irreversible.
The Pyrothermic Reaction begins as
the material descends further into
the reactor, constantly mixed and
goes through charring. At this point
the material becomes very hot and
descends still further into the reactor
base.
At the reactor base is a layer of
refractory lining, engineered to cope
with the extreme temperatures
inside the reactor. A layer of molten
slag like material gathers and
behaves much like a liquid filter bed
covering the reactor’s lower section.
This residue then forms superheated
particles which are rapidly cooled by
means of the water filled quench
tank to create nodes of glass like
beads which render the residue
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NEW ERA: THE MODEL PROCESS
PRE-HEAT ZONE
This area is where the pre-heat chamber
removes residual moisture and partial
destruction commences.
DE-GASIFICATION ZONE
Converts all gases into fuel gasses, creating
syngas to assist later combustion.
THERMIC ZONE
Waste is subjected to indirect high
temperatures, destroying major pollutants,
producing char like material, and releasing
energy.
MOLTEN ZONE
A layer of slag is formed, acting as a filter for
the super-heated material. Residue from
here passes through the reactor base as
molten granules, where quenching takes
place in a controlled catchment base tank.
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POWER PROCESS
REACTOR
BOILER
GENERATOR
Exhaust gases move from the reactor base to a
heat exchanger. Some of the gas is used to
maintain the reactor’s pre-heat zone.
In the U.K. the
generated power is
suitable for inclusion
within the latest
Renewables Obligation
Certificate (ROC) program
administered by Ofgem,
qualifying for ROC certificates
that can be traded internationally.
The process is also rated as
“Carbon Neutral”.
The rest of the gas is converted to hot exhaust that
is sent to a specialized boiler to create high-energy
superheated steam.
The superheated steam is then
sent to a steam turbine to
generate electricity.
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MAINTENANCE
Based on previous installations, over a tenyear period the total maintenance budget
amounted to less than 1% of the capital
cost, mostly relating to cleaning the waste
heat boilers.
All the wearing parts are external to the
unit, enabling replacement without
downtime.
Cold start lead time is between 6 and 8
hours. Shutdown would require a similar
time, though this could be dramatically
reduced by the utilization of reverse flow
fan action.
One of our
earlier generation PTRs
on the job in Japan.
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PROCESS FLOW DIAGRAM
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DESALINATION
The system makes large quantities of low-pressure
steam at no additional cost and thus is able to feed
thermal desalination plants.
Regarding drainage and sewage derived water, a
pre-treatment process would be recommended
prior to the desalination plant, ensuring that the
desalination unit is being presented with water that
could be processed safely.
DESALINATION
PLANT
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OPERATOR CONTROLS
Operator control is by touchscreen. Each screen is
dedicated to an area of the
plant with all streams
interlaced allowing
the presented
data to be
viewed.
Operator control is by touchscreen. Each screen is
dedicated to an area of the
plant with all streams
The converter screen details plant status. In this screen the
interlaced allowing
reactor’s vital statistics are monitored, and the whole process
the presented
is automatically controlled by software.
data to be
viewed.
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OPERATOR CONTROLS
Each critical plant operation is also monitored by a hardwired backup system, allowing the operator to override any
section for comprehensive control on all systems operation.
Operator control is by touchscreen. Each screen is
dedicated to an area of the
plant with all streams
The Water Systems Screen monitors stages of water flows
interlaced allowing
and levels, giving the operator are no-nonsense, fast, and
the presented
clear input of plant operations at all critical process stages.
data to be
viewed.
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OPERATOR CONTROLS
The consumption of water is negligible; the mobile unit
carries a 500-gallon storage tank on the trailer.
Water has two uses
in the system: first to
form airtight seals
around the rotating
section of the main
body, and second
within the quench
tank that receives
the residue as it falls
from the lower
section of the main
body.
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OPERATOR CONTROLS
The Emissions Screen allows the operator to closely monitor
and record all emission levels. The recorded data is used to
evaluate compliance and give an early warning system in the
unlikely event of higher than normal output from any of the
large group of monitored elements.
The PTR unit
meets all WID,
EU, US EPA, and the
Japanese National
Standard levels. All of
the PTR units are fitted
with an emission
monitor connected
by Internet to
our UK offices.
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CONSTRUCTION
3D concept drawings are used to verify individual
component performance; computer aided design is
utilised throughout construction. Benefit is derived from
an engineering team with skills gleaned from years of
experience.
While responsibility for design rests with our Principals,
they occasionally use the services of local manufacturers
to produce certain parts. This is primarily when the PTR
is being sold overseas. This saves shipping costs and
creates fabrication work in the client area, benefitting
local business.
Although subcontractors are occasionally used the
overall quality control and routine inspection remains
with our Principals. This is essential, as all projects are
underwritten However, all critical sections of our units
are manufactured in house to ensure quality,
performance and service.
All PTR electrical controls are engineered exclusively in
house and systems are updated regularly.
Please see the accompanying
brochure provided by our
WACS representative for
technical diagrams, including Mass Balance
Diagram, electrical
schematic, and
plant drawings
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PLANT LIST
MODEL:
TONNE/HOUR
TONNE/DAY
Bio Therm 500 B
1500 B
0.5 t
3t
12 t
72 t
Mobile
150 M
2.5 t
60 t
Static
100S
120S
150S
200S
250S
300S
350S
450S
500S
550S
1t
1.7 t
3t
5t
6t
7.5 t
8.5 t
10 t
14 t
17.5 t
24 t
41 t
72 t
120 t
144 t
180 t
204 t
240 t
336 t
420 t
Twenty nine PTR
units
have
been
designed, built, and
are operating in seven
different countries.
One company in
Japan purchased and
installed 7 units.
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MOBILE PLANT
The mobile version of the Pyro thermic reactor
(PTR) is completely self-contained. The entire
operation can be controlled by a single operator
from his high-level control position, from which
he can monitor digitally and visually all aspects
of the entire reactor.
The mobile reactor is capable of disposing most
known waste materials. In order to produce
electrical power, a second trailer with the waste
heat boiler, the steam turbine, generator, and
condenser and control panel is needed.
The mobile PTR is carried upon a standard 15meter trailer, and when fully equipped weighs
approximately 30 tons. The unit is sufficiently
low to pass beneath most “A” road bridges once
the exhaust stack been lowered.
The mobile PTR can handle up to 3 tonnes per
hour and will produce 3MWe of power.
One of two mobile units WACS has constructed.
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CONTACT
RobertSkelton@wacs-global.com
(Managing/Technical Director)
Mobile +447904323708
davidsimpson@wacs-global.com
(Business Development Director)
Mobile +447982421036
MikeCastlehouse@wacs-global.com
(Asia & Pacific Region)
Mobile +66892467866
peterca@wacs-global.com
(Australia)
Mobile +61 438 856 080