Pyrolytic Heat Recovery with
Enhanced Gasification
Sustainable Value Recovery
Solutions for Your Organic Waste
Value Recovery Solutions for
Organic Waste Disposal
Pyrolytic Gasification yields a high quality Synthesis Gas from Waste
Materials such as:
–
–
–
–
–
–
Municipal Solid Waste (Landfill after resource recovery at $25 -$150/ton)
Biomass and Agricultural Wastes (Burn on Site – emissions problems)
Sewer Plant Sludge (Limited landfill availability - Landfill at $50 -$150/ton)
Medical & Hospital Waste (Hazardous Landfill at $250 - $500/ton)
Refinery & Oil Processing Wastes (Hazardous Landfill at $250- $1500/ton)
Used Tires (Hazardous Landfill, Local Nuisance, Fire Danger – equiv fuel
to coal)
– Food, Beverage, & Cosmetic Manufacturing Waste (Very High BOD to
Sewer, Landfill Disposal at $25 - $150/ton)
– Construction & Demolition Wastes (Landfill after resource recovery at $25 $150/ton)
If it contains organics…it’s a fuel to us and a disposal problem solved for
you !
Why Pyrolysis ?
Incineration inherently emits oxidized hazardous pollutants (NOx, SOx, ClOx,
FlOx, dioxins, furans, aldehydes, ketones, others) promoted by direct
combustion of waste material
Pyrolysis in PHREG unit occurs in a reducing atmosphere.
Hazardous components of off-gas are NH3, H2S, HCl, HF, HCN, amines, etc.
easily and economically scrubbed with existing technology.
Cleanup equipment capital costs are 20-40% less for PHREG than for
incineration processes.
PHREG process avoids conditions favorable to the production of dioxins via the
deNovo synthesis reaction.
Low nitrogen in Syngas Product reduces NOx formation tendencies during
combustion. Air combustion of waste makes NOx formation a recurring
problem for incinerators. Impossible to make a true low NOx solids burner.
Why Pyrolysis ?
Incineration is pretty much limited to Combined Cycle CoGen units. PHREG
product gas can be used in a number of ways.
Incinerators generate large amounts of ash
difficult to handle
typically must be treated and disposed of as a hazardous waste.
Greater flue gas and ash cleanup
Inherently higher cost of a steam power system
net cost per ton of equivalent feed is 20-25% greater than pyrolysis
Grate efficiency of burn is at best 30% - more likely below 25%.
PHREG net efficiency is 22% of feed LHV
capital cost 20% below that of “Trash burn “ plant
eliminates ash disposal headaches.
Product
Gas
Condensor
Clean
Pyrogas
Organic Feed
Solutions
Water
Recycle
Acid
for Scrubbing
Gas
Recycle
Fuel
Fresh Fuel
(As Needed)
Steam
&
Aux.
Water
Boiler
(Optional)
Pyrolysis/
Gasification
Reactor W/
Jacketing
Dirty
Gas
Particulate
Solids / Liquids
Removal
Absorber
Scrubber Soln.
Regeneration
Scrubber
Salt
To Disposal
Burner (Typ. 4-8)
Air
O2 (As
Needed)
Slag Collection
Disposal/Recycle
Oxygen Plant
(Optional)
PHREG PYRO & GASIFICATION PROCESS DETAILS
Process Units:
Individually Proven – New Application!
 Waste Receiving
– Sorting
– Surge Piles





Waste Pre-Processing
Feed Conveying
PHREG Reactor
Overhead Gas Cleaning & Recovery
SynGas product utilization
Equipment Needed

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
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


Receiving Pad
Sorting Table
Shredder
Pan conveyors
Airlock
Solids/Droplets Removal
Acid Gas Treatment
Oxygen Supply
Sulfur Recovery Unit
– tire / refinery waste disposal only
Waste Sorting & Conveying
One Supplier’s solution for recycling and
destruction of solid wastes
Shredder with Feed Conveyor
A commercially available unit
for shredding tires
Shredder Options
Other commercially available solutions
Airlock Feeder
Commercially available from multiple
suppliers
Dual Flap-valve construction is less
likely to experience damaged seals –
easier to clean and repair than rotary
valves
Wet Feed
Solids Hopper
Feed Flow Controller
CLOSE
(OPEN)
OPEN
(CLOSE)
Air Lock Feeder
Pyrogas &
Steam Vent
100- 120 C
Liquid Organic
Feed (optional)
Pyroliquids
Recycle(optional)
Pyroliquids
Draw (optional)
350- 400 C
PHREG REACTOR
CONCEPT
Solids Drying Zone I
Figure 2
Solids Pyrolysis Zone II
850- 900 C
Char Gasification Zone III
Air/O2/Steam
To each burner
1200- 1600 C
1700- 2000 C
Reactor Fuel
Slag/Glass
recovery
Insulation &/or Jacketing
Segmental Flange
Injector/Burner Ring
Metals
recovery
Ash/Slag Liquefaction
Zone IV
Slag / Glass/ Metals Collection Pit
PHREG Reactor
 Derived from Blast Furnace Technology
– more than 800 years of technological history!
– High Temp, Low Pressure, Cost Effective design
– Chemical Engineers call this a “counter-current falling bed reactor”
 Gas injection is through Tuyeres
– No elemental oxygen in contact with feed material
– Complete flow and temperature control of driver gas outside of reaction
zone
 Slag collection is from the hearth
– No char handling !
 Air Separation Unit needed for max Syngas Production
– 95% purity membrane or PSA
 Use Natural gas to start, switch to completely autothermal recycle ops
in minimal time
 Net SynGas product proportional to organic content in feed
 Cold Gas Efficiency of 75-80% on feed LHV
Exhaust Gas Treatment

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Separate out dust and condensable mists
Condenser
Cyclone
Scrubber
Dryer / Desiccator
Salt Recovery & Removal
Sulfur Recovery Unit
– tires/refinery waste only
Dust / Mist Collectors
Wet Scrubber useful for Acid Gas removal as well
SynGas Utilization
Several commercially viable options available
Clean SynGas
Power From
Gas Turbine
Generator
Power & Steam from
Combined cycle
Cogen Unit
Alt Fuels &
Chemicals
(H2, CH3OH,
CH4, Hydrocarbons)
What’s Left to Dispose of ?
Maybe Nothing !!
Scrubber Salts (which may be recyclable to chemical
manufacturer) – 0.2-1.0% of original feed wt
Non-hazardous Vitreous slag ( which may be used as
construction fill or primary material ) – 0.5-2.5 % of original
feed weight
The rest is all revenue streams - $$$$
SynGas Utilization Option 1
Power from Gas Turbine-Generator Set
1. Lowest capital, quickest implementation
2. Lots of equipment “optimized” for low-Btu
gas feed to GTG
3. Net Feed Gas Efficiency of 33-45%
4. Baseload operations with waste feed
5. Support peaker ops with supplemental
import gas for minimal extra (5-10%) capital
cost
SynGas Utilization Option 1
Power from Gas Turbine-Generator Set
FEED LHV
BTU/LB
FEED RATE
NET POWER
TONS/DAY
GEN MW
CAPITAL COST
APPROX $MM
CAPITAL RECOVERY
APPROX YRS
REMARKS
4500
500
0
50
6
MSW MINIMUM
SELF SUSTAINING
8500
500
20
75
7
BASELOAD MSW
8500
2500
100
250
5
BASELOAD MSW
12500
50
4
15
2
MED WASTE TYP
15000
100
11
28
24
OLD TIRES TYP.
15000
500
55
85
5
OLD TIRES TYP.
BASIS:
GIVEN TONS/DAY OF TRASH @ LHV 7500 HRS/YR UTILIZATION
ANNUAL OP COSTS @ 10% OF CAPITAL
BASELOAD POWER REVENUE @ $200/MWH
FEED TIPPING FEE AT $ 100 /TON MSW
AT $ 500 /TON MED WASTE
AT $ 100 /TON TIRES