concord blue – thermal based waste to enery
TRANSCRIPT
CONCORD BLUE – THERMAL BASED WASTE TO ENERY PRESENTATION
Copyright © 2011 ROCHEM
ENVIRONMENTALLY FRIENDLY W2E SOLUTION UNSEGREGATED MSW FOR MUNICIPAL
CORPORATION
THE TEAM
PRAYAS GOEL • GROUP HEAD
PRERAK GOEL • DIRECTOR – FINANCE
DR. H.J. MUHLEN • ADVISOR – CONCORD BLUE
CHARLIE THANNHAUSER • CEO – CONCORD BLUE
DR. H. MODAK • GROUP PRESIDENT
LOCATIONS
CORPORATION OFFICE - BANDRA CONCORD BLUE - THANE
MANUFACTURING FACILITY - VASAI REGIONAL OFFICE - NAGPUR
CORPORATE OFFICE • BANDRA, MUMBAI
CONCORD BLUE OFFICE • THANE, MUMBAI
MANUFACTURING FACILITY • VASAI, MUMBAI
REGIONAL OFFICE • NAGPUR
CONCORD BLUE – A THERMAL BASED SOLID WASTE TO ENERGY SOLUTION
CONCORD BLUE TECHNOLOGY (I) PVT. LTD.
ABOUT CONCORD BLUE
• World-wide patented (filed) staged
reforming waste disposal technology: CONCORD BLUE TOWER™ • The only global Concord Blue Tower
general contractor and manufacturer. • German-Indian Engineering &
Manufacturing company with offices in UAE, India, USA, Germany & Turkey
• Currently building six Concord Blue
Towers in India, Germany and the USA.
• We develop turn key waste-to-energy solutions for municipalities, private industries, states and even countries.
• Focus on Waste to Energy with non conventional Feedstock
Concord Blue – History
1. 2007 – Technology Transfer with DM2
Germany, company with operating plants on Japan & German since 2004.
2. 2007-2008 – Joint Technology Development between Indian & German Partners led to development of CBR2 patented Gasification system for low CV MSW streams.
3. 2011 – Over 10,000 hours Pilot operation on various waste streams, process validation & fine tuning. 3 CBR2 pilots supplied & commissioned in Las Vegas (USA), Herten (Germany) and Mumbai (India).
PROJECTS UNDER EXECUTION contd.
CUMULATIVE TONNAGE CONTRACTED PER DAY
MW
PO
WE
R G
EN
ER
AT
ED
0.8
1.0
1.2
3.2
4.2
5.5
8.5
10.0
TOTAL –
34 MW 50 70 100 250 300 400 600 700
TOTAL –
2470 tpd
FEATURS OF OUR WASTE MANAGEMENT SOLUTION
•No Smell / Open dumping of Waste
•No mixing of Leachate with Ground Water
•No Burning of Waste
•Minimal Rejects to Landfill
• Minimum Space utilized for waste disposal
SOME OF THE INDUSTRIES WE CATER TO 1 P a g e | 1
SOME OF THE INDUSTRIES THAT WE CATER TO:
ROCHEM GREEN ENERGY
MSW DISTILLERIES MISCELLANEOUS
PHARMA
BIO-MEDICAL
AGRI WASTE
POULTRY LITTER
INDUSTRIES
CONCORD BLUE
WASTE TO POWER THE TECHNOLOGY
CONCORD BLUE
MIXED SOLID WASTE (MSW) – CHALLENGES
The problems associated with MSW management are complex because of the
quantity and diversity of the nature of waste and financial limitations on public
services in large cities. The problem is not only confined to land, it includes air and
water as well. Some of them are:
Health Hazards • Skin and eye infections are common
• Dust in the air at dumpsites can cause breathing problems in children and adults
• Flies breed on uncovered piles of rotting garbage and spread diseases like diarrhoea, dysentery,
typhoid, hepatitis, and cholera. Mosquitoes transmit many types of diseases like malaria and
yellow fever.
• Oxidation of plastics (pvc) lead to emissions of dioxins and furans
Ground water pollution An extremely serious problem is groundwater contamination. As water filters through any material,
chemicals in the material may dissolve in the water, a process called leaching. The resulting mixture
is called leachate. Contaminated water can have serious repercussions on biological life forms
Air pollution When waste is burnt heavy metals like lead, toxic gases and smoke spreads over residential areas.
The wind also carries waste, dust and gases caused by decomposition. Putrefaction of waste in
sunlight during daytime results in bad smells and reduced visibility.
SOLID WASTE - CHARACTERISTICS
MOISTURE
SAMPLE REPORTS
INFERENCE FROM
REPORTS OF MSW
ANALYSIS ASH
CV
WHY IS CBR SUITABLE FOR DISPOSAL OF MIXED SOLID WASTE
NO OPEN DUMPING OF WASTE – HENCE NO INGRESS
OF VECTORS FOR SPREAD OF DISEASES
COMPLETELY SEALED STORAGE UNIT – NO SMELL;
COMPLETE LEACHATE CONTROL BY ROCHEM’S R.O
SYSTEM
SEGREGATION INVOLVES REMOVAL OF METALS,
GLASS AND INERTS –MUCH SIMPLER THAN SORTING
OF BIODEGRADABLES FROM NON-BIODEGRADABLES
NO OXIDATION/BURNING OF WASTE – NO AIR
POLLUTION; ONLY PHASE CHANGE FROM SOLID TO
GAS; SAFE DISPOSAL OF PLASTICS INCLUDING PVC
CLEAN GREEN HYDROGEN RICH GAS FROM WASTE
FOR POWER PRODUCTION
LEAST AMOUNT OF SPACE REQUIRED FOR SYSTEM
MINIMAL REJECTS TO LANDFILL – INCREASES ITS LIFE
WHAT IS GASIFICATION
1. Non Incineration Thermal Waste to Energy Solution 2. Thermal Phase Change from Solid to Gas Phase in
complete absence of Oxygen 3. Produces as SYNGAS FUEL ! This can be used to
Generate electricity. WHY IS GASIFICATION FEASIBLE ? 1. Since it uses the Gas Cycle to convert fuel to Electric. 2. High efficiency (proven) Reciprocating Gas Engines are
used, as against lower efficiency Medium pressure Steam Turbines 3. Waste Heat is used efficiently to Create a viable feed-
stock from MSW. Since non-incineration it is safe to use plastics, which
augment feed CV.
FEATURES OF A 600 TONNES PER DAY UNSEGREGATED MSW TO ENERGY PLANT (AS AN ILLUSTRATION)
Sr. No. Description Value
1. AMOUNT OF WASTE RECEIVED (TONNES PER DAY - UNSEGREGATED)
600
2. TOTAL WASTE DISPOSED PER DAY (TONNES PER DAY)
600
3 TOTAL ELECTRIC POWER GENERATED (MWel) 8.0
4 TOTAL NO. OF DAYS THAT WASTE WOULD BE RECEIVED PER YEAR
365
5 TOTAL NO. OF HOURS PER ANNUM OF ELECTRICITY GENERATION
7500
6 TOTAL NET SELLABLE POWER GENERATED PER ANNUM (MWel)
60,000
6. TOTAL SPACE REQUIRED (METER SQUARE/ACRES) 12000-16000/3.0-4.0
7 TOTAL REJECTS TO LANDFILL (% OF WASTE RECEIVED – INCLUDING C & D WASTES)
<15
8 TOTAL TIME TAKEN TO IMPLEMENT THE PROJECT (MONTHS)
10-12**
**Subject to approvals and favorable climatic conditions
The ABC of the Concord Blue Solution
A B C
PRECONDITIONING STEAM GASIFICATION POWER GENERATION
• Unsegregated MSW delivered to designated waste disposal site;
• Waste stored at enclosed storage facility;
• The waste is segregated in a fully automated segregation and sorting m/c and the recyclables/inerts are separated and sold to appropriate buyers/disposed;
• The waste is subsequently dried by utilizing the waste heat from the system, and shredded to make it input ready for the Concord Blue System;
• The Preconditioned Waste is conveyed in enclosed conveyors to the Concord Blue System;
• The waste undergoes a thermo-chemical degradation by high temperature heat transfer in completely inertized chamber in the CBS;
• This results into a producer gas which is steam reformed to finally result into a hydrogen intensive syngas;
• The syngas is subsequently cooled and cleaned of pollutants and supplied to the gas engine for power generation;
• The engine processes this clean gas to produce Green Power that can be evacuated to the Grid.
• The Flue gas from the Engine is
treated and the heat from therein is utilized for the captive requirements of the CBS;
Concord-Blue_final_flash_Presentation.exe
The ABC of the Concord Blue Solution
PRECONDITIONING
Unsegregated Waste to Storage Facility
Inerts Storage Silos
Segregation & Sorting
Drying & Shredding
PYROLYSER
Heat Carrier Media
Biochar
HEAT CARRIER BUNKER
REFORMER
Char Combustor
GASIFICATION
Steam Generator
Re-circulating media
Gas Cooler
Gas Cleaning
POWER GENERATION
Gas Engine Grid Ash for
sale/disposal
Pre-Conditioned
Waste
FEASIBILITY OF MSW GASIFICATION – CONCORD BLUE GASIFICATION – Energy Balance
PRECONDITIONING OF SOLID WASTE
SEG – SORT in CBS
MSW
Input to
Automated
Seg-Sort
system
PRIMARY SHREDDER
Primary Drier
Size
Reductio
n occurs Moisture
Removal
SEGREGATION – SORTING UNIT
Manual Picking
Recycled/Dispo
sed
Trommel
Screens
Inerts for
Disposal
Magnetic and Eddy Current
Separators
Recyclables for
Sale
Manual
Picking
Recycled/Dispo
sed
SEGREGA
TED
WASTE
Preconditione
d Feed to the
Concord Blue
System
Secondary Drier
Moisture
Removal
Secondary
Shredder
Pre-Dried
Waste
Size
Reductio
n occurs
PRECONDITIONING OF SOLID WASTE
SEGREGATION SORTING EQUIPMENT
DRYER SHREDDER SHREDDER
THE PROCESS FLOW
UNSEGREGATED WASTE FROM
DUMP TRUCKS TO WASTE STORAGE
UNITS
WASTE STORAGE
UNIT
STACK
Waste to Primary
Shredder
Primary Shredder
Primary Drier
Waste from Primary
Shredder to Stage I drier
Automated Segregation/Sorting UNIT
Segregated Waste to Secondary Shredder
& Drier
Waste to Segregation Unit
Secondary Drier & Shredder
Inerts/Ash Removal < 15%
Preliminary Storage for Preconditioned Waste
Preconditioned Waste from 2nd. Stage Drier +
Shredder to Storage Bunker
C B S
Preconditioned Waste to CBS facility
Ash Silos
Ash from the Silos for Disposal
Ash from CBS facility
Gas Cleaning Unit
Gas from CBS facility to Cleaning Unit
ENGINE ROOM
Cooled & Cleaned Gas to Engine
Power to Switch Yard for Grid Upload
Switch Yard
Utilities
Utilities to Engine Room & CBS facility
Flue Gas from Engine to Stack
600 tpd
Layout of the Waste Disposal Facility
LAYOUT FOR A WASTE TO ENERGY FACILITY UTILIZING THE REVOLUTIONARY CONCORD BLUE TECHNOLOGY
Concord Blue Reformer
Storage, Segregation & Sorting Unit –
Power Generation Unit –
ANY ORGANIC WASTE
OUTPUT INPUT
Municipal Solid Waste/Bio-garbage/ Restaurant-food waste
Sewage sludge/waste
Animal manure, other animal wastes like carcasses
Any agricultural biomass waste (including plant residuals)
Hazardous Industry Wastes
Plastic Wastes
Bio Medical Wastes
High quality, high energy value syngas: Hydrogen: Already proven to be one of the most efficient energy carriers; Electricity: Turn key system creates electricity via proprietary syngas firing gas-motors Bio Char: Is currently used in fertilizer and as a soil amendment
Ash, for the Cement Industry
Our W2E FACILITIES
VASAI
PUNE
MAHAD
VASAI – 250 KWTH. W2E PLANT
CONCORD BLUE
CONCORD BLUE – VASAI PLANT
Operation details of HJ2.1 for 19th Aug.
Feedstock = Pre-conditioned
MSW
Feed rate = Raw MSW
equivalent 100 kg/hr.
Pre-conditioned feed = 40 kg/hr
Syngas Production = 20-25 Nm3/hr
Syngas = > 35% H2 content by
GC analysis
Electric Engine operation = 15/30 kW
UTILITIES
FLARE ENGINE/COOLING TOWER
SITE FOR WASTE TO ETHANOL FACILITY
MAHAD – 3 MWTH. W2E PLANT
• Fully automated Thermolysis unit; • 3MWth Capacity; • Self – Sustaining; • Centrally controlled SCADA based system; • Gas cooling and Cleaning ; • Automated char extraction system; •Gas Flaring System
CONCORD BLUE
CONCORD BLUE – MAHAD – PROCESS FLOW
AUXILIARIES
CONCORD BLUE – MAHAD – PROJECT MODALITIES
SCHEMATIC FLOW DIAGRAM
Digester
Overflow
EAT as
settling
tank
Polyelectrolyte
dozing
Clarifier
Sludge
Removal
TA10
RO Feed
Tank
(existing)
Permeate
RO
UNIT
TA80
DEGASSER
TANK
(existing)
PK21 TA110
RO Reject
Tank
(existing)
PK22
Multi
Effective
Evaporator
TA210
EVAP
Reject
TANK
Dryer
BIOMASS
STORAGE
CONCORD
BLUE
SYSTEM CHAR
OUTLET
STEAM STEAM
RO
Rejects
EMBIO SCOPE
PK221
HJ3 Design Inputs – Outputs
Input = 1 ton/hr (input ready)
= 3.5 MWth
Output= Syngas total Production
= > 700 Nm3/hr
= BioChar
= 6-8 tons/day
SIKAR – 1.0 MWelec. (net sellable) W2E PLANT
CONCORD BLUE
CONCORD BLUE - SIKAR
Broad Input / Output Input – Unsegregated Municipal Solid Waste – 100
tonnes per day (36,500 tonnes per annum); Receipt of waste – 365 days a year; Plant Uptime (Defined as the amount of time for
production of electricity) – 7500 hours/annum; Amount of Electricity Produced – 1.0 MWel (Gross
electric power); Rejects from the system:
o Inerts & Recyclables - A function of the feed – estimated at APPROX 15% of the received waste
o Ash - A function of the feed – estimated at APPROX 1 TONS/DAY ( subject to actual feed analysis)
Space required - 28,000 square meters;
CONCORD BLUE – SIKAR LAYOUT
PUNE – 10 MWelec. (net sellable) W2E PLANT
CONCORD BLUE
The completed HJ4 CBR™ will be the largest of its kind waste to clean energy gasification facility in the world. With an in input of 700 tpd of fresh, unsegregated low calorific municipal solid waste, the HJ-4 CBR™ is expected to commence its first phase of commercial operations in October 2011. Today the construction site is about 85% completed.
CONCORD BLUE - PUNE
Broad Input / Output Input – Unsegregated Municipal Solid Waste – 700 tonnes per day (2,55,500 tonnes per annum); Receipt of waste – 365 days a year; Plant Uptime (Defined as the amount of time for production of electricity) – 7500 hours/annum; Amount of Electricity Produced – 11.0 MWel (Gross electric power); Rejects from the system:
o Inerts & Recyclables - A function of the feed – estimated at APPROX 15% of the received waste o Ash - A function of the feed – estimated at APPROX 6 TONS/DAY ( subject to actual feed analysis)
Space required - 10,000 square meters;
PUNE 10 MWelec - Associates
SEGREGATION SORTING – UNIT LAYOUT
PUNE – PLANT SITE – PRECONDITIONING EQUIPMENT
PUNE – PLANT SITE – PRECONDITIONING EQUIPMENT
GAS ENGINE MANUFACTURERS
Gas Engine MWM - Germany
The CBR produces an ultra clean gas due to reformation that does not produce any PoPs;
The DIOXINS and FURANS are not formed as the plastic (or any chlorinated) wastes are not burned, but thermo chemically degraded;
The engine emissions as well as the flue gas from syngas furnace chamber are treated with the state-of-the art control mechanisms like SCRs and Oxidative Catalysts to keep the emissions way below even the most stringent control norms;
EMISSIONS
EMISSIONS
WORK STREAM FOR DESIGNING A CBR FACILITY
CONCORD BLUE – BUILDING A BETTER TOMORROW