The Cleaner World Through Pyro Thermic Reaction

IntroductionTime LapseTechnology ComparisonsNew EraTreatment ZonesPower ProcessMaintenance

Process Flow DiagramDesalination

Operator ControlsConstruction

Plant ListMobile Plant

Contact Details

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1 INTRODUCTION TO WACSWaste 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.

1 INTRODUCTION TO WACS

municipal wasteindustrial waste

clinical wasteasbestos waste

tyres, rubber, plasticsoil waste

nuclear wastechemical waste

pharmaceutical wasteoffal waste

sewage sludgecontaminated water

EXAM

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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.

1 INTRODUCTION TO WACS

NontoxicNonporous

Contaminant-freeMineral composition

Dust-freeSterile

Vitrified bead-like structureTotally inert

PROPERTIES OF W

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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.

2 TIME LAPSE, A WACS HISTORYDesigned 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. MUNICI

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3 TECHNOLOGY COMPARISONS

TEMPERATURE 800° TO 850°C 1700°C

WASTE CONTROLuncontrolled, uncontained 100% contained

PERCENT RESIDUE 30% to 40% 3%

POWER OUTPUT 250-300 KWH/T 1000 KWH/T

PYRO THERMIC REACTORMOVING GRATE

FURNACE

PYROTHER

MIC S

YSTEM

COMPA

RISON

There are many

pyrolysis systems

in use but they havesignificant problems in

conforming to WID, EPAand EU directives. We would

emphasise that the Pyro Thermic Reactor is not a pyrolysis system but also

incorporates gasificationas a combined function.

4 NEW ERA: THE MODEL PROCESS

SHREDDING DRYING ANDDEGASIFICATION

PYROTHERMICSTEP 1 STEP 2 STEP 3

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 multi-shafted 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.

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.

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 material inert and sterile

Pyrothermic Reaction is a thermal chemical decom- position 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.

4 NEW ERA: THE MODEL PROCESSPRE-HEAT ZONE

This area is where the pre-heat chamber removes residual moisture and partial destruction commences.

DE-GASIFICATION ZONE

THERMIC ZONE

MOLTEN ZONE

Converts all gases into fuel gasses, creating syngas to assist later combustion.

Waste is subjected to indirect high temperatures, destroying major pollutants, producing char like material, and releasing energy.

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.

5 POWER PROCESS

REACTOR1

BOILER2

GENERATOR3

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.

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.

TRANSM

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N CERTIF

ICATION

In the U.K. the generated power is

suitable for inclusion within the latest

Renewables ObligationCertificate (ROC) program

administered by Ofgem,qualifying for ROC certificates

that can be traded internationally. The process is also rated as

“Carbon Neutral”.

6 MAINTENANCEBased on previous installations, over a ten-year 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 ourearlier generation PTRs

on the job in Japan.

7 PROCESS FLOW DIAGRAM

8 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.

DESALINATIONPLANT

10 OPERATOR CONTROLSOperator control is by touch-

screen. Each screen isdedicated to an area of the

plant with all streamsinterlaced allowing

the presenteddata to be

viewed.

10 OPERATOR CONTROLSThe converter screen details plant status. In this screen the reactor’s vital statistics are monitored, and the whole process is automatically controlled by software.

Each critical plant operation is also monitored by a hard-wired backup system, allowing the operator to override any section for comprehensive control on all systems operation.

Operator control is by touch-screen. Each screen is

dedicated to an area of the plant with all streams

interlaced allowingthe presented

data to beviewed.

10 OPERATOR CONTROLS

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.

The Water Systems Screen monitors stages of water flows and levels, giving the operator are no-nonsense, fast, and clear input of plant operations at all critical process stages.

The consumption of water is negligible; the mobile unit carries a 500-gallon storage tank on the trailer.

Operator control is by touch-screen. Each screen is

dedicated to an area of the plant with all streams

interlaced allowingthe presented

data to beviewed.

The PTR unitmeets all WID,

EU, US EPA, and the Japanese National

Standard levels. All ofthe PTR units are fittedwith an emission

monitor connectedby Internet to

our UK offices.

10 OPERATOR CONTROLSThe 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.

11 CONSTRUCTIONPlease see the accompanying

brochure provided by ourWACS representative for

technical diagrams, inclu-ding Mass Balance

Diagram, electricalschematic, and

plant drawings

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.

12 PLANT LIST

MODEL: TONNE/HOUR TONNE/DAY

Bio Therm 500 B 0.5 t 12 t1500 B 3 t 72 t

Mobile 150 M 2.5 t 60 t

Static 100S 1 t 24 t120S 1.7 t 41 t150S 3 t 72 t200S 5 t 120 t250S 6 t 144 t300S 7.5 t 180 t350S 8.5 t 204 t450S 10 t 240 t500S 14 t 336 t550S 17.5 t 420 t

Twenty nine PTRunits have been designed, built, and are operating in seven different countries.

One company in Japan purchased and installed 7 units.

WORLD

WID

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13 MOBILE PLANTThe 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 15-meter 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.

14 CONTACTRobertSkelton@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