Transcript Inorganic waste April 2005

Plasma Special Waste Treatment
Tetronics / StarPower Italia experience
Technology for a cleaner
environment
© StarPower Italia - 2005
Overview
•
Who we are
MMG/CDC
•
The Markets
CDC
•
Environmental Drivers
CDC
•
Tetronics Environmental Plasma System (TEPS)
CDC
•
Cost Analysis
MMG
•
Waste Management in the production cycle
MMG
•
Conclusion
MMG
© StarPower Italia - 2005
Starpower Italia s.r.l. - who we are
•
StarPower Italia s.r.l. is a limited liability company actively
engaged in promoting and marketing innovative waste
management technology in Italy since 2002.
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StarPower Italia is the Tetronics ltd agent in Italy.
© StarPower Italia - 2005
Tetronics Limited – who we are
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World Leader in thermal plasma applications
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>30 years experience
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Proven, established technology
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International and credible customer base
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33 environmental solutions engineered
to date (upto 35,000 tonnes per year, 9MW)
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Key Environmental Sectors
•
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Inorganic waste treatment (Haz waste)
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Organic waste treatment (Haz + Non Haz)
Advanced Rand D facilities >1MW Power, 6
operating stations
Commercial operations and plant supply
© StarPower Italia - 2005
Tetronics: The Markets 1
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Clean Heat
•
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Market leader in heating of steel in continuous
casting process,
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25 systems predominantly in the far East
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Customers include Posco, NSC, NKK,
Sumitomo, Kobe
Advanced Materials
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Prime opportunity is in the synthesis of powders
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Strategic alliance with QinetiQ for
nanotechnology
•
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Most advanced processing facility in UK for
thermal production of nanopowders
Opportunities in micron powders and glass
melting
© StarPower Italia - 2005
Tetronics: The Markets 2
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Environmental Market
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Inorganic wastes
•
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Extensive commercial experience:
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Recovery of precious metals from autocats
(US, South Korea)
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Treatment of steel plant dusts (Italy, US)
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Vitrification of incinerator ashes (Japan)
Organic wastes
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Major opportunity in treatment of hazardous
organic and mixed wastes
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Oily sludges and solvents
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Food, meat and other agro-wastes
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Clinical and pharmaceutical wastes
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LLRW
© StarPower Italia - 2005
Environmental Drivers: Hazardous Wastes
ENVIRONMENTAL FACTORS
PLASMA TREATMENT OF WASTES
-More severe regulations
-Landfill of certain wastes restricted
ENVIRONMENTAL BENEFITS
-Avoidance of leaching of toxins
- Efficient destruction of organics
-Prevention of dioxins and toxic gases
- Vitrification of wastes
POLITICAL FACTORS
-Targets for reduction in landfill
-Recycling/utilization
-Energy recovery
-Sustainable, clean solutions
-Support of clean technologies
- Meets most severe standards
- Non-toxic slag
ECONOMIC & SOCIAL BENEFITS
- Revenues from electrical generation
- Cost savings from avoidance of landfill
- Saleable by-product
TECHNICAL BENEFITS
ECONOMIC AND SOCIAL
- High energy efficiency
-Limited landfill and landfill tax
- Robust, reliable, simple and flexible
-Increased cost of disposal
- Easy to automate
-Tax incentive schemes
- Proven in wide range of applications
-Recovery of energy by CHP
- Clean
-Poor perception of incineration
© StarPower Italia - 2005
TEPS: Solution to Hazardous wastes
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Strong regulatory and economic drivers
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Clean process solution
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Robust and proven DC Plasma arc technology
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Simple to operate and maintain
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High destruction efficiency of persistent organics
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Stable vitrified slag, with good utilization potential
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Minimisation of waste by-products
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Recycling of valuable metals
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Economic
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Strong position within the waste management hierarchy
© StarPower Italia - 2005
TEPS: Typical Plasma Reactor
Furnace Off Gas
Combustible Gases and
Volatile Species
PLASMA ZONE > 10,000 K
High Temperature Destruction of
Organics
High Intensity UV Catalysis
of Photo-Chemical Reaction
Metallic Phase
Recovery of Metal
Value
Environmentally Stable
Slag Repository for Heavy
Metals
© StarPower Italia - 2005
TEPS: Inorganic / Organic Haz Waste Treatment
ORGANIC (gasification)
INORGANIC
(vitrification/smelting)
Raw material > 5% carbon. Furnace off gas
has calorific value (CO and H2)
Raw material < 5% carbon. Furnace off gas
has no significant calorific value
Air, water or oxygen added to furnace
No oxidant added to furnace
LLRW, contaminated meat, oil sludges,
solvents, POPS, clinical,
Metallurgical residues, contaminated soils,
incinerator ashes, asbestos
© StarPower Italia - 2005
TEPS: Process Mechanism
INPUTS
OUTPUTS
FEED
GAS
CO, H2, CO2, H2O,
HCL, Zn, Pb, Hg etc
CnHm …..MeO, Me,
O, S, Cl, P etc
SLAG
OXIDANT
MeO (e.g. SiO2, CaO, Al2O3,
P2O5, Cr2O3, FeO etc)
H2O, O2, Air
METAL
Cn H m  nC 
m
H2
2
PYROLYSIS
Me (Fe, Cu,
etc)
FEATURES
• High destruction efficiency
Cn Hm  O2  nCO  mH2
• High UV and temperature
C  H 2O  CO  H2
• Metal recovery
1
C  O2  CO
2
GASIFICATION
• Non leachable slag
© StarPower Italia - 2005
TEPS: Key Stages
PLASMA
POWER
OXIDANT
(AIR,
WATER)
SECONDARY
OXIDATION,
COMBUSTION
HEAT
RECOVERY
GAS
CLEANING
PROCESS PREHEATING
PLASMA
WASTE
MATERIALS
HOT WATER / STEAM
CONVERTOR
ELECTRICITY GENERATION
FLUXES
SLAG PRODUCT
METAL
PRODUCT
SECONDARY
USES,
RECYCLING,
SAFE DISPOSAL
Organic waste only
© StarPower Italia - 2005
TEPS: Process Flow Sheet
© StarPower Italia - 2005
TEPS: Layout of a Plasma Waste Treatment Plant
GAS DISCHARGE
FEED RECEIVER
GAS CLEANING
SHREDDER
THERMAL OXIDISER
PRODUCT DELIVERY
PLASMA REACTOR
© StarPower Italia - 2005
TEPS Product Utilization Cycle
STEAM/
ELECTRICAL
CHP
WASTE
PLASMA
MATERIAL
TREATMENT
Export of
electricity
PLANT
Production of chemicals,
hydrogen
Vitrified
Product
© StarPower Italia - 2005
TEPS:Typical composition and impurities of Syn-gas
Syn-gas quality
Syn-gas Pollutants
Gas Species
Volume %
Pollutant
mg/Nm3
H2
20-40
SOx
<10
CO
20-30
HCl
<5
CO2
<5
CO
<20
N2
<20
NOx
<20
CnHm
<1
Heavy Metals
<1
© StarPower Italia - 2005
TEPS: Plasma Destruction of Dioxins
PRIMARY ASH
~ 50ng TEQ/g
Plasma
Convertor
SLAG<0.001 ng
TEQ/g
GAS EMMISSION
< 0.05ng TEQ/M3
Gas
Handling
SECONDARY FLY ASH
<0.005 ng TEQ/g
© StarPower Italia - 2005
TEPS: Leachate Test results (steel dust)
Slag
TCLP Limits
6
PPM
4
5
5
0.14
0.04
2.5
2
0
5
0.04
1
0.02
Arsenic
Cadmium
0.06
Cr 6+
Lead
Silver
Toxic Leachate Species
© StarPower Italia - 2005
Cost Analysis
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Tetronics can provide custom-made solutions optimized to address
specific waste problems
Capital costs are dependant on the type and quantity of waste to be
treated
When the waste chemical composition is known StarPower Italia
can employ its financial analysis model to forecast costs of
disposal and Return of Investment rates
© StarPower Italia - 2005
Cost Analysis
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Case study – 50 tpd plant / pharmaceutical waste / 348dx24h /
tipping fee 0.41 €/kg
•
•
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1.6MwH torch
0.09 €/kWh power costs
Labour rates per year:
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Plant Manager
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Shift Supervisor
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System Operator
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Assistant x 3
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Other (secretary)
88,000 euro
26,000 euro
26,000 euro
26,000 euro
23,000 euro
© StarPower Italia - 2005
Cost Analysis
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Break even point for plant in operation after 9 months
from start of project without considering revenues from
system by-products
© StarPower Italia - 2005
Cost Analysis
© StarPower Italia - 2005
Waste Management in the Production Cycle
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•
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The TEPSTM can be easily integrated into companies existing
production cycle to treat their waste streams
Reduce waste management costs in the balance sheet
Generates by-products and energy that could be fed in the
production cycle
Guarantees the compliance with all current and future
environmental regulations
Produce valuable products from “GARBAGE”
© StarPower Italia - 2005
Conclusion
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TEPSTM is as an effective and versatile solution for the treatment
of hazardous waste streams
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The products arising are readily recycled, reused or disposed
of in a safe manner
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The slag products are stable and non-leachable
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Potential savings by diverting vitrified slag product away from
landfill
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Technical risk minimised by industrial track record
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Economic risk stabilised against future regulatory drivers
© StarPower Italia - 2005
For more information:
StarPower Italia s.r.l.
www.star-power.it
Tetronics Ltd:
www.tetronics.com
© StarPower Italia - 2005