WO2004048851A1 - Procede a induction et frequence plasmique integree pour traitement de dechets, recuperation de ressources et dispositif associe - Google Patents

Procede a induction et frequence plasmique integree pour traitement de dechets, recuperation de ressources et dispositif associe Download PDF

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Publication number
WO2004048851A1
WO2004048851A1 PCT/EP2002/013228 EP0213228W WO2004048851A1 WO 2004048851 A1 WO2004048851 A1 WO 2004048851A1 EP 0213228 W EP0213228 W EP 0213228W WO 2004048851 A1 WO2004048851 A1 WO 2004048851A1
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WIPO (PCT)
Prior art keywords
syngas
waste
waste material
plasma
frequency
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PCT/EP2002/013228
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English (en)
Inventor
Ricardo Blach Vizoso
Original Assignee
David Systems Technology, S.L.
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Publication date
Application filed by David Systems Technology, S.L. filed Critical David Systems Technology, S.L.
Priority to AU2002368399A priority Critical patent/AU2002368399A1/en
Priority to PCT/EP2002/013228 priority patent/WO2004048851A1/fr
Publication of WO2004048851A1 publication Critical patent/WO2004048851A1/fr

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    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/72—Other features
    • C10J3/723—Controlling or regulating the gasification process
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/02—Fixed-bed gasification of lump fuel
    • C10J3/06—Continuous processes
    • C10J3/18—Continuous processes using electricity
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/72—Other features
    • C10J3/74—Construction of shells or jackets
    • C10J3/76—Water jackets; Steam boiler-jackets
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
    • C10K1/00—Purifying combustible gases containing carbon monoxide
    • C10K1/002—Removal of contaminants
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
    • C10K1/00—Purifying combustible gases containing carbon monoxide
    • C10K1/002—Removal of contaminants
    • C10K1/003—Removal of contaminants of acid contaminants, e.g. acid gas removal
    • C10K1/004—Sulfur containing contaminants, e.g. hydrogen sulfide
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
    • C10K1/00—Purifying combustible gases containing carbon monoxide
    • C10K1/02—Dust removal
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
    • C10K1/00—Purifying combustible gases containing carbon monoxide
    • C10K1/02—Dust removal
    • C10K1/024—Dust removal by filtration
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
    • C10K1/00—Purifying combustible gases containing carbon monoxide
    • C10K1/08—Purifying combustible gases containing carbon monoxide by washing with liquids; Reviving the used wash liquors
    • C10K1/10—Purifying combustible gases containing carbon monoxide by washing with liquids; Reviving the used wash liquors with aqueous liquids
    • C10K1/105—Purifying combustible gases containing carbon monoxide by washing with liquids; Reviving the used wash liquors with aqueous liquids containing metal compounds other than alkali- or earth-alkali carbonates, -hydroxides, oxides, or salts of inorganic acids derived from sulfur
    • C10K1/106—Purifying combustible gases containing carbon monoxide by washing with liquids; Reviving the used wash liquors with aqueous liquids containing metal compounds other than alkali- or earth-alkali carbonates, -hydroxides, oxides, or salts of inorganic acids derived from sulfur containing Fe compounds
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
    • C10K1/00—Purifying combustible gases containing carbon monoxide
    • C10K1/08—Purifying combustible gases containing carbon monoxide by washing with liquids; Reviving the used wash liquors
    • C10K1/10—Purifying combustible gases containing carbon monoxide by washing with liquids; Reviving the used wash liquors with aqueous liquids
    • C10K1/12—Purifying combustible gases containing carbon monoxide by washing with liquids; Reviving the used wash liquors with aqueous liquids alkaline-reacting including the revival of the used wash liquors
    • C10K1/122—Purifying combustible gases containing carbon monoxide by washing with liquids; Reviving the used wash liquors with aqueous liquids alkaline-reacting including the revival of the used wash liquors containing only carbonates, bicarbonates, hydroxides or oxides of alkali-metals (including Mg)
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
    • C10K1/00—Purifying combustible gases containing carbon monoxide
    • C10K1/20—Purifying combustible gases containing carbon monoxide by treating with solids; Regenerating spent purifying masses
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
    • C10K1/00—Purifying combustible gases containing carbon monoxide
    • C10K1/32—Purifying combustible gases containing carbon monoxide with selectively adsorptive solids, e.g. active carbon
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/006—General arrangement of incineration plant, e.g. flow sheets
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    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/02—Incineration of waste; Incinerator constructions; Details, accessories or control therefor with pretreatment
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/08—Incineration of waste; Incinerator constructions; Details, accessories or control therefor having supplementary heating
    • F23G5/085—High-temperature heating means, e.g. plasma, for partly melting the waste
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
    • F23G5/44—Details; Accessories
    • F23G5/46—Recuperation of heat
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23J—REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J15/00—Arrangements of devices for treating smoke or fumes
    • F23J15/006—Layout of treatment plant
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23J—REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J15/00—Arrangements of devices for treating smoke or fumes
    • F23J15/02—Arrangements of devices for treating smoke or fumes of purifiers, e.g. for removing noxious material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23L—SUPPLYING AIR OR NON-COMBUSTIBLE LIQUIDS OR GASES TO COMBUSTION APPARATUS IN GENERAL ; VALVES OR DAMPERS SPECIALLY ADAPTED FOR CONTROLLING AIR SUPPLY OR DRAUGHT IN COMBUSTION APPARATUS; INDUCING DRAUGHT IN COMBUSTION APPARATUS; TOPS FOR CHIMNEYS OR VENTILATING SHAFTS; TERMINALS FOR FLUES
    • F23L7/00—Supplying non-combustible liquids or gases, other than air, to the fire, e.g. oxygen, steam
    • F23L7/007—Supplying oxygen or oxygen-enriched air
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23M—CASINGS, LININGS, WALLS OR DOORS SPECIALLY ADAPTED FOR COMBUSTION CHAMBERS, e.g. FIREBRIDGES; DEVICES FOR DEFLECTING AIR, FLAMES OR COMBUSTION PRODUCTS IN COMBUSTION CHAMBERS; SAFETY ARRANGEMENTS SPECIALLY ADAPTED FOR COMBUSTION APPARATUS; DETAILS OF COMBUSTION CHAMBERS, NOT OTHERWISE PROVIDED FOR
    • F23M5/00—Casings; Linings; Walls
    • F23M5/08—Cooling thereof; Tube walls
    • F23M5/085—Cooling thereof; Tube walls using air or other gas as the cooling medium
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2200/00—Details of gasification apparatus
    • C10J2200/15—Details of feeding means
    • C10J2200/154—Pushing devices, e.g. pistons
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0903—Feed preparation
    • C10J2300/0906—Physical processes, e.g. shredding, comminuting, chopping, sorting
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0953—Gasifying agents
    • C10J2300/0959—Oxygen
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0953—Gasifying agents
    • C10J2300/0973—Water
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/16—Integration of gasification processes with another plant or parts within the plant
    • C10J2300/164—Integration of gasification processes with another plant or parts within the plant with conversion of synthesis gas
    • C10J2300/1643—Conversion of synthesis gas to energy
    • C10J2300/165—Conversion of synthesis gas to energy integrated with a gas turbine or gas motor
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/18—Details of the gasification process, e.g. loops, autothermal operation
    • C10J2300/1861—Heat exchange between at least two process streams
    • C10J2300/1884—Heat exchange between at least two process streams with one stream being synthesis gas
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
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    • F23G2201/00—Pretreatment
    • F23G2201/40—Gasification
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    • F23G2201/80—Shredding
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2204/00—Supplementary heating arrangements
    • F23G2204/20—Supplementary heating arrangements using electric energy
    • F23G2204/201—Plasma
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F23G2204/00—Supplementary heating arrangements
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    • F23G2204/204—Induction
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F23G2206/00—Waste heat recuperation
    • F23G2206/20—Waste heat recuperation using the heat in association with another installation
    • F23G2206/202—Waste heat recuperation using the heat in association with another installation with an internal combustion engine
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    • F23G2209/28—Plastics or rubber like materials
    • F23G2209/281—Tyres
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    • F23J2217/00—Intercepting solids
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    • F23L2900/00—Special arrangements for supplying or treating air or oxidant for combustion; Injecting inert gas, water or steam into the combustion chamber
    • F23L2900/07005—Injecting pure oxygen or oxygen enriched air
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E20/00—Combustion technologies with mitigation potential
    • Y02E20/34—Indirect CO2mitigation, i.e. by acting on non CO2directly related matters of the process, e.g. pre-heating or heat recovery
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E50/00—Technologies for the production of fuel of non-fossil origin
    • Y02E50/30—Fuel from waste, e.g. synthetic alcohol or diesel

Definitions

  • This invention relates to the destruction of organic and inorganic waste, containing low or reduced quantities of oxygen, and, more particularly, to the large scale conversion of various heterogeneous waste, including worn-out tires, municipal solid waste and medical waste in integrated electrothermal equipment including arc plasma treatment and simultaneous frequency induction melting and conversion of inorganic ingredients of waste with full resource recovery.
  • Waste A major problem facing modern society is the disposal of various waste materials in a manner, which provides destruction of waste, resource recovery and minimizes impact on the environment.
  • Waste are sorted in several classes according to their origin (municipal, hospital, industrial), their nature (mineral, biological, chemical, nuclear), their state (solid, liquid, gaseous) and the level of pollution that they cause (inert, ordinary, special, toxic, hazardous).
  • the classical techniques brought into operation for destruction of waste are the following: reconversion, recycling, biological treatment, chemical oxidation, confinement, incineration and the ultimate solution, the suppression of waste generating processes. This situation however is not satisfactory, indeed to-day some waste are inadequately treated or are not treated at all because of the lack of suitable means.
  • An ideal waste disposal system is one, which is capable of reducing waste to compounds suitable for environmental disposal. Such suitability is, of course, defined in terms of acceptable levels of pollution as determined by a variety of regulatory agencies.
  • waste disposal has taken in the form of direct burial in landfills, or thermal processing of the waste, followed by burial of the solid residue, and release to the atmosphere of the volatile residue. None of these approaches have proven acceptable, due to the fact that the materials released to the environment remain as unacceptable sources of pollution.
  • the disposal of worn-out tires (WOT), municipal solid waste (MSW) and other waste of such kind has become a major issue over the past few decades in many countries due to space limitations for landfills and problems associated with siting new incinerators.
  • increased environmental awareness has resulted in a major concern of many large metropolitan areas and to the country as a whole to ensure that the disposal of solid waste is properly handled.
  • waste-to-energy incinerator will process the solid combustible fraction of the waste stream, produce steam to drive a steam turbine, and as a result of the combustion process produce a waste ash material.
  • the ash is buried in a municipal landfill.
  • the incineration of MSW in pure oxygen at temperature of 2000 C is completed with full gasification of MSW organic ingredients and production of gas energy carrier, so called synthetic gas (further - syngas);
  • the by-products are mineral granulite utilized in the building industry, the alloyed metallic rest (metallic granulite) - a raw material for metallurgy.
  • the by-products comprise the residual fractions such as salt mixtures, sulphur etc. having demand in industry.
  • Thermoselectmaschine process and equipment operate as follows. Finely divided MSW are overloaded into a preparation chamber, where they are pressed and briquetted. MSW briquettes are fed into a horizontal heated conduit designed for degassing, supplied with a pushing drive. Heat conductivity of pressed briquettes improves; as a result they are dried very rapidly and degassed at temperature of 600 C. Therewith organic portion of MSW is converted to carbon which is fed by gravity into a zone of vertical high temperature reactor together with gaseous decomposition products - carbon oxides, hydrogen, steam, hydrocarbons; all these products enter continuously into the said reactor, where they are treated by oxygen.
  • a carbonized solid residue is gasified and converted at the temperature of 2000 C to syngas consisting predominantly of hydrogen, carbon monoxide, carbon dioxide, steam, some simple hydrocarbons.
  • Temperature at the upper portion of the reactor is of 1200 C; therewith all the organic substances are destroyed within 4 seconds.
  • Mineral and metallic ingredients of MSW melt Such metals as zinc, lead, cadmium, mercury go into gas phase, manganese, chromium, calcium, magnesium go into melt.
  • the main components of the mineral melt are oxides of iron, silicon, aluminium.
  • Mineral and metallic melts are unloaded into the homogenizing reactor and granulated with the use of water jets. Owing to distinct viscosity, density and surface tension the melts are separated and granulated. Under such conditions any possibility of inclusion of water into granules is precluded.
  • Mineral melt (-230 kg/t.MSW) consists predominantly of oxides of silicon, aluminium, iron, sodium, manganese, chromium, calcium, magnesium.
  • Residues of hazardous admixtures are localized in this granulite.
  • Mineral granulite corresponds to building material requirements.
  • Metallic granulite is about 29 kg/t. MSW.
  • the main portion of the metallic granulite is low-alloyed iron (>90 %) with admixtures of copper, nickel, chromium, zinc, phosphorus, silicon. Concentration of toxic elements (thallium, cadmium, lead, mercury, arsenic) is very low.
  • Metallic granulite can be admixed to mineral granulite for building industry or used as a raw material for metallurgy and at production of simple cast irons. So far as "Thermoselectmaschine" operates with pure oxygen, the volumes of purified gas are about 15 % the volumes of flue gases of the incinerators.
  • the syngas consists of mono- and dioxides of carbon, hydrogen, steam, small drops of melted mineral substances, volatile vapours of heavy metals and includes hydrogen chloride, hydrogen fluoride, sulphur and nitrogen oxides, hydrogen sulphide etc.
  • a multi-stage purification process consisting of quenching (rapid cooling of gas from 1200 C to 70 C), dust cleaning, acid and base washing, isolation of sulphur, fine filtration on active coke. Quenching enables to prevent re-synthesis of organic substances, e.g. dioxines, furans and their derivatives.
  • the most portion of steam, heavy metals, their compounds and the most part of hydrogen chloride are separated at this stage. After quenching the syngas is subjected to water treatment.
  • the remaining toxic admixtures such as hydrogen chloride, hydrogen fluoride, heavy metals traces are separated at this stage. Sulphur from hydrogen sulphide is oxidized to elemental sulphur and separated. At the following base treatment chlorine, fluorine and sulphur compounds are separated from the syngas finally. Final purification of the syngas of the hazardous admixtures is attained at passing through an activated coke filter and a cloth filter.
  • Average enthalpy of MSW is about 10,000 MJ/t.
  • About 900 nm 3 of the syngas are produced from 1 ton of MSW.
  • the syngas is used partly for heating of the degassing conduit and in the high temperature reactor.
  • the surplus syngas is used for generation of electric energy in the gas turbine and for producing heat.
  • Waste heat of the apparatus is used for current need for purification of the syngas, for preparation of water, for drying slime etc.
  • energy surplus attains 7 MW.
  • "Thermoselectmaschine" standard production line has production 10 t/h, therefore 75,000 t/a at 85 % loading of the equipment.
  • Thermoselectmaschine possesses with some shortcomings decreasing its efficiency: High concentration of carbon dioxide (-47 %) as compared to concentration of carbon monoxide (43 %); moreover considerable quantity of hydrogen recombines to steam. This, in combination with combustion of a portion of the syngas in the vertical reactor, lowers regeneration level of the
  • MSW energetic resources Preliminary thermal treatment of MSW in the horizontal conduit at temperature of 600 C promotes to carrying away of considerable portion of carbon and oxygen, containing primarily in MSW, in the form of carbon dioxide.
  • MSW metallic ingredients 4.6 - 7.7 % is oxidized, i.e. transforms to less valuable ceramic ingredients (so-called inserts, of which primary content in MSW was in the range 3.3 - 7.7 %).
  • inserts of which primary content in MSW was in the range 3.3 - 7.7 %).
  • oxygen from MSW is used to oxidation of the metallic components.
  • MSW condensed products content of the metallic granulate was of 19.8 kg/n.MSW (-2 %); at the same time content of the mineral granulite (predominantly oxide phase) becomes - 183.6 kg/t.
  • Plasma technique can advantageously replace conventional burners in incineration plants.
  • the comparison of plasma technique with classical incineration processes should not be limited to the energy and investment cost; it should include other advantages such as better performance, respect of standards, maximum rate of destruction.
  • arc plasmatrons provide an advantage over traditional incinerator or combustion processes under certain operating conditions because the volume of gaseous products formed from the plasma arc plasmatron may be significantly less than the volume produced during typical incineration or combustion, fewer toxic materials are in the gaseous products, and under some circumstances the inorganic remainders of the waste material can be glassified.
  • U.S. Pat. No. 5,280,757 to Carter et al. discloses the use of a plasma arc plasmatron in a reactor vessel to gasify municipal solid waste. A product having a medium quality gas and a slag with a lower toxic element leachability is produced thereby.
  • a process for remediation of lead-contaminated soil and waste battery material is disclosed in U.S. Pat. No. 5,284,503 to Bitler et al.
  • a vitrified slag is formed from the soil.
  • Combustible gas and volatized lead, which are formed from the waste battery casings, are preferably transferred to and used as a fuel for a conventional smelting furnace.
  • the prior art plasma waste decomposition systems aforesaid suffer from a variety of shortcomings which have prevented their widespread use in commercial applications.
  • One shortcoming results from the fact that the waste material generally cannot be introduced directly into the plasma arc because such introduction causes contamination of the arc electrodes and subsequent erratic operation of the arc.
  • the waste material is introduced downstream of the arc and is indirectly heated by the plasmatron gas. This technique shortens the high temperature residence time of the waste material, resulting in incomplete decomposition. It concerns especially the multi-component heterogeneous waste containing metal, ceramic and salt ingredients, as well as both high melting compounds and low-melting hazardous metals.
  • there is a need to combine plasma technological and plasma metallurgical treatment of waste to complete their gasification and to systems provide stable, non-leachable solid products.
  • the arc plasma furnace and joule heated melter developed by the authors .4/ are formed as a fully integrated unit with a common melt pool having circuit arrangements for the simultaneous independently controllable operation of both the arc plasma and the joule heated portions of the unit without interference with one another
  • the systems provide the capability for highly efficient conversion of waste into high quality combustible gas and for high efficiency conversion of the gas into electricity by utilizing a high efficiency gas turbine or an internal combustion engine
  • the solid product can be suitable for various commercial applications
  • the preferred configurations of this systems utilize one or more arc plasma electrodes with an elongated chamber for the molten pool such that the molten pool is capable of providing conducting paths between electrodes with the use of direct induction heating of the melt in the chamber said Waste is converted in an arc plasma-joule heated melter system utilizing arc plasma electrodes and a plurality of joule heating electrodes
  • the arc plasma electrode(s) can be configured for operation utilizing alternative current (AC) or direct current (DC)
  • the integrated arc plasma-melter unit 10 for treatment of waste is shown in Fig 1
  • the unit includes reaction vessel 12 having top 12a, bottom 12b, and sides 12c and 12d.
  • Reaction vessel 12 further includes at least one port or opening 14a (or a plurality of ports or openings 14a and 14b), through which waste material 40 is introduced into reaction vessel 12.
  • Reaction vessel 12 also includes gas port or opening 16 and metal/slag pouring port or opening 20. Gas exiting from port 16 preferably will enter conduit 18 and will be sent to a scrubber, turbine or the like for further processing.
  • Port 16 may be provided with a flow control valve so that gas formed in reaction vessel 12 may be selectively released into conduit 18.
  • Metal/slag port 20 is designed to have a flow control valve that metal and/or slag may be removed and introduced into metal/slag collector 22.
  • Metal port 20 may be positioned to protrude through the bottom of unit 12 and elevated a predetermined distance there above. In this manner, port 20 may function as a submerged counter electrode to arc plasma electrodes 24a and 24b. Port 20 may also be provided with inductive heating coils 26 to provide additional heating when it is desirable to pour metal and/or slag.
  • Inductive heating coils 26 may also be designed to provide cooling when it is desirable to cease pouring metal and/or slag.
  • Reaction vessel 12 also includes a plurality of AC joule heating electrodes 50a and 50b. Electrodes 50a and 50b may be positioned across from one another on sides 12c and 12d, respectively. In addition, electrodes 50a and 50b may be positioned across from one another on sides 12c and 12d, respectively. In addition, electrodes 50a and 50b may be positioned across from one another on sides 12c and 12d, respectively. In addition, electrodes 50a and 50b may be positioned across from one another on sides 12c and 12d, respectively. In addition, electrodes
  • 50a-50b are positioned so as to be partially or totally submerged in the slag 42 mix when the process is in use.
  • Air/oxygen and/or a combination of air and/or steam may be added to eliminate char from the melt surface and adjust the redox state of the glass. Positioning electrodes 50a and 50b at angles 52a and 52b respectively, while simultaneously preventing the escape or release of gas facilitates the replacement of electrodes as needed.
  • Unit 10 may also include auxiliary heater 30 to assist in glass tapping or pouring. Due to differences in specific gravity, metal in metal/slag layer 42 moves toward bottom 12b in vessel 12. Slag in metal/slag layer 42 exits through opening or port 36a into conduit 36. Conduit 36 may be provided with heating coils (not shown) to ensure that the temperature of slag 44 flowing therethrough is sufficient. Slag conduit 36 is preferably, positioned such that slag 44 exits unit 12 and flows in an upward direction. The temperature of slag 44 is maintained in chamber 30 by heaters 32a and 32b for a time and under conditions sufficient to provide a fluid glass or slag to pour into slag collector 46. Ohmic heaters are suitable for use as heaters 32a and 32b in chamber 30.. Alternatively or in addition to heaters 32a and 32b, the temperature of slag 44 may be maintained by plasmatron 58. Slag
  • Magnetic coils 54a and 54b may be utilized for inductive heating and/or mixing.
  • additional stirring or mixing beyond that normally produced by the melter portion of the furnace and the DC arc portion of the furnace may be desirable. This may be accomplished by the addition of strategically placed magnetic coils such as coils 54a and 54b to create greater J. times. B forces which in turn causes additional mixing and/or heating in the molten bath. Coils
  • Secondary plasma off-gas chamber 56 ensures that these oils are converted to noncondensable combustible materials resulting in an enhanced recovery of energy value from the incoming waste materials.
  • Secondary thermal boost system 56 may be placed proximate to or within port 16. This system may include heating elements or an arc plasma in a chamber to provide the desirable or necessary thermal energy to further crack and reform condensable fractions exiting the primary plasma-melter unit.
  • the systems provide high quality combustible gas for high efficiency conversion of the gas into electricity by utilizing a high efficiency gas turbine or an internal combustion engine.
  • the appropriate recalculation to weight percent was done for comparison to Thermoselectmaschine , % BEC-: CO. - 63.4; CO 2> - 7.1 ; H 2 - 6.9; CH 4 - 4.9; N 2 - 20.2.
  • content of carbon monoxide increased 1.46 times, content of carbon dioxide lowered 6.56 times, content of hydrogen increased 2.3 times, therefore quality of syngas improved.
  • the systems provide stable, non-leachable products and a gaseous fuel.
  • the gaseous fuel can be utilized in a combustion or non-combustion process to generate electricity.
  • the methods and apparatus for such conversion include the use of a molten pool having predetermined electrical, thermal and physical characteristics capable of maintaining optimal joule heating and glass forming properties during the conversion process.
  • One of the shortcomings aforesaid results from a need in plurality of joule heating electrodes for more or less uniform heating of the melt pool.
  • Plurality of electrodes requires a plurality of independent power sources or ballast resistors for simultaneous operation of several electrodes supplied from one power source; this is difficult for implementation, expensive and does not ensure proper uniformity of heating of the whole melt pool.
  • Another shortcoming - it is difficult and dangerously to use a molten pool as a main gasifying medium for industrial large scale treatment of such waste as outworn tires or municipal solid waste (MSW) where routine production capacity was of 10 - 20 t/h. Under such production rates a loading conduit diameter must be measured in metres. Actually, when density of waste loaded into a melt is -0.2 t/m 3 and production capacity 10 t/h, a MSW volume, which must be passed through a molten pool is -50 m 3 /h.
  • a cylindrical pool containing e.g. 70 ton of molten metal with density -7 t/m 3 has a volume -10 m 3 , i.e. at a height 2.5 m a pool diameter is of 2.25 m.
  • a volume of waste treated increases several orders of magnitude. Under such ratios it is very difficult to retain a melt in a pool even without considering a volume of gasifying reactant introduced into the same pool.
  • waste streams do not contain materials having proper glassification and/or electrical conducting characteristics. These waste streams can be particularly difficult to process. For example, waste containing materials that do not glassify or vitrify such as tires from automobiles and other vehicles have been difficult to process. Similarly, low-ash producing organics have typically been difficult to process in a manner that produces a glassified product. In addition, highly electrically conductive waste streams with waste metals are not amenable to effective heating in melters operating
  • the present invention was developed to overcome various problems associated with a number of prior art destruction processes. More specifically, the present invention comprises a method and apparatus for the large scale destruction of worn-out tires, municipal solid waste and medical waste utilizing a totally sealed system, which is based on combined simultaneous plasma arc and direct induction heating of preliminary briquetted waste in integrated apparatus named further as electrothermal treatment. Electrothermal reprocessing of waste with low content of oxygen is reinforced by injection of oxygen into the melt through metallurgical oxygen lance(s) installed in the apparatus bottom. Using oxygen injection into the molten pool enables to reduce radically electrical power of surficial plasma heating. As a matter of fact, a production rate of a modulus apparatus as applied to outworn tires or municipal solid waste is about 10 t/h.
  • the system of the present invention is capable of effective high temperature electrothermal conversion of outworn tires, municipal solid waste and medical waste in the medium of oxygen containing gas to fuel gases comprising predominantly hydrogen and carbon monoxide
  • the conversion is implemented in the sealed system
  • This combination operates as tunable integrated systems
  • This plasma induction system combines the advantages of the induction frequency melting unit of direct heating , which can handle a wide range of waste, containing in the general case metallic, ceramic, salt inorganic and organic constituents in varying sizes and aggregate states, with those of the plasma arc, which melts the solid constituents of the waste, destroys any molecular structure of hazardous organic waste, sustains a required electrical conductivity of the melt in the frequency melter to provide a proper coupling of frequency power source with a loading - a melt of metallic, ceramic and salt ingredients
  • the direct induction heating circuit operates simultaneously with operation of the plasmotrons without detrimental interaction to each other Nevertheless, plasma treatment of the melt pool enclosed in the zone of direct inductive heating enhances electric conductivity thereof and, as a result, permanent and stable coupling of the frequency power source with loading.
  • Frequency of the power source for direct induction heating is selected depending on nature of solid constituents of the waste: low frequency for metallic constituents, high frequencies - for ceramic and salt constituents. It is still a further object of the invention to provide methods and apparatus for converting waste materials using tunable, rapid pyrolysis, thereby providing high purity gases suitable for combustion.
  • an auxiliary fuel such as natural gas, diesel or some other fuel
  • the present invention provides a compact waste processing system that has the advantage of complete or substantially complete conversion of waste materials into useful gases and/or product streams at a single location.
  • the combination of the arc plasma furnace and the induction melter as a tunable, integrated system with gas turbine or internal combustion engine generating equipment provides a net energy producing waste treatment and power production facility that is capable of being deployed in relatively small modular units and that can be easily scaled to handle large volumes of waste materials.
  • Waste are briquetted prior to electrothermal treatment without heating not to produce carbon dioxide at this stage. Briquetting operation results in removing air and in increasing of heat conductivity, therefore in providing better contact with electrothermal treatment zone.
  • waste materials are loaded into a feed hopper supplied with a receptacle in its lower portion designed for briquetting the waste material by hydraulic press arranged horizontally. The same press forces through a briquette into a short unheated horizontal conduit attached to the electrothermal treatment zone where the waste material enters without preliminary degassing. Upper portion of the zone said is cooled metallic vertical cylindrical plasma reactor.
  • Upper portion of the electrothermal treatment zone of waste material is performed first as a conical widening, then conical narrowing in the form of truncated cones; several plasmatrons (not less three) generating oxygen-containing plasma streams, directed downwards under some angle to the reactor axis, are introduced into the electrothermal treatment zone through the conical widening surface; the zone of plasma treatment grades into the treatment zone in the molten pool induced by direct induction heating of the waste inorganic ingredients in the water-cooled frequency melter.
  • Plasma reactor is manufactured of stainless steel without lining, equipped with combined water - air cooling along the whole length, that are responsible for stable temperature of 600 - 700 C is held on the reactor walls
  • the oxygen lance(s) are installed in the bottom of the apparatus for injection of pure oxygen into the molten pool volume
  • the oxygen said converts a considerable portion of carbon to carbon monoxide in the molten pool volume, provides good heat exchange of the waste with the melt and reduces radically a required electrical power of plasma heating
  • a terminal role of plasma heating can be reduced to creation of high temperature zone in the upper portion of the electrothermal treatment zone and to providing of the required level of electrical conductivity of the molten pool to ensure a stable coupling of frequency power source with loading and to clean the molten pool surface of carbon floating up to the surface from the volume.
  • the required expenditures of telectrical energy reduce and are minimized at full substitution of steam plasma to oxygen.
  • the syngas has the following composition, % vol.: CO - 37.80; CO 2l - 0.062; H 2 - 61.3;
  • Both oxygen-containing plasma feed and oxygen feed through a melt is selected in such a way, that a content of oxygen was close to stoichiometric one for a full conversion of the waste organic fraction predominantly to carbon monoxide and hydrogen; admixtures of methane, acetylene are minor.
  • the compounds, including fluorine, chlorine, sulfur, nitrogen are converted respectively to gaseous compounds having, as applied to environment, a status of toxic substances: hydrogen fluoride, HF, hydrogen chloride, HCl, sulfur oxides, SO x , nitrogen oxides, NO y .
  • the sulfur carried away from the electrothermal treatment zone as hydrogen sulfide or silicon sulfide must be caught and reprocessed with the use of the known technology, e.g. the technology developed in the frame of Thermoselectmaschine on the basis of using reduction ability of hydrogen sulfide.
  • So-called Sulferox Process is used for this purpose, in which sulfur from hydrogen sulfide is oxidized to elemental sulfur; therewith the reactant used (iron complex compound) is regenerated. Vapors of heavy, low-melting metals (mercury, zinc, lead, cadmium) accompany the syngas.
  • the frequency melter is an appliance made of nonmagnetic metal, consisting of vertical, water-cooled elements separated with narrow (1 - 2 mm) clearances, transparent for frequency electromagnetic field from the coil of frequency power source.
  • the "cold crucible” operates, depending on waste composition, on a frequency in the range 0.44 - 13.56
  • Performance of the frequency melter is sensitive of the electrical conductivity of the melt inside the induction volume. Electrical conductivity of the melt is stimulated by arc heating. Walls of the frequency melter are cold, therefore inner surface of the frequency melter which is in contact with the melt is automatically lined with a thin solid layer of the refractory waste preventing a melt of contact with a plurality of copper tubes to be transparent for outer frequency electromagnetic field and forming a wall of induction reactor.
  • the performance of the frequency melters is exhibited as applied to application of low and high frequencies for direct inductive heating of metallic and ceramic loadings accordingly. Mixing the waste material with the melt pool and homogenization of the pool itself is facilitated by electromagnetic forces which stir the melt inside the frequency melter.
  • melt in the frequency melter must be not lower 1 Siem./m to keep induction coupling of a generator with a loading, but preferably in the range 1 - 100 Siem./m.
  • the melt in the frequency melter is stirred and homogenized by electromagnetic forces, which are arisen in the melt at inducing frequency power from a coil of frequency power source.
  • the MSW organic and inorganic residues are converted completely both in the molten pool volume in oxygen medium and on surface of the melt in the steam medium.
  • the melt as it fills the frequency melter, is overflowed from the said melter into the collector.
  • Metals and slag (mineral products, oxide phase) are taken out from the melt using conventional metallurgical methods.
  • Temperature in the frequency melter is in the range 1700 - 2500 C depending on a load composition, power, frequency.
  • the organic ingredients of waste material are destroyed at interaction with the molten metal and converted to the gas product - syngas consisting of simple molecules such as hydrogen, H 2 , carbon monoxide, CO, methane, CH 4 , acetylene, C 2 H 2 etc.; excessive carbon floats up to surface of the molten pool processed by oxygen-containing plasma (e.g. steam plasma) streams distributed on the whole surface of the pool said. Steam streams eliminate carbon, floating up to surface, in the form of carbon monoxide.
  • Metallic, ceramic and salt ingredients melt and overflow from the frequency melter via the pouring pipe located above the coil of the frequency melter. These components are separated from the melt collector with the use routine metallurgical technique. Pure and halogenated (chlorinated, fluorinated) hydrocarbons, dioxine- and furan-compounds are atomized. Nevertheless, at temperature close to
  • CH 2 , CH 3 -, atoms O, H, F, Cl, N, S etc. are available in the syngas.
  • temperature of the syngas exiting the plasma reactor is of 1800 -
  • the syngas including, in addition to the fuel components, admixtures of hydrogen fluoride, HF, hydrogen chloride, HCl, sulphur oxides, SO x , nitrogen oxides, NO y , vapours of low-melting heavy metals such as mercury, zinc, lead, cadmium, is directed at the exit from the plasma reactor to cooling, cleaning of technological dust, purification and utilization.
  • the syngas directed to cleaning of technological dust and to purification of chemical impurities, has the next composition according to admixtures: Disperse phase 5 - 6 mg/m 3
  • the syngas must be purified to the level at least, mg/m 3 :
  • Nitrogen oxide NO x 200 Sulfur dioxide, SO 2 50
  • the syngas may contain and other admixtures, e.g. hydrogen sulphide, but purification of this admixture is not discussed here, because this problem is solved technically, for example in the process Thermo selectmaschine on the basis of using reduction ability of hydrogen sulphide.
  • So-called Sulferox Process is used for this purpose, in which sulphur from hydrogen sulphide is oxidized to elemental sulphur; therewith the reactant used (iron complex compound) is regenerated.
  • dioxins and furans and their halogenated derivatives are demolished at temperature of 1200 C during 4 sec, it is known, that they can recombine within 250 - 450 C again at slow cooling, but use of quenching operation with a rate not lower 10 6 C/s results in prevention of this recombination.
  • Quenching is rapid cooling of gas from 2000 C to 70 - 90 C. Quenching enables to escape formation of organic substances like dioxins and furans, so far as there is no recombination of dioxins and furans at temperature in vicinity of 70 - 90 C.
  • the conduit for transportation of the syngas into the utilization zone comprises, except the recuperative heat exchanger, installed one after another an appliance for cleaning syngas of technological dust and an unit for chemical
  • the syngas consisting of hydrogen, carbon monoxide with small admixtures of steam, carbon dioxide, methane and containing admixtures of fluorine as hydrogen fluoride (HF), chlorine as hydrogen chloride (HCl), sulphur as sulphur oxides (SO 2 , SO 3 ) or hydrogen sulphide, nitrogen oxides (NO, NO 2 ) is directed to selective purification system to obtain each admixture toxic for environment in the form of stable chemical product having commercial value. Catching of hydrogen fluoride. HF.
  • the syngas is directed primarily by a gas blower into the sorption column filled up with granulated sodium fluoride, NaF. Content of HF in the primary syngas - 10 mg/m 3 .
  • the syngas is directed into the absorption column filled up with water suspension of calcium oxide, CaO. Content in the syngas - 250 mg/m 3 , annual syngas output from the arc plasma reactor at production rate 10 t.MSW/h is 1.531 -10 8 nm 3 . Overall annual output of hydrogen chloride, HCl (during 7446 hours/annum) - 38.3 t. Hydrogen chloride is caught practically completely in the column filled in with suspension of calcium oxide, CaO as calcium chloride: CaCI 2 and removed from there periodically as a saturated solution. Utilization of CaCI 2 is not a problem: this salt can be introduced into the salts used for cleaning of the city streets in winter time.
  • Syngas flow having composition, % vol.: .) CO - 37.80 - 38; CO 2l - 0.1 - 0.2; H 2 - 61 - 61 .3; H 2 O - 0.3 - 0.4, CH 4 ,- 0.01 - 0.02 is directed, at a need, to purification of other admixtures, e.g. hydrogen sulphide, and further to production of electrical energy into a gas turbine or to an internal energy engine.
  • other admixtures e.g. hydrogen sulphide
  • the computer is used for monitoring and control the process parameter according to technological order. Parameters of both the arc plasma reactor and the frequency melter are controlled to provide an appropriate operating mode of processing of the waste materials depending of their nature and feed.
  • Fig. 1 is a block diagram showing a known tunable, self-powered arc plasma-melter electro conversion system for waste treatment and resource recovery" /4/, where Cohn D.R., Surma J.E, Titus OH. disclosed a tunable waste conversion systems and apparatus for complete or substantially complete conversion of a wide range of waste streams into useful gas and a stable, nonleachable solid product at a single location with greatly reduced air pollution to meet air quality standards.
  • Fig. 2 is a block diagram showing the overall system employing the plasma reactor equipped with arc plasmotrons operating on steam and frequency melter with direct induction heating operating as a fully integrated unit with a common molten bath for conversion of the waste to fully utilizable products; the frequency melter is supplied with the bottom metallurgical oxygen lance(s) for injection of oxygen into the molten pool said; the block diagram includes a feed of waste material and auxiliary reactants into the system and a system of cooling, cleaning and purification of syngas of technological dust and admixtures.
  • Fig. 3 presents a flow sheet of one of the variants of the "cold crucible" - an frequency melter operating in combination with plasma arc reactor designed for melting of the waste materials containing metallic or/and ceramic ingredients.
  • Fig. 4 is a schematic diagram showing the details of two-stage cleaning of syngas designed for combustion and generation of electrical energy.
  • Fig. 5 is a schematic diagram showing the details of fine purification of syngas designed for combustion and generation of electrical energy.
  • FIG.1 there is shown a block diagram showing a known tunable, self-powered arc plasma-melter electro conversion system for waste treatment and resource recovery" 121.
  • Fig.1 is described in detail in the section Background of the Invention.
  • FIG. 2 there is shown a block diagram of the destruction system 1 for large scale treatment of outworn tires, municipal solid waste (MSW) and medical waste designed in accordance with the present invention.
  • It is a block diagram showing the overall system employing the plasma arc reactor equipped with arc plasmotrons operating on steam and frequency melter with direct induction heating operating as a fully integrated unit with a common molten bath for conversion of the waste to fully utilizable products; the block diagram includes a feed of waste material into the system and a system of cooling, cleaning and purification of syngas of technological dust and admixtures.
  • the plasma - frequency induction system 1 is configured to process both solid and viscous liquid waste materials.
  • the waste is heterogeneous, i.e., it - is composed of different chemical compounds or substances, rather than a single chemical compound or substance.
  • Vertical cylindrical plasma reactor 28 is made of stainless steel, supplied in its lower portion first with conical widening 13, then conical narrowing 14 in the form of truncated cones; the reactor said is without lining, equipped with combined water - air cooling along the whole length: inner cooling jacket (between the walls 10 and 1 1 ) is cooled by air stream, the outer cooling jacket (between the walls 9 and 10) is cooled by water flow.
  • inner cooling jacket between the walls 10 and 1 1
  • the outer cooling jacket between the walls 9 and 10
  • arc plasmotrons 12 (not less three) possessing with permanent electrodes, operating on steam, are introduced into the electrothermal treatment zone through a surface of conical widening 13; they are directed downwards at an 45° angle to the plasma reactor axis in such a way to provide contact of the plasma streams with the molten pool and lack of direct contact with the reactor wall.
  • Three (or more) plasmotrons said are disposed on the surface 13 at a degree 120° to each other; the angle between the plasma reactor axis and an DC plasmotron axis is in the range 30 - 45°; the angle between the generatrixes to the surfaces of conical widening and narrowing is of 90°.
  • Each arc plasmotron 12 is supplied from an individual thyristorized rectifier 37; each is supplied with overheated steam generator 38 with a damper 39 for suppression of steam feed fluctuations.
  • Temperature of oxygen - containing plasma streams exiting the plasmotrons is within 4000 - 6000 C, temperature in the plasma treatment zone is of 2000 -2500 C.
  • the water-cooled frequency melter is designed for direct induction heating of inorganic ingredients of the waste material; it is performed as a so-called "cold crucible" to be transparent to flux of electromagnetic power from the coil 26 of the frequency generator 36.
  • the melter said is attached to the lower portion of the truncated cone with the use of a flange 15.
  • the melter said is situated coaxially in a coil 26. Diameter of the frequency melter 29 is not less a diameter of the conical narrowing of the plasma reactor 28.
  • Coupling of the frequency generator with a loading is inductive; the frequency melter is installed coaxially in the coil of the frequency power source.
  • Frequency melter 18 is manufactured to be transparent for electromagnetic power flux from the coil 26 powered from the frequency power source 36.
  • the melter sheath 27 consists of water-cooled tubular or rectangular extended elements separated by narrow clearances. Clearances are, depending on a composition of the initial waste materials filled in with dielectric inserts sealed with high temperature dielectric cement. Totality of these water-cooled elements, which is transparent for electromagnetic power flux from the coil 26 is defined for brevity as "cold crucible". Technology of such direct induction heating is defined as “cold crucible" technology.
  • Water inlet 24 is in the lower part of each element, water outlet 35 is in the upper part thereof.
  • the frequency melter is situated inside the sheath 25 made of non-magnetic metal and tightened between the cover 15 and the bottom 30.
  • the entries of the coil (33, 34) are lead out hermetically via the gaskets 31 a, 31 b in the wall of the sheath 25 towards to the frequency power source 36.
  • Frequency melter said is primarily filled in with ferrous metal scrap to create the initial molten metal pool as a medium for treatment of waste material introduced into the volume of the melt. It is obligatory operation - to immerse the waste material inside the molten pool and to mix the waste material with the melt and to use the power potential of the molten pool in a proper way. Mixing the waste material with the melt pool and homogenization of the pool itself is facilitated by electromagnetic forces, which stir the melt inside the frequency melter volume, and by oxygen jet injected through the oxygen lance 32.
  • An output terminal of the frequency power source 36 is connected through a variable load adjusting capacitor to the upper high voltage turn of the coil 26. A variable tuning capacitor is used for tuning power on the coil 26.
  • the plasma - frequency induction system 1 combines many of the advantages of induction, electric arc and plasma heating.
  • the principal metallurgical advantages provided by the system 1 can be summarized as follows:
  • the high temperature in the plasma impingement zone results in low slag viscosity and good mixing, thereby improving mass transfer with beneficial effect of reaction kinetics.
  • the system 1 said is supplied with conduit 16 for removing the melt: it is situated just above the upper turn of the coil 26 and functions as a straight- through pouring the melt as a level of the melt pool ascends above the coil level.
  • the melt is collected in the collector 19, from where it is unloaded through the heat valve 21.
  • the collector 19 is supplied with detachable cover 17 and bottom 20 and with an outer heater 18. After filling in the collector 19 slag and metallic components and directed to utilization.
  • the conduit 8 for transportation of waste material arranged horizontally is introduced through side surface of the plasma reactor 28 above the conical widening zone 13.
  • the hopper 4 for loading waste 2 is arranged at the end of said conduit 8 distant of the plasma reactor 28.
  • the conduit 40 for removing and transportation of the syngas to cooling, cleaning, purification and utilization is arranged in the upper part of the plasma reactor 28.
  • Next equipment is installed after the plasma reactor: recuperative heat exchanger 43 for cooling the syngas, two - stage appliance 45 for cleaning the syngas of technological dust and the unit 49 for sorption - chemical purification of toxic admixtures.
  • the syngas flow 51 purified of dust and toxic admixtures, containing hydrogen, carbon monoxide, hydrocarbons etc. is directed via the pipeline 51 either to additional purification of any specific admixtures or directly to utilization either into gas turbine, or into internal- combustion engine, or into boiler.
  • conduit 42 for returning a bulk of technological dust to the loading hopper 4 There is the conduit 42 for returning a bulk of technological dust to the loading hopper 4; small quantity of technological dust containing low-melting heavy metals is removed with the use of a pipe 46 and concentrated in a small volume 47.
  • Fig. 3 illustrates more in detail a flow sheet of the "cold crucible" - the frequency melter 29 exhibited in Fig. 2 in the general form and designed for melting of the waste materials containing metallic or/and ceramic ingredients.
  • Frequency melter 29 is manufactured to be transparent for electromagnetic power flux from the coil 26 powered from the frequency power source 36.
  • the melter sheath 27 consists of water-cooled tubular or rectangular extended elements 53 separated by narrow clearances 54.
  • the frequency melter is situated inside the sheath 25 made of non- magnetic metal and tightened between the cover 15 and the bottom 30
  • the entries of the coil (33, 34) are lead out air - tight via the gaskets 31 a, 31 b in the wall of the sheath 25 towards to the frequency power source 36
  • the overflow conduit 16 for overflowing melt passes through a section of the frequency melter or alternatively through a non-cooled portion of the flange 15 (this variant is not shown in Fig 3)
  • the conduit said is lined with graphite or silicon carbide to prevent cooling of melt flow
  • the frequency melter is situated coaxially inside the water-cooled coil 26 (water inlet 55, water outlet 56) in such a way that a distance from the upper and lower turns of the coil to the upper and lower ends of the clearances were equal to a height of the coil It is necessary to escape power losses in the upper and lower portion of the frequency melter
  • the frequency melter is designed for melting and processing the waste heterogeneous material containing both metallic and ceramic ingredients
  • the same embodiment of the frequency melter can be configured for melting the waste material containing predominantly the metallic ingredients.
  • frequency of the power source is of 2000 - 2400 Hz and the "cold crucible" sizes are increased 2-5 times.
  • the "cold crucible" of the system 1 is made of the set of rectangular elements made of non-magnetic metal; both ends of these elements are closed to the water collector. Clearances are sealed with synthetic mica.
  • Fig. 4 is a schematic diagram showing details of the two - stage appliance 45 designed for cleaning of the syngas flow of technological dust.
  • the syngas said is cooled preliminary in the cooling appliance 43.
  • the conduit 44 connects the upper part of the recuperative heat exchanger and the lower part of the appliance 45.
  • any industrial equipment for cleaning the syngas must include the equipment for catching a bulk of technological dust and an appliance for fine cleaning of the syngas to satisfy the requirements for a fuel gas designed for combustion in a gas turbine or in a internal combustion engine. Therefore, the appliance 45 must be two-stage.
  • the first stage is a routine electrical filter 45a which catches a bulk of technological dust containing in the syngas flow entering the conduit 44.
  • the syngas cleaned of a bulk of technological dust is directed into the cleaning appliance 45b designed for fine cleaning of the syngas.
  • the second stage is appliance 45b for fine cleaning of the syngas is performed as a hopper 61 with a conical bottom 74.
  • the hopper is supplied inside with a hermetically installed barrier 62 which is pierced by the cylindrical tubular filter elements 73 made of anisotropic ceramics. Bottom of each element 73 is hermetically welded up, the top is open.
  • the nozzles 65 for ejection impulse blow-back regeneration are installed above through the cover 64 of the hopper in such a way that each nozzle 65 are aligned along the axis of the appropriate filter element 73.
  • the unit of impulse ejection blow back regeneration of each filter elements 73 include pipeline 66, electromagnetic valve 67 with timer, controlling regeneration impulse time t p (the timer is not shown in the scheme) and with electronic control from the computer, receiver 69 with compressed syngas.
  • Manometer 68 measures pressure in the receiver 69
  • manometer 72 measures a pressure gradient between the clean and dusty chambers of the filter
  • manometer 60 measures pressure at the inlet into the cermet filter
  • the dusty syngas flow enters via the conduit 44
  • the cleaned gas flow 48 leaves the cleaning appliance said via the pipe 63
  • the bottom of the cermet filter is performed as a narrowing cone 74 for unloading of the fine technological dust 46 into the dust collector
  • This fine dust usually contains aerosols of heavy low-melting metals condensed in the recuperative heat exchanger
  • the bulk of technological dust is usually returned to the loading hopper via the pipeline 42
  • the operation of the appliance for fine cleaning of the syngas thus described is as follows
  • the dusty syngas flow enters the cleaning appliance 45a via the conduit 59, passes through the filter elements 73 which function according to sieve mechanism
  • the dust precipitated on the outer surface of the filter elements said is shaked off by an impulse of compressed syngas entering into the nozzle 65 from the receiver 69 via the electromagnetic valves
  • FIG. 5 Schematic diagram showing the appliance 49 in details designed for purification of the syngas of the toxic admixtures such as chlorine, fluorine, sulfur in the form of hydrogen chloride (HCl) and hydrogen fluoride (HF), sulfur oxides (SO 2 , SO 3 ), moreover the nitrogen oxides (NO, NO 2 ) is shown in Fig 5
  • the appliance is designed for in-line purification of the syngas of the admixtures aforesaid and for isolation of these admixtures in the form of stable chemical compounds having a commercial value
  • the appliance includes a gas blower 77, conduit 48 and two stages for fine purification of the syngas
  • the conduit 48 connects the open part of the cleaning appliance 45 with lower part of the purification appliance 49
  • the first stage designed for separation of hydrogen fluoride consists of two sorption column 78 .(78a, 78b) filled with pelletized sodium fluoride, NaF, installed in parallel operating mode of the column - sorption/desorption, one operates for sorption, another one is
  • the syngas flow 82a or 82b completely purified of HF is sent for catching other admixtures.
  • the syngas flow containing the toxic admixtures (HCl, SO 2 , SO 3 , NO, NO 2 . ) is directed into one of two absorption columns 83 (83a or 83b) filled up with suspension of calcium oxide, CaO; this suspension captures all the admixtures remained, which further are separated completely or partly owing to different solubility of calcium salts (chlorides, sulfates, sulfites and nitrates) in water.
  • Hydrogen chloride is caught practically completely in the column 83b (or 83a) in the form calcium chloride, CaCI 2 and removed from there periodically as a saturated solution 87 which is collected in the evaporator 88. Then the dried salt of CaCI 2 89 is directed into the collector 90 and to utilization 91 . Removal of sulphur oxides from the syngas flow occurs in the same absorption column 83b (or 83a) filled up with suspension of CaO and results in formation of suspension of sulphate and sulphite of calcium (CaSO 4 - CaSO 3 which are slightly soluble in water). The suspension said 84 is subjected to vaporization in the apparatus 85. The dried salt of CaSO 4 - CaSO 3 is unloaded into the hopper 85 and directed to utilization as well.
  • Syngas flow having composition, % vol.: .) CO - 37.80 - 38; CO 2) - 0.1 - 0.2; H 2 - 61 - 61.3; H 2 O - 0.3 - 0.4, CH 4l - 0.01 - 0.02 is directed, at a need, to purification of other admixtures, e.g. hydrogen - sulphide, and further to production of electrical energy into a gas turbine or to an internal energy engine
  • the present invention lends itself to the use of computer based on monitoring and control systems which provide near instantaneous control of the operation either in the arc plasma reactor 28 and in the frequency melter 29
  • FIG 2 shows a computer monitoring and control system 54 which is connected to control the arc plasmotrons 12, to power sources 37 and 36, the water pump 23, the heater 18, the drives for briquetting, transportation and feeding waste in the feeding tube 8 and other control systems for cooling, cleaning and purification of the syngas and is also connected to monitor a variety of sensors used to monitor the flow conditions in the various lines and the thermal and other conditions in the system 1
  • the control system 54 can be configured to provide automatic system operation and safety functions with a minimum of complications
  • Fig. 2 is realized as follows as applied to worn-out tires; other waste materials
  • the electrothermal treatment zone is prepared simultaneously with preparation of waste material.
  • the inner volume of the frequency melter 29 is loaded with ferrous metal scrap.
  • the walls 27 of the frequency melter 29, the arc plasma reactor 28 are cooled by running water.
  • the electrodes of the arc plasmotrons 12 are energized from the DC power sources 38, the plasmotrons are supplied with dry steam.
  • the arc operates in- noa-transferred operating mode and generate streams of steam plasma.
  • the coil 22 is energized from the frequency power source 36 resulting in heating and melting the scrap aforesaid.
  • the frequency power source operates generally in the range of 2 kHz to 13,56 MHz depending on a content of non-metallic constituents in the waste material flow.
  • the melt pool yields in the frequency melter 29.
  • Simultaneously oxygen is injected into the molten pool from below resulting in intensifying of the conversion of the waste in the molten pool said.
  • Temperature of the molten pool volume attains 2000 - 2500 C
  • temperature of the arc column is of 4000 - 6000 C
  • the average temperature of gas medium above the molten pool surrounded the arc is of 2000 - 2500 C.
  • the electrothermal treatment medium is thermodynamically opportune for predominant conversion of organic ingredients of MSW to hydrogen and carbon monoxide.
  • the briquettes falling down on melt surface are treated by the descending streams of oxygen-containing (steam) plasmas generated by DC arc plasmotrons 12.
  • Total power of the plasmotrons and the frequency melter are kept in such a way to provide expenditure of energy not less 4.1 MW-h/t. MSW, when an oxygen-containing gas is pure steam plasma.
  • MSW when an oxygen-containing gas is pure steam plasma.
  • the expenditures of energy required for reprocessing of the waste reduce proportionally.
  • Melt is collected in the frequency melter 29; on filling the said melter volume the melt overflows via the conduit 16, situated above the coil 26, into the collector of melt 19.
  • the collector 19 is supplied with additional electric heater 18 to retain the condensed products leaving the frequency melter 29 in the molten state.
  • the conduit 16 is supplied with the similar heater when there is a need.
  • Pouring off metallic and ceramic products from the frequency melter 29 is implemented through a heat valve 21 in periodical operating mode as a level of the melt attains the top.
  • the slag and the metal are subjected to routine chemical and metallurgical processing to separate, to isolate and to utilize the ceramic, salt and metallic ingredients.
  • Mineral and metallic melts are unloaded into homogenizing reactor and granulated with the use of water jets. Owing to distinct viscosity, density and surface tension the melts are separated and granulated. Under such conditions any possibility of inclusion of water into granules is precluded.
  • Mineral melt consists predominantly of oxides of silicon, aluminium, iron, sodium, manganese, chromium, calcium, magnesium. Residues of hazardous admixtures are localized in this granulite. Mineral granulite (30 - 85 kg/t. MSW) corresponds to building material requirements.
  • the main portion of the metallic granulite (46 - 75 kg/t. MSW) is low-alloyed iron (>90 %) with admixtures of copper, nickel, chromium, zinc, phosphorus, silicon. Concentration of toxic elements (thallium, cadmium, lead, mercury, arsenic) is very low.
  • Metallic granulite can be admixed to mineral granulite for building industry or used as a raw material for metallurgy and at production of simple cast irons.
  • the syngas possessing with temperature of 1700-2000 C is carried off via the pipe 40 straight-through into the recuperative heat exchanger 43 for cooling the syngas to temperature 70 - 90 C and for quenching with a rate rate not lower 10 6 C/s. to prevent recombination of dioxins, furans and their chlorinated and fluorinated derivatives.
  • Low-fusible toxic metals such as Zn, Pb, Cd, Hg are condensed in the recuperative heat exchanger 40 in the form of technological dust.
  • the dusty syngas is directed into the two-stage appliance 45 for cleaning the syngas of technological dust.
  • the syngas, cleaned of mechanical particles and aerosols, but containing toxic admixtures such as hydrogen fluoride (HF), hydrogen chloride (HCl), sulfur oxides (SO 2 , SO 3 ), the nitrogen oxides (NO, NO 2 ), is subjected to additional selective treatment in the series of apparatuses 49 designed to retain and to isolate fluorine in the form of HF, chlorine - as calcium chloride (CaCI 2 ), sulfur oxides as sulfate and sulfite, nitrogen oxide - in the form of nitrates.
  • toxic admixtures such as hydrogen fluoride (HF), hydrogen chloride (HCl), sulfur oxides (SO 2 , SO 3 ), the nitrogen oxides (NO, NO 2 )
  • HF hydrogen fluoride
  • HCl hydrogen chloride
  • SO 2 , SO 3 sulfur oxides
  • NO, NO 2 the nitrogen oxides
  • the syngas flow 39 purified of dust and hazardous admixtures, containing hydrogen, carbon monoxide, hydrocarbons etc. is directed via the pipeline 38 to utilization either into gas turbine, or into internal-combustion engine, or into boiler.
  • other admixtures e.g. hydrogen sulphide etc.
  • the syngas is directed for it to additional washing. Then, at a need, the syngas is directed to final purification on coke filter and is sent to utilization.
  • Thermoselectmaschinen in which sulfur from hydrogen sulfide is oxidized to sulfur elemental according to Sulferox Process; therewith the reactant used (the iron complex compound) is regenerated.
  • the computer is used for monitoring and control the process parameter according to technological order. Parameters of both the arc plasma reactor and the frequency melter are controlled to provide an appropriate operating mode of processing of the waste materials depending of their nature and feed.
  • a small - scale prototype of the system 1 including arc plasma reactor 28 and frequency melter 29 supplied with all the technological lines for feeding of the waste materials and unloading of the condensed and gas products has been designed and used for processing a variety of waste materials including crushed outworn vehicle and truck tires.
  • the same apparatus (Unit 1 ) shown schematically in Fig. 2 was used for treatment of crushed outworn truck tires.
  • the parameters of the said unit are exhibited below.
  • the tires contain -83 % of organic nature (gross formula C 12 H 15 ), 15 % of metal (cord), 1.35 % of sulfur and other admixture of inorganic nature (compounds of nitrogen, aluminium, calcium, silicon etc.).
  • Composition of the syngas leaving the cooling appliance is as follows (% vol.): CO -38.8; CO 2 - 0.2; H 2 - 60.97; CH 4 - 0.22; C 2 H 2 - 0.0002.
  • Composition of the syngas leaving the cooling appliance is as follows (% vol.): CO -38.8; C0 2 - 0.2; H 2 - 60.97; CH 4 - 0.22; C 2 H 2 - 0.0002.
  • the prototype system may be easily scaled up in size to accommodate a variety of waste processing rates.
  • the following operating parameters are anticipated for a large scale version of the system (Unit 2) designed for processing of the heterogeneous waste material including predominantly municipal solid waste (MSW), which contain 75 - 84 % of inorganic ingredients, 4.6 - 7.5 % of ferrous and non-ferrous metals, 3 - 8.5 % of ceramic and salt components.
  • MSW Municipal solid waste
  • Electrothermal reprocessing of waste with low content of oxygen is reinforced by injection of oxygen into the melt through metallurgical oxygen lance(s) installed in the apparatus bottom.
  • Using oxygen injection into the molten pool enables to reduce radically electrical power of surficial plasma heating.
  • a production rate of a modulus apparatus as applied to outworn tires or municipal solid waste is about 10 t/h.
  • electrical power of such apparatus must be of 41 and 14 MWt accordingly. It is a great problem to provide such powers taking into account the waste needs and a modern level of plasma technique. Especially it concerns an equipment for reprocessing of outworn tires. Therefore, it is a very actual to use additional saturation of the molten pool with oxygen through bottom and side oxygen lance(s).
  • Such technology is selected for an industrial modulus having a production capacity of 10 t/h. Using oxygen saturation of the molten pool redults in decreasing a required electrical power from 14 MWt to 6 MWt. Installed power of the power source of DC plasmotron - 1000 kW;
  • Composition of the syngas leaving the cooling appliance is as follows (% vol.): CO -38.8; C0 2 - 0.2; H 2 - 60.97; CH 4 - 0.22; C 2 H 2 - 0.0002.

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  • Oil, Petroleum & Natural Gas (AREA)
  • Organic Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
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Abstract

L'invention concerne un procédé et un dispositif servant à effectuer la destruction sur une grande échelle de pneus usés, de déchets urbains solides et de déchets médicaux au moyen d'un système présentant une étanchéité totale et basé sur la combinaison simultanée d'un arc plasmique et d'un chauffage direct par induction des déchets compactés au préalable en briquettes dans le dispositif intégré. Le retraitement électrothermique des déchets à basse teneur en oxygène est renforcé par l'injection d'oxygène dans les déchets en fusion au moyen d'une ou plusieurs lances d'oxygène métallurgique montées au fond du dispositif. L'injection d'oxygène dans les déchets en fusion permet de limiter radicalement le courant électrique nécessaire au réchauffement superficiel au plasma. Ce procédé et ce dispositif consistent, de plus, à décharger les éléments inorganiques contenus dans les déchets, à refroidir et à éteindre simultanément le gaz synthétique produit dans le système intégré de « fusion par fréquence réactionnelle plasmique », à nettoyer le gaz synthétique afin d'en supprimer la poussière technologique et de le purifier de mélanges toxiques, et à isoler ces derniers sous forme de produits chimiques possédant une valeur commerciale.
PCT/EP2002/013228 2002-11-25 2002-11-25 Procede a induction et frequence plasmique integree pour traitement de dechets, recuperation de ressources et dispositif associe WO2004048851A1 (fr)

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AU2002368399A AU2002368399A1 (en) 2002-11-25 2002-11-25 Integrated plasma-frequency induction process for waste treatment, resource recovery and apparatus for realizing same
PCT/EP2002/013228 WO2004048851A1 (fr) 2002-11-25 2002-11-25 Procede a induction et frequence plasmique integree pour traitement de dechets, recuperation de ressources et dispositif associe

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