Batch Oxidation System - International Bioenergy Conference and ...

Waste to Energy Canada, Inc.
Environmental and Socioeconomic Solutions
Batch Oxidation System (BOS)
Two-Stage Advanced Thermal Gasifier
Overview
This document and the information presented is confidential and proprietary and may not be released to third parties without the express, written consent of Waste
to Energy Canada Inc. © WTEC 2012

WTEC
• WTEC is a private Canadian based OEM with their core business and expertise in the
design and manufacturing of Patented and Proprietary Advanced Thermal Treatment of
non-Homogenous and Homogenous waste streams.
• Technology has 15 successful years of commercial deployment and technical advancement.
• WTEC is a leader in the Advanced Thermal Treatment of waste and excels at process
design and project execution, taking a holistic approach with each client.
• WTEC maintains an international presence with key strategic partners in EPC, EPCM,
Finance, and Government. Offices in BC, Alberta and UK.
• Additionally, WTEC draws on a vast network of global technology partners and specialists
which continuously provide us with up to date dialogue on technology advances and
current courses of action within the Solid Waste Treatment industry. Our modular and
scalable design platform allows us to design and deploy treatment systems that fit our
clients demands.
• WTEC has established a close relationships with our clients due to our “knowledge to
share” philosophy.
©WTEC 2012

Advanced Thermal Gasification
‣ Modular and scalable in design, centralized or decentralized.
‣ Batch or continuous.
‣ Robust, simple to operate, low O&M, low cap, long service life.
‣ Unsorted and unprocessed solid wastes are gasified by exothermic reaction at
moderate temperature under quiescent, air-starved conditions in Primary
Gasification Chambers to produce hot, energy-rich synthetic gas (“syngas”).
‣ Liquid waste fuels can be injected separately into BOS.
‣ Small amount of fuel to start process, self sustaining reaction.
‣ Heat energy in the form of hot flue gas can be recovered as process heat or
steam for industry or district heating and/or used to produce electricity, central
chilling, and/or desalinated water.
©WTEC 2012

Shortlist of Acceptable
Solid Waste Types:
‣ Municipal solid waste
‣ Wood fiber
‣ Industrial & commercial
‣ Construction & demolition
‣ Medical & pharmaceutical
‣ Tires (whole or shredded)
‣ Fish and animal remains
‣ Wastewater bio-solids (sludge)
‣ Biomass crops
‣ Hazardous waste
©WTEC 2012

©WTEC 2012

Mobile Gasification System
The mBOS is a mobile version of the sBOS.
Perfect for remote locations, rapid response, and industrial sites
©WTEC 2012

Low Impact
Low-Profile Building, Small
Site Footprint, Modest Stack
Height.
‣Site footprint 0.7 hectares (1.75
acres)
‣Building area 5400 m2(1.3
acres)
Stack Height: 20 m (65 ft)
©WTEC 2012

Monitoring Results for Dioxins & Furans at Scotland
cBOS Plant Compared to EU Limits
Independent tests show emissions at only 35% of stringent EU limits.
©WTEC 2012

First Nations
Dynamic
communities, ownership, traditions, respect, holistic
approach.
• Ahousaht
• Kelly Lake Metis Society
• Vuntut Gwitchin
• Tl’azt’en Nation
©WTEC 2012

Old Crow - Yukon

Old Crow - Yukon

Tl'azt'en Nation
• Parallel socioeconomic project development:
• Projects owned and operated by community.
• Eliminate the flow of municipal waste to the landfill via small scale BOS
• Mobile system to remediate the current landfill – training, business model,
ongoing revenue stream.
• Small scale biomass gasifier located within the community providing
centralized heating – school, administrative buildings, small scale
greenhouse.
• Large, scalable biomass gasifier located at the current sawmill location –
use of current infrastructure, scaled project starting at 5MWe to grid with a
growth potential to 20-30MW – PPA or private off-take.
• Commercial greenhouses 3-klm diet, Silva culture.
©WTEC 2012

Local and International
• UK - 9
• Poland - 5
• Ukraine -2
• Russia- 4
• South America - 6
• US - 2
• Canada – 4
Strategic Partners (capacity):
• MACE
• Costain
• Diani
• Suez/SITA
• EnergyGap
• EDC
• 2012 Olympics
• Featuring BC and Intl
projects.
©WTEC 2012

ROCs
• The RO is the main support mechanism for renewable electricity projects in
the UK. Smaller scale generation is mainly supported through the Feed-In
Tariff scheme (FITs)
• The RO came into effect in 2002 in England and Wales and in Scotland and in
2005 in Northern Ireland. It places an obligation on UK electricity suppliers to
source an increasing proportion of electricity they supply to customers from
renewable sources.
• Renewables Obligation Certificates (ROCs) are green certificates issued by the
Authority to operators of accredited renewable generating stations for the
eligible renewable electricity they generate. Operators can then trade the ROCs
with other parties, with the ROCs ultimately being used by suppliers to
demonstrate that they have met their obligation.
• Where suppliers do not have sufficient number of ROCs to meet their
obligation, they must pay an equivalent amount into a ‘buy-out’ fund. The
administration cost of the scheme is recovered from the fund and the rest is
distributed back to suppliers in proportion to the number of ROCs they
produced in respect of their individual obligation.
©WTEC 2012

Thank You
©WTEC 2012

BOS Thermal Gasification
Waste-to-Energy Process Flow Diagrams
1 st stage: Solid waste is heated under starved-air conditions in Primary
Gasification Chamber to form hot, energy rich syngas.
©WTEC 2012

BOS Thermal Gasification
Waste-to-Energy Process Flow Diagrams
2 nd stage: Syngas is drawn into the Secondary Combustion Chamber
where it burns at high temperature under excess-air conditions.
©WTEC 2012

BOS Thermal Gasification
Waste-to-Energy Process Flow Diagrams
3 rd stage: Heat Energy in fully combusted flue gas is recovered in
boiler or other heat exchanger.
©WTEC 2012

BOS Thermal Gasification
Waste-to-Energy Process Flow Diagrams
4 th stage: Steam powers turbine generator to produce electricity.
©WTEC 2012

BOS Thermal Gasification
Waste-to-Energy Process Flow Diagrams
5 th stage: Cooled flue gas is scrubbed by Best Available Technology.
©WTEC 2012

Interior of 20 Metric Ton per Day BOS Waste-to-
Energy Facility Generating Steam –Husavik Iceland
2 Primary Gasification Chambers (grey rectangles)
1 Secondary Combustion Chamber (grey cylinder)
1 heat recovery boiler (blue cylinder).
In operation since 2004 ©WTEC 2012

Primary Gasification Chambers convert solid waste into hot, energyrich
syngas by slow, undisturbed thermal decomposition under airstarved
conditions at moderate temperature (~ 450°C). Conversion
process takes 12 to 14 hours per batch. Cool down takes 6 to 8 hours.
©WTEC 2012

‣Only a few gallons fuel required to start
reaction in 65m3chamber.
‣Self-sustaining thermal reaction turns
solid waste into hot, energy-rich gases
leaving behind clean, non-toxic,
carbon-free ash.
‣ Produces no slag or clinkers.
‣ Reduces waste volume up to 97%.
‣Greatly reduces particulate matter,
heavy metals, NOx and other
pollutants.
©WTEC 2012

Hot syngas is drawn into Secondary Combustion
Chamber where excess air is added to create violent
combustion of syngas at temperatures up to 1300°C.
Retention time ≥ 2 seconds. Energy conversion efficiency
≥ 95% to the boiler.
©WTEC 2012

The BOS Waste-to-Energy Solution
‣Cleaner and more efficient than incineration.
‣Lower emissions than central power plants.
‣Eliminates Greenhouse Gases (GHGs) from landfills and
reduces GHGs from power generation and other sources.
‣No sorting or pre-processing of waste required.
‣Bottom ash is sterile, non-toxic, virtually free of carbon, and
valuable as concrete aggregate.
‣Cuts landfill waste to zero or near zero.
‣Increases recycling of glass and metals.
‣Produces clean, renewable energy for
electricity, steam, heating, cooling, and purifying water.
©WTEC 2012

BOS 2-Stage Thermal Gasification Process
• Unsorted and unprocessed solid wastes are gasified by exothermic
reaction at moderate temperature under quiescent, starved-air
conditions in Primary
• Gasification Chambers to produce hot, energy-rich synthetic gas
(“syngas”).
• Liquid wastes can be injected separately.
• Hot syngas is drawn off into Secondary Combustion Chamber
where it burns cleanly and safely under excess-air conditions at
temperatures up to 1300°C with retention time ≥ 2 seconds.
• 24-hour batch processing in each Primary Gasification Chamber.
• 4 Primary Gasification Chambers with staggered startup times
supply even, continuous energy to secondary chamber.
• Heat energy in the hot flue gas can be recovered as process heat or
steam for industry or district heating and/or used to produce
electricity, central chilling, and/or desalinated water.
• Flue gas can be cleaned further to meet any emissions limits.
©WTEC 2012

No Sorting or Pre-Processing of Waste Cuts Capital &
Operating Costs & Downtime
Loose, baled, and densified wastes can all be loaded
directly into the BOS with no sorting or preprocessing.
©WTEC 2012

Easy Batch Loading by Extension-Boom Loader or
Automatic Conveyor
15 minutes to load 15 metric tons of waste into Primary Gasification
Chamber. No more labour required for 23 hours.
©WTEC 2012

BOS Can Also Convert Liquid Wastes
Liquid wastes can be injected into
BOS to be destroyed safely while
boosting energy recovery.
Shortlist of Acceptable Liquid Wastes:
‣ Used motor oil
‣ Oil and latex paints
‣ Organic solvents
‣ Anti-freeze
‣ Transformer fluid
‣ Organic refrigerants & propellants
‣Persistent Organic Pollutants
(POPs) such as pesticides &
herbicides in liquid or solid form
©WTEC 2012

BOS Bottom Ash
Sterile.
Non-toxic.
Virtually no carbon.
Passes EPA’s “Toxicity
Characteristics Leaching
Procedure” test.
Can be sold as aggregate
for concrete and asphalt
road surfacing.
Landfilling not required.
©WTEC 2012

BOS Increases Recycling of Metals and Glass
Glass and metals
are not melted
Metals can easily
be compacted on
site for safe and
economical
transport.
Glass is also
crushed and
bagged on site.
Metal and glass can be recovered from bottom ash for
recycling. White color of ash shows it is virtually free of
carbon.
©WTEC 2012

Easy Removal of Bottom Ash
& Recyclables after Cool Down
Bottom ash together with metals and glass recovered for
recycling can be scooped out front door or removed by
automatic conveyor.
©WTEC 2012

Energy Recovery
Heat energy can be recovered in boiler (low-pressure boiler
shown above), Organic Rankine Cycle (ORC) turbine generator,
absorption chiller, or flue-gas-to-air heat exchanger.
Recovered energy can be used for industrial processes,
heating and cooling, generating electricity, and desalination.
©WTEC 2012

Research and Development
A key focal point for WTEC is R&D. We are continuously looking for ways to
further incorporate our technology into closed loop sequestering while providing
increased socioeconomic value to communities while driving out costs.
‣ Greenhouses: excess heat providing free
energy and nutrients (scrubbed C02) to
community or commercial scale
greenhouses. 100-mile diet.
‣ Photo Bioreactors:
Excess heat and scrubbed C02 for
Pharmaceutical grade Algae production.
Low capital and skilled labour options –high
revenue.
‣ Direct fire : refining options for utilizing
syngas in direct fire engines
©WTEC 2012

Indicative Energy Recovery and Electric Power
Generation
Type of Waste
Metric Tonnes of Steam/hr
per metric Tonne of Waste
Municipal 2.4 tonnes 430 kW hrs
50% Municipal
3.6 tonnes 650 kW hrs
50% Industrial
Packaging 4.7 tonnes 850 kW hrs
Tires and Industrial Plastics 9.4 tonnes 1700 kW hrs
Kilowatt hrs of Electricity
per Metric Tonne of Waste
Actual energy recovery and power generation depends on
calorific value and moisture content of waste, types of
power technology selected, their design and
configuration, and other factors.
©WTEC 2012

Clean Air Emissions
160
140
120
100
80
US ≤ 250 tpdl
US > 250 tpd
Scotland cBOS 200
tpd
60
40
20
0
PM
mg/dscm
HCl
ppmdv
NO2
ppmdv
SO2
ppmdv
CO
ppmv
BOS emissions pass all EPA tests in US & European.
BOS waste-to-energy facilities can be designed to achieve
even lower emissions that those shown here.
©WTEC 2012

Example of Design Basis for Emissions at New
Scotland cBOS Facility Compared to EU Limits
Substance
BOS
Design Basis
Maximum Limits
EU Regulations
Particulate Matter (PM) < 5 mg / Nm 3 10 mg / Nm 3
Nitrogen Oxides (NO x ) < 90 mg / Nm 3 200 mg / Nm 3
Carbon Monoxide (CO) < 8 mg / Nm 3 50 mg / Nm 3
Sulphur Dioxide (SO 2 ) < 10 mg / Nm 3 50 mg / Nm 3
Total Organic Carbon (TOC) < 2 mg / Nm 3 10 mg / Nm 3
Hydrogen Chloride (HCl) < 3 mg / Nm 3 10 mg / Nm 3
Dioxin & Furans < 0,08 ng / Nm 3 0,10 ng / Nm 3
BOS plants can also be designed to achieve even lower emissions.
©WTEC 2012

Monitoring Results for Dioxins & Furans at Scotland
cBOS Plant Compared to EU Limits
Independent tests show emissions at only 35% of stringent EU limits.
©WTEC 2012

Flue Gas Treatment System
Inherently low BOS emissions are further
reduced by advanced treatment of flue gases:
View of stack with BOS
operating at full capacity
Flue gas retention time ≥2
sec at temps up to 1300°C.
Sodium bicarbonate to
neutralize acids.
Activated carbon to remove
trace dioxins, furans, and
heavy metals.
Flue gas recirculation and
selective non-catalytic
reduction (SNCR) to control
NOx.
Filter bag-house to collect
scrubber consumables and
residual fly ash.
©WTEC 2012

Continuous BOS (cBOS)Configuration for Continuous
Power Generation
cBOS Process Train with Four
Primary Gasification Chambers
Feeding One Secondary
Combustion Chamber Provides
Even, Continuous Supply of
Energy
Start-up times of the four Primary Gasification Chambers in each
process train are staggered by six hours. This start-up schedule
together with the large capacity of each Primary Gasification
Chamber, the slow gasification of wastes at moderate
temperature, and WTEC’s proprietary control system ensures that
batch processing of a mixed and variable waste stream results in
production of an even, continuous supply of energy to the power train.
©WTEC 2012

Automated cBOS Process Controls
‣Operator interface by touch-screen controls.
‣SCADA (Supervisory Control & Data Acquisition)data
logging capability.
‣Real-time remote monitoring by WTEC technical
staff.
©WTEC 2012

Functionally Independent cBOS Process Trains
Can Be Added to Achieve Desired Capacity
Standard cBOS process train with 4 Primary
Gasification Chambers converts 246 m3 of solid waste.
©WTEC 2012

Layout of Waste-to-Energy Facility with Three
cBOS Process Trains
180 metric tons per day waste-to-energy facility. First
two process trains (left) recently commissioned in
Scotland. Plant can produce up to 9 MW electricity.
©WTEC 2012

Interior of cBOS Waste-to-Energy Facility with
Two Process Trains Installed
Shown during commissioning in Scotland, October 2009.
Addition of third cBOS process train scheduled for 2010.
©WTEC 2012

Advantages of Modular cBOS Plant Design
Modules are pre-fabricated and tested at the factory, which
cuts costs, ensures quality, and speeds installation on site.
Capacity can be added or taken off line as needed.
Cuts initial and life-cycle capital costs because plant can be
built for near-term rather than long-term capacity needs.
Cuts risk of incorrectly forecasting waste and recycling
volumes.
Cuts down time because maintenance and repair on one
module does not affect operation of other modules.
One or more cBOS process trains can be paired with each
functionally independent power train to provide full
redundancy.
Allows cost-effective waste processing and power generation
even at small capacities.
©WTEC 2012

cBOS Allows
De-Centralized Waste
Processing &
Distributed Power
Generation
Cuts costs and environment effects of waste hauling.
Cuts or eliminates capital & operating costs of transfer stations.
Allows communities to take responsibility for their own waste.
Co-locate waste-to-energy plant at site of end user.
No power distribution costs or line losses.
©WTEC 2012

Small BOS (sBOS) with Single Primary Gasification
Chamber
The sBOS was developed over 15 years ago.
Many sBOS installed in North America, South Pacific and the Caribbean.
Energy can be recovered for 8 to 10 hours per day.
©WTEC 2012

Mobile (mBOS) with Single Primary Gasification
Chamber
The mBOS is a mobile version of the sBOS.
Perfect for remote camps, rapid response, and industrial sites
©WTEC 2012

Touch-Screen Control Panel
sBOS have automatic controls with manual override that operators
can monitor or adjust using the simple touch-screen control panel.
©WTEC 2012

BOS can be designed to manage specialized waste
Ronald Reagan Ballistic Missile Defence Test Site, Kwajalein Atoll.
Plant is raised to enable ash removal from bottom.
©WTEC 2012

Skid-Mounted sBOS
sBOS starting at from 1.0MTPD can be skid-mounted
for easy delivery and installation.
©WTEC 2012

sBOS Treating Complete Waste Stream at Remote Industrial Sites
One of two 3.5 metric ton per day sBOS destroying industrial and municipal
waste at a remote oil company site in Alaska, in operation since 1999. Note
automatic waste feed conveyor at right.
©WTEC 2012

All BOS Achieve Complete Destruction of Medical Waste
1.0 ton sBOS processing medical waste in Cayman
Islands, 1999.All BOS achieve complete destruction of
waste in regulatory terms.
©WTEC 2012

Potential BOS Revenue Streams
Disposal or “tipping” fees.
Electricity.
Process heat to industry.
Process steam to industry.
Low-pressure steam for district heating.
Chilled water or air for central cooling.
Desalinated water.
Scrap metal recovered from bottom ash.
Bottom ash sold for concrete aggregate.
Carbon credits.
Renewable energy credits.
Renewable energy grants and tax credits.
©WTEC 2012

Summary of BOS Financial and Environmental
Advantages
Low capital cost.
Low labour, fuel, and other operating costs.
Very low air emissions.
Cuts Greenhouse Gases.
Sterile, non-toxic, low-volume bottom ash.
No sanitary landfill required for bottom ash.
Increase recovery of metals and glass for recycling.
Small site footprint and low stack height.
Building looks much like ordinary warehouse.
De-centralized waste processing cuts financial and
environmental costs of waste hauling and transfer stations.
De-centralized waste processing allows communities
to take responsibility for their own waste.
©WTEC 2012

Summary of BOS Design and Operating Advantages
Proven technology with commercial plants built & operating.
Simple, robust design with very few moving parts.
High facility availability factor.
Processes a wide range of solid and liquid wastes.
No sorting or pre-processing of solid waste required.
High efficiency of energy conversion.
Produces no slag or clinkers.
Very low use of auxiliary fuel.
No intermediate step of cleaning and storing syngas or RDF.
Computerized controls and real-time remote monitoring.
Functionally independent process trains.
Process trains can be added to achieve optimum capacity.
Low costs and modular design allow de-centralized
Waste processing and distributed power generation.
©WTEC 2012

Recent Customers
US Air Force, Wake Island –Municipal Solid Waste, Tires and
Waste Oil –sBOS.
Scotgen Ltd, Scotland –Municipal and Industrial Waste –
cBOS.
US Department of Defence, Kwajalein Atoll, Marshall Islands
–Municipal and Industrial Waste –cBOS.
Husavik, Iceland –Municipal Solid Waste and Tires –cBOS.
Cayman Islands –Medical Waste –sBOS.
Egigik, Alaska –Municipal Solid Waste –sBOS.
Gudang, Indonesia –Agricultural Waste –COR.
Crow Business Services, Australia –Wood Waste –COR.
©WTEC 2012