ENERGYRECOVERY

TECHNOLOGY[(ERT)

Private LimitedEQUIPMENTINDUSTRIALINNOVATIVE

502,5 floor,GotmareMarket,WHC Road,Dharampeth,Nagpur-440010,Tel:917122558318,Fax:917122550277,Email:r avinafde iieindia.com,Web:www.iieindia.tradeindia.comth . . .

Energy RecoveryTechnologyA Review

Planned and produced by :Innovative Industrial Equipment Pvt. Ltd.,502, 5 Floor Gotmare Market, Laxmi BhavanSquare,Dharampeth, Nagpur - 440 010, India.Copywrite c IIE India,2008.

th

All rights Reserved. No part of this book may be reporduced

in any form or by any means without permission in writingfrom the publisher.

Front Cover :5 tpd plant for recovery of Energy from nonrecyclable Waste Plastics.Conceptualised, Designed & Commissioned byInnovative Industrial Equipment, Nagpur, India.

1930 Mahatma Gandhi in his pursuit for freedomestablished an ashram in a remote village, inthe central India called SEVAGRAM.

Sevagram had no electricity but India'selite would make their way in the dark to talkwith Mahatma Gandhi about the bright future.

Early2008

However, with India's economy growing ataround 10% a year, the staggering financialoutlay needed for the energy sector across thecountry to maintain such a growth pattern hasprompted significant reforms.

16 -17October

2008

th th Energy Recovery Technology ERT[ ].A truly sustainable waste management solution,diverting waste plastics from MSW & BMW wasdemonstrated at [

], Dehradoon on therequest from [

].

UREDA Uttara Khand RenewableEnergy Development Agency

Hiltron A State GovernmentOrganisation

22 -24October

2008

forevaluation as anprocess systems of disposal

nd th Energy Recovery Technology ERT

SGPGI Sanjay Gandhi PostGraduation Institute, Lucknow UPPCB UttarPradesh Pollution Control Board

[ ].A truly sustainable BMW management solution, wasdemonstrated to [

] and [],

, environmentally friendlythan conventional .

16 -20Dec

th th

2008

Energy Recovery Technology ERT

DST Department of Science &Technology

[ ] is atruly sustainable waste management solution,diverting plastic waste from MSW & BMW wasdemonstrated to [

] at MES, Vasco, Goa.

2009 Two tERT Plant for MSW &are proposed by Hiltron at Uttar Khand,

based on the technology and know-how from IIEPL.

wo ERT Plants forBMW

One ERT Plant for BMW at SGPGI Hospital isproposed under the advice of UPPCB, Lucknow.

One ERT Plant for BMW at GMC [GovernmentMedical College] Bimbolin, Goa is advocated byGEDA [Goa Energy Development Agency]

Three ERT Plant are proposed in DPR forforth coming financial year at Goa.

The amount of energy that can be recoveredfrom waste depends upon the type of waste, themoisture content, and the caloric (BTU) value.For example, a 400 ton per day system utilizingMSW is capable of producing approximately 6 or10 mega watts of electricity.

1990 to liberate Rural IndiaOur concernstarted way back in the year 1991, when westarted exploring the wonderful Energy EfficientMaterial BAMBOO and developed a range productsof commercial applications.

2000 We further focused goal to develop thesystem and infrastructure required forgenerating energy from waste and specificallyform post consumer plastics gained result.

5 -7March2003

Trials and test runs on the mixed varietyof Waste Plastics were tested by Indian OilLimited at their Faridabad R & D Center.

thth

9March2003

UNI reported an exciting development fromNagpur. uel hydrocarbons locked inplastics. It is just rearranging a few bondswhich ultimately results in the conversion ofplastic waste into energy. ne kg ofplastic was converted into fuelwithin three and a half hours.

th

F from

O WasteHydrocarbon

June2003

Trials and test runs on the variety ofmixed and hazardous Waste Plastics were testedby Indian Oil Limited at their Faridabad R & DCenter.

2004 India's first ever Waste Plastic to energyplant was designed by IIE under closesupervision of IOL R&D.

2005.

India's first ever Waste Plastics toenergy plant was commissioned by IIE

2007R

y.

Sixty two years after gainingindependence, only 30% of ural Indianhouseholds have access to sustained electricitysuppl

INDEX1 Introduction 05

2 Benefits of plastics 06

3 Loss of Resources 07

4 Damage to Environment 08

5 Oil Fuels modern world 08

6 Plastics 10

7 Waste Plastics Disposal 11

8 Bio Medical Waste [BMW] 12

9 BMW Treatment 13

10 ERT Process 14

11 Plant Specifications 15

12 Operations 16

13 Process Specifications 17

14 Process Diagrams & Graph 18

15 Waste to Energy 19

16 Energy Recovery 16

17 Fuel Overview 21

18 Typical Analysis 22

19 Certified Usage 24

20 Photographs 25

01 INTRODUCTION

Energy is life.Generating energyfrom waste Plastics is a greatpromise.

Our concern for environment started out

ur effortsbear fruit and we realised the potential shiftedto develop the system and infrastructure required forgenerating energy from waste plastic [post consumerplastics/non recyclable plastics].

here are about 50 different groups ofplastics, with hundreds of different varieties. Alltypes of plastic are recyclable. To make sorting andthus recycling easier, the American Society ofPlastics Industry developed a standard marking code tohelp consumers identify and sort the main types ofplastic. These types and their most common uses are[Table 1]:

wayback in the year 1991, when we started exploring thewonder material Bamboo the energy efficient materialand developed a range products of commercialapplications. The concept further extended toeliminate the waste and recover energy. O

. We

s

T

The world's annual consumption of plasticmaterials has increased from around 5 million tones inthe 1950s to nearly 100 million tones today. Packagingrepresents the largest single sector of plastics use.The sector accounts for 35% of plastics consumptionand plastic is the material of choice in nearly half ofall packaged goods.

Awisemansometimesaid`therearetwowaystostudy

chasethem with nets theninspecttheirdeadbodies,

Sit quietlyinagardenandwatchthemdanceamongtheflowers,

we selectedthesecond.

without hazel

BUTTERFLIES:

OR

We RECOVER ENERGY FROMWASTE

PET Polyethylene terephthalate - Fizzy drink bottles and oven-ready meal trays.

HDPE High-density polyethylene - Bottles for milk and washing-up liquids.

PVCPolyvinyl chloride - Food trays, cling film, bottles for squash, mineralwater and shampoo.

LDPE Low density polyethylene - Carrier bags and bin liners.

PP Polypropylene - Margarine tubs, microwaveable meal trays.

PSPolystyrene - Yoghurt pots, foam meat or fish trays, hamburger boxes and eggcartons, vending cups, plastic cutlery, protective packaging for electronicgoods and toys.

OTHERAny other plastics that do not fall into any of the above categories. - Anexample is melamine, which is often used in plastic plates and cups. 5

,

,

The considerable growth in plastic use is dueto the beneficial properties of plastics. Theseinclude:

Extreme versatility and ability to betailored to meet very specific technicalneeds.Lighter weight than competing materials,reducing fuel consumption duringtransportation.Extreme durability.Resistance to chemicals, water and impact.xcellent thermal and electrical insulationproperties.Good safety and hygiene properties for foodpackaging. xcellent thermal and electricalinsulation properties.Relatively inexpensive to produce.

Source : Analysis ofhousehold waste composition and factors drivingwaste increases

The amount of plastic waste generated

annually in the UK is estimated to be nearly 3million tones. An estimated 56% of all plasticswaste is used packaging, three-quarters of whichis from households. It is estimated that only 7%of total plastic waste arising are currently beingrecycled. The production and use of plastics has arange of environmental impacts. Firstly, plasticsproduction requires significant quantities ofresources, primarily fossil fuels, both as a rawmaterial and to deliver energy for themanufacturing process. It is estimated that 4% ofthe world's annual oil production is used as afeedstock for plastics production and anadditional 3-4% during manufacture.

reduction of energy consumption by two-thirdsproduction of only a third of the sulphurdioxide and half of the nitrous oxidereduction of water usage by nearly 90%reduction of carbon dioxide generation bytwo-and-a-half times.

S

S

SS

S

S

[

]

•

•

? ,•

E

E

Plastics makes up around 7% of theaverage household dustbin.

A report on the production of carrier bagsmade from recycled rather than virgin polytheneconcluded that the use of recycled plasticresulted in the following environmental benefits:

02 B E N E F I T S O FPLASTICS

6

Many everyday consumer items now containelectronic parts. Every year an estimated 1 milliontones of waste electronic and electrical equipment(WEEE) are discarded by householders and commercialgroups in the UK. Dealing with this waste is animportant issue as electronic goods are becomingincreasingly short lived, and so ever increasingquantities of obsolete and broken equipment arethrown away. Electronic and electrical equipmentmakes up on average 4% of European municipal waste,and is growing three times faster than any othermunicipal waste stream.

Electrical waste includes digital watches,fridges, TVs, computers and toys. Not only is thiswaste stream disparate in function but in additionthe materials of which they are comprised varyconsiderably. For example an average TV contains 6%metal and 50% glass whereas a cooker is 89% metal andonly 6% glass. Other materials used includeplastics, ceramics and precious metals. The complexarray of product types and materials make wasteelectrical and electronic equipment difficult tomanage.

The main component of waste electronicequipment is large household appliances known aswhite goods, which make up 43% of the total. The nextlargest component is IT equipment which accounts for39%. Much of this is made up of computers, whichrapidly become obsolete. Televisions also representa large proportion, with an estimated 2 million TVsets being discarded each year.

The disposal of electronic and electricalappliances in landfill sites or through incinerationcreates a number of environmental problems.

When obsolete materials are not recycled, rawmaterials have to be processed to make new products.This represents a significant loss of resources asthe energy, transport and environmental damagecaused by these processes is large.

In 1998 it was estimated that of the 6 milliontones of electrical equipment waste arising inEurope the potential loss of resources was

2.4 million tones of ferrous metal1.2 million tones of plastic652,000 tones of copper336,000 tones of aluminum336,000 tones of glass

This was in addition to the loss of heavymetals, lead, mercury, flame retardants and more.The production of these raw materials and the goodsmade from them entails environmental damage throughmining, transport, water and energy use. Forexample, according to a recent UN study, themanufacture of a new computer and monitor uses 240kgof fossil fuels, 22kg of chemicals and 1500 liters ofwater. Similar quantities of materials are used inthe manufacture of an average car. The nature of manyof these materials is such that they can be recycledwith relative ease preventing the waste associatedwith producing new raw materials.

?????

03 Loss of RESOURCES

7

04 DAMAGE TO THEENVIRONMENT 05 OIL FUELS THE

MODERN WORLD.Another major problem is the toxic nature of

many of the substances, including arsenic, bromine,cadmium, halogenated flame retardant, hydrochlorofluorocarbons (HCFCs), lead, mercury andPCBs.

The estimated number of fridges and freezersbeing disposed in the UK is 3 million units annually.These units contain gases such asc h l o r o f l u o r o c a r b o n s ( C F C s ) a n dhydrochlorofluorocarbons (HCFCs) used for thecoolant and insulation. Both CFCs and HCFCs aregreenhouse gases which when emitted into theatmosphere, contribute to climate change.

Fluorescent lighting contains potentiallyharmful substances such as highly toxic heavymetals, in particular mercury, cadmium and lead. Ifthey enter the body, these substances can causedamage to the liver, kidneys and the brain. Mercuryis also a neurotoxin and has the potential to buildup in the food chain. The mercury content is the mainconcern with fluorescent lighting. A four-foot longfluorescent tube may contain over 30 milligrams ofmercury. The EC permissible limit for mercury indrinking water is 1 part per billion, equivalent to0.001mg a litre.

According to a survey by consultancy ERATechnology, electrical equipment manufacturers arereacting "very slowly" to a legal requirement toremove lead from their products; most of thecompanies have no planned date for completing theswitch to lead-free technologies.

Finding suitable landfill sites is alsobecoming an increasing problem, where largequantities of electronic waste arise. New rules inforce call for the cessation of co-disposal ofhazardous and non-hazardous wastes.

It brought great changes to economies andlifestyles in a short span of time. Nothing else todate can equal the enormous impact which the use ofoil has had on people, so rapidly, and in so many waysaround the world. With global oil prices shooting up,there is all-round fear that petrol and diesel priceswill go up and the subsidy burden for kerosene andLPG will swell. With crude touching an all-time high$70 a barrel, fears are mounting over inflation.

The speed at which the human race is usingenergy resources has become a serious issue. Not onlyare these energy resources being depleted at analarming rate, but they are also causing some severe

damage to the environment.

Rapid growth of industry has increased thedemand for crude which is presently being imported.70 per cent of India's oil requirement is met byimports; the oil bill constitutes more than onefourth of total country's import; oil is the secondbiggest conventional energy and world prices areunlikely to drop significantly; and the country'sproduction of crude has remained stagnant at 32-33million tones.

Most types of fuel reserves were formedmillions of years ago by the natural decomposition oftrees and other plant material. On land, thecombination of heat and pressure slowly changed theplant matter into coal. Natural gases and petroleumwere also formed in a similar way but in the ocean. As8

you can see we are exhausting these resources farfaster than they are being restored, and if wecontinue this practice, the earth will be completelystripped of all of its life-giving properties.

Oil is a unique energy source that has nocomplete replacement in all its varied end uses. TheBritish scientist Sir Crispin Tickell concludes,"...we have done remarkably little to reduce ourdependence on a fuel [oil] which is a limitedresource, and for which there is no comprehensivesubstitute in prospect."

Coming to realize that oil is finite, any andall suggestions of means to replace oil are welcomed.Cheerful myths are enthusiastically embraced. Theseinclude: that dams and their reservoirs are a sourceof indefinitely renewable energy and that they areenvironmentally benign; that solar, wind, geothermal,and hydro-electric power can supply the electricalneeds, from the Arctic to the tropics, of the Earth'snearly six billion people (likely to become at least10 billion in the next fifty years); that coal, oilfrom oil sands, and biofuels can replace the 72million barrels of oil the world now uses daily; andthat somehow electricity produced from variousalternative energy sources can readily provide thegreat mobility which oil now gives to the more than 600million vehicles worldwide. Regrettably, none ofthese cheerful myths appear to be valid.

The reality appears to be that the world israpidly running out of a resource that in many ways isirreplaceable. The result will be a great change ineconomies, social structures, and lifestyles. We willsoon exhaust this capital, and we will have to go towork to try to live on current energy income. It willnot be a simple easy transition.

Oil is a finite resource. Life will go on, butin a different paradigm. Oil will be sorely missed.Alternative energy is useable energy from any sourceother than by involving the burning of fossil fuels(natural gas, coal and oil) or the splitting of atoms(nuclear power). It includes renewable energy (hydro,geothermal, biomass and wind) as well as solar energy.Alternative energy is very important today since theaverage consumption of electricity is increasing invirtually every country in the world.

Plastics for the most part are derived frompetroleum and natural gas and have heating valuesmeasured in British thermal units (Btu) competitivewith coal and heating oil and superior to wood, paper,

and other biomass fuels. Because of their high heatingvalue, the residual plastics in MSW provide anexcellent fuel for waste-to-energy plants. Residualplastics mean those plastics that remain in MSW aftersome plastic is diverted from MSW for environmentallyand economically sound material recovery. Even incommunities with extensive recycling, residualplastics at less than 10 percent by weight of MSW canprovide over 20 percent of the fuel value for a localWTE plant.

Detailed study has recently documented theability of plastics to improve combustion in a modernWTE plant. The study also looked at the contributionof plastics to air emissions. This was done byintentionally adding plastics to the regular MSW feedto the plant and carefully monitoring the release ofpollutants. Plastics were shown to have negativeeffect on air pollution loads to the environment. Thestudy included a specific examination of and

emissions, this means that the danger to theozone layer from green house gases will continue torise, if alternative energy cannot keep pace.

Indeed, many people remain concerned about thepotential for WTE plants to negatively impact airquality and increased recycling. For these reasons,along with the relatively low landfill tipping feesthat exist in many parts of the U.S., WTE is notgrowing.

dioxinfuran

9

06 PLASTICS

A plastic is a type of synthetic or man-madepolymer; similar in many ways to natural resins foundin plants and trees. Their usage over the past centuryhas enabled society to make huge technologicaladvances. The first man-made plastic was unveiled byAlexander Parkes at the 1862 Great InternationalExhibition in London. Parkes claimed that this newmaterial could do anything that rubber was capable of,yet at a lower price. He had discovered a material thatcould be transparent as well as carvedinto thousands of different shapes.

In 1907, Leo HendrikBaekland, stumbled upon the formulafor a new synthetic polymeroriginating from coal tarsubsequently named "bakelite". By1909, Baekland had coined "plastics"as the term to describe thiscompletely new category ofmaterials.

Plastics did not really takeoff until after the First World War,with the use of petroleum, asubstance easier to process thancoal into raw materials. Plasticsserved as substitutes for wood,glass and metal during the hardshiptimes of World Wars I & II. Plasticshad thus come to be considered'common' - a symbol of the consumersociety. Since the 1970's, we havewitnessed the advent of 'high-tech'plastics used in demanding fieldssuch as health and technology. Newtypes and forms of plastics with newo r i m p r o v e d p e r f o r m a n c echaracteristics continue to bedeveloped.

From daily tasks to our most unusual needs,plastics have increasingly provided the performancecharacteristics that fulfill consumer needs at alllevels. Plastics are used in such a wide range ofapplications because they are uniquely capable ofoffering many different properties that offerconsumer benefits unsurpassed by other materials.

They are also unique in that their properties may becustomized for each individual end use application.

Waste plastic problem is an ever-increasingmenace for global environment. Because offlexibility, durability and economy, a phenomenalrise is observed in the plastic consumer base.Throughout the world, research on waste plasticmanagement is being carried out at war-footing. Indeveloped countries, few waste plastic disposal /conversion methods have been implemented but are notefficient and economically feasible.

Plastics being non biodegradableget accumulated in the environment. Ifthis problem is not addressed properly,it will lead to mountains of wasteplastic. Environment protection AgencyU.K. estimates that by the year 2005 theamount of waste plastic throw will be65% more than that in year 1997.

In the manufacture of PVC,common salt is added to the oil-basedfeedstock to provide the chlorineelement in the long chain polymer. It isthis chlorine element that may causetoxic dioxins and furans to be produced,when PVC is burnt. Without the chlorinethere would be no dioxins or furansemissions. These two are the most toxicchemicals known to humans and can causea variety of serious health problemsincluding damage to the reproductivesystem, the immune system and cancer. Asfar as possible PVC plastics shouldtherefore not be burnt.

A penchant for wrappingeverything in plastic and then burningthe rubbish indiscriminately has turnedJapan into the dioxin centre of the

world. Dioxins, a highly toxic group of chemicalsthat are known to cause birth defects, skin diseaseand cancer, are produced when polyvinyl chloride(PVC) and other plastic waste is burned attemperatures below 700 degrees Celsius. So toxic isdioxin that a dose no bigger than a single grain ofsalt can kill a man.

10

07 WASTE PLASTICSDISPOSAL

EU focus on waste management EuropeanCommission, Directorate-General Environment,Nuclear Safety and Civil Protection discloses thefollowing key facts about the European wastesituation [Table 2].

Land Fill Composting Incineration Recycling Transportation Energy Recovery

AirEmission of CH4,CO2; odours

Emission of CH4,CO2 ; odours

Emission of SO2 ,NOx, HCl, HF,NMVOC, CO, CO2

N2O, dioxins,dibenzofurans,heavy metals(Zn,Pb, Cu, As)

Emissions of dust

Emissions of dustNOx, SO2, releaseof hazardoussubstances fromaccidental spills

No Emissions underthe controlledreaction conditions.Emission normsacceptable to CPCB& MPCB.

Water

Leaching of salts,heavy metals,biodegradableand persistentorganics togroundwater

Deposition ofhazardoussubstances onsurface water

Wastewaterdischarges

Risk of surfacewater andgroundwatercontaminationfrom accidentalspills

Water is not aprocess component.It is only a coolingmedia which can beoptionally replacedby compressed air.

SoilAccumulation ofhazardoussubstances in soil

Land filling of slag,fly ash and scrap

Land fillingof finalresidues

Risk of soilcontaminationfrom accidentalspills

The bulk material isconverted in the fueland hence no sideeffects to the soil.

LandscapeSoil occupancy;restriction onother land uses

Soil occupancy;restriction onother land uses

Visual intrusion;restriction onother land uses

Visualintrusion

Traffic The landscape is notdamaged.

EcosystemContamination andaccumulation oftoxic substances inthe food chain

Contamination andaccumulation oftoxic substances inthe food chain

Contamination andaccumulation oftoxic substances inthe food chain

Risk ofcontaminationfrom accidentalspills

Totally safe for ecosystem. Nocontaminantsreleased toenvironment.

UrbanArea

Exposure tohazardoussubstances

Exposure tohazardoussubstances

Noise

Risk of exposureto hazardoussubstances fromaccidental spills;traffic

The plants can beinstalled in the urbanarea withoutdisturbance.

11

08 PLASTICS IN BIO-MEDICAL WASTE

EU focus on waste management EuropeanCommission, Directorate-General Environment,Nuclear Safety and Civil Protection discloses thefollowing key facts about the European wastesituation & Bio Medical Waste [Table 3]

Bio-medical Waste Treatment Facility can bean added feature where bio-medical waste generationfrom a number of healthcare units, is impartednecessary pre treatment to reduce adverse effectsthat this waste may pose. The treated waste mayfinally be sent for recovery of energy in the ERTprocess. Installation of individual treatmentfacilities by small healthcare units requires

comparatively high capital investment. In addition,it requires separate manpower and infrastructuredevelopment for proper operation and maintenance oftreatment systems.

The concept of BMW integrated with the non recyclablePlastic Waste not only addresses such problems butalso prevents proliferation of treatment equipment ina city. In turn it reduces the monitoring pressure onregulatory agencies. By running the treatmentequipment at to its full capacity where theavailability is low due to land character, density ofhabitation, life style, Medical facility, etc.. Thecost of treatment of per kilogram gets significantlyreduced. Its considerable advantages have made BMWpopular and proven concept in many developedcountries

S N Waste Category Disposal Method

1. Plastic wastes after disinfection and shredding Recycling or municipal landfill

2. Disinfected Sharps (except syringes)

(i) If encapsulated Municipal landfill

(ii) If non-encapsulated Municipal landfill/ Possibility of recycling shall be explored

3. Incineration ash Secured landfill

4. Other treated solid wastes Municipal landfill

5. Oil & grease Incineration

6. Treated waste water Sewer/drain or recycling

12

09 BMW INCINERATION

Medical waste incineration is a Major Sourceof Dioxins and Many Other Air Pollutants. U.S. EPA'sdioxins emissions inventory estimated that medicalwaste incineration was the nation's third largestdioxins source, emitting 15% of all the dioxins onthe national inventory. The prevalence of chlorine-containing polyvinyl chloride (PVC) plasticproducts in medical waste is one contributor todioxins formationstudies show that increasing theamount of chlorine or chlorine-containing PVC in a

particular combustor (like a specific medical wasteincinerator) increases its dioxins emissions.

Medical waste incineration releases manyother air pollutants that are problems for humanhealth, like mercury, carbon monoxide, nitrogenoxides, sulfur oxides, hydrogen chloride, fineparticulate matter, polycyclic aromatichydrocarbons, cadmium, and lead.

Advantages and Disadvantages of CommonMedical waste Treatment Systems [Table 4]

Type Factors Advantages Disadvantages

Incineration

Turbulence and mixingMoisture content of wasteFilling combustion chamberTemperature and residence timeMaintenance and repair

Volume and weightReductionUnrecognizable waste Acceptablefor all waste typesHeat recovery potential for largesystems

Public oppositionHigh investment & operation costsHigh maintenance costSignificant air pollutants requiring expensive controlequipmentBottom and fly ash may be hazardous

Steam Autoclave

Temperature & pressureSteam penetrationSize of waste loadLength of treatment cyclesChamber air removed

Low investment costLow operating costEase of biological testsLow hazard residue

Appearance, volume unchanged a

Not suitable for all waste typesPossible air emissionsErgonomic concerns

Microwave

Waste characteristicsMoisture content of wasteMicrowave strengthDuration of exposureExtent of waste mixture

Unrecognizable wasteSignificant volume reductionAbsence of liquid discharge

Mod -High investment costNot suitable for all waste typesPossible air emissions

Mechanical/Chemical

Concerns for chemicals,temperature,pH Chemical contact time Waste &chemical mixing Recirculation vsflow-through

Significant volumereductionUnrecognizable wasteRapid processingWaste deodorization

High investment costNot suitable- all waste typesPossible Air emissionsNeed for chemical storageErgonomic concerns

Plasma /Pyrolysis

Waste characteristicsTemperatureLength of treatment cycle

Almost no waste remainsUnrecognizable wasteHeat recovery potential

Novel technology b

Air emissions must be treatedSkilled operator needed

ERTWaste characteristicsTemperatureLength of treatment cycle

Almost no waste remainsUnrecognizable wasteHeat recovery potential

Novel technology c

Air emissions must be treatedSkilled operator needed

A Autoclaveincorporatemacerationorshreddingduringthe treatment processthatresultsinavolumereductionofupto80%aswellasanunrecognizablewaste stream.

b Twotechnologieshave demonstratedthecapabilitytotreatpathologicalwaste.

13

10 ERT PROCESS

The subject system is designed indigenouslyhaving modular process units for providingflexibility in operations, production &maintenance. The process is flexible enough todesign the end products on-line without a break inthe continuity of process. The process is designedfor the Waste Plastic sourced from the MunicipalWaste stream with a factor of variation at 5.0 % to20.0 % for normal feed. The process is also suitablefor a dedicated feed if required with initial testingand trial. The process modules, which house theequipment, components, sensors, piping, valves &controls are designed as follows [Table 5]

PARTICULARS DESCRIPTION VOLUME (lXbXh m)

01 Pre- Feed Sizing, Grading Cleaning and Storing in day-bin, 3.0X35.0X10.002 Feed Conveying from Day-Bin, Feeding & Heating, 3.0X7.5X9.003 Melting Melting & separating non plastic solids coke etc., 3.0X7.5X9.004 Reactor Reacting plastic with catalytic additive, 3.0X7.5X8.005 Final Product Separating and collecting liquid and gaseous hydrocarbons, 3.0X7.5X7.006 Instrumentation Process controls, date acquisition etc., 4.5X9.0X3.5

14

11 PLANT SPECIFICATIONS

Operating Ranges of the Plant [Table 6] -

SECTIONS DESCRIPTION RANGE UNIT

A Pre Feed Section Energy [Ele]Temperature

1530 – 35

kW0C

B Feed SectionEnergy [Ele]HeaterTemperature

5.58175- 200

kWkW0C

C Melting VesselHeater [Ele]Geared MotorTemperature

150.5250 - 300

kWkW0C

D Reactor VesselHeater [Ele]Geared MotorTemperature

150.5350 - 450

kWkW0C

E Vapor Density Flow Rate 4004.0 – 5.0 Kg/hr kg/m3

F Feed Rate 420 – 450 Kg/hr

Mixed W aste Plastic of Bulk density 0.3 – 0.4 kg/m3

HDPELDPEPP

55 – 60 %

PVCPET

10 – 15 %

Polyester 10 – 15 %

G Feed Type

ABS & Others 10 – 15 %

H Calcium Hydroxide[optional]

Feed RateFeed Ratio

0 – 201 : 175

kg/hr

I Additive Feed RateFeed Ratio

2.0 – 2.51 : 200

kg/hr

15

12 OPERATIONS[Table 7]

16

SECTIONS UNITA Pre Feed Section 0C

B Feed Section 0C

C Melting Vessel 0C

D Reactor 0C

E Normal System Pressure kg/cm2

F Calcium Hydroxide Flow Rate kg/hr

G Additive Flow Rate kg/hr

13 PROCESSSPECIFICATIONS

PRE FEED SYSTEMThis process of sizing, grading and cleaning

the waste is manual and semi mechanized. The machinesare charged with the waste manually which iscollected and transferred to the storage / day binfor feeding the vessels [Table 8].

FEED SECTIONThis Auto/manual section consists of the

Feeding Hopper, Pre-melting feeder, Cooling Waterjackets, Pressure gauges, Temperature sensors,outlets & gaseous vents, etc. The mixed waste plasticfrom the day bin is fed into the pre melting Feederand then charged in the melting vessel. The solidmetal, glass etc. is removed from the melting sectioncontinuously after the charging is over [Table 9].

SECTION PARTICULARS UNIT

Materials of construction M.S. & HSS

Waste material feed rate 450 – 500 kg/hr

Temperature 30 – 40 0C

SECTION PARTICULARS UNIT

Materials of construction SS – 310, SS – 316

Feed Rate[Section Input]

420 – 450 [Min - Max]435 [Average]

kg/hr

Vessel Pressure 10 – 15 kg/cm2

Temperature 175 – 200 0C

Output Rate[Section Output]

Semi molten plastic with all the extraneousmatter such as glass, stone, metal etc.435 [Average]

kg/hr

17

PROCESS SECTIONThis Auto/manual section consists of the

Inlet of Melting Vessel, Ceramic Insulation Jackets,Cooling water, Pressure Gauges, TemperatureSensors, Outlets & Gas Vents [chlorine /Hydrochloric acid gaseous] etc. The mixed wasteplastic from the pre feeder is received from theinlet in the Melting Vessel. The solid non molten /non plastic is removed from the melting sectioncontinuously after the initial charging is over. Thenon plastic contents are continuously removed,cooled and collected for disposal [Table 10].

SECTION PARTICULARS UNIT

Materials of construction SS – 310, SS – 316

Feed Rate[Section Input]

420 – 450 [Min - Max]435 [Average]

kg/hr

Vessel Pressure 10 – 15 kg/cm2

Temperature 175 – 200 0C

Output Rate[Section Output]

Extraneous matter such as glass, stone, metal etc.435 [Average]

kg/hr

18

14 PROCESS DIAGRAM& PRODUCTIONGRAPH

19

15 WASTE TO ENERGY 16 ENERGY RECOVERY

The sharp increase in energy consumptionparticularly in the past several decades has raisedfears of exhausting the globe's reserves ofpetroleum and other resources in the near future. Thehuge consumption of fossil fuels has caused visibledamage to the environment in various forms.Approximately 90% of our energy consumption comesfrom fossil fuels. Due to industrializations andpopulation growth our economy and technologies todaylargely depend upon natural resources, which are notreplaceable.

Now, the world is looking for alternate energyresources. Hence, it is necessary to encourage andemphasize the research and development activitiescovering a broad spectrum of possible renewableresources, as their contributions are substantial.Renewable Energy sources are not depleted. This won'tcreate any environmental pollution. The mainadvantage of using renewable resource is it isavailable throughout the year. A one time investmentcan drew energy for many decades without affecting theenvironment. Implementation of renewable energysources would result in country's economicdevelopment.

Power sector is one of the key sectorscontributing significantly to the growth of country'seconomy. Our country largely depends on the thermalpower generation and a right fuel mix, based on well-diversified portfolios of indigenous and importedfuel. The major advantage using renewable resourcesis that they are distributed over a wide geographicalarea, ensuring that developing regions have access toelectricity generation at a stable cost for the long-term future. This is not the case with fossil fuels inparticular petroleum products.

Every year human activity dumps roughly 8billion metric tons of carbon into the atmosphere, 6.5billion tons from fossil fuels and 1.5 billion fromdeforestation. It creates lot of environment problemand finally our ecological cycle will be affected.

Energy from waste in its strictestrefers to any waste treatment that creates energy inthe form of electricity and/or heat from a wastesource such as Municipal Solid Waste, Bio MedicalWaste, Non Recyclable Waste Plastics etc.. Suchtechnologies reduce or eliminate waste that istraditionally streamed to a "greenhouse gas"emitting landfill, or consume waste materials fromexisting landfills. Energy from waste is also calledenergy recovery process producing electricitydirectly through combustion, or produces acombustible fuel commodity, such as methane,methanol, ethanol or synthetic fuels.

The renewable sources are cost effective,user-friendly, so that they can easily beat the fossilfuels. By promoting renewable energy sources we canavoid, Air pollution, soil pollution and waterpollution. Country's Economy will increase.Throughout the year these sources are availablewithout affecting the Environment.

In India the amount of waste generated percapita is estimated to increase at a rate of 1%-1.33%annually. It is estimated that the total wastequantity generated in by the year 2047 would beapproximately about 260 million tonne per year. Theenormous increase in waste generation will haveimpacts in terms of the land required for wastedisposal. It is estimated that if the waste is notdisposed off in a more systematic manner, more than1400 sq. km of land would be required in the country bythe year 2047 for its disposal.

sense

Table 11 below gives the details of the energypotential from various sources and the level ofachievement from them.

SN Sources Potential Achievement01 Wind 45,000.00 2,980.0002 Hydro Power Plant 15,000.00 1,700.0003 Biomass Power 19,500.00 750.0004 Solar Panel [MW/km²] 20.00 2.0005 Waste to Energy [MW] 20,000.00 50.00

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17 FUEL Overview

Fuels used for electricity generationfall into one of Three main categories the

municipal waste is being considered as a potentialsource for energy production due to high volumegenerations, easy availability, low procurementcost and directly helping environment and saving thefossil fuel [Table 12].

broadly

The individual characteristics of these fueltypes tend to shape the choice and optimum size ofthe combustion technology employed, however ingeneral the unit cost of production varies and can begeneralized as follows per [Table 13].

Fossil fuels Biomass fuels Nuclear Municipal Solid Waste

Coal, fuel oil and natural gas whichare traded on the internationalmarket.

Crops, agricultural waste for example short-rotation coppice, or by-products from other cropand organic processes.

Uranium or‘MOX’ fuel.

Waste generated from house hold waste,industrial waste etc. generally classified asorganic, plastics and non organic.

INR / MWhMethodMin Max

Gas 1,345.50 1,518.00Wind 1,380.00 2,070.00Coal 1,656.00 1,897.50Hydro 1,759.50 3,898.50Biomass 2,001.00 4,002.00Nuclear 3,829.50 5,002.50

For conventional large size plant

Waste Plastics[Non recyclable]

2,250.00 2,810.00For small plants up to 1MWLarge plants the cost of production per unit shall reduce further.

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18 Typical ANALYSIS

The chemical properties of the PlasticDerived Fuel [PDF] liquid and gaseous are as follows-

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19 CERTIFIED USAGE

The Plastic Derived Fuel [PDF] liquied andgaseous can be efficiently used in current scenarioof fuel and energy crisis to various industrialusage.

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Some Visuals

Opposite Page the PlantView

Above the demonstrationof PDF in progress.

Right Demonstrating thepotential of PDF.

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