MIDI ROTARY KILN PLANTS - wecleantheworld.international

MIDIROTARY KILN PLANTS

EXPERIENCE SIZE

INPUTS

AMOUNTS

EFFICIENCY

FEATURES ECONOMIC

ATECHNICALDESCRIPTION

You need a detailed description of the MIDI-plant, to understand

• the main idea of the MIDI-concept

• the differences to other suppliers

• what units are included into the standard MIDI

You have a basic understanding in

• rotary kiln technology

• pyrolysis, thermolysis and gasification

• waste treatment

You need arguments about a “German engineering” due to European standards.

You don’t have own experience and want to show the experience of your partner, means a skilled team for the technical and project work

You want to share your experiences with others and will also benefit from their experiences.

EXECUTIVE SUMMARY

FINANCING CLEARED

OPERATING COMPANY FOUNDED

GROUNDBOUGHT

LOCAL MANUFACTURERS

GOVERNMENT PERMISSION

YOUR PROJECT

EXECUTIVE SUMMARY

PLASTICS

WASTE TREATMENT

SCRAP TIRESDRY MANURE

UNDIGESTEDSEWAGE SLUDGE

DIGESTEDSEWAGE SLUDGE

WASTE WOODTO ACTIVATED CARBON

ThermolysisPlant Type MIDI

WASTE-2-PRODUCT

MIDI Technology• Technology Features

• Process Features

• Regulations

• Unit Features

• Sizing + Throughput

• Possibilities

• Experiences

• WWW of MIDI

TABLE OF CONTENTS

MIDI

A wide variety of

• inputs

• temperatures

• processes

By an optimum of

• energy efficiency

• safety

MIDI TECHNOLOGY FEATURES

A Core for Waste/Product Treatment


MIDI INPUTS

MINI plants

• Yokohama: industrial sludge

• Maizuru: dioxin contaminated soil

• Semirara: lignite

• Bergheim

MAXI plants

• Bönen: tar contaminated soil

• Herne: chemical contaminated soil

• Nassau: electronic waste

• Marktredwitz: mercury contaminated soil

• Leverkusen: pigments

• Ludwigshafen: pigments

• Spolana: dioxin contaminated soil

• Limassol: scrap tires

MASTER plants

Burgau: RDF, municipal waste

Contherm: RDF

Mie: waste wood

Tokyo: undigested sludge

Neuss: aluminium delacquering

SUMMARY: MIDI TECHNOLOGY

1. Various Inputs

• Plastics (PE / PP / PET / PVC)

• Scrap tires

• Sewage sludge (digested / undigested)

• (Dioxin) Contaminated soils

• Digestate

• Used activated carbon

• Waste wood / railway ties

2. Various Temperatures

• < 200 °C ( drying)

• 200 – 400 °C (torrefication)

• 400 – 800 °C (pyrolysis)

• > 800 °C (gasification)

• Calcination

• Thermolysis

3. Various Processes

• Patent comprehensive treatment

• Residence time from 10 to 120 minutes

• Temperature profiles

• Additives before/after thermal process

• Side stream processes



4. Energy Efficiency

• Electrical heating causing

• less heat loss

• temperature independent efficiency

• Combination with green power possible

• windmill with our frequency controller

• Solar-panels

• biogas-CHPs, CHP instead of flare

5. Emissions

• Separated heating and process atmosphere (indirect heated system)

• No off gas from burning chamber

• Sealings with purge gas + sensors

• Drawing-off air treatment

• Noise reduction plant

• Liquid trough implemented

6. Safety

• Fully automatic process control system

• Man-free operation possible

• HAZID & HAZOP

• Long life materials



7. Containerized Layout

• Ready assembled in workshop

• Cold test run in workshop

• Shipping by standard containers

• Easy relocating with in 4 weeks

• “Movable equipment” better for

• Leasing

• Permission




• Regulations

• Unit Features


• Possibilities

• Experiences

• WWW of MIDI

TABLE OF CONTENTS

MIDI

MIDI:ONE PLANT FOR DIFFERENT PROCESSES

Main Process Targets:

• Destroying waste

• Destroying hazardous ingredients

• Reducing waste volume

• Waste 2 Energy

Main Process Feature:

• Lambda > 1,0

• Waste from gas cleaning




• Destroying hazardous components


• Waste 2 Energy


• Zero oxygen in pyrolysis

• Low calorific process gas

• No condensates




• Destroying hazardous ingredients


• Waste 2 Energy


• Less oxygen in pyrolysis

• High heating value process gas

• No condensables



• Syngas production for Fischer-Tropsch

• Waste 2 Product

• Small equipment


• Less oxygen in pyrolysis

• Clean process gas

• Fuel production



• Waste 2 Products

• No incineration

• Emission free

• Small equipment



• liquid production

• Open for side stream technologies




• No incineration

• Emission free

• Small equipment



• Forced chemical reactions

• Defined liquids production





• No incineration

• Emission free

• Small equipment




• Gas recovery






• No incineration

• Emission free

• Small equipment




• Gas recovery





• Regulations

• Unit Features


• Possibilities

• Experiences

• WWW of MIDI

TABLE OF CONTENTS

MIDI

CLASSIFICATION

Calcination:The heating of solids to a high temperature for the purpose of removing volatile substances, oxidizing a portion of mass, or rendering them friable. Calcination, therefore, is sometimes considered a process of purification.

A typical example is the manufacture of lime from limestone. In this process the limestone is brought to a temperature high enough to expel the carbon dioxide, producing the lime in a highly friable or easily powdered condition.

Calcination in special cases may be carried on in furnaces designed to exclude air, for which an inert gas may be substituted.

Read more https://www.britannica.com/technology/calcination

https://www.britannica.com/technology/calcination

CLASSIFICATION

Incineration:Waste destruction in a furnace by controlled burning at high temperatures. Incineration removes water from hazardous sludge, reduces its mass and/or volume, and converts it to a non-burnable ash that can be safely disposed of on land, in some waters, or in underground pits.

However, it is a highly contentious method because incomplete incineration can produce carbon monoxide gas, gaseous dioxins, and/or other harmful substances.

Read more http://www.businessdictionary.com/definition/incineration.html

Producing flames

Read more: https://dictionary.cambridge.org/de/worterbuch/englisch/burning

Burning:

http://www.businessdictionary.com/definition/incineration.html

https://dictionary.cambridge.org/de/worterbuch/englisch/burning

CLASSIFICATION

Thermo-processing plant VDMA 24202:"Ein Industrieofen (auch Thermoprozessanlage) ist nach VDMA 24202 definiert als ein „von Wänden umschlossener Raum […], [in dem] einem Gut […] Wärme zugeführt wird, um bestimmte Vorgänge […] im Gut oder an seiner Oberfläche ablaufen zu lassen.“ Ohne Ofenraum spricht man von einer „industriellen Erwärmungseinrichtung“.

Firing plant Umweltbundesamt :„Feuerungsanlagen erzeugen Strom und Wärme durch Verbrennungsprozesse. Der Begriff umfasst die unterschiedlichsten Anlagen: von der häuslichen Heizung über Industriefeuerungen zur Dampf- und Prozesswärmeerzeugung bis hin zu großen Kraftwerksfeuerungen.“

CLASSIFICATION

Thermo-processing / firing

Thermo-processing plantoff gas mass = 0

Firing plantoff gas mass >> input mass

Thermo-processing plantoff gas mass <= input mass

CUSTOMS TARIFF NUMBERS

Customs tariff number 8514 3080Electrical heated industrial or laboratory kilns

Elektrische Industrie- oder Laboratoriumsöfen, einschließlich Induktionsöfen oder Öfen mit dielektrischer Erwärmung; andere Industrie- oder Laboratoriumsapparate zum Warmbehandeln von Stoffen mittels Induktion oder dielektrischer Erwärmung

Customs tariff number 8419 4000Machines, equipment or laboratory instrumentation, also electrical heated

Apparate, Vorrichtungen oder Laborausstattung auch elektrisch beheizt (ausgenommen Öfen und andere Apparate der Position 8514), zum Behandeln von Stoffen durch auf einer Temperaturänderung beruhende Vorgänge, z. B. Heizen, Kochen, Rösten, Destillieren, Rektifizieren, Sterilisieren, Pasteurisieren, Dämpfen, Trocknen, Verdampfen, Kondensieren oder Kühlen, ausgenommen Haushaltsapparate; nicht elektrische Durchlauferhitzer und Heißwasserspeicher

Distillation and rectification equipment

Destillier- und Rektifizierapparate

CUSTOMS TARIFF NUMBERS

Customs tariff number 4906 0000Constructional plans and drawing, technical drawings and other plans and drawings

Baupläne und -zeichnungen, technische Zeichnungen und andere Pläne und Zeichnungen zu Gewerbe-, Handels-, topografischen oder ähnlichen Zwecken, als Originale mit der Hand hergestellt; handgeschriebene Schriftstücke; auf lichtempfindlichem Papier hergestellte fotografische Reproduktionen und mit Kohlepapier hergestellte Kopien der genannten Pläne, Zeichnungen und Schriftstücke



• Regulations

• Unit Features


• Possibilities

• Experiences

• WWW of MIDI

TABLE OF CONTENTS

MIDI

Main• Containerized system for easy transport to

site

• System is designed for quick change over to new site

• Designed with 100,000h material values for lifetime > 10 years

• Designed for continuous processing 24h/7d

• Standard operation of 7,500 hours per year

MIDI UNIT FEATURES

MIDIFEATURES

Units

Maintenance

Lifetime Values

Control System

Safety Devices

Power Supply

Input Feeding System• Dockings stations for roll-off containers for

easy load and change of input feed

• Over-size comb-out to protect the system

• Bucket feeding system for abrasion free feeding

• Weighing system for input documentation

• Optional: metal separation

• Optional: over-size crushing

MIDI UNIT FEATURES

MIDIFEATURES

Units

Maintenance

Lifetime Values

Control System

Safety Devices

Power Supply

Rotary Kiln System• Proven kiln technology with high grade

materials• Proven sealings with monitored purge gas

connection • Kiln operation temperature up to 1,000 °C• Various stress calculations: break, lifetime,

collapsing• Electrical heated for best temperature

control• Temperature profiles with 22 step possible• Cardanic support• Ball bearing support with sensors and

automatic lubrication system• Gear drive with sensor controls and

automatic lubrication system

MIDI UNIT FEATURES

MIDIFEATURES

Units

Maintenance

Lifetime Values

Control System

Safety Devices

Power Supply

Char Post-Processing• Indirect cooling system with possibility of

steam or liquid injection

• Crushing

• Feeding into big packs (standard or defective output)

• Feeding into silos

• Optional: milling or briquetting

MIDI UNIT FEATURES

MIDIFEATURES

Units

Maintenance

Lifetime Values

Control System

Safety Devices

Power Supply

Process Gas Treatment• 1st step: dedusting + cooling

• 2nd step: column for heating oils

• 3rd step: column for various liquids (water, acids, light oils)

• 4th step: column for high ignitable liquids

• 5th step: cooler dewatering

• 6th step: activated coal filters as police filters

• 7th step: gas micro turbine or emergency flare

• Optional: membrane separation

MIDI UNIT FEATURES

MIDIFEATURES

Units

Maintenance

Lifetime Values

Control System

Safety Devices

Power Supply

Process Gas Treatment• Fully parametric tune-up of condensation

ranges

• Closed thermal system with integrated chiller, but open for external heat exchanger connection

• Open for additional technologies for oil treatment or gas treatment

MIDI UNIT FEATURES

MIDIFEATURES

Units

Maintenance

Lifetime Values

Control System

Safety Devices

Power Supply

Electric & Controls• Fully automatic control system with large

documentation storage

• Self-learning controls

• Remote control after enabling possible

• Interface to design tools

• 10 kV main transformer, optional 20 kV

• Emergency oil CHP, optional use as standard CHP

• Gas micro turbine for emergency power

MIDI UNIT FEATURES

MIDIFEATURES

Units

Maintenance

Lifetime Values

Control System

Safety Devices

Power Supply

Safety Devices• Emergency flare for safe incineration of

process gas

• CO-sensors for detection gas leakages

• Pressure and temperature sensors (> 200 sensors)

• Torque controlled motor FCs for detecting any blockings

MIDI UNIT FEATURES

MIDIFEATURES

Units

Maintenance

Lifetime Values

Control System

Safety Devices

Power Supply

Maintenance Features• Concept for maintenance during operation to

reduce downtime

• Critical devices are double for changing during operation

MIDI UNIT FEATURES

MIDIFEATURES

Units

Maintenance

Lifetime Values

Control System

Safety Devices

Power Supply



• Regulations

• Unit Features


• Possibilities

• Experiences

• WWW of MIDI

TABLE OF CONTENTS

MIDI

SYSTEM SIZE

Criteria MICRO MINI MIDI MAXI MASTER

Throughput 80 kg/h 300 kg/h 600 kg/h 1,200 kg/h 2,400 kg/h

Economic state laboratory semi-production production

Erection state mobile containerized static

Automation Unattended operation given by control system – check for regulations!

Product variability high mid low

Temperature range < 1,000 °C < 800 °C <600°C

0 t/h

1 t/h

10% 15% 20% 25% 30% 35% 40%

Inp

ut

Kiln Filling Degree

Input Material with 0.2 t/m³depending on residence time

20 min 30 min 45 min 60 min 90 min

• plastic scrap

• tetra-pack

• wood shavings

Counter measure if not acceptable:

• Compacting, ex.g. pelleting of biomasses

• Granulating, ex.g. for plastics

INPUT AMOUNT DUE TO DENSITY

Fluffy Materials

• Shredded wood

• Nut shells

• Rubber granulate


• Shredding to get finer grain



Standard Materials

0 t/h

1 t/h

2 t/h

10% 15% 20% 25% 30% 35% 40%

Inp

ut

Kiln Filling Degree



• Sewage sludge

• Contaminated soil

• Metal powders




Heavy Materials

0 t/h

1 t/h

2 t/h

3 t/h

4 t/h

10% 15% 20% 25% 30% 35% 40%

Inp

ut

Kiln Filling Degree



• The higher the water content the more the rotary kiln becomes an (expensive) dryer!

• Up to 95 %WC is possible by technology. Sometimes this is needed in case for hazardous chemicals

• Standard for best economy is given at less than 10% WC

• Check for ATEX-regulations if less than 20% WC

• Sewage sludge has a lime point.

• Lime/glue points can cloak the rotary kiln!

INPUT AMOUNT DUE TO WATER CONTENT

Water Content

0

500

1.000

1.500

2.000

2.500

3.000

1% 5% 10% 15% 20% 30% 40% 50% 60%

kg/h

water content

Input Amountdue to process temperature

500 °C 600 °C 700 °C 800 °C 900 °C

• In gas heated systems only a part of the hot gas energy can be used for the process heating. Most heat given off is waste heat.

• The off gas temperature is by standard appr. 200 °C higher the process temperature inside the kiln.

• The higher the burning chamber temperature and the lower the process temperature inside the kiln, the better the efficiency.

Please note: The MIDI is electrical heated and has no off gas, so the reactor heat efficiency is nearly 100%. Of course you have energy losses by producing electrical energy…

But a good natural gas CHP has an electric efficiency of >40%, independent of the process temperature!

ENERGY EFFICIENCY COMPARISATION

Energy Efficiency

0%

10%

20%

30%

40%

50%

60%

500 °C 600 °C 700 °C 800 °C 900 °C 1.000 °C

Effi

cien

cy

Process Temperature

Energy Efficiency for gas-heated rotary kilns

900 °C 950 °C 1.200 °C 1.400 °C 1.600 °C



• Regulations

• Unit Features


• Possibilities

• Experiences

• WWW of MIDI

TABLE OF CONTENTS

MIDI

POSSIBLE & SENSEFUL

Technologically possible?

Railroad ties

Scrap tires

Cable insulation

Nut shells

Lignite

PE / PP

PVC

PCB

Oil sludges

Waste wood

Chicken manure

Electronic waste

Contaminated soil

Sewage sludge, dry

Industrial sludges

Hazardous sludges

Sewage sludge, wet

TetraPack

Food waste

slaughterhouse waste

unsorted waste

Wood chips

Glass

Wind engine blades

Car compounds

PV-Compounds

Economically Sound?

MIDI INVOLVED SOLUTION: SCRAP TIRES


• Find the optimum process chain

• Don’t fix to only one technology

• Accept all products

• Stable the process!





MIDI INVOLVED SOLUTION: MIXED WASTE


• Find the optimum process chain

• Don’t fix to only one technology

• Accept all products

• Stable the process!







• Regulations

• Unit Features


• Possibilities

• Experiences

• WWW of MIDI

TABLE OF CONTENTS

MIDI

• Mechanical design

• Process engineering

• Manufacturing & assembling

• Shipping

• Erection & start-up

• Maintenance

THERE IS A REASON WHY…

PERSONAL EXPERIENCE BACKGROUND

High Potential Award Winner 2011

Certified experts testimony 2013

Kiln Crack 2005

THE EXPERIENCE – MINI SIZE

Honmuko Plant

• Location: Yokohama –Dockyards

• Start-up: 2000

• Input: 120 kg/h

• industrial hazardous sludge

• Heated by pyrolysis gas

Maizuru Plant

• Location: Maizuru – Test facility

• Start-up: 2001

• Input: 300 kg/h

• dioxin contaminated soil

• Heated by LPG

Semirara Plant

• Location: Semirara Island -Philippines

• Start-up: 2005

• Input: 300 kg/h

• lignite 25% WC


THE EXPERIENCE – MAXI SIZE

Herne Plant

• Location: Herne - Germany

• Start-up: 1992

• Input: 10.0 t/h contaminated soil


Spolana Plant

• Location: Spolana - Czechia

• Start-up: 2006

• Input: 10.0 t/h dioxin contaminated soil

• Heated by natural gas

Limassol Plant

• Location: Ypsonas - Cyprus

• Start-up: 2009

• Input: 600 kg/h scrap tire granulate


THE EXPERIENCE – MASTER SIZE

Burgau Plant

• Location: Burgau - Germany

• Start-up: 1984

• Input: 2x 2.0 t/h

• RDF up to 40% WC


Contherm Plant

• Location: Hamm - Germany

• Start-up: 2001

• Input: 2x 6.5 t/h

• RDF max 25% WC

• Heated by natural gas

Mie Plant

• Location: Mie prefecture - Japan

• Start-up: 2005

• Input: 4.0 t/h

• waste wood 20% WC


MIDI – THE ENGINEERING TEAM

Customer

Permission

Architect

Civil work

Manager

on site

Start-up

Manufacturer

Manufacturing

Ordering

Assembling

Wiring

Cold test run

Project manager

QM

Supervisor

Lead Process

PFD / PIDs / KKS

Interlocks

Chemcad

HAZOP

CFD

Lead Engineering

Unit

Specifications

Welding

Piping

Statics

Preparing Documents

Lead EMSR

Sensors

E-Plan

Control Cabinet

Programming

Lead Design

Layout design 3D

Detail Design

3D

Drawings 2D

List of parts

Judge Commercial



• Regulations

• Unit Features


• Possibilities

• Experiences

• WWW of MIDI

TABLE OF CONTENTS

MIDI

MIDI – PROJECTS

Worldwide 2018/08

Fixed interest

• LOI

• MOU

• Pre-Contract

Attention

• Project description

• Governmental suggestion

• Governmental cooperation

CONNECT MIDI TODAY

NACHHALTIGKEIT

THERMOLYSE

ENTSORGUNG VON RESTSTOFFEN

DEZENTRALE LÖSUNGEN

WIRTSCHAFTLICHKEIT

ROHSTOFFE AUS ABFALL

GREEN THE WORLD BE PART OF A WORLD WIDE WEB OF OPERATORS!

Preparing a LOI addressed

The LOI contains• The full company address and registration data of the project developer

• The full company address and registration data of the requested licensee

• The possible cooperation partners for manufacturing

• A short project description (input, localization, targets)

• A schedule estimation

NEXT STEPS

YOUR CONTACTS:

Michael SeraphinCEO

Hopfentwete 1a • 38173 Evessen

M: +49 177 500 6155

E: [email protected]

Dirk GerlachCTO

Hopfentwete 1a • 38173 Evessen

M: +49 1525 484 5906

E: [email protected]