Pyrolysis Combustion Process

An Innovative Hypobaric technology works in Italy.

Testo in Italiano

Ideal to transform :
Waste tires and Indian' rubber to
fuel oil + charcoal
and to produce electricity.

Reactor Temperature: 1,000 - 1,200 °C - 1,830 - 2,220 °F
Electricity Consumption: 2,880 Kw / day max.
Water Consumption: 0,2 cu.mt / day - 7,06 cu.ft. / day.
Natural gas consumption @ 75% capacity:
1 cu.mt. / h - 35,3 cu.ft / h

Plant type "100"
Production Rate : 100 Kg./ h. - 200 Lbs / h
Input: cm 10 x 10 max. admitted size.
Plant requested installation area: mq. 200 - sq.ft 2,100
Shipment: # 1 x 40' container.

Plant type "500"
Production Rate : 500 Kg./ h. - 1,000 Lbs / h
Input: cm 50 x 50 max. admitted size. ( compressed Diam 60 cm tyres )
Plant requested installation area: mq. 1,500 - sq.ft 16,140
Shipment: # 3 x 40' container.

New Plant under construction

Plant type "1,000"
Production Rate : 1,000 Kg./ h. - 2,000 Lbs / h
Input: cm 120 x 120 max. admitted size. ( 4' Max. Diam. )
Plant requested installation area: mq. 2,000 - sq.ft 21,000
Shipment: # 4 x 40' container.

Plant type "2,000"
Production Rate : 2,000 Kg./ h. - 4,000 Lbs / h
Input: cm 240 x 240 max. admitted size. ( 8' Max. Diam. )
Plant requested installation area: mq. 4,000 - sq.ft 40,000 approx.
Shipment: # 8 x 40' container.

50 - 60 Kg./h - 100 - 120 Lbs /h of FUEL OIL with the following specification:

Calorific factor: 43,000 Kj/Kg ( Kacl: 10,120 ) -
Density: 930 Kg/cumt.
Boiling Point: 112 °C
Flow point: - 6°C

C = 85.9 %
H = 10.6 %
N = 1.4 %
O = 1.2 %
S = 0.9 %
Standard # :NO4ASTM

DISTILLATION CURVE.
- Analysis System: ASTM D 86.

0% Initial Boiling Point at 62 °C
5% at 108 °C
10% at 133 °C
20% at 140 °C
50% at 228 °C
90% at 283 °C
95% at 294 °C
FBP at 378 °C

5% sticky residue: craking at 380 °C

Fuel is similar to blended oil made by:

69% kerosine and 26 % Diesel fuel.

Type of produced Oil as per USA Standard

Pyrolysis gas is condensed by four surface-condensers producing D-4, D-2 and D-1 oil as follows:

Condenser # 1 Operating at 160 °C - approx 30% of fuel oil type D-4
Condenser # 2 Operating at 120 °C - approx 25-30% of fuel oil type D-2 ( heavy )
Condenser # 3 Operating at 80 °C - approx 25 -30% of fuel oil type D-2 ( light)
Condenser # 4 Operating at 40 °C - approx 8 - 10 % of fuel oil type D-1 ( Extra light )

30 Kg./h - 60 Lbs / h of CHARCOAL, with the following specification:
C = 94.78%
H = 1.11 %
N = 1.19 %
O = 0.56 %
S = 2.36 %

Main specification:

Yodic Number 151.5
Volatiles 2.8
Loose at 105 °C 0.2
Ash 11.4
Temperature at final production stage: 400 °C
Temperature after cooling: 80 °C
Status: dry powder

Charcoal use: combustible for cement-kiln and any suitable furnace.

From the industrial quality charcoal to high quality pulvirized active carbon

Upgrading of charcoal quality by using high temperature steam ( 800 - 900 °C) generated by the treatment plant installed on the Ro-Ro vessel.

Pulvirized active carbon ( Yodic Number 700 ) is ideal for air and water filter.
Kit should be manufactured as a part of the ordered plant.
Weight reduction factor: from 5% to 8%
Fuel consumption: 5% of self-produced oil.

Produced quantity: from 2 % to 8 % on distilled tyres weight.

Gas elements are:

C = 85.76 %
H = 14,24 %
N = trace
O = trace
S = trace

Gas components are:

H2 = 32 % in volume.
CO = 5 % in volume.
CO2 = 8% in volume.
O2 = ( 0 - 2 ) % in volume.
N2 = 5 % in volume.
CH4 = 25 % in volume
CnHm (from C2 to C5 ) = 21.5 % in volume
CnHm (from C5 to C6 ) = 2.5 % in volume CnHm = 1 % in volume

SMOKE

Smoke produced quantity.( N cumt/h - Normal cubic metre each hour )

Treatment capacity: 500 Kg/h = 1,100 Ncumt/h
Treatment capacity: 1,000 Kg/h = 2,200 Ncumt/h
Treatment capacity: 2,000 Kg/h = 4,400 Ncumt/h

Smoke analysis - after smoke treatment - 2,000 Kg/h treatment plant.

Powder: 8 mg/cumt.
HCl: 3 mg/cumt.
SO2 : 5 mg/cumt.
CO : 2 mg/cumt.
NOx : 8 mg/cumt.

STEEL :
Quantity related to distilled type

Average value: 8 - 9 Kg. from 100 Kg of treated tyres.

Plant available installed on a Ro-Ro vessel for a port-to-port activity managed by:
- Acquarius Inc. - The "Aquarius" shipping Company home page.

- MOBILE WASTE TREATMENT PLANTS - The Project

- IMPIANTI MOBILI di TRATTAMENTO RIFIUTI - Il Progetto -

5 - ELECTRICITY PRODUCTION -

Kit suitable for a 2,000 Kg/h waste-tyres treatement plant producing 1,200 Kg/h of oil

The power station is composed by four (4) Isotta Fraschini-Sulzer
Diesel Generating Packages, three unit running + one unit in stand-by.

Electric output for each engine is: 1860 kVA at 6.6 kV - 50 Hz.
Total generated electric power is:
5,580 kVA - standard mode with 3 units -
7,440 kVA - short time mode with 4 units-
average 6,300 kVA - medium mode.

Fuel consumption at 100% power will be:

approx. 921 Kg/h for three units.
approx. 1,228 Kg/h for four units.

Diesel Generating Package includs:

Engine, Radiator, Alternator, Baseframe and all necessary Auxiliary Accessories.

Layout, Foundations, Civil Work specification and drawings available at order.

Standard Production Endurance time: 8,000 hours per year.

Maintenance time : 20 / 30 hours every 90 days.

A - SINGLE GENERATING SET PERFORMANCES.

1.1 - Nominal Power 1860 kVA
1.2 - Power factor 0,8
1.3 - Active power 1490 kWe
1.4 - Frequency 50 Hz
1.5 - Rated voltage 6,600 Volt
1.6 - Engine speed 1,000 r.p.m.
1.7 - Time from start to 15 sec.
1.8 - Weight of each generating unit: 23,000 Kg

B - DIESEL ENGINE - MAIN SPECIFICATION

1.1 - Type: Sulzer-Isotta Fraschini 9S20U
1.2 - Engine operation four stroke
1.3 - Turbocharged and intercooled yes
1.4 - Number of cylinders 9 in line
  1.5 - Bore/stroke 200 / 300 mm
1.6 - Total displacement 84825 cudm
1.7 - N. of valves per cylinder 4
1.8 - Fuel to be used sim . to 4 ASTM
1.9 - Lube oil to be used SAE 30/40
1.10 - Max power at 1,000 rpm 1,575 kW
1.11 - Environmental conditions at site:
1.11.1 - Air temperature 5 / 40 °C
1.11.2 - Altitude ( a.s.l.) sea level
1.11.3 - Relative humidity 60%
1.12 - Derating factor 0 %
1.13 - Max. Power at site condition accord. point 1.11 = 1575 kW
1.14 - M.E.P. at power indicated 22,3 bar.
1.15 - Main Piston speed at 1,000 rpm 10 m/sec.
1.16 - Fuel consumption at max power ( +/- 5%) 195 g/kWh
1.17 - Fuel consumption at required power 195 g/kWh ( +/- 5%)
1.18 - Fuel consumption at 75% load 187 g/kWh ( +/- 5%)
1.19 - Fuel consumption at 50% load 196 g/kWh ( +/- 5%)
1.20 - Lube oil consumption 1,5 g/kWh
1.21 - Rotating facing flywheel clockwise
1.22 - Dry mass 23,000 Kg

C - ALTERNATOR - MAIN SPECIFICATION

1.1 - Manufacturer/type A VK 130/i6
1.2 - Rated Power 1,860 kVA
1.3 - Rated power factor 0,8
1.4 - Rated voltage 6,600 V
1.5 - Rated frequency 50 Hz
1.6 - Rated speed 1,000 r.p.m.
1.7 - Coolant temperature 45 °C
1.8 - Installation altitude sea level
1.9 - Insulation class F
1.10 - Temperature class F
1.11 - Radio interference filter level N
1.12 - Design IMB 16
1.13 - Enclosure protection class IP 23
1.14 - Terminal box protection class IP 44
1.15 - Position terminal box vertical
1.16 - N. of terminals 6
1.17 - Droop transformer for parallel operation.
1.18 - Temperature control :
6 x PT 100 for stator windings
1 x PT 100 for bearings
1.19 - Anti condensation heater yes
1.20 - Automatic voltage regulator Cosimat
1.21 - Voltage range between no load and full load:95% - 105%
1.22 - Voltage adjustement range +/- 5%
1.23 - Voltage adjustement range for siynchronisation: +/- 10%
1.24 - Voltage accurancy at continuous operation: +/- 1%

D - TERMS and CONDITIONS

- Price in US Dollar ex-work - Bari - Italy
- Payment by Conf. Irrev. L/C , with one year validity, available:
20% on opening
80/% at shipment
- Delivery time: five to seven months

E - PRICE

1.1 - Four packages $ 1,661,000.=
1.2 - Four exhaus gas silencers $ 16,000.=
1.3 - One Air starting device
( compressor + diesel engine ) $ 8,500.=
1.4 - Lub. oil treatment equipment $ 40,000.=
1.5 - Control panel + medium tension
switchboard $ 440,000.=
1.6 - Grounding device for medium
tension alternators $ 7,500.=
==================
$ 2,173,000 (A)
==================

F - EXTRA:

1.7 - Supervision for eraction and
commissioning $ 73,000.=
1.8 - Training for operating people
( 1 week for two persons ) $ 23,000.=
1.9 - 12,000 hours service spare parts $ 75,000.=
1.10- Tools for normal Maintenance and
Overhaul $ 16,000.=
====================
TOTAL $ 187,000.= (B)
TOTAL (A) + (B) $ 2,360,000 (C)
==============================================
G - TOTAL INVESTMENT for a 2,000 Kg/h treatement plant.

- 1 - Treatment plant : $ 2,500,000.=
- 2 - Electric Power Generator set $ 2,360,000.=
- 3 - Transport: $ 100,000.=
- 4 - Civil work on site ( approx.) $ 300,000.=

TOTAL $ 5,260,000.=
=================================

H - DELIVERY TIME:

Plant will be able to operate within one year from order confirmation.

I - REFERENCE:

A - Small size old tyres treatment plant: located in South Italy.
Produced oil is utilized as combustible for a gassification plant treating toxic hospital waste.

B - GENERATOR SET: similar unit is operating in Taiwan

L - SMALL SIZE diesel generating packages

Plant Treatement capacity: 500 Kg/h
Produced oil: 300 Kh/h
Produced Electricity: 1,860 kWA
Single engine
Genset Cost Unit, approx. $ 600,000.=

Plant Treatement capacity: 1,000 Kg/h
Produced oil: 600 Kh/h
Double engines
Produced Electricity: 3,720 kWA
Genset Cost Unit, approx. $ 1,200,000.=

Plant Treatement capacity: 2,000 Kg/h
Produced oil: 1,200 Kh/h
Produced Electricity: from 5,548 kVA to 7,440 kWA Max.
Triple engines plus one stand-by unit
Genset Cost, Unit approx. $ 2,300,000.=

1 - General features.

While any trunk-piston diesel engine is running, its lubricanting oil will be slowly contaminated by small particles originating from combustion process.
Burning residual fuel oil, particularly if it is of low grade, increases this contamination rate due to the higher content of carbon residues.

Lubricating oil treatment gives the following results:

- Substantially longer life of lub oil.
- Reduced lub oil consumption.
- Low wear of berings.
- Lower operating costs.

- 2 - Basic system equipment.

2.1 - Self-cleaning separator.
2.2 - Flexible connections.
2.3 - Intermediate sludge tank
2.4 - High level switch
2.5 - Low pressure switch
2.6 - Level switch with indicator.
2.7 - Pneumatic actuator.
2.8 - Control unit with:
2.8.1 - Pneumatic 3-way valve.
2.8.2 - Selenoid valve to block water
2.8.3 - Selenoid valve to block air.
2.9 - Electric motor and starter
2.10 - Oil feed pump with strainer and starter
2.11 - Oil heating system
2.12 - Temperature control system
2.13 - Foundation frame.

The separation system is designed for automatic operation.
The separation system may be operated in single, parallel or in series.

N - FOUR ENGINES POWER STATION : CONTROL PANEL - MEDIUM TENSION SWITCHBOARD -

Control Panel and switchboard needs an high degree of functional safety.
Construction is in accordance to E.C. Quality and Safety Standard.

Switchboard unit specification.

Nr. 1 compartment with power circuit breaker 4 x 5000 for outgoing to plant. ( Outgoing panel 1 )
Nr. 1 compartment with power circuit breaker 4 x 3000 for incoming from Gen. 1 and one circuit breaker to MCC1 ( Incoming/Outgoing panel Gen. 1 )
Nr. 1 compartment with power circuit breaker 4 x 3000 for incoming from Gen. 2 and one circuit breaker to MCC1 ( Incoming/Outgoing panel Gen. 1 )
Nr. 1 compartment with power circuit breaker 4 x 3000 for incoming from Gen. 3 and one circuit breaker to MCC1 ( Incoming/Outgoing panel Gen. 1 )
Nr. 1 compartment with power circuit breaker 4 x 3000 for incoming from Gen. 4 and one circuit breaker to MCC1 ( Incoming/Outgoing panel Gen. 1 )
Nr. 1 compartment with power circuit breaker 4 x 5000 for outgoing to plant. ( Outgoing panel 2 )
Nr. 1 compartment for starter auxiliary motors compleated with circuit breakers, fuses, contactors, T, TV and all accessories ( MCC Panel for Gen. 1 )
Nr. 1 compartment for starter auxiliary motors compleated with circuit breakers, fuses, contactors, T, TV and all accessories ( MCC Panel for Gen. 2 )
Nr. 1 compartment for starter auxiliary motors compleated with circuit breakers, fuses, contactors, T, TV and all accessories ( MCC Panel for Gen. 3 )
Nr. 1 compartment for starter auxiliary motors compleated with circuit breakers, fuses, contactors, T, TV and all accessories ( MCC Panel for Gen. 4 )

Control panel specification.

Nr. 1 Compartment for sequence controls compleated with PLC protection relays, indicators, push-buttons, selector switchs, lamps, circuit breakers, trasducer and all accessories for Gen. 1
Nr. 1 Compartment for sequence controls compleated with PLC protection relays, indicators, push-buttons, selector switchs, lamps, circuit breakers, trasducer and all accessories for Gen. 2
Nr. 1 Compartment for sequence controls compleated with PLC protection relays, indicators, push-buttons, selector switchs, lamps, circuit breakers, trasducer and all accessories for Gen. 3
Nr. 1 Compartment for sequence controls compleated with PLC protection relays, indicators, push-buttons, selector switchs, lamps, circuit breakers, trasducer and all accessories for Gen. 4

O - COMMISSIONING and START-UP.

For commissioning and strat-up activity are calculated 2 months for 2 engineers.
Daily working time is 10 hours for 5 days a week.

Operative manuals, drawings etc. are included and will be provided by manufacturer.

Taiwan production unit - Containerized 6000 kVA Power Station -
Power Station operating on Kimmen Island - Taiwan -

1520 kW diesel unit - Thermal power station for electricity production.
Power Station operating at Federal Technical University of Zurich - Switzerland -

Taiwan' plant lay-out

Prices related to Transport from Miami, On - Site Installation, Foundation works, Operators' Training, are not included.

7 - Publications:

1 - Luciano Angelin - Paolo Canu - Valentino Grinzato-
"Termodistruzione di rifiuti e derivati mediante gassificazione o pirolisi.
- La Termotenica - November 1997

FROM THE PRESS.

8 - The United States Market / development

1999, January 4th

BENEFICIAL ROLE FOUND FOR USED TIRES

In an effort to turn the nation's piles of used tires into something beneficial to the environment, a group of researchers is recycling the tires into activated-carbon adsorbents for air quality control applications.

"In the United States alone, more than 200 million tires are disposed of annually," said Mark Rood, a University of Illinois professor of environmental engineering.
"These waste tires can serve as an inexpensive and plentiful feedstock for carbon adsorbents that have commercial value in gas separation, storage and cleanup applications."

There are currently an estimated 3 billion waste tires stockpiled in the United States.
Mounds of old tires can mar the landscape, collect rainwater that fosters breeding sites for mosquitoes and ignite into long-lasting fires that pollute the air.

The researchers from the University of Illinois and the Illinois Geological Survey are tailoring the properties of tire-derived activated carbons to help solve troublesome air-pollution issues.

Potential commercial applications of tire-derived activated carbons include the removal of toxic pollutants from fossil-fuel-fired power plants, storage of alternative fuels such as natural gas in vehicles and the removal of volatile organic compounds from industrial gas streams.

To date, the researchers have determined that the tire-activated carbons are comparable or superior to some commercial carbons.

"The next step is to produce enough quantities of tire-derived activated carbon for pilot-scale testing to show that this material works under actual industrial test conditions," said Massoud Rostam-Abadi, an engineer at the university.
"This is what we are doing now."

Activated carbon is commonly produced from carbonaceous materials such as wood and coal.
With its high carbon content and plentiful supply, "tire rubber could potentially serve as an ideal material for making low-cost adsorbents," said Rood.
"In addition, almost 70 percent of tire rubber is volatile material that can be recovered as oils and gases and used as an energy source for processing the tires."

Source: Environmental News Network.

- Pyrolysis Plant picture - - Front side view -
- Process flowsheet - - Pyrolysis process -

Gasification Plant page - Specification -

Plant available installed on a Ro-Ro vessel for a port-to-port activity managed by:
- Acquarius Inc. - The "Aquarius" shipping Company home page.

This site received visits since June '95

Juniper publication : 'The Market for Pyrolysis & Gasification of Waste in Europe: a Technology & Business Review'.

Click:
Juniper publication