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Marek Pilawski, Ph., D. European Engineer
SYNTHETIC FUELS AND MULTI - FUELS
1. Introduction. Thermocatalytic degradation of the hydrocarbon polymers An overview of the applied technology and equipment with an assessment of the environment
protecting installations.
The core of used technology is thermocatalytic degradation of hydrocarbon polymers( i.e.
recycled flake plastics and other hydrocarbons) resulted with an effluents consisted of liquid
hydrocarbon mixed compounds being residuum of conventional fuels and paraffin, so called
synthetic paraffin.
Thermocatalytic degradation proceeds at temperature 180 – 350 Celsius degrees and is
characterized by effluent of highest purity with neither sulphur containing species, nitrogen
compounds nor after combustion ash contents.
Final proportions of various fractions of the liquid hydrocarbon output depend on the quality and
kind of catalyst used for processing.
An installation for hydrocarbon polymers thermocatalytic degradation has been designed as
special container with main unit utilizing stainless steel for extra long life and freedom from
wear. The unit is electrically heated, equipped with stirrer of an innovative shape and is jointly
operating with patented feeder features worm gear mechanism.
All the process is controlled by totally automatic microprocessed computerized control system
that can be operated by one or two persons only.
The processing unit is additionally equipped with many self- controlling emergency sensors and
has also safety clutch that emphasis safety protecting either system’s operator or workplace
environment.
This is the unique installation either in country or worldwide.
The average monthly supply of flake plastics per one processing system is of 200 Mg while
average per month production remains below 200 Mg due to losses caused by plastic’s
fulfillment chemical micro-contaminations.
Applicability of the above presented technology allowed to reach ecologically and economically
reasonable level of the installation’s work cycle.
The main goal of waste chemical recycling process performed through environment friendly
catalytic depolimerisation is to transform recyclabe materials into a new products of high quality
confirmed by detailed laboratory researches.
Sorted ripped and crushed plastic waste creating processing material is collected in an enclosed
part separated from production area and then brought to a location near processing line. Further
feedstock flake plastic are loaded into main container of infeed system and since this moment the
processing starts with paraffin oil as final product. Paraffin oil can be directly forwarded to main
storage tank where it is held until collected by special cistern trucks for transport to purchaser.
The complete work cycle of thermocatalytic installation consists of five stages, i.e.: loading
phase, plastic batch mollification, destillation phase, cooling phase and effluent collecting phase.
Phase No. 1: Characterized by relatively high personal engagement of the installation’s
operators. Employee should manually meter the recycled flake plastic devoted for processing.
Final thermal processing performance tightly determines an amount of plastic waste to be
prepared for such processing.
Phase No. 2: Plastic batch reactor mollification. The advanced infeed worm gear system
automatically meters the recycled crumb rubber into processing unit where is gradually heated
and worked.
Phase No. 3: An exact recycling phase is carried out on plastics compounds converted – in the
presence of catalyst – into paraffin form. Under own pressure equal to atmospheric pressure
output is forwarded to the cooling system and then continued on reaching next phase of the
process.
Phase No. 4: Thanks to cooler manifold installation maintaining the proper operating temperature
an effluent remains of liquid nature not transferable into paste form.
Phase No. 5: Output collection. The thermal processing is carried out on installation where under
adequate conditions and in presence of catalyst treated plastic waste are completely converted
into quality product of a new chemical compound. Either plastic waste feedstock or effluent have
same temperature equal to atmospheric one.
Standard installation is designed for indoor location in closed room without chimney ventilation
required. Exploitation of the installation does not cause energy emission such as noise, heat,
vibrations and electromagnetic fields.
Installation is low impact with operational heavy duty system devoted to meet all present
standards and provisions enforced by the Environment Protection Agency according to modern
engineering technologies and has proven to work considering the rules of economic
effectiveness.
The basic features of the installation proving high quality of the engineering superiority are:
unique design due to its compactness and small workplace, low power consumption and high
performance in respect to production efficiency, quick start, low operational cost and cost-
effective stand- by technical requirements and own sources of power supply.
The installation has been designed utilizing newest up-dated and advanced technology solutions.
Based on above it is worth to mention highly safe work cycle of the installation with maximum
efficiency assured by sophisticated electronic and mechanical control and management system
proving maximum safety and extremely minimalizing the risks of installation damages.
The final output of the process is not a waste product, but in contrary it is of full standard value
and widely used in many industries, for example in the petrol industry as soft paraffin component
or valuable engines petrol and diesel fuel component.
The product has been tested at Lab “GLIMAR S.A.” Refinery in Poland with an excellent
evaluation report clearly stated that the product can be added by refineries as an component to
petrol and diesel fuel not causing overpassing of their standard value, unanimously confirming
high quality of the product.
The chemical recycling process belongs to relatively expensive investments therefore
government and local authorities are obliged to support any initiatives of the investors not joined
with public sector and willing to set- up new facility devoted to implement chemical recycling
technology leading to diminishing the presence of ordinary material recycling method resulted
with products of low market standards.
The chemical recycling system and especially catalytic depolymerization belongs to the
processes of high ecological and economic achievements and ecological features of the product
significantly overpasses other products originated from material recycling as re-granulates of
doubtful quality.
Above described advanced technology has been I - st prize awarded in the International
Competition titled “Recycling of the technics and technics of the recycling” supported by
National Fund of Environment Protection what was proudly and officially announced during
International Fair “POLEKO” at Poznań, Poland.
2. Natural base of hydrocarbons depolymerization
Hydrocarbons are normal fuel on the Earth. These fuels present in free state on Earth. Anyway
hydrocarbons are elements of many chemical organic and inorganic compounds. Hydrocarbons
are the example of organic compounds containing hydrogen and carbon. Chemical compounds
containing hydrogen and carbon are called basic raw materials to fuels production.
Table I. Chemical composition and calorific value of some organic compounds
Name
Chemical composition
(% of weight)
Calorific
value
C H O Other MJ/kg
Carbon 80 - 85 4 – 6 - 15 - 20 28
Car tires 75 6 - 19 30 - 33
Organic fraction
of municipal wastes
54 6 38 2 1,4 - 3,5
Polyethylene PE 85,6 14,4 - - 43
Polypropylene PP 85,6 14,4 - - 44
Polystyrene PS 92,3 7,7 - - 40
PET 74,9 5,0 20 0,1 31
PCV 38,4 4,8 - 56,8 18
Polyacetylene 92,3 7,7 - - 45
Wood 50,0 6,0 44,0 - 18
Next analysis take into consideration only polyolefin waste plastics – polyethylene (PE) and
polypropylene (PP) composed only of carbon in 86% of weight and hydrogen in 14% of weight.
Calorific value of polyolefin plastics is estimated for 44 MJ/kg. Process of oxidation
(combustion) of carbon and hydrogen participates in achieving this value.
Carbon in a combustion process oxides to gas carbon dioxide CO2 with heat emission according
to reaction:
1kg C + 2,67 kg O2 = 3,67 kg CO2 + 33,8 MJ ( 9,39 kWhh
Hydrogen in a combustion process oxides to water vapor H2O with heat emission according to
reaction:
1 kg H2 + 8 kg O2 = 9 kg H2O + 120 MJ ( 33,33 kWhh ).
Weight index of carbon in 1 kg of hydrocarbon carrier of hydrogen fuel (which are polyolefin
waste plastics) is 86% - so acquired energy is 29,068 MJ ( 8,0744 kWhh) according to equation:
0,86 x 33,8 MJ = 29,068 MJ ( 8,0744 kWhh),
and weight index of hydrogen in polyolefin waste plastics is 14% so acquired energy is 16,8 MJ
(4,6666 kWhh) according to equation:
0,14 · 120 MJ = 16,8 MJ ( 4,6666 kWhh).
It means that theoretical combustible value of polyolefin plastics is 45,868 MJ (12, 74 kWhh)
according to equation:
29,068 MJ + 16,8 MJ = 45,868 MJ.
Carbon and hydrogen have different combustible values therefore carbon percentage
participation in development of heat energy is 63,4%, according to equation:
29,068 MJ : 45,868 MJ = 63,4%,
and percentage participation of hydrogen in development of heat energy is 36,6%, according to
equation:
16,8 MJ : 45,868 MJ = 36,6%.
Municipal wastes include app. 12% of waste plastics and polyolefin waste plastics have 60%
participation in this. With 12 million Mg of yearly produced municipal wastes there are 86,400
Mg polyolefin waste plastics created. Taking into consideration also industrial wastes we can
assume that such type of hydrogen fuel carriers are produced in Poland in quantity of 1 million
Mg – carbon participation in this is 860,000 Mg and hydrogen participation is 140,000 Mg .
Taking into consideration real combustible value of this fuel equal to 44 MJ/kg (12.22 kWhh/kg),
its power potential is equal to 44,000 TJ (12.22 TWhh), where carbon has 27.896 TJ (7.75 TWhh
– 63.4%) participation, and hydrogen – 16.104 TJ (4.47 TWhh – 36,6%), where, of course,: 7.75
TWhh + 4.47% TWhh = 12.22 TWhh.
Industrial hydrocarbons non ecologic fuels they are transformed into liquid hydrocarbons which
are ecological (no Cl, S, N and cinders after burning) synthesis fuels.
In the future hydrocarbons and water can become raw materials for renewable fuel production of
the future – hydrogen.
3. Technical and technological base transformation of polyolefin waste plastics into ecological components of liquid fuels
The construction of devices for transformation of package waste plastics to liquid hydrocarbons
with structure of paraffin oil can be very different. Especially they can be liquid metal reactors
assuring regular disposition of necessary temperature in reaction space.
In this case crumbled polyolefin waste plastics 19 are poured to pour funnel 18, and with worm
20 across the pipe 15 they are moved to the reaction space 11 and they are dropping on the
catalyst 8 disposed in a layer on surface of liquid metal alloy 4. Plastics transforms into vapor of
heating oil 22 with presence of catalyst in temperature of some hundreds of degree centigrade,
those vapors are then guided with pipe 16 to the condenser 23, and further as liquid to heating
tank 24. Oil tank is ventilated with fan 25, which removes all gas products of transformation of
polyolefin plastics after burn across the chimney duct 26 directly to the atmosphere. (pict.1).
Temperature sensors 7 and 9 located in liquid metal layer and reaction space are controlling work
of device. Ceramic crucible 2 with heat insulation 3 is the element of induction heater 1 or tub
heated with stream 27 to keep process running.
Pict. 1 Liquid metal reactor as device for transformation of plastics into mixture of liquid
hydrocarbons
Pict. 2 Picture of device for transformation of plastics into liquid hydrocarbons
The final effect of device’s work in this example of usage becomes the heating/diesel oil
assigned for sale in 90% of production quantity. Picture of device with 300 l/h efficiency is
presented on picture 2.
The process of thermo-catalytic transformation of polyolefin plastics needs the process heat. This
heat consists of :
- Heat of plastic warming to the temperature of 400°C app.. 400 kcal
kg
- Heat of transformation phase I (plastifying) app.. 300 kcal
kg
- Heat of transformation phase II (melting) ok.. 300 kcal
kg
- In total 1.000 kcal
kg = 4.190
kJ
kg
Gram-molecule of the hydrocarbon polymer of 1 kg weight looks approximately like C71H144.
Break of C-C bond in one mole of polymer needs use of heat (energy) 350kJ
mol. Simplifying that
molecule of liquid hydrocarbon includes 7 atoms of carbon, gram molecule of initial polymer
divides into 10 gram molecules of liquid polymer.
To break bonds in gram molecule of transformed plastic one need then additionally 3 500 kJ
kg of
energy. Total value of heat (energy) of transformation is then approximately 7 690 kJ
kg.
In case of 100% efficiency of process one should get from 1 kg of plastic exactly 1 kg of heating
oil having 43 000 kJ
kg of combustible value – that means 43 000 kJ of energy.
In real system from 1 kg of plastic one may achieve 0.8 kg of oil (that means 1l), from which we
can recover energy of 0,8 × 43000 kJ = 34 400 kJ. Approximately 20% of weight becomes gas
during the process. If we can use this gas for energetic purposes then efficiency of whole system
is high – the gas is source of energy 0,2 × 43 MJ / kg = 8 600kJ
kg, which covers need for process
heat 7 690kJ
kg. In other case possible to recover initial energy decreases for further 8 600
kJ
kg
corrected for energetic efficiencies of individual technology points in real system.
Heat gained in process of thermal utilization of other groups of municipal wastes can be used for
transformation process of polyolefin waste plastics to the liquid fuels. With this the idea of
“wastes works for wastes” can be achieved.
Production of liquid hydrocarbon mixture using package waste plastics is profitable business
because transformation of this type of plastics is relieved from income tax what refers to both –
individuals and corporate bodies. Furthermore when taking such wastes for transformation
recycling fee can be taken according to resolution of act about produce fee.
Main laboratory of CPN has tested fuel properties of hydrogen mixture gained from polyolefin
waste plastics[5].
Results of these tests seems to be very interesting comparing to light standard heating oil (table II
and III).
Table II. Physical and chemical properties Table III. Chemical composition and of liquid fuels gained from plastics properties normal of light h. oil
Description Polyolefine oil Petrol
fraction : 53 %
Oil fraction 33 %
Paraffin : 14 %
Description Normal light heating oil (for consideration)
Density with 20°C g/ml 0,785
Color Yellow
Transparency Clear Carbon % 86, 0
50% dest. do st. C 186 Hydrogen % 13, 4
do 250°C dest. % 73 Sulfur % 0, 28
do 350°C dest. % Oxygen % 0, 35
Solidification temperature -18 Nitrogen % 0, 02
Contents of mechanical pollutants
0,005% Water % <0, 01
Water in ppm 438 Cinders % 0, 02
Sulfur in % 0,007 Combustion heat. kJ/kg 45 850
Calorific value kJ/kg 42 900 Calorific value kJ/kg 42 800
Filter temperature in. oC
-14
Cetane index 46,0 Density kg/m3 850
Lepkość w 20°C w cst. 1,37 Viscosity c St 5, 8
Combustion temperature M.P. in oC
20 (CO2) max 15, 34
Using energy potential of 10% weight of liquid hydrogen mixture during transformation process
their total energetic potential decreases to 90% comparing to previously count and it is now 39
600 TJ (11 TWhh), where participation of carbon is 25 106 TJ (6.975 TWhh), and hydrogen
participation - 14 494 TJ (4.0 TWhh).
The source of process heat can be biomass in one of practical construction solutions of device for
chemical recycling of waste plastics. General energetic balance shows that burning 1 kg of
biomass with calorific value 4 kWh/kg causes transformation of 1 kg of plastics for 1 liter of fuel
component with calorific value 10 kWh/1l. With such kind of production of the alternative fuels
one may say that using local energetic potential of bio fuels we can gain alternative fuels with
energetic potential 2,5 times bigger than potential of used bio fuels.
4. Liquid - metal reactor design for the transformation of waste plastics polyolefin synthetic liquid fuels and parameters of such fuels
Recycling installations have a modular design. A single module has a productivity of 50 l/h up to
100 l/h. The dimensions for example of a 50 l/h module are: (LxWxH) 400 cm x 97,5 cm x 150
cm, total weight is 1 MT.
Pict. 3,4 The 50 l/h capacity plastic waste recycling unit. Feed chute mounted on top of a screw conveyor/plasticizing system, in the center the flow reactor box (silver – stainless steel), situated
above gas burner (red colour). At the front exhaust pipes for gaseous reaction products
An essential component of the recycling installation is the new continuous fractional distillation
staged cooler with horizontal flow. The complex internal structure of the component is designed
to obtain controlled staged condensation and separation of final product fractions.
Pict. 5 Continuous fractional distillation staged cooler with horizontal flow.
The staged cooler breaks up the raw product into eight fractions in a predictable and controllable
manner. The composition of each fraction can be altered accordingly to specific needs of the user
or customer for whom the product is made. Fractioning process is done without the need for use
of a typical petro – chemical distillation column.
Apart from the ability to convert plastics, the recycling installation has eight additional target
applications, of which every single one leads to the establishment of alternative and renewable
ecological fuels production from waste. Therefore, it can become a versatile environmental
protection tool transforming troublesome garbage into useful products. The net manufacturing
cost of the recycling installation for the capacity of 300 l/h amounts to 1 000 000 €. Thanks to
small dimensions of the recycling units with the capacity of up to 100 l/h fit on the lorry
platform, which makes them suitable for a self – sufficient mobile installation. The only
additional equipment needed is a portable petrol engined power generator.
The technical solutions of the recycling installation are protected by a numerous patents.
Pict. 6 The 8 different final product fractions (detailed description in 4)
Table 4. Final product fractions - description
1. Light petrol 5. Oil 2. Petrol 6. Heavy oil 3. Heavy petrol 7. Light paraffin
4. Light oil 8. Solid paraffin
5. Fuel parameters of synthetic fuels derived from various types of hydrocarbon waste
Fuel parameters of synthetic fuels derived from various types of hydrocarbon waste are shown in
the following table. For comparison, in columns 1, 2 and 3 of the table shows the parameters of
normal fuels used in Poland, and the columns 4, 5, 6 and 7 are presented fuel parameters
obtained respectively : used motor oils, used tires, waste polyolefin plastic and waste bioglycerol
(waste bioglycerol arising in the manufacture of diesel from rapeseed).
One will notice a large convergence of the parameters of all fuels.
After long research and technical tests failed to choose and mix these fractions of synthetic fuels
that meet the conditions for long-term operation of power generators at full load.
.
Waste Transformation
TABLE OF SYNTETIC OILS PARAMETERS (4, 5, 6, 7) ON THE BACKGROUND PARAMETERS OF NORMAL OILS (1, 2, 3)
Characteristic to be determined Research conditions Normal
furnance oil „ekoterm”
(1)
Noramal
furnance oil „ekoglin”
(2)
Normal light
diesel oil „DP”
(3)
Oil from used
motor oils (4)
Oil from used car tieres
(5)
Oil from waste
poliolefin plastics
(6)
Oil from technical
bioglycerol „glicer”
(7) Density at 20oC ; g/ml 0,880 0,870 0,810 – 0,870 0,812 – 0,840 0,830 0,785 – 0,850 0,8744
Colour brown dark brown yellow,1,0 – 2,0 dark brown
Clarity clear clear clear clear clear
50% (v/v) is distilled at a temp. 0 C --- --- 290 --- 230 start 46 - 54 0C start by 72 0C
portion distilled at a temp. 250 0C ; % 65 --- --- 45 61 19
portion distilled at a temp. 350 0C ; % 80 85 90 87 95 74 -89 76
Solidification point 0 som, -20 wint -5 som, -15 winter 0 -30 -13 +3 --- -18 -16 flow temp.
Mechanical impurities ; % 0,05 0,05 - - - - - - 0,005
Water content ; % 0,1 0,1 brak 440 ppm 560 ppm 438 ppm
Sulphur content ; % 0,3 0,3 0,3 0,289 0,283 0,007 39 ppm
Coking residue ; % 0,2 0,2 0,2 0,06 0 0
Incineration residue ; % 0,1 --- 0,01 0,006 --- ---
Water extract reaction ; pH ~7 ~7 ~7 5,5 - 7 5,5 - 7 5,5 - 7 ---
Calorific value ; kJ/kg 41 500 41 500 42 300 42 300 42 500 42 900 30 600
Cetane index ; --- --- 45 56,2 42,5 46
Kinematic viscosity at 20 0 C ; cst. 4,0 – 8,0 4,0 – 8,0 --- 7,90 2,36 1,37 – 4,80
Kinematic viscosity at 40 0C ; cst. --- --- 1,7 – 4,7 4,53 --- 1,45 – 2,49 6,29
Flash point at a temp. ; 0C 56 50 45 60 20 0 - 20 32
Freeze temp. of filter ; 0C --- --- -12 -9 -10 0 --- -14 -19
6. Electric power and energy consumption of plastics distillator
Production = 200 l/h = 170 kg/h, 4 800 l/day = 4 080 kg/day. 1 l of product = 0,85 kg of product
Unit of energy consumption = 4 560 kWh/day : 4 800 l/day = 0,95 (kWh/l), 4 560 kg/day : 4 080 kg/day = 1,12 (kWh/kg).
In this case one can use Diesel Electric Power Generator - electric power 200 kW – to supply all devices of complete system.
Specific fuel consumption of DEPG = ab. 70 l/h.
Plastic raw Pressed Steam
waste mate and hot of rial plasics product product Electric Install 55 kW 4 x 14 kW = 4 x 30 kW = 20 kW 8 kW 259 kW Power = 56 kW = 120 kW Average Using of 50 kW 50 kW 80 kW 5 kW 5 kW 190 kW Electric Power Energy Consumption
Per day 1 200 kWh 1 200 kWh 1 920 kWh 120 kWh 120 kWh 4 560 kWh
Shredder
Raw
materials
input devices
Reactor
Cooler
Automatic Control System and Other
TOTAL
7. Wiew of the structure of several distillators - devices for the transformation of plastics waste into paraffin oil - synthetic fuel
1 ….. 9 generation number of plastics distillator
1 – efficiency : 50 l/h
2 – efficiency : 50 l/h
3 – efficiency : 100 l/h
4 – efficiency : 75 l/h
5 – lab efficiency : 5 l/h
6 – efficiency : 50 l/h
7 – efficiency : 100 l/h
8 – efficiency : 150 l/h
9 – efficiency : 200 l/h
1 2
4
3
5 6
7 8 9
In distillator we use two electric generators. Both are working on own multifuel.
One feeds the plant back, the second produces electricity for sale.
100
10 - one of the last distillators designed for simultaneous
processing of waste plastics polyolefin into synthetic fuel
– paraffine oil and used tieres into synthetic fuel –
pyrolytic oil.
It is equipped with an induction heating system of the
reactor.
10. distiller produces multifuel.
In distillator was used output hot pyrolytic carbon
from the reactor.
8. Multifuels Multifuel is a multi-component fuel, said multi - fuel behaves as a single -component fuel.
There are a number of different types of fuels multicomponent. An example of a multi-
component fuel - multifuel - is for example biofuel produced by dissolving ethanol
(bioethanol) in specific proportions in the oil / gasoline.
Another example is the fuel - multifuel - produced in the biomass obtained by drying sludge,
the fraction of biological municipal waste or other biomass and soaking the prepared dry
biomass paraffins synthetic obtained in the process of chemical recycling of waste plastics
and liquid components of combustible vegetable origin obtained in another way.
Multifuel based on biomass takes the calorific value of coal.
9. Multifuel on the base on liquid synthetic fuels
Final products in special construction distillator include:
- admixture paraffin oil produced from PE and PP plastic waste,
- pyrolytic oil produced from used car tyres,
- fuel oil being a mixture of the above substances,
- post-pyrolytic carbon (technical carbon black),
- manganese steel,
- pyrolytic gas (process gas). Paraffin oil
Paraffin oil is composed of a mixture of hydrocarbons and is entered in the Systematic List of
Products under number SLP 1249. From a chemical point of view, it is synthetic paraffin,
which differs from natural paraffin by a greater number of hydrocarbons with double bonds.
This enables synthetic paraffin to react more easily once these double bonds have been
cleaved and free valence has become available.
Synthetic paraffin is an ecological product since it does not contain sulphur, chlorine, nitrogen
or water. Synthetic paraffin is good fuel.
The results of testing the fuel properties of synthetic paraffin :
[Translation of the copy of the document in Polish inserted above.] Oil and Gas Institute Research Report No. TA2/56/1/2012 Oil Analysis Department Crude Oil and Standard Analysis Laboratory
Page 2 of 2 RESEARCH RESULTS
The Institute has implemented a quality management system compliant with the ISO: 9001: 2008 standard Name of the sample provided by the Client: Average sample obtained by mixing provided samples numbered 2, 3, 4, 5, 6 and 3+4+5.
(average sample code: TA2/56/12 No. Characteristic to be determined
Research conditions Unit Measurement result Research method based on
1. Density at 20oC g/ml 0.8016 PN-EN ISO 12185:2002A
2. Fractional composition: - temp. at the beginning of distillation oC 100 PN-EN 3405: 2011A - 50% (v/v) is distilled at a temp. of no
more than
oC 288
- portion distilled at a temp. of no more than 250oC
%(V/V) 36
- portion distilled at a temp. of no more than 350oC
%(V/V) 74
- portion distilled at a temp. of no more than 370oC
%(V/V) 81
- temp. at the end of distillation oC 387 - distillate yield %(V/V) 95 - distillation residues %(V/V) 2.0 - loss %(V/V) 3.0 3. Pour point oC + 27 PN-ISO 3016: 2005A 4. Water content %(m/m) < 0.03 PN-83/C-04523/Ap2-
2004A 5. Sulphur content %(m/m) 0.031 PN-EN ISO 8754: 2007A 6. Chlorine content %(m/m) < 0.0050 PN-91/C-04071A 7. Silica content mg/kg 498 ICP-OESN 8. Coking residue %(m/m) 0.065 PN-EN ISO 10370:
1999A 9. Incineration residue %(m/m) 0.023 PN-EN ISO 6245: 2008A 10. Water extract reaction - Subacid
(pH=5.5) PN-84/C-04064 method
AA 11. Calorific value MJ/kg 43.082 PN-86/C-04062A 12. Cetane index - 65.8 PN-EN ISO 4264:2010A 13. Kinematic viscosity at 40oC mm2/s 3.215 PN-EN ISO 3104: 2004A 14. Flash point oC 28.0 PN-EN ISO 2719: 2007A 15. Acid number mg KOH/g 0.84 PN-88/C-04049A 16. Lubricity at 60oC 1) Μm 211 PN-EN ISO 12156-
1:2008A 17. Corrosive properties in distilled water,
on steel (after 5 hours)1) corrosion
degree Moderate PN-81/C-04082A
(ASTM D 665-2006)A 18. Examination of corrosive impact on
copper (3 hours, 50oC) corrosion
degree corrosion degree
1 PN-EN ISO 2160: 2004A
Note: the research results constitute an integral part of Research Report No. TA2/56/2012, which may not be used in part without the consent of the Oil and Gas Institute. Date of commencement of the research: 21 May 2012. Date of ending the research: 4 July 2012. Supplementary information: A – Accredited method N – Non-accredited method 1) – Research conducted in the Operating Properties Assessment Department of the Oil and Gas Institute (Cert. No. AB 170). Date of the report: 4 July 2012. Approved by: Deputy Manager of the Oil Analysis Department /-/
Pyrolytic oil
The results of tests of the fuel properties of pyrolytic oil produced from tyres :
Oil and Gas Institute Research Report No. TA2/72/1/2012, Oil Analysis Department, Crude Oil and Standard Analysis Laboratory
Page 2 of 2 RESEARCH RESULTS
The Institute has implemented a quality management system compliant with the ISO: 9001: 2008 standard Name of the sample provided by the Client: Average sample obtained by mixing 5 provided samples numbered from 1 to 5 in the following proportions by volume: 46:9:18:11:16.
(average sample code: TA2/72/12 No. Characteristic to be determined
Research conditions Unit Measurement
result Research method
based on 1. Density at 20oC g/ml 0.9106 PN-EN ISO
12185:2002A 2. Colour - D 8.0 ASTM D 1500N 3. Fractional composition: PN-EN 3405: 2011A - temp. at the beginning of distillation oC 109.0 - 50%(v/v) distilled at a temp. of no more
than
oC 255.5
- portion distilled at a temp. of no more than 250oC
%(V/V) 48
- portion distilled at a temp. of no more than 350oC
%(V/V) 81
4. Pour point oC - 12 PN-ISO 3016: 2005A 5. Water content %(m/m) > 0.1 (0.16) PN-EN ISO 12937-
2005A 6. Sulphur content %(m/m) 0.96 PN-EN ISO 8754: 2007A 7. Chlorine content %(m/m) < 0.0050 PN-91/C-04071A 8. Silica content mg/kg 107 ICP-OESN 9. Coking residue %(m/m) 0.17 PN-EN ISO 10370:
1999A 10. Incineration residue %(m/m) 0.002 PN-EN ISO 6245: 2008A 11. Water extract reaction - Subacid
(pH=5.5) PN-84/C-04064A method
AA 12. Calorific value MJ/kg 40.366 PN-86/C-04062A 13. Cetane index - 29.6 PN-EN ISO 4264:2010A 14. Kinematic viscosity at 20oC mm2/s 4.478 PN-EN ISO 3104: 2004A 15. Kinematic viscosity at 40oC mm2/s 2.756 PN-EN ISO 3104: 2004A 16. Flash point oC 35.5 PN-EN ISO 2719: 2007A 17. CFPP oC + 9 PN-EN 116:2001A 18. Acid number mg KOH/g 4.3 PN-88/C-04049A 19. Lubricity at 60oC 1) μm 225 PN-EN ISO 12156-
1:2008A 20. Corrosive properties in distilled water,
on steel (after 5 hours)1) corrosion
degree none PN-81/C-04082A
(ASTM D 665-2006) 21. Examination of corrosive impact on
copper (3 hours, 50oC) corrosion
degree corrosion degree
1 PN-EN ISO 2160: 2004A
Note: the research results constitute an integral part of Research Report No. TA2/72/1/2012, which may not be used in parts without the consent of the Oil and Gas Institute. Date of commencement of the research: 13 June 2012. Date of ending the research: 19 June 2012. Supplementary information: A – Accredited method N – Non-accredited method 1) – Research conducted in the Operating Properties Assessment Department of the Oil and Gas Institute (Cert. No. AB 170). Date of the report: 19 June 2012. Approved by: Deputy Manager of the Oil Analysis Department /-/
Multifuels on the base of mix of oils – synthetic fuels
The name fuel oil has been created to refer to any mixture of paraffin oil and pyrolytic oil. If
we adopt pyrolytic oil as the reference base, fuel oil has much better fuel properties than
pyrolytic oil.
Samples of paraffin oil (left) and pyrolytic oil (right)
As compared with pyrolytic oil, fuel oil is characterised by:
- a positively higher cetane number, which will make the unit work better under loads,
- positively better lubricity, which is very important in the case of diesel engines running for a
long time,
- a positively lower sulphur content,
- a positively lower (if applicable) water content,
- a positively lower silica content, which is not without significance in the case of generation
unit engines,
- a positively higher calorific value,
- a positively lower coking process residue, etc.
(The first attempts to produce fuel oil were undertaken by the Author in 1996.)
PRODUCTS OF THE TRANSFORMATION OF CAR TYRE POST- PYROLYTIC OIL IN DISTILLERS
Sample 1.1 – Pyrolytic oil after being transformed in the Distiller. Sample 1.2 – Raw pyrolytic oil. Sample 1.3 – Tar residue after transforming raw pyrolytic oil in the Distiller. Residue form: dense slurry-tar. Residue quantity: 150 ml. Quantity of processed raw oil: 2.2 l. Limit temperature in the Distiller: 400 0C.
1.1 1.2 1.3
PRODUCTS OF JOINT AND SIMULTANEOUS TRANSFORMATION O F POST-PYROLYTIC OIL OBTAINED FROM CAR TYRES AND PLASTICS IN DISTILLERS
Sample 2.1 – Mixture of post-pyrolytic paraffin oil after transformation in the Distiller. Sample 2.2 – Raw pyrolytic oil + paraffin oil – mixture. Sample 2.3 – Post-transformation residue of a mixture of raw oil (2.8 l) and plastics (0.9 kg) in the Distiller. Residue form: dense slurry /tar - 160 ml. Limit temperature of transformation in the Distiller : 400 0C.
2.1 2.2 2.3
10. Multifuel on the base on biomass
Currently, there are attempts to compose multiple fuels. Such popular example is a simple
multi - fuel mixture of carbon and biomass waste. Multi - fuel combustion is the process of co
- firing. Co - firing is mainly used to get rid of troublesome waste such as sewage sludge,
municipal waste, and others, and is an expression of helplessness technological
environmentalists. Co - incineration of carbon and biomass waste is simply thrown into the
furnace of carbon and waste in such a small amount that does not degrade too much harmful
emissions into the atmosphere. And that is the whole technology. Attempts to co - firing are
therefore aimed at increasing the efficiency of combustion, just get rid of the least
burdensome way of waste.
Currently, attempts are made to use a mixture of fuels : coal and biomass, where each
component alone is a good fuel in its class.
Multi - fuel in the form of a simple mixture of fuels having different calorific values is always
worse conditions than required for combustion of the individual components. It is burned in
the furnace because of the structure adapted to the calorific value of only one of the
components of such a multi - component fuel.
Types of compositions A, B, C and D of the two component fuel mix are shown in picture 7.
If the fuel is a mixture of coal and biomass, is for efficient combustion of 1 kg of coal is
needed 11 m3 of air, and for efficient burning 1 kg of biomass - an average of 4 m3 of air.
Meanwhile, furnace design provides only a steady string or blowing air. As you can see, it is
not possible to provide such a quantity of air to the two components burned in an energy
efficient manner, and thus - ecological. Always either one component will not be burned
completely or excessively ventilated, or both components of fuel mixture to be burned
inefficiently. Therefore, the effect of the energy and ecological burning a mixture of fuel is
always less than the sum of the effects of efficient combustion of each fuel separately.
This problem is solved by new generation multifuels.
Multifuel is a multi - component - fuel. Multifuel usually consists on base fuel and a
component or components. Base fuel is mostly covered by the standard fuel. Component is
indeed a flammable substance, but does not have to be a standard fuel.
An example of a multi-component fuel - multifuel - is, for example biofuel produced by
dissolving ethanol (bioethanol) in specific proportions in the oil / gasoline.
Multifuel characteristic feature is that the component is dissolved in the base fuel or
connected with it so that it is a homogeneous fuel. Freely small part multifuel therefore has
the same properties as multifuel as a whole. In this context, the multi-component fuel -
multifuel - there is not a mixture of fuel. For example in a mixture of carbon and biomass
each component is different and it burns alone while also affecting each other and the burning
one of them changes conditions the other component burning.
A B Air 1, 2, 3, 4, 5 Air 1, 2, 3, 4, 5 1, 2, 3, 4, 5 – Uniform air flow C D
Air 1, 2 , 3, 4, 5 Air 1, 2, 3, 4, 5 Pict. 7 Model cases of solid fuels mixtures
This effect of mutual influence does not occur when multifuel is burning.
In real conditions can be shaped calorific value multifuel choosing it carefully to the
requirements of the power equipment to ensure optimal conditions for combustion.
Multi-fuel - multifuel - formulated in order to improve the properties of fuels.
The following was described multifuels witch was made on the base of biomass and liquid
components - synthetic paraffin wax obtained from waste plastics or “glicer“- liquid fuel
obtained from waste glycerol resulting in the production of biofuels rapeseed - or ethyl
alcohol
Both “glicer” and ethyl alcohol are of organic origin and are classified as renewable energy
sources.
This effect of mutual influence does not occur when multifuels are burning.
Biomass has a porous structure and paraffin, “glicer” and alcohol are inherently substances
diffusing deep into the ground, where they are located.
In this case multifuel formed by impregnation of the biomass by paraffin, synthetic “glicer” or
alcohol, resulting in a multi-fuel - multifuel - with specific physicochemical properties.
If, for example, every kilogram multifuel so prepared contains 75% of the dried biomass with
a calorific value of 14 MJ / kg and 25% paraffin wax or synthetic “glicer” calorific value of
42 MJ / kg and consequently formed multifuel with calorific values of :
14 MJ / kg + 0.75 x 42 MJ / kg x 0.25 = 10.5 MJ / kg 10.5 MJ / kg = 21 MJ / kg
The calorific value so prepared multifuel in this case is equal to the calorific value of good
quality of coal. The demand of the combustion air so composed multifuel is the same as
carbon. Such multifuel can without fear of losing the energy efficiency of burning coal or co-
burning with multifuel in owen.
Especially good basic fuel for the production of multifuel are dried sewage sludge.
Multifuels with a calorific value of coal are a commodity in demand by the power industry.
11. Sewage sludge and biological fraction of municipal waste as biofuel base of multifuel
Tool for the production of biofuels in the form of dry biomass can be a simple layout liquid -
metal drying sewage sludge and municipal biological waste fractions schematically shown in
the picture 8 below.
Pict. 8 Scheme of liquid-metal sludge drying
HO - hopper
C - cuvette
LM – LM M liquid metal - a liquid metal mirror
AS - the axis of the worm
S - scroll
WS - wet sludge (compost raw)
DS - dry sludge (biomass)
CB - covers the litter box
RS - spout
GB / O - a gas burner (oil)
OL – outlet
The main component of liquid-metal hair is cuvette C formed hopper HO. Through a hopper
into the cuvette is introduced wet sludge WS or wet fraction separated from biological waste.
The cuvette is filled with an liquid-metal alloy set so as melting point that is higher than the
evaporation temperature of water, the lower the temperature of biomass carbonization. At the
level of the liquid surface of liquid-metal LMM fixed axis AS scrolls S.
GB/O
LM
OL
CB
WS
DS LMM AS
S
HO
RS
C
Further working surfaces of the worm wheel are interconnected by thin blades forming the
blade. The rotating scroll layer having a thickness of wet biomass equal to the radius of the
worm wheel moves from the hopper towards to the outlet OL. Half of the volume of the worm
wheel is always immersed in the liquid metal transferring heat from the gas burner (oil) GB /
O to the dried biomass. In addition, the worm wheel blades moist biomass is mixed with the
liquid metal causing evaporation of moisture from it. Evaporated from the wet sludge water
vapor escapes into the environment through the holes in the lid CB of the cuvette C. The pre-
dried biomass DS in the form of the pre-dried sludge DS pours by gravity to a discharge spout
RS, followed by moving to a storage tank is dried by exhaust gases emitted by the burner.
A layer of liquid metal ensures a uniform distribution of the desired temperature in an oven
and causes the material being dried do not adhere to the bottom and walls of the dryer.
Performance dryer is controlled simply by varying the speed of the worm wheel.
In the particular case gas burned in the dryer may be integral to the burner of the gasifier in
this way of dried biomass.
From one ton of sludge with 80% H2 O is 200 kg dry matter of10% of biological moisture. To
evaporate the water contained in such sludge should be used 0.5 MWh.
From calculations carried out that in the case of liquid-metal dryer for drying of municipal
waste biological fraction of approx. 32% of this waste to be recycled to the process and could
be used as a heat source necessary for drying the next batch of wet biomass. The remaining
68% of the biomass may be used in this case outside of the dryer system, for example for the
multifuel production.
Utility model of liquid-metal dryer is already made.
For example in Poland, without further processing, currently in arrears:
* 500 thousand tonnes of dry matter contained in the biological sludge and
* 3.6 million tonnes of biological waste fraction.
Both the dry matter contained in the biological sludge and biological fraction of municipal
solid waste are a renewable sources of energy.
12. Multifuel composing method
The method of multifuel composing involves infiltration of dry biomass, preferably in the
form of wood chips, shavings, sawdust, dried sewage sludge or dried fractions of biological
municipal waste or from the processing of agri-food by liquid fuel components, particularly
paraffin synthetic obtained by the method described above or impregnating it with other liquid
fuels component obtained by transforming waste motor oils, edible oils and glycerol or
“glicer” or ethyl alcohol.
5
3
6
1 2
7 4
::::::::::::::::::::::::::::::::::::::::::::::::::: ::::::::::::::::::::::::::::::::::::::::::::::::::: :::::::::::::::::::::::::
Pict. 9 Example of multifuel composing
Example way of composing fuel compound is shown in picture 9 illustrating the substrate 1
moving in any direction 2 with respect to the sprinkler five receiving the hopper 3 of the dried
and shredded biomass 4 crosslinkable humidified in a mist (aerosol) the component of the fuel
6 obtained from the sprinkler component 5 so that the sprinkler 5 is obtained moistened
(hydrated) component 7 constituting multifuel on the base of biomass.
The method of composing multiple fuels lets you compose multifuels of different calorific
value.
The group "Clinic of Environment Energy New Technologies" – Poland - mastered multifuels
technology and production and technology of compaction (solidifying) the liquid component
of multifuels : synthetic paraffin, wax, “glicer” and ethyl alcohol, the process of compaction
(solidifying) the multifuels liquid component above is carried out after soaking the biomass
components already in the porous structure of the biomass.
13. Closed „materials – energy” circuits in the waste management systems with the multifuels participation
Fuel properties of waste creates an opportunity to design and build such waste management
systems, where "waste work to waste." Consistent implementation of this idea on the level of
technical solutions leads to the waste “self-destruction" systems. In some of these systems are
a source of waste energy needed to destroy the other waste groups.
At the moment there are devices each separately that you can assemble a complete installation
of realizing the idea of "waste work to waste." However, for financial reasons, despite the
very good economic and environmental efficiency of work of such installations one of these
devices is not compiled in such a system.
You can design a variety of systems in which they work on the waste disposal. One of them
can be a system in which the central unit is equipped with a electric generator with compact
steam engine (Pict.10).
Compact Steam Generator Set electrical capacity of 1.2 MW requires the use on the input
thermal energy fuel 7 MWh. The product of the work of this unit is also downright pair of
thermal energy 6 MWh. The exhaust steam engine of steam generator in turn and it has the
same parameters that are needed to operate the steam dryer sludge. Dryers are produced in
such country. Using this pair can dry the 8.57 t/h of sludge per hour with an initial degree of
hydration of 80%. After drying 6.86 t/h of steam returns to the wastewater treatment plant
and 1.7 t/h of dry biological matter collected in the Biofuels Storage. From Biofuels Storage
0.8 t/h of biofuels is directed to the sale or other use, and 0.9 t/h of dry matter is directed to
Base Biological Fuels Storage - multifuels.
Pict. 10 Wiew of a compact steam electric generator with the power of 1.2 MWe
From the Base Fuels Storage biomass is transported to Multifuels Storage where it is saturated
by the amount of 0.3 t h of liquid component obtained from two waste plastics distillators
forming just multifuel with efficiencyf 1.2 t/h of thermal power required for proper operation
of Steam Compact Electric Energy Generator.
Part (25%) produced by the unit of electric energy is consumed to sustain the work of two
distillators and the remainder of electric energy (75%) is intended for sale or designed for
other use.
In this example the “material and energy circuits” are closed. In that case "waste work to
waste."
For the illustrated system are (in the figure marked by a double arrow) only two supplay
elements : 0.3 t/h of waste plastics and 8.57 t/h of sludge after the press. Output elements of it
(the figure marked with an arrow in bold) : 0.8 t/h of dry biological matter intended for sale or
any other land and 0.75 MW of electric energy for sale or other disposal.
Energetic Net 0.25 MWe 0.75 MWe
6.86 t/h H2O 0.3 t/h plastics waste
0.3 t/h 1 MWe 8.57 t/h sludge
component 7 MWh
1.2 t/h Multifuel 0.9 t/h dry biomass 6 MWh 1.7 t/h dry biomass 0.9 t/h dry biomass 0.8 t/h dry biomass
Pict. 11 Example of system
System operation is related to four revenue streams :
2 x Distillator
Component 42 MJ/kg
Multifuel Storage
21 MJ/kg
Base Fuel
Storage 14 MJ/kg
Cleaner of
Sludge
Steam
Dryer of Sludge
Biofue Storage
Compact
Steam Electric
Unit
1) revenue stream associated with taking fees for admission to recycling waste plastic
packaging materials in the unit price of 0.1 PLN/kg :
300 kg/h x 0,1 PLN/kg = 30 PLN/h.
2) revenue stream associated with taking fees for admission to dry sewage sludge in the unit
price of 80 PLN/1 Mg :
8.57 Mg/h x 80 PLN/1 Mg = 686 PLN/h.
3) The stream of revenue related to the sale of excess electricity unit price of 200 PLN/1
MWh :
0.75 MWhe/h x 200 PLN/1 MWh = 150 PLN/h.
4) The stream of revenue related to the sale of excess amount of dry matter as biological
biofuels in the unit price of 17.5 PLN/1 GJ :
0.8 Mg/h x 14 GJ/1t x 17.5 PLN/1 GJ = 196 PLN/h.
Total revenues from the operation of the system [1) + 2) + 3) + 4)] = 1 062 PLN/h.
When operating the system in the dimension of 8 000 hours per year, with 8 760 h per year,
annual revenues are at a height of approx. 8.5 million PLN.
The simple payback period is estimated in this case for 1 year.
14. Biomultifuels summary
In the biomultifuels production process as described above you can control the calorific value
of multifuels obtained by changing the saturation level of biomass components. This allows
you to adjust the calorific value multifuels to the construction of power boiler, so that energy
efficiency and ecological his work as high as possible.
You can design and build a wide variety of fuel-energy systems and “closed circuit material
and energy”, in which the "waste work to waste." Their diversity and technological base of
operation are limited only by designers and technologists imagination.
The great variety multifuels also follows from the fact that to produce them one can use the
biomass of different forms, eg. crushed into sawdust - adapted to power burners dust, chips -
suitable for gasification in gas-generators of synthesis gas and wood chips/pellets - adapted
for stoker-fired boilers. Besides of thet the components one can use them in a natural pure
form or use paraffin-“glicer” emulsions, paraffin - alcohol emulsions and the “glicer” -
alcohol emulsion, in terms of renewable energy sources.
15. Examples of waste biomass and sludge management combined system
Biomass waste is a valuable biofuel that is produced by the forces of nature and emerging as a
result of human economic activity not only in rural areas but also in cities. The source of
waste biomass (biofuels) in the cities are : forest parks, allotment gardens, parks, promenades,
cemeteries, stadiums, lawns, etc. As well as municipal sewage plants produce sludge.
Rational management requires proper use of advantages of energy waste biomass.
Rational biomass waste will be discussed on the example of the proposed system for the big
city, in which biomass waste and sewage sludge are working in a closed circulation of
materials and energy. In this system waste biomass is involved in drying sewage sludge and
dried sewage sludge including biomass waste are involved in the production of electricity and
heat.
The amount and properties of waste biomass fuel in big city (example)
• The volume of biomass harvested annually in big city 55 000 m3 / a
• The volume of the above crushed biomass crushed 14 000 m3 / a
• Bulk density of raw chips 400 kg / m3
• Relative humidity of raw chips 60 %
• The mass of raw wood chips 5 600 Mg / a
• The calorific value of the raw chips 6 000 kJ / kg
• Limit of autoenergetic gasification process 5 800 kJ / kg
• The energy potential of raw wood chips 33 600 GJ = 9.333 MWh
• The mass of wood chips dried to a relative humidity of 30 % 3 110 Mg / a
• The calorific value of drained chips 10 800 kJ / kg
• The energy potential of drained wood chips 33 600 GJ = 9,333 MWh
• Equivalent mass of coal worth calorific operating 25 000 kJ / kg 1 333 Mg / a
• Thermal power source (biomass) with uniform (8 760 hours per year)
load of 1.065 MW
A specific type of waste biomass are sewage sludge. Sewage sludge belong to the group of
hazardous waste. The Big City Wastewater Treatment Plant (example) created their 150 tons
per day.
.
The quantity and fuel properties of sewage sludge available for disposal :
• The amount of sludge : 150 tons / d, 6.25 Mg / h, 54 900 Mg / a
• Relative humidity deposits 80 %
• The dry matter content of 20 %
• Theoretical total mass of dry biomass 10 980 Mg / a
• Weight of biofuels, ie sludge dried to a moisture content of 30 % 16 000 Mg / a
• The calorific value of dried biofuels 10 800 kJ / kg
• The energy potential of biofuels 172 800 GJ = 47 777 MWh
• Equivalent mass of coal worth calorific 25 000 kJ / kg 6 912 Mg / a
• Thermal power source (biofuel) at steady (8 760 hours per year) load 5.454 MW
Mass – Energy Balance
• Thermal power sources - biomass 1.065 MW
• Thermal power sources - biofuel 5.454 MW
• Total year-round thermal power 6.520 MW
• The amount of sludge drained 6.250 Mg / h
• Unit energy consumption net drying 1 Mg sediment for 1 hour ~ 0.522 MWh
• Separate the gross energy consumption to dry
1 Mg sediment for 1 hour (steam drying efficiency : 65%) of ~ 0.8 MWh
• Energy demand for drying 6.250 Mg of sludge within 1 hour ~ 5 MWh
• Power needed for drying sludge of 6.25 tons per hour ~ 6.25 MW
• Available year-round source of thermal power 6.52 MW
• The relative amount of ash in the dried biomass (wood chips) 0.4%
• The amount of ash from dried biomass (wood chips) 12.44 Mg / a
• The relative amount of ash in the dry matter
mineralized by the fermentation process 20 %
• The amount of ashes from biofuels 2 196 Mg / a
• The total amount of the ashes 2 208 Mg / a
• The amount of by heat dried biomass :
chips 0.355 Mg / h 3 110 Mg / a
biofuel 1.825 Mg / h 16 000 Mg / a
a total 2.180 Mg / h 19 110 Mg / a
• The unit amount of exhaust gas from the process of
thermal utilization of dried biomass 3.6 Nm3 / kg
• The amount of exhaust gas from thermal processes of
dried biomass utilization 68.8 million Nm3 / a
7 854 Nm3 / h
2.2 Nm3 / s
Ecological Power Plant as an example of a rational system of biomass and waste
energy management
With various technologies use energy values of different groups of generic waste
biomass can assemble different lines for the comprehensive utilization of waste.
Among the many different possible arrangements for the comprehensive utilization of
bio-waste, which operates according to the principles of rational comprehensive
system, is eco-power (CHP) using sewage sludge. Action ENVIRONMENTAL
POWER PLANT, as an example of a complex economy, are given below.
Fuel energy in the form of dried sewage sludge energetically enriched with organic
fuel communal in the tray Z1.
Tray Z1 stored energy fuel in an amount to provide a multi-day work of the power
plant. A fuel is transported to the gasifier G by conveyor T1.
Conveyor belt conveyor T1 are electrically driven. The electric motor is controlled
electronically, and his work is automatically synchronized with the operation of the
automatic dispenser gasifier G.
Gas generator G is the power unit with the gasification process. Gas generator is a source of
high energetic gas rich in carbon monoxide and hydrogen. The synthesis energy gas is
directed from the gasifier G to the afterburner D (stream of "cold" gas gz).
Afterburner turbo-thermo-reactor D has special construction, in which the post-
combustion produced in a gasifier synthesis gas is burning in temperature 1200 0C.
An important characterized element of Thermoreactor is retention time fumes. Thermoreactor
design provides retention time of the flue gas in the burning area 0,5 - 2 seconds.
In the gasifier and afterburner followed by the stabilization of the exhaust gas temperature
too. The retention time of the exhaust gas and the temperature is kept within the limits in
order to prevent an increase in emissions of nitrogen oxides. In the case of temperature rise
over 1200 0C to the reservoir of organic carbon is supplied superheated steam from the steam
boiler KP or water (condensate).
The steam supplied to the gasifier has four functions :
• lowers the temperature of the synthesis gas to 900 0C so that the metal oxides do not get into
the exhaust gas,
• synthesis gas enriched water gas emerging energy of the endothermic reaction C + H2O =
CO + H2
• diluted exhaust,
• led to full bed gasification of organic carbon (char).
A remnant of the process of the pyrolysis fu is ash in the amount of approx. 5% of the batch
volume. The ash and the minerals are periodically scraped. The stream of hot and stabilized
exhaust gases gc obtained from the afterburner D is then routed to the boiler KP.
Steam boiler KP, which is to address the hot and stabilized exhaust gases works as a waste
heat boiler. This boiler at nominal conditions produces superheated steam in an amount of 5.6
Mg / h at a pressure of 26.5 bar and temperature 380 0C. The stream of hot gas after putting
the heat in the waste heat boiler is directed as a stream of raw exhaust sn, the band filters ZF.
The band filters ZF is a block fluidized bed flue gas cleaning station. This station includes a
three-phase filter ensures cleaner performance standards set by the European Union.
Contaminated exhaust gas has a temperature (200-300) 0C after passing through the filter unit
ZF penetrate as cleaned flue gas SO2, to the chimney PK.
Chimney PK - part of the installation - creates the basic technological line of Ecological
Power Plant and its design and dimensions closely correspond complex process. Element
structurally related to the exhaust flue is fun WW.
Extractor fan WW fulfills an important function in the system. Fan drive scripting system
automation and control keeps the pressure within the system at the appropriate level and
determines the intensity of the processes of gasification and heat dissipation by the exhaust
gases. The cleaned flue gases are emitted into the atmosphere.
Steam Boiler KP is a steam generator with a "high" performance, which stream b is
transferred to the transmitter PM - transducer pair - Mechanical Movement.
AM transmitter is a team of two steam engines operating on a common shaft. The
parameters of the steam boiler are selected so that closely correspond to the input parameters
of steam engines. The first of the engine reduces the vapor pressure from 26.5 bar to 12 bar.
The second - from 12 bar to 1.5 bar steam at a temperature of 116 0C. On a common shaft
steam engine is placed converter ME - mechanical-electrical converter.
The transmitter ME is a three-phase generator with the power of 635 kW processing into
electricity approx. 11% of heat energy.
Electric Power Network SE has parameters 220/380 V, 50 Hz. Between the generator and
the grid is set electricity meter, which indications are the basis for settlements between
producer and buyer power.
Guides PM - ME - commercial steam generator gets the steam process with "high"
performance and the execution of its work reflects the process steam with "low" parameters,
the so-called a vapor waste (waste heat). Vapor waste has 116 0C temperature and pressure of
1.5 bar. Vapor waste stream is directed to the condenser KS.
KS condenser cools and condenses vapor waste. As a result of condensation of vapor waste
are produced condensate - water at 90 0C, which streams d is pumped to the water treatment
plant SUW.
Water Treatment Plant WTP de-mineralized water, treats her to work in a complex with the
technological parameters. The treated water is directed to the steam boiler and KP stream.
Steam-water circuit a-b-c-d-a is a closed circuit.
KS capacitor is essentially action the steam sewage sludge dryer derived from a sewage
treatment plant on the OS so selected parameters that waste steam from the generator has
steam parameters input to the dryer.
Dryer sewage sludge KS by A stream of sludge assumes a degree of hydration of about 80%
with about 20% dry weight. The water evaporated from the sludge stream that is directed to
the wastewater treatment plant OS.
Sewage Treatment Plant OS on one side adopts post-process water coming from the drying
sludge, on the other hand is a source of organic fuel system of communal stream B driven on
the conveyor T2.
T2 conveyor belt or screw moves the sludge of about 30% hydration, a dry biomass content
of about 70%, to the reservoir of organic dry biomass Z2.
Z2 tank is a tank of transition collecting dry organic matter equivalent to several days of
work Power. The dry organic biomass is drained from the tank Z2 by transporters Tt1 and T1.
Tt1 conveyor belt or screw forward part of the dried waste tray Z1 complementing the supply
of alternative energy and turning it into ecologically correct and commercially reasonable
closed cycle of matter in nature.
Tt2 conveyor belt can discharge a dried residue on the outside of the plant.
Ecological power plant shown in the figure can realize a closed circuit of biomass waste, ie.
can with the participation of waste biomass to produce such a quantity of dried waste sludge,
which will satisfy the energy requirements for drainage of additional quantities of raw sludge
and produce electricity (picture 10) discharged to the network.
Estimated energy balance of the system
• power thermal energy input of 6.52 MW
• dissipation of thermal energy (12%) 0.77 MW
• power thermal energy supplied to the steam engine of electric generator 5.75 MW
• power electricity efficiency (~ 11%) 0.63 MW
• power thermal energy on dryers input ~ 5.00 MW
Methods for improving the energy balance of the system
In case of shortage of energy :
- You can increase the amount of biomass waste used as a natural biofuel,
- You can reduce the amount of drained sludge,
- Can be in municipal wastewater treatment plants applied microbiological preparation
"Trigger 2", which changes the secondary structure of the sludge. It is estimated that the
change in the structure of deposits can cause a reduction in energy consumption of the drying
process deposits by 5%,
- Should take advantage of ash waste heat,
- Should take advantage of waste heat condensate discharged into the sewage treatment plant
in the amount of approx. 4.2 Mg per hour.
In the case of heat excess :
- You can allocate the surplus power for sale,
- You can allocate the surplus thermal energy for technological purposes in sewage treatment
plants and / or for sludge drying,
- Be part of the hot syngas before afterburner pick up and when it is cooled and cleaned gas as
a fuel for gas engines that drive generators to produce additional quantities of electricity for
sale.
Conclusions
1. Sewage sludge are not utilized systematically in the main. Most of these are simply
deposited on sedimentary plots. These kind of waste are left to municipalities. It
municipalities are obliged to implement the technology to complete the work of the sewage
treatment plant.
A small part of sediments containing a small load of heavy metals is used commercially for
fertilizer purposes. Sometimes it happens that the sediments tcontains 80% water, they can
not be used for agriculture for economic reasons. Transport costs so moist sludge fertilizer in
many cases exceed the revenues from the sale of these fertilizers.
Negligible part of the sludge is dried and used for further energy. And as demonstrated in this
work - this is the most effective way of getting rid of sediment. This method is costly and is
therefore not applied until used for drying the sludge expensive conventional energy sources.
The situation changes radically when drying sludge is used properties of these fuel deposits
and biomass of different origin.
In this case we can say that from an energy point of view the "biomass waste and sludge
recycle themselves."
2. There is a set of equipment for the energy utilization of sewage sludge and other biomass
for drying sewage sludge.
3. The drying sludge brings ecological effects. Is reduced because the need for energy
consumption equivalent amount of coal: 1.333 tons of carbon per year (chips) and 6.912
metric tonnes of coal per year (biofuel). A total annual reduction of carbon, therefore is 8.245
metric tonnes.
The energy sector and district heating based on conventional fuels are the main source of
environmental pollution. Power is responsible for the discharge to the atmosphere of 70% of
the total emissions of carbon dioxide, 63% sulfur oxides, 41% nitrogen oxides and
particulates 30% and 10% of waste.
Below are the effects of environmental and financial savings due to reduced emissions of
harmful substances into the atmosphere as a result of the replacement unit (metric tonne) of
traditional fuels with renewable energy resources (biomass).
This analysis showed that the replacement of one metric tonne of coal with calorific value of
18.8 MJ / kg, renewable energy sources will reduce carbon dioxide (CO2) emissions by
nearly 2.2 tons, sulfur dioxide (SO2) by 20 kg, 7 kg of dust, nitrogen oxides (NOx) by 5 kg
and heavy metals of 0.8 kg. They will also be reduced solid waste by 284 kg.
Emissions associated with the burning of 1 metric tonnes and 8.245 tons of coal are shown in
Table 1.
Table 1
Specification 1MT of coal 8,245 MT of coal
Calorific value MJ/kg 18.8 -
CO2 (kg) 2 200 18.139.000
SO2 (kg) 20 164.900
Dust (kg) 7 57.715
NO× (kg) 5 41.225
Heavy metals 0.8 6.596
4. Financial effects of work of the system
a) Reduction of emissions to the atmosphere will result in financial savings due to not brought
charges for their implementation. These benefits have been calculated based on the expected
ecological effects – 8 € by the burning of the 1 MT of coal.
In this case the financial savings achieved by replacing coal with biomass in the amount of :
8,245 MT x 8 €/MT = 65,960 €
b) Additional financial benefits of replacing carbon by renewable energy sources (biomass)
except that contributes to the reduction of environmental pollution, it also reduces the
expenditure on the purchase of coal. Currently the purchase cost of 1 MT of coal is 50 € / MT.
Such financial effects get so giving up the use of units of this fuel. Resigning from the
purchase of 8,245 tons of coal per year will therefore be the emergence of savings in the
amount of 412,250 €.
c) Financial benefits also result from the fact that there is no additional charge for the disposal
of sludge. For companies performing tasks ecological processes of drying sludge can be a
source of revenue as the adoption of recycling 1 MT of sewage sludge can download fee of a
minimum of 20 €. Thus, the total annual revenue associated with the adoption of 54,900 MT
of sludge for disposal is the amount of 1,098 million € . Additional financial benefits resulting
from the sale of electricity transmission to the National Energy System. With energy
production of 600 kWh / h and selling it at a price of 0.05 € / kWh obtained revenues per hour
30 € / h and annual revenues in the amount of 240 400 €/a. .
The cumulative effect of the financial per year : {a) + b) + c) = 1 816 210 €}
It is a measure of the achieved environmental effect, otherwise - is a measure of relief the
environment felt. The investment is built up but not to a year but, for example, for 10 years.
Consequently, the integrated environmental effect in Euro is 18 million euros and is much
bigger than the value of the investment. ………………………………………………………..
Summary
The use of waste biomass as fuel in a closed-circuit material and energy yield tangible
ecological and economic profits. These effects can be the basis of "business plans"
determining the acquisition of investors funds for the implementation of environmentally
friendly investments.
Energy Charter EU - guidelines for the future
Poland is a signatory to the Energy Charter Protocol the European Union on energy efficiency
and related environmental aspects.
The protocol is signed on the basis of :
- European Energy Charter adopted in the Final Act of the Hague Conference on the European
Energy Charter signed at the Hague on 17 December 1991 ,
- Treaty of the European Energy Charter of 17 October 1994,
• The protocol introduces the concept of the Energy Cycle.
"Cycle Energy means the entire energy chain, including activities related to prospecting,
exploration, extraction, processing, storage, transport, distribution, consumption of the
various forms of energy and processing and waste disposal, as well as the decommissioning,
cessation or closure of these activities while minimizing environmental impact."
• Protocol encourages innovative approaches to investing in energy efficiency improvements,
such as third-party financing and co-financing.
• Protocol sample list of possible areas of cooperation provides an analysis of energy
efficiency in refining, conversion, transport and distribution of hydrocarbons.
• The Protocol introduces, with regard to municipal waste, the concept of the energy cycle.
Energy Charter EU also introduces the concept of whole energy cycle.
If the concept of "The Cycle Energy" understood as a “Closed Cycle Energy”, this means that
the waste matter should be proceed as Nature progressing of Renewable Energy Sources.
