Proprietary Waste Conversion Pyrolysis technology
The Waste Conversion Pyrolysis technology implements a high-temperature continuous feed pyrolysis process and transforms mixed municipal waste that comes unsorted to the landfills into 90-98% of combustible syngas and 2-10% of solid carbon char which has further use.
In order to meet the needs of today's polluted environment, our Waste Conversion Pyrolysis units are constructed with a production capacity of 305 TPD (with average waste moisture content 60%), assuming 40 TPD (15%) of recyclable materials are filtered out at the pre-processing line for further sale and that 265 tons of waste with average moisture content 60% per day are converted into energy. The electric energy output is 5+ MW (depending on the feedstock).
Process flow diagram incorporating a waste pre-processing line offered by the German manufacturers (Weima/Westeria/Spaleck):
The modular design of our systems allows for multiple processing lines making the whole system capacity infinitely expandable. A multi-system comprising 3 modules is recommended by GLES to allow for quick and timely service without interrupting the conversion process and to ensure constant guaranteed energy supply to the consumers.
Based on the required project capacity, each Waste Conversion Pyrolysis system will be made up of one or several processing lines, or modules, operating independently. A layout of the WCP waste treatment complex comrising three processing lines is provided below:
The systemís components:
The waste materials initially pass a pre-processing line comprising a sorting line, a shredder, a dryer and a bunker for pre-processed waste. The sorting line filters out recyclable goods which cannot be pyrolized: metals, glass and inerts like concrete, stones, sand, ceramics, etc. These materials, usually making for 15-20% of the initial amount, can be sold to the recyclables' market as an additional source of income for the project. The remaining waste will go into a shredder, where it is chipped up to 50 mm in diameter and then sent off to the dryer. The dryers are used to lower moisture content in the feedstock to 20% in order to produce higher power generating results.
Passing the bunker the waste materials are then conveyed into the pyrolytic chamber through a specifically designed loading unit with a series of valves and gates being synchronized to prevent unwanted oxygen or air from entering the chamber. The production capacity of the reactor is 125 TPD with waste moisture content 20% (which equals to approx. 265 tons of waste with average moisture content 60%). A pyrolytic process which applies indirect heat in an environment free of flame and oxygen is the most important stage. Subjected to temperatures as high as 700-750C the waste is reduced to a carbon char residue and a gaseous product - syngas. The amount of carbon residue is 2-10% of the initial feedstock mass, depending on its composition. Specific temperature continuously maintained in the process chamber, eliminates any dioxins or furans in the carbon char residue, allowing further use of this by-product.
Waste heat from the reactor is recovered and reused in order to minimize outside energy sources used in the operation of the system.
The syngas is then directed to a thermal oxidizer for further degradation leaving the solid carbon char to drop through a retort chamber floor. Inside the oxidizer the gasses are combusted at temperatures exceeding 1200C for 2,5-3 seconds, which allows for molecular decomposition of dioxins, furans and other harmful components contained therein while completely destroying them.
Thermal energy captured from the oxidized gas is converted into high-temperature steam supplying energy to turbine generators which in turn produce clean electrical power. Alternatively, the system can produce hot water.
We maintain a consistency in power generation because there is never a limit of waste material.
The oxidized off-gasses are dealt with using our gas cleaning system comprising a bag house and a wet scrubber with De-NOx system ensuring control of the off-gas composition and compliance with strictest world's air quality standards. According to resluts of the independent testing conducted by SGS, WCP off-gases can be safely released into the environment. The carbon char is collected for either sale as a useful product in asphalt production, as combustible fuel or alternate daily cover at a landfill.