03.06.2015

From Concept to Technology and Construction of Demo Waste-to-Energy Facility.

 

GLES is not a new comer on the Waste-to-Energy market. We have made a long way on the “clean energy generation and sustainable waste disposal” road – from the philanthropic and very abstract idea of delivering mankind from landfills to the WCP (waste conversion pyrolysis) technology implementation and demo-facility construction.  Currently we have reached the breaking point where the emerging sustainable technology gradually penetrates into business environment and becomes an integral part of every advanced society. Innovative technology is what makes any market “go round” and especially the emerging one. We have gained a considerable experience in implementing innovative sustainable technology and would like to share it defining three benchmarks in form of advices for younger experts and curious colleagues.

 

1. Consult many times and various experts before giving up the concept implementation.

 

Initially the company started out as a discussion about the alternative waste treatment methods. Then the idea became so pressing that Alex Feerer, that in far 2006 Alex Feerer (president and founder of the company) began drafting up technical plans for a large-scale waste-to-energy unit in collaboration with American academics and engineers, but they finally doubted technology implementability.

 

Nevertheless, a very reputable team of scientists and design engineers from Moscow has finalized production blue-prints, assembling documentation, construction and foundation drawings, owner's manual, automation system and programming of a new high-temperature pyrolysis system. 

 

2. The principle “The best is the enemy of the good” can work sometimes, but not in the innovative technology market . Estimate you concept by the number of technical challenges – the more of them you face, the more state-of-the-art idea you have. Respond them and the technology will become even more unique and innovative.

 

An emerging market suggests only serious challenges especially while dealing with the innovative technological solutions, as no one can suggest you to learn from the prior experience and no one can know anything for sure. In case with GLES the main technology challenges we faced were:

 

·    To find the right production partners and work out the manufacturing techniques. The most difficult thing was to produce the large sections of the pyrolysis reactor’s retort from casted iron. We had to develop a special formula to allow the retort withstand the aggressive atmosphere it is exposed to during the conversion of mixed municipal waste and stay corrosion resistant.


·    To arrange the process under 700-750C in an oxygen-free atmosphere which allows transforming waste materials into a gaseous product (pyrolysis gas) and a carbon char residue. Responding to this, the specific temperature regime and innovative reactor design, which both have not been implemented previously on a commercial scale, were chosen to avoid the main problems of the prior low-temperature pyrolysis systems. To name few, they produced char contaminated with dioxins, liquid fractions of heavy tar and were very unstable in terms of feedstock variances and energy generation from the process gas. Those systems could not be continuously operated due to long downtime required to clean the reactor from tar and incompletely converted waste materials and fix the mechanisms inside it.

 

3. Do not ignore spending time and money for certifications and licensing, as one day it will work for you.

 

One of the most frequent questions we still get almost every day is about the ecological safety guarantees. This is also about operating on the emerging market where there are only several or no alternative solutions, no big market players using the same technology to appeal to. We had to create preproduction model and officially check the emissions quality.

 

The full-scale ready-to-use pilot facility implementing GLES’ Waste Conversion Pyrolysis technology was launched. Then the independent international agency SGS (a worldwide leader of the certification, expertize, control and testing services market) made the environmental expertize of the WCP pilot facility, and released the official report.

 

The obtained results of the off-gas emissions and carbon char testing confirmed compliance of the equipment and technological process to the environmental standards imposed by Environmental Protection Agency (EPA) of the USA. Testing has revealed extremely low concentrations of dioxins providing the best proof of complete decomposition and destruction of these contaminants in the process.

 

Testing results have strengthened our confidence in the operational characteristics of the facility, and the SGS signed report is the official “credibility passport” of the technology now.


Currently GLES launches commercial sales of the unique Waste Conversion Pyrolysis Equipment. The company manufactures and supplies key equipment of the Waste Conversion Pyrolysis that generates electrical energy, harvests process heat, reclaims industrial-grade water, and minimizes or even  eliminates the need for a landfill while processing  municipal solid waste (MSW).


Kindly watch the video showing WCP facility in operation during tests.


We are glad to announce that the full set of the equipment documentation including operations manual is completed and commercial production is launched.

For more photos from the production site please visit Photo Gallery.