Mobile units for plasma pyrolysis and plasma fractionation for produce fuel PLAZARIUM MPS

• Description

  PLAZARIUM MPS mobile plasma pyrolysis units intended for thermal degradation (pyrolysis) of carbonaceous waste to produce synthetic liquid fuel, carbonaceous residue and hydrocarbon gas, followed by rectification of liquid synthetic fuel into gasoline and diesel fractions, hydrocarbon gas and distillation residue into heavy hydrocarbon fraction, with further processing of heavy hydrocarbon fraction in plasma cracking unit to obtain a mixture of gasoline and diesel fractions and hydrocarbon gas. Possible raw materials for processing are oil slimes, plastics, tires, biomass, and municipal solid waste; removal of organic contaminants from the surface of pipes and various metal structures. PLAZARIUM MPS mobile plasma pyrolysis units can be used and integrated as an auxiliary unit for hybrid plant, together with plasma gasification unit for waste.

  Plasma pyrolysis unit consists of four separate or integrated units: Pyrolysis unit; Fractionation unit with fractionating column; Plasma cracking unit; Fuel storage unit (liquid synthetic fuel, heavy hydrocarbon fraction, gasoline and diesel fraction). Each unit is equipped with hydrocarbon gas exhaust system to the PLAZARIUM MGS plasma gasification unit and a system of carbonaceous residue exhaust from pyrolysis to the PLAZARIUM MGS plasma gasification unit; supporting systems equipment; independent digital and analog control automation and additional devices. The mobility of plasma pyrolysis unit structure provides ease of transportation, minimum assembly work at the site, and the possibility of parameter settings adjustment (with minimal cost of unit adaptation to the conditions of a particular company – on the composition and volume of recyclable waste). In addition to mobility, plasma pyrolysis unit offer modular design to improve performance, both of the entire process flow diagram, and individual units. This allows to combine different versions of flowsheet for processing a wide range of waste on the same fundamental base, represented by one to four 20/30/40-foot shipping containers (number of containers depends on the performance of plasma pyrolysis unit and its individual parts).

  Combustion chamber of pyrolysis and fractionation units is equipped with one or more versions of heating and temperature rising in the reactor: Oil burner - able to operate on any type of liquid fuel (diesel fuel, liquid synthetic fuel, oil, etc.). Electric heating elements - provide an opportunity to increase the rate of process stabilization facilitate the work process. Gas burner - able to run on natural gas, hydrocarbon gas produced during pyrolysis, fractionation and cracking, or synthesis gas coming from the plasma waste gasification unit.

  The main advantages of plasma waste pyrolysis unit with fractionation unit and heavy distillation residue plasma cracking unit: Mobility; Easy unit and waste processing control system operation; Easiness and safety during installation and operation; no contact between unit personnel and waste; Ability to work in the open air and in a wide range of ambient temperatures (from - 60 ° C to + 50 ° C) as well as at high humidity (environment settings defined by the terms of reference for the development of waste processing pyrolysis unit); Use of synthesis gas (СО + Н2) from plasma gasification unit to maintain the temperature in fractionation reactor offers the advantage of heating process, process stabilization, and temperature maintenance cost reduction, as well as absolute ecology of the process and increased volume of the fuel produced; Total environmental friendliness of waste processing: all pyrolysis residues are used as raw materials for PLAZARIUM MGS plasma gasification unit; Production of liquid synthetic fuel at the exhaust from the pyrolysis unit with subsequent fractionation and obtaining of gasoline and diesel fractions in the fractionation unit; Complete processing of heavy fractions residue into gasoline and diesel fuel in plasma cracking unit delivers process from heavy residue and provides a significant increase in the amount of produced fuel (petrol and diesel fractions); Ability to operate directly in the place of waste collection and accumulation; Maximum allowable emission corresponds to GOST SanPiN 2.2.112.1.1.567-96 and regulations of the EU Directive. Note! In case of plant’s hybrid design consisting of combination of two units (PLAZARIUM MPS plasma pyrolysis unit and PLAZARIUM MGS plasma gasification unit), atmospheric emissions are completely absent. In case of plant’s hybrid design consisting of combination of two units (MPS plasma pyrolysis unit and PLAZARIUM MGS plasma gasification unit), the ability to produce electricity, heat and fuel allows operating in fuel- and energy-independent mode.

• Application

  Recycling oil sludge and sludge pit sediments into synthetic liquid fuel and subsequent rectification of gasoline and diesel fraction Any kinds of oil sludge: Soil (as a result of unforeseen equipment occurrences or in emergency cases), Near-bed (as a result of oil spills sedimentation on the bottom of containers that accommodate a large amount of water), Reservoir (in different structures during transportation and storage) Formed directly during oil production. Oil sludge is hazardous waste, so choosing PLAZARIUM MPS plasma pyrolysis units and PLAZARIUM hybrid plants for its processing or disposal, you provide care for ensuring maximum work safety, impossibility of harmful components release into natural areas, and maximum ecological friendliness of the recycling process. Thermal effect in the pyrolysis reactor produces hydrocarbon gas with subsequent condensation into a synthetic liquid fuel and mineral residue as slag. Slag is used as a raw material for plasma gasification units, while liquid synthetic fuels can be commercialized in the production of gasoline and diesel fraction. Plasma pyrolysis technology based on PLAZARIUM MPS units is applicable for processing and recycling of secondary sludges and sediments followed by the production of motor fuel. More...

  Plasma pyrolysis of plastics into synthetic liquid fuel and subsequent rectification of gasoline and diesel fraction Thermal effect on plastics in the pyrolysis reactor produces a hydrocarbon gas with subsequent condensation into a synthetic liquid fuel and mineral residue as slag. Slag is used as a raw material for plasma gasification units, while liquid synthetic fuels can be commercialized in the production of gasoline and diesel fraction. Any kinds of plastics: PET, PETF - Polyethylene terephthalate (lavsan) (containers for mineral water, soft drinks and fruit juices, packaging, blisters, and lining); HDPE - High density polyethylene, low-pressure polyethylene (bottles, jars, rigiflex packaging); LDPE - Low density polyethylene, high-pressure polyethylene (tarpaulin, trash bags, bags, films and flexible containers); PP - Polypropylene (automobile equipment and bumpers, toys, food packaging, polypropylene pipes for water); PS - Polystyrene (slabs for heat insulation of buildings, food packaging, cups and cutlery, CD boxes and other packaging (food wrap and foam materials), toys, utensils, and pens); PVC - Polyvinylchloride (pipes, garden furniture, flooring, window profiles, blinds, duct tape, containers for detergents, and oilcloth) (Note 1). Other (Polycarbonates); Notes: 1 - PVC is potentially dangerous because it may contain dioxins, bisphenol A, mercury, and cadmium. Its processing by plasma pyrolysis to produce synthetic liquid fuel and subsequent rectification yielding gasoline and diesel fractions is possible only in the case of hybrid plant design combining of two units (PLAZARIUM MPS plasma pyrolysis units and PLAZARIUM MGS plasma gasification units).

  High-speed plasma pyrolysis of bituminous coals, brown coals, peat, coal slime and all types of oil shale to produce liquid synthetic fuel with subsequent rectification and production of gasoline and diesel fraction. Thermal treatment by the method of high-speed coal pyrolysis to produce primary products of processing (synthetic liquid fuels) and its additional ennoblement for quality stable fuel through fractional distillation (for producing gasoline from brown coals, 12÷13 wt% of hydrogen is added – hydrogenation: to obtain gasoline from coal, it is necessary first to disintegrate the initial coal into a finer material – fragments simple in structure – radicals, which then should be saturated with hydrogen). The additional hydrogen is obtained from synthesis gas through plasma gasification of bituminous coal, brown coals, peat, coal slime, and all types of oil shale.

  Plasma pyrolysis of tires and rubber products All types of tires: Automobile tires (from cars and trucks); Bicycle tires; Motorbike tires; Farm tires; A thermal effect on tires in the pyrolysis reactor produces hydrocarbon gas, followed by its condensation into synthetic liquid fuels and mineral residue as slag. Slag is used as a raw material for plasma gasification units, while liquid synthetic fuels can be commercialized in the production of gasoline and diesel fraction. Steel cord is graded out at the preparation stage or discharged through the mineral residue output system and is used as a raw material for sale.

  Plasma pyrolysis of municipal solid waste (MSW) PLAZARIUM MPS mobiles units may be employed for use on MSW landfills for plasma pyrolysis to yield hydrocarbon gas followed by its condensation into synthetic liquid fuels and mineral residue as slag. Slag is used as a raw material for plasma gasification units, while liquid synthetic fuels can be commercialized in the production of gasoline and diesel fraction using fractionation unit and heavy-fraction plasma cracking unit.

  Plasma pyrolysis of wood waste into synthetic liquid fuel with subsequent rectification of gasoline and diesel fraction Any waste of timber processing; Unclaimed roundwood; Chips; Sawdust; Offcut; Bark;

  Plasma pyrolysis of biological and organic raw materials with subsequent production of fuel (gasoline and diesel fraction) Solid biofuels Liquid biofuels Poultry farms waste Pig farms waste Sugar factories waste Distilleries waste Olive production waste Other biological and organic waste

• Specification

  Pyrolysis unit: Specifications Value Pyrolysis unit capacity (Note 1) from 50 up to 1000 kg/h (from 1 up to 25 TPD) Feeding continuous or intermittent (once every 10-12 hours) AC mains voltage, V 3 phases, 380±10% (Note 2) Supply voltage frequency, Hz 50/60 Power consumption of basic technological equipment, kW for every 2.5 tons per day up to 20 Weight average temperature in pyrolysis reactor, °С up to 650 Weight average temperature in combustion chamber, °С up to 750 Fuel condensation system cooling water, closed (Note 3) Range of operating ambient temperature, °С from - 60 up to + 50 Overall dimensions, L×W×H, m correspond with the size of shipping containers (20/30/40 feet) Number of containers from 1 to 2 and more (Note 4) Total unit weight, tonnes from 8 to 40 (depending on the capacity) Operation mode (duty cycle factor) Continuous (Restarting=100%) Fractionation unit: Specifications Value Fractionation unit capacity (Note 1) from 50 to 1000 litters per hour (from 1 to 25 tons per day) Feeding continuous or intermittent (once every 10-12 hours) AC mains voltage, V 3 phases, 380-400 ±10% (Note 2) Supply voltage frequency, Hz 50/60 Power consumption of basic technological equipment in kW for every 2 tons per day up to 5 Operating temperature in fractionating column, °С up to 380 Weight average temperature in fractionating reactor, °С up to 560 Weight average temperature in combustion chamber, °С up to 680 Fuel condensation system cooling water, closed (Note 3) Range of operating ambient temperature, °С from - 60 to + 50 Overall dimensions, L×W×H, m correspond with the size of shipping containers (20/30/40 feet) Number of containers from 1 to 2 and more (Note 4) Total unit weight, tonnes from 6 to 30 (depending on the capacity) Operation mode (duty cycle factor) continuous or non-stop (100% duty cycle in 2 shifts) Plasma cracking unit: Specifications Value Plasma cracking unit capacity (Note 1) from 30 to 1000 kg per hour (from 0.5 to 25 tons per day) Feeding continuous / intermittent AC mains voltage, V 3 phases, 380-400 ±10% (Note 2) Supply voltage frequency, Hz 50/60 Power consumption of basic technological equipment, kW corresponds to 10% of plasma system power Plasma system power, kW from 50 and more (depending on unit capacity) Operating temperature in the contact area of plasma jet and processed material, °С 1000-1400 Fuel condensation system cooling water, closed (Note 3) Range of operating ambient temperature, °С from - 60 to + 50 Overall dimensions, L×W×H, m correspond with the size of shipping containers (20/30/40 feet) Number of containers from 1 to 2 and more (Note 4) Total unit weight, tonnes from 3,5 to 30 (depending on the capacity) Operation mode (duty cycle factor) Continuous (Restarting=100%) Fuel storage unit: Specifications Value Volume of fuel for storage and exchange between pyrolysis, distillation and plasma cracking units (Note 1) corresponds to double capacity of pyrolysis, fractionation and plasma cracking unit Types of stored fuel liquid synthetic fuel, heavy hydrocarbon fraction, gasoline and diesel fractions AC mains voltage, V 3 phases, 380-400 ±10% (Note 2) Supply voltage frequency, Hz 50/60 Power consumption of basic technological equipment, kW 2 Range of operating ambient temperature, °С from - 60 to + 50 Overall dimensions, L×W×H, m correspond with the size of shipping containers (20/30/40 feet) Number of containers from 1 to 2 and more (Note 4) Total unit weight, tonnes from 1 to 40 (depending on the capacity) Operation mode (duty cycle factor) continuous, non-stop (100% duty cycle) Notes: 1 - Production of units on order for plasma pyrolysis with capacity up to 80 tons per day (HGP-3000) and up to 100 tons per day (HGP-5000) is possible. 2 - Power source provides automatic adjustment to any input voltage in the range of 380-450 V for three phases. 3 - Selection of cooling depends on the terms of reference for the development of plasma pyrolysis unit. 4 - The unit is based on standard 20/30/40 feet-containers; the number of containers from 1 to 6 or more (depends on the desired parameters of disposal, number, and capacity of basic units, type of waste, and customer's request). 5 - All parameters of plasma pyrolysis unit are manufactured according to customer's request.

• List of Equipment

  Pyrolysis unit: Item Number, pieces Hopper, service platform, and raw materials charging system 1 Pyrolysis reactor 1 Combustion chamber with heating system (oil burners, gas burners, electrical heating elements) 1 Heat exchanger 1 Gas separator 1 Gas drying column 1 Hydrocarbon gas cooling and condensation system 1 Fuel storage and pumping system 1 Pyrolysis unit control system 1 Solid residue discharge system for use in plasma gasification unit 1 Smoke removal system, transmission of hydrocarbon gas to the plasma gasification unit and feeding synthesis gas to the gas burners of the combustion chamber 1 Guide and complete design and technical documentation manuals 1 Fractionation unit with fractionating column: Item Number, pieces Fractionating column 1 Fractionation reactor 1 Combustion chamber with heating system (oil burners, gas burners, electrical heating elements) 1 Heat exchanger 1 Gas separator 1 Gas drying column 1 Hydrocarbon gas cooling and condensation system 1 Fuel storage and pumping system 1 Fractionation unit control system 1 System of heavy residue output to plasma cracking unit 1 Smoke removal system, transmission of hydrocarbon gas to the plasma gasification unit and feeding synthesis gas to the gas burners of the combustion chamber 1 Guide and complete design and technical documentation manuals 1 Plasma cracking unit: Item Number, pieces Complete set of PLAZARIUM TPS plasma system 1 Plasma cracking reactor 1 Viscous heavy residue heating and feeding into plasma cracking unit 1 Heat exchanger 1 Gas separator 1 Hydrocarbon gas cooling and condensation system 1 Fuel storage and pumping system 1 Plasma cracking unit control system 1 Smoke removal system, transmission of hydrocarbon gas to the PLAZARIUM MGS plasma gasification unit 1 Guide and complete design and technical documentation manuals 1 Notes: 1 - The unit is based on standard 20/30/40-feet containers; the number of containers from 1 to 2 per unit (depends on the capacity of each unit, type of waste, and customer's request). 2 - The completing units of a plant and parameters of plasma pyrolysis unit are manufactured according to customer's request.