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© StarPower Italia - 2005 Plasma Special Waste Treatment Tetronics / StarPower Italia experience Technology for a cleaner environment
© StarPower Italia - 2005 Overview Who we areMMG/CDC The MarketsCDC Environmental DriversCDC Tetronics Environmental Plasma System (TEPS)CDC Cost AnalysisMMG Waste Management in the production cycleMMG ConclusionMMG
© StarPower Italia - 2005 StarPower Italia s.r.l. is a limited liability company actively engaged in promoting and marketing innovative waste management technology in Italy since 2002. StarPower Italia is the Tetronics ltd agent in Italy. Starpower Italia s.r.l. - who we are
© StarPower Italia - 2005 Tetronics Limited – who we are World Leader in thermal plasma applications >30 years experience Proven, established technology International and credible customer base 33 environmental solutions engineered to date (upto 35,000 tonnes per year, 9MW) Key Environmental Sectors Inorganic waste treatment (Haz waste) Organic waste treatment (Haz + Non Haz) Commercial operations and plant supply Advanced Rand D facilities >1MW Power, 6 operating stations
© StarPower Italia - 2005 Tetronics: The Markets 1 Clean Heat Market leader in heating of steel in continuous casting process, 25 systems predominantly in the far East Customers include Posco, NSC, NKK, Sumitomo, Kobe Advanced Materials Prime opportunity is in the synthesis of powders Strategic alliance with QinetiQ for nanotechnology Most advanced processing facility in UK for thermal production of nanopowders Opportunities in micron powders and glass melting
© StarPower Italia - 2005 Tetronics: The Markets 2 Environmental Market Inorganic wastes Extensive commercial experience: Recovery of precious metals from autocats (US, South Korea) Treatment of steel plant dusts (Italy, US) Vitrification of incinerator ashes (Japan) Organic wastes Major opportunity in treatment of hazardous organic and mixed wastes Oily sludges and solvents Food, meat and other agro-wastes Clinical and pharmaceutical wastes LLRW
© StarPower Italia - 2005 ENVIRONMENTAL FACTORS -More severe regulations -Landfill of certain wastes restricted -Avoidance of leaching of toxins -Prevention of dioxins and toxic gases POLITICAL FACTORS -Targets for reduction in landfill -Recycling/utilization -Energy recovery -Sustainable, clean solutions -Support of clean technologies ECONOMIC AND SOCIAL -Limited landfill and landfill tax -Increased cost of disposal -Tax incentive schemes -Recovery of energy by CHP -Poor perception of incineration PLASMA TREATMENT OF WASTES ENVIRONMENTAL BENEFITS - Efficient destruction of organics - Vitrification of wastes - Meets most severe standards - Non-toxic slag ECONOMIC & SOCIAL BENEFITS - Revenues from electrical generation - Cost savings from avoidance of landfill - Saleable by-product TECHNICAL BENEFITS - High energy efficiency - Robust, reliable, simple and flexible - Easy to automate - Proven in wide range of applications - Clean Environmental Drivers: Hazardous Wastes
© StarPower Italia - 2005 TEPS: Solution to Hazardous wastes Strong regulatory and economic drivers Clean process solution Robust and proven DC Plasma arc technology Simple to operate and maintain High destruction efficiency of persistent organics Stable vitrified slag, with good utilization potential Minimisation of waste by-products Recycling of valuable metals Economic Strong position within the waste management hierarchy
© StarPower Italia - 2005 PLASMA ZONE > 10,000 K High Temperature Destruction of Organics Metallic Phase Recovery of Metal Value High Intensity UV Catalysis of Photo-Chemical Reaction Environmentally Stable Slag Repository for Heavy Metals Furnace Off Gas Combustible Gases and Volatile Species TEPS: Typical Plasma Reactor
© StarPower Italia - 2005 TEPS: Inorganic / Organic Haz Waste Treatment Metallurgical residues, contaminated soils, incinerator ashes, asbestos LLRW, contaminated meat, oil sludges, solvents, POPS, clinical, No oxidant added to furnaceAir, water or oxygen added to furnace Raw material < 5% carbon. Furnace off gas has no significant calorific value Raw material > 5% carbon. Furnace off gas has calorific value (CO and H 2 ) INORGANIC (vitrification/smelting) ORGANIC (gasification)
© StarPower Italia - 2005 PYROLYSIS 2 mH 2 nCOOHC mn 22 HCOOHC OC 2 2 1 INPUTSOUTPUTS FEED OXIDANT GAS SLAG METAL CO, H 2, CO 2, H 2 O, HCL, Zn, Pb, Hg etc MeO (e.g. SiO 2, CaO, Al 2 O 3, P 2 O 5, Cr 2 O 3, FeO etc) Me (Fe, Cu, etc) C n H m …..MeO, Me, O, S, Cl, P etc H 2 O, O 2, Air GASIFICATION FEATURES High destruction efficiency High UV and temperature Metal recovery Non leachable slag TEPS: Process Mechanism
© StarPower Italia - 2005 WASTE MATERIALS FLUXES PLASMA CONVERTOR PLASMA POWER SLAG PRODUCT SECONDARY OXIDATION, COMBUSTION GAS CLEANING SECONDARY USES, RECYCLING, SAFE DISPOSAL HEAT RECOVERY PROCESS PREHEATINGHOT WATER / STEAMELECTRICITY GENERATION OXIDANT (AIR, WATER) Organic waste only METAL PRODUCT TEPS: Key Stages
© StarPower Italia - 2005 TEPS: Process Flow Sheet
© StarPower Italia - 2005 FEED RECEIVER GAS DISCHARGE GAS CLEANING THERMAL OXIDISER PLASMA REACTOR PRODUCT DELIVERY SHREDDER TEPS: Layout of a Plasma Waste Treatment Plant
© StarPower Italia - 2005 TEPS Product Utilization Cycle PLASMA TREATMENT WASTE MATERIAL CHP PLANT STEAM/ ELECTRICAL Vitrified Product Export of electricity Production of chemicals, hydrogen
© StarPower Italia - 2005 TEPS:Typical composition and impurities of Syn-gas Gas SpeciesVolume % H2H2 20-40 CO20-30 CO 2 <5 N2N2 <20 CnHmCnHm <1 Pollutantmg/Nm 3 SOx<10 HCl<5 CO<20 NOx<20 Heavy Metals<1 Syn-gas qualitySyn-gas Pollutants
© StarPower Italia - 2005 Plasma Convertor PRIMARY ASH ~ 50ng TEQ/g SLAG<0.001 ng TEQ/g SECONDARY FLY ASH Gas Handling < 0.005 ng TEQ/g TEPS: Plasma Destruction of Dioxins GAS EMMISSION < 0.05ng TEQ/M 3
© StarPower Italia - 2005 TEPS: Leachate Test results (steel dust)
© StarPower Italia - 2005 Cost Analysis Tetronics can provide custom-made solutions optimized to address specific waste problems Capital costs are dependant on the type and quantity of waste to be treated When the waste chemical composition is known StarPower Italia can employ its financial analysis model to forecast costs of disposal and Return of Investment rates
© StarPower Italia - 2005 Cost Analysis Case study – 50 tpd plant / pharmaceutical waste / 348dx24h / tipping fee 0.41 €/kg 1.6MwH torch 0.09 €/kWh power costs Labour rates per year: Plant Manager88,000 euro Shift Supervisor26,000 euro System Operator26,000 euro Assistant x 326,000 euro Other (secretary)23,000 euro
© StarPower Italia - 2005 Break even point for plant in operation after 9 months from start of project without considering revenues from system by-products Cost Analysis
© StarPower Italia - 2005 Cost Analysis
© StarPower Italia - 2005 The TEPS TM can be easily integrated into companies existing production cycle to treat their waste streams Reduce waste management costs in the balance sheet Generates by-products and energy that could be fed in the production cycle Guarantees the compliance with all current and future environmental regulations Produce valuable products from “GARBAGE” Waste Management in the Production Cycle
© StarPower Italia - 2005 Conclusion TEPS TM is as an effective and versatile solution for the treatment of hazardous waste streams The products arising are readily recycled, reused or disposed of in a safe manner The slag products are stable and non-leachable Potential savings by diverting vitrified slag product away from landfill Technical risk minimised by industrial track record Economic risk stabilised against future regulatory drivers
© StarPower Italia - 2005 StarPower Italia s.r.l. Tetronics Ltd: www.star-power.it www.tetronics.com For more information:
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