Waste machine with 20t daily capacity
Developed an patented method ( low temperature, continuous pyrolysis), it can produce energy carriers from any kind of organic waste, solid waste (fuel, fuel oil, gas, pyro-carbon or matched complementery devices(gasmotor, generator), that can produce electricity and steam energy.
The system is totally autonomic, automatic, safety.
The complex is eco safety and totally eco-friendly.
We can ship the version of mobile as well.
The complex is able to recycle the following waste
– household solid waste
– agriculture facilities/farms waste
– technical rubber waste, rims
– oil-contained waste
Briefly about the technology
At the end of the description you will find the operating scheme, that shows the basic machine, which convert the waste into liquid-, gas form and solid energy carriers.
The waste processing has 2 parts ( mechanical shredding and thermal pyrolysis), which is merged into a continuous technological progress.
The machine is installed on a strong frame. In the bunker of the mill – the raw material is palced in the collection tank, which is shredded mechanically, then it is processing with pyrolysis; end of the process the classifier- and distributor system separate the end products, like: liqued, solid- and gas form end products, which as energy carriers will be recycled.
The machine is able to supply continuous raw material to the mill (no casetta,etc). The process is totally automatic, the temperature of pyrolysis does not exceed the +700 Celsius. The machine does not emit any toxic, harmful materials. The safety operation of the complex is guaranteed by the structure solution.
Analysis of laboratory prove, that the related substance to the oil-gasoline- kerosine fractional mixture in the component and quality can be certificated and used as alternative fuels for oil boiler.
After further rectification, it can exploit gasoline, diesel, fuel and oil from the mixture.
As long as, the processed waste will be exploited mainly as heat and/or electricity, the extracted liquid raw material does not need further retification.
The operation of the machine
After the separation of the organic parts, the household waste does not need further separation, it can go into the mill bunker, where it will be dried with a calorifer (heater-dryer) at the top of the bunker.
The waste will be compact in the size of 5-8mm at the bottom of the bunker. The shredded and compact waste will form a cork, that close hermetically the entrance of the rotating reactor. The waste warm up to more than +100°C during the friction.
When the material get to the rotating reactor, the blast will drop suddenly, the water boils up explosively in the cork and disintegrate. The rotating reactor is placed into a common rezervoir with the burner and a cooling tank. The shredded waste proceed into the rotating reactor and warm up by the burner and due to the external heat.
The process occurs without adding oxygen, when it reaches +(450–650)°C the destruction (thermolysis) of the raw materials come up, in form of steam- and gas fraction or pyro-carbon.
The mixture will cool down at the last stage of the reactor rezervoir and then goes to another tank. The conveyor belt of the water tank brings up the pyro-carbon to the collection container.
The flue gases go to the chimney, which has another chimney tube inside; then it carries the steam-gas fraction to the separators, where the fluid, tarry pyrolysis liquid and the air in it, solid soot parts will be separated.
The steam-gas part of the fraction goes to the capacitor from the separators, where the steam is emitted from the mixture, The remaining steam-gas fuel-mixture goes to the column of retification, over there it warms up to +350°C and distilled to the liquid fraction of petrol products.
The remaining gas fraction is gathering into the rezervoir, then as a heater goes back to the burner of the rotating reactor and the column of retification.
The processing of the waste-pyrolysis, the pyrolysis liquid with a pump goes back to the rotating reactor.
Water pumped through the cooler tank and goes back to calorifer, it transfers the heat of the pyro-carbon through the calorifer to the wet waste in the bunker.
The technical data and price of the machine
Dimension of the machine: 2,4m x 2,4m x 10m;
Weight of the machine: 12 tons;
Energy consumption: 20 kWh;
Operating mode: continuous;
Production capacity: 20 tonna/24óra;
Staff : 3-4 people/shift;
Production time: 6 months from the order;
Prototype price: 2 500 000 EUR.
End product
Depending on waste component, the waste-pyrolysis end products are the following:
| The type of waste | The products of pyrolysis, % mass. | |||
| Synthetic fuel
|
Pyro-gas | Pyro-carbon,
|
Pyro-water | |
| Solid household waste | 55 | 13 | 15 | 8 |
| Tire (rim) | 60 | 10 | 28 | 2 |
| Plastic | 88 | 7 | 3 | – |
| Wood waste | 50 | 18 | 27 | 10 |
| Guano (birds manure), manure
(dry – 15% wet
|
41 | 25 | 20 | 14 |
| Peat | 50 | 27 | 14 | 9 |
| Oil derivatives (clay)
|
42 | 12 | 27 (mineral materials) | 10 |
| Straw, tegument
|
51 | 20 | 26 | 3 |
| Livestock waste
(dry -10-15% wet)
|
40 | 25 | 20 | 15 |
It consists of gas-kerosine-oil fraction in 75-80 %; it is like oil and fuel oil with +56°C outbreak degree (blaze) and – 40°C freezing temperature.
After retification, diesel and/or gasoline can be exploited. The quantity of the engine fuel is 10-15% less, than the synthetic fuel at starting point.
The daily processing capacity of the machine (20tons), in case of solid household waste, it can produce the following oil products in quantity and quality :
M40 quality liquid fuel -10 tons
As the diagram shows, 18tons fuel can be produced from the fraction of plastic of the pretreated waste
Further retification of the end product is 10tons for fuel oil
Gasoline – 3tons (quality is on the diagram) Diesel – 3tons, Oil – 3tons;
Red gas: components – methane, propane, hydrogen, monoxide. The red gas calorific value is up to 20MJoule/m³. The red gas will be used in the waste-pyrolysis technology for the synthetic fuel retification and its power generation.
Pyro-carbon: It depends on the type of the waste, it has a solid (rim and plastic utilization) or micropore (wood waste, peat, straw) structure and it is semi charcoal. The pyra-carbon calorific value is like Donetsk coal.
Utilization: as a solid fuel, it is used in the metallurgical industry or as an absorbent in the industrial water purification
Pyro-water: water condensate, which consists of low molecule organic acids, phenol, ammonium, organic bases and soluble tar.
The above mentioned technology is build on the new generation machine, that is radically different from the cyclic pyrolysis machine, so it has not have the following shortcomings:
– non hermetic bunkertop
– large amount of heat input at the starting point
– huge reactors, that explosive and flammable
– Cooling the reactor with inert gases, that can cause reactor defects
– Cyclic reactor needs safety valve, that increases the environmental damage;
– Small production capacity with large metal and energy capacity
Advantages of the machine
- Continuous operation mode, without pause
The machine does not have safety valve and other elements, which could connect the machine to the outer environment
- No waste separation by hand
- The bunker continuous raw material utilization is automatic, that illuminates any human factor
- Starting the process needs low energy input
- The machine provides the energy for the operation
The raw material goes to the reactor shredded, where it is stirred intensively; that make the waste-polyrysis efficient
- We use our designed shredder, that consumption is10kWh, it is very unique in the world
The machine is totally safe for the staff
- No toxic materials in the machine, like dioxin, fenol, sulphide, benzopyrene, hydrogen-chloride, etc. beacuse of the continuous low temperature
- It is a patented machine, that eco-, explosive- and flammable safe
- The machine does not have toxic output
ROI of the machine for processing 20tons daily
Price of the machine with tax: 3 125 000 EUR;
The quantity of the processed waste: 6.900 tons/year( 0,83 tons/hour);
Variant – the finished product of the stove in fuel oil and pyro-carbon (carbon)
Variant –the annual quantity of the finished products
Liquid stove fuel oil: 3.450 tons/year;
Pyro-carbon (carbon): 1.035 tons/year;
Selling price of he finished products with tax on the A variant
Liqued stove fuel oil: 660 EUR/tons;
Pyro-carbon (carbon): 5 EUR/tons;
Annual income on the A variant with tax:
Liquid stove fuel oil: 2.277.000 EUR;
Pyro-carbon (carbon): 5.175 EUR;
Net, annual income after tax according to the A variant:
Gross income with tax: 2.282.175 EUR;
Operation expensis (10%) with tax: – 228.217 EUR;
Deductible tax 25%: – 456.435 EUR;
Taxes (Corporate tax – 19%+ Local industry tax – 2%):
[(2.282.175 EUR-228.217 EUR-456.435 EUR) x
x 0,19 + (2.282.175 EUR-228.217 EUR) x 0,02] =
= 303.529 EUR+41.865 EUR = 345.394 EUR;
Total net, annual income after tax according to the A variant: 2.164.999 EUR;
B variant – Gasoline, diesel, fuel oil and pyro-carbon (carbon) finished products
B variant – The annual ammount of the finished products:
Gasoline: 3 tons /day x 345 days= 1.035 tons;
Diesel: 3 tons /day x 345 days= 1.035 tons;
Fuel oil: 3 tons /day x 345 day= 1.035 tons;
Pyro-carbon (carbon): 1.035 t/year;
Selling price of the finished products with tax according to B variant:
Gasoline: 275 Ft/l= 1 EUR/l;
Diesel: 275 Ft/l= 1 EUR/l;
Fuel oil: 0,6 EUR/l;
Pyro-carbon (carbon): 5 EUR/tons;
Annual income with tax according to B variant:
Gasoline: 1.035 tons x 1.100 l/tons x 1 EUR/l= 1.138.500 EUR;
Diesel: 1.035 tons x 1.100 l/tons x 1 EUR/l= 1.138.500 EUR;
Fuel oil: 1.035 tons x 900 l/tons x 0,6 EUR/l= 558.900 EUR;
Pyro-carbon (carbon): 5.175 EUR;
Net, annual income after tax according to B variant:
Gross income with tax: 2.841.075 EUR;
Operating expenses (10%) with tax: – 284.107 EUR;
Deductible tax 25%: – 568.215 EUR;
Taxes (Corporate tax – 19%+ Local industry tax – 2%):
[(2.841.075 EUR-284.107 EUR-568.215 EUR) x 0,19 +
(2.841.075 EUR-284.107 EUR) x 0,02] = 377.863+51.139= 429.002 EUR;
Total net, annual income after tax according to B variant: 2.696.181 EUR;
Declaration of the quality of the synthetic fuel (with pyro-water)
| N | Indicators | Dimension | ||
| 1. | Density at +20°C, [kg/m3] | 893,9 | GOSZT 3900 | |
| 2. | Water mass fraction [%] | 0,3 | GOSZT 2477 | |
| 3. | Chloride salt concentration [mg/l] | 83,6 | GOSZT 21537 | |
| 4. | Fire point in closed jar [°C] | 0 | GOSZT 6356 | |
| 5. | Relative (fraction) composition | GOSZT 2177 | ||
| Temperaure at the beginning of distillation[°C] | 72 | |||
| Distillation up to +100°C, [% quantity] | 7,0 | |||
| Distillation up to +150°C [% qnt.] | 30,0 | |||
| Distillation up to +200°C, [% qnt.] | 58,0 | |||
| Distillation up to +250°C [% qnt.] | 72,0 | |||
| Distillation up to +300°C [% qnt.] | 78,0 | |||
| Distillation up to +350°C [% qnt.] | 91,0 | |||
| End of the source, [°C] | 354 | |||
| End, [% qnt.] | 94 | |||
| 6. | Kinematic viscosity: +20°C, [mm²/s]
+40°C, [mm²/s] |
2,05
1,50 |
DSZTU GOSZT 33 | |
| 7. | Gross calorific value, [Kjoule/kg]
[kcal/kg] |
38789,22
9257,6 |
GOSZT 21261 | |
| Distillation: +200°C (fuel fraction) | ||||
| 8. | Detonation resistance:
– octan rating: with research method – octan rating: with motor method |
86,7
84,3 |
IROX 2000, express analyzator | |
| 9. | Mass fraction of Benzol, [%] | 4,26 | EN 238 | |
| 10. | Aromatic hydrocarbons whole content
[% qnt.]
|
46,48 | EN 238 | |
| 10.1 | – toluene, [% qnt.] | 12 | ||
| 10.2 | – xylene, [% qnt.] | 4,6 | ||
| 10.3 | – ethyl-benzol, [% qnt.] | 17,4 | ||
| 11. | Mass fraction of Olefins [%] | 8,2 | IROX 2000, express analyzator | |
| 12. | Color of distillation | yellow | ||
