Waste treatment process and apparatus

• US 7,658,155 B2
• Filed: 06/06/2006
• Issued: 02/09/2010
• Est. Priority Date: 06/29/2005
• Status: Active Grant

• Current Assignee: Advanced Plasma Power Limited
• Original Assignee: Advanced Plasma Power Limited
• Inventors: Chapman, Chris, Deegan, David, Ovens, David, Ismail, Saeed
• Primary Examiner(s): Silverman; Stanley
• Assistant Examiner(s): Smith; Jennifer A
• Application Number:
  US11/577,336
• Publication Number:
  US 20080097137A1
• Time in Patent Office: 1,344 Days
• Field of Search: 588/311, 110/250, 110/346, 219/121.36, 219/121.38
• US Class Current: 110/346
• CPC Class Codes: F23G 2201/303 Burning pyrogases
• CPC Class Codes: F23G 2201/304 Burning pyrosolids
• CPC Class Codes: F23G 2201/40 Gasification
• CPC Class Codes: F23G 2203/50 Fluidised bed furnace
• CPC Class Codes: F23G 2204/201 Plasma
• CPC Class Codes: F23G 2206/203 with a power/heat generating installation
• CPC Class Codes: F23G 2900/50208 Biologic treatment before burning, e.g. biogas generation
• CPC Class Codes: F23G 5/006 General arrangement of incineration plant, e.g. flow sheets
• CPC Class Codes: F23G 5/02 with pretreatment
• CPC Class Codes: F23G 5/027 pyrolising or gasifying stage pyrolisation of sludge C02F11/00; destructive distillation of carbonaceous materials C10B53/00
• CPC Class Codes: F23G 5/085 High-temperature heating means, e.g. plasma, for partly melting the waste
• CPC Class Codes: F23G 5/30 having a fluidised bed
• CPC Class Codes: F23G 5/46 Recuperation of heat
• CPC Class Codes: Y02E 20/12 Heat utilisation in combustion or incineration of waste

Abstract

A process for the treatment of waste, the process comprising: (i) either (a) a gasification step comprising treating the waste in a gasification unit in the presence of oxygen and steam to produce an offgas and a char, or (b) a pyrolysis step comprising treating the waste in a pyrolysis unit to produce an offgas and a char; and (ii) a plasma treatment step comprising subjecting the offgas and the char to a plasma treatment in a plasma treatment unit in the presence of oxygen and, optionally, steam.

Claims

1. A process for the treatment of waste, the process comprising:

(i) a gasification step comprising treating the waste in a gasification unit in the presence of oxygen and steam to produce an offgas and a non-airborne, solid char material; and

(ii) a plasma treatment step comprising subjecting all said offgas and the non-airborne, solid char material to a plasma treatment in a plasma treatment unit in the presence of oxygen and, optionally, steam, wherein the plasma treatment unit is separate from the gasification unit.

2. The process of claim 1 further comprising a pyrolysis step prior to the gasification step.

3. A process as claimed in claim 1 wherein the waste is gasified during the gasification step at a temperature greater than 650°

C.

4. A process as claimed in claim 3, wherein the waste is gasified during the gasification step at a temperature of from 800°

C. to 950°

C.

5. A process as claimed in claim 1 wherein the amount of oxygen introduced to the gasification unit during the gasification step is from 300 to 350 kg per 1000 kg of waste fed into the gasification unit.

6. A process as claimed in claim 1 wherein the amount of steam introduced to the gasification unit during the gasification step is up to 300 kg per 1000 kg of waste fed into the gasification unit.

7. A process as claimed in claim 1 wherein the waste contains less than 20% by weight of moisture and the amount of steam introduced to the gasification unit during the gasification step is from 300 to 350 kg per 1000 kg of waste fed to the gasification unit.

8. A process as claimed claim 1 wherein the waste contains 20% or more by weight of moisture and the amount of steam introduced to the gasification unit during the gasification step is from 0 to 150 kg per 1000 kg of waste fed to the gasification unit.

9. A process as claimed in claim 1 wherein the gasification step is carried out in a fluid bed gasification unit.

10. A process as claimed in claim 1 wherein the waste is fed to the gasification unit through an air-lock device.

11. A process as claimed in claim 1, wherein the process further comprises subjecting the waste to a microbial digestion step prior to the gasification step.

12. A process as claimed in claim 11, wherein the microbial digestion is aerobic microbial digestion.

13. A process as claimed in claim 12, wherein the microbial digestion is carried out in an aerobic microbial digestion unit in which the oxygen content of the gas in the unit is not less than 5% by volume.

14. A process as claimed in claim 12, wherein the aerobic microbial digestion is carried out in a rotary aerobic digestion unit.

15. A process as claimed in claim 14, wherein the waste is rotated in the rotary aerobic digestion unit at a rate of from one revolution every minute to one revolution every ten minutes.

16. A process as claimed in claim 11, wherein the moisture content of the waste prior to microbial digestion is from 20 to 75% by weight.

17. A process as claimed in claim 11, wherein the waste has an average moisture level of 30% or less by weight after the microbial digestion treatment.

18. A process as claimed in claim 1 wherein the gasification unit and the plasma treatment unit are in fluid connection.

19. A process as claimed in claim 1, wherein the ratio of oxygen to steam in the plasma treatment step is from 10:

1 to 2;

5, by weight.

20. A process as claimed in claim 1, wherein the plasma treatment of the waste is carried out at a temperature of from 1100 to 1600°

C.

21. A process as claimed in claim 1, wherein the plasma treatment of the waste is carried out in the presence of a plasma stabilizing gas.

22. A process as claimed in claim 21, wherein the plasma stabilizing gas is selected from one or more of nitrogen, argon, hydrogen, carbon monoxide, carbon dioxide and steam.

23. A process as claimed in claim 1, further comprising collecting the gas produced in the plasma treatment unit.

24. A process as claimed in claim 1, further comprising collecting the solid and/or molten material produced in the plasma treatment unit.

25. A process as claimed in claim 1, wherein the gas produced from the gas plasma treatment is used in a gas engine or gas turbine to generate electricity.

26. A process as claimed in claim 2, wherein the waste is pyrolysed during the pyrolysis step at a temperature of 400°

C. or more.

27. A process as claimed in claim 1, further comprising the step of drying the waste before its treatment in the gasification step.

28. A process as claimed in claim 27, wherein waste is dried by using the heat produced in any of the other steps of the process.

29. A process as claimed in claim 27, wherein the waste is dried by blowing heated air or steam over or through the waste.

30. A process as claimed in claim 27, wherein the moisture content of the waste immediately before treatment in the gasification is 20% or less by weight.

31. A process as claimed in claim 30, wherein the moisture content of the waste immediately before treatment in the gasification step is 15% or less by weight.

32. An apparatus for carrying out the process as defined in claim 1, the apparatus comprising:

(i) a gasification unit and

(ii) a plasma treatment unit which is separate from the gasification unit, wherein the gasification unit has an inlet for oxygen and optionally an inlet for steam and the plasma treatment unit has an inlet for oxygen and optionally an inlet for steam, and means are provided for transporting all said offgas and the solid, non-airborne char material from the gasification unit to the plasma treatment unit.

33. An apparatus for carrying out the process as defined in claim 11, the apparatus comprising:

(i) a microbial digestion unit,

(ii) a gasification unit which is separate from the microbial digestion unit, and

(iii) a plasma treatment unit wherein the gasification unit has an inlet for oxygen and optionally an inlet for steam and the plasma treatment unit has an inlet for oxygen and optionally an inlet for steam, and means are provided for transporting all said offgas and the solid, non-airborne char material from the gasification unit to the plasma treatment unit.

34. An apparatus as claimed in claim 32, wherein the gasification unit is adapted to gasify the waste at a temperature of more than 650°

C.

35. An apparatus as claimed in claim 32, wherein the gasification unit is adapted to gasify the waste at a temperature of at least 800°

C.

36. An apparatus as claimed in claim 32, wherein the gasification unit contains an airlock device through which the waste can be introduced into the gasification unit.

37. An apparatus as claimed in claim 32, the apparatus further comprising a unit for microbial digestion of waste.

38. An apparatus as claimed in claim 37, wherein the unit for the microbial digestion of waste is a rotary aerobic digestion unit.

39. An apparatus as claimed in claim 32, wherein the apparatus comprises a microbial digestion unit, and the microbial digestion unit is in fluid connection with the gasification unit, and the gasification unit is in fluid connection with the plasma treatment unit, to allow waste treated from the microbial treatment to be transported to the gasification unit, and to allow offgas and char resulting from the gasification step to be transported to the plasma treatment unit.

40. An apparatus as claimed in claim 39, wherein the apparatus is adapted to treat the waste in a continuous process.

41. An apparatus as claimed in claim 32, further comprising a gas engine or gas turbine for generating electricity, the turbine being in fluid connection with the plasma unit, so that the plasma-treated gas from the plasma unit can be fed to the turbine.

42. An apparatus as claimed in claim 32, further comprising a pyrolysis unit.

43. An apparatus as claimed in claim 33, further comprising a pyrolysis unit.

44. An apparatus as claimed in claim 42, wherein the pyrolysis unit is adapted to pyrolyse the waste at a temperature of at least 400°

C.

45. A process as claimed in claim 1, wherein the waste comprises refuse derived fuel.

46. The process of claim 11 further comprising a pyrolysis step prior to the gasification step and after said microbial digestion step.