6. Technology Presentations

6.2 (b) Argon Plasma

Mr. Robert Hawkes, Australia

Argon Plasma

Robert HawkesSLR Plasma Ltd., Australia

Process Description

The argon plasma ODS destruction technology is an "in flight" plasma process,which means that the waste mixes directly with the argon plasma column. Argonwas selected as the plasma gas since it is inert and does not react with the torchcomponents. Waste is rapidly heated (one millisecond, or ms) in the reactionchamber (a flight tube) to about 3000°C, where pyrolysis occurs in about 20 ms.Oxygen is added at the injection manifold to ensure that any carbon formed duringpyrolysis is converted to carbon monoxide. Pyrolysis is followed by rapid (2 ms)alkaline quenching from 1500°C to less than 100°C. Such rapid quenchingprevents the formation of dioxins and furans. The cool gas from the quench isfurther scrubbed with alkaline liquor in a counter-current packed column toneutralize HCl and other acid gases. The off-gas from the column, which consistsmainly of CO, H2, Ar and some CO2, then passes to a small ground flare thatconverts CO to CO2 and H2 to H2O.

A destruction efficiency of 99.9999% has been achieved at destruction rates of150 kg/hr. The halide salt solution from the scrubbing system is stored anddischarged on weekends to the local municipal wastewater treatment systemduring periods of reduced industrial activity.

Development and Operating History:

The argon plasma arc process, was developed in Australia by SRL Plasma Ltd. inconjunction with the Commonwealth Scientific and Industrial ResearchOrganisation (CSIRO). The process was developed over an eight year periodand commercialized in 1992 with extensive pilot studies on various CFCs andhalon compounds being conducted in 1993.

The plant was commissioned at Australia's National Halon Bank for the destructionof Australia's surplus halons and CFCs in 1996 and since then about 1000 MT ofHalon 1011 and about 100 MT of CFCs have been destroyed at destruction ratesof 115-120 Kg/hr. Key advantages of this process are the very high destructionefficiencies and negligible dioxins/furans emissions demonstrated on acommercially operating system. Direct costs of the electricity, argon, sodiumhydroxide (caustic) and other consumables and maintenance involved in thedestruction of halon 1211 are estimated at US$570/t.

United Nations Environment Program

ODS Disposal Workshop

United Nations Environment ProgramUnited Nations Environment Program

ODS Disposal WorkshopODS Disposal Workshop

OVERVIEW OF PRESENTATIONOVERVIEW OF PRESENTATIONOVERVIEW OF PRESENTATION

!! PLASCON PLASCONTMTM - development overview - development overview

!! SRL Plasma - business profile SRL Plasma - business profile

!! Plasma technology overview Plasma technology overview

!! Case study - ODS Destruction Case study - ODS Destruction"" Research IssuesResearch Issues

"" Plant Design CriteriaPlant Design Criteria

"" Operational ExperienceOperational Experience

"" PerformancePerformance

"" EconomicsEconomics

!! The international need? The international need?

DEVELOPMENT OVERVIEWDEVELOPMENT OVERVIEWDEVELOPMENT OVERVIEW

!! 1987 Generic technology grant from Federal 1987 Generic technology grant from Federal Gov’tGov’t..

!! 1990 Nufarm Ltd - 1990 Nufarm Ltd - GreenpeaceGreenpeace (dioxin in effluent?) (dioxin in effluent?)

!! 1992 First pilot plant installed - Nufarm Ltd 1992 First pilot plant installed - Nufarm Ltd

!! 1993 “Independent Panel” request ODS trial 1993 “Independent Panel” request ODS trial

!! 1993 MOU with Federal 1993 MOU with Federal Gov’t Gov’t - accelerated R&D- accelerated R&D

!! 1995 ODS Conversion Agreement signed 1995 ODS Conversion Agreement signed

!! 1995 Second Nufarm PLASCON 1995 Second Nufarm PLASCONTMTM installed installed

!! 1997 SRL Plasma ODS operations underway at NHB 1997 SRL Plasma ODS operations underway at NHB

!! 1997 BCD Technologies PCB PLASCON 1997 BCD Technologies PCB PLASCONTMTM installed installed

SRL PLASMA LTDSRL PLASMA LTDSRL PLASMA LTD

!! Wholly owned division of Wholly owned division of SiddonsSiddons Ramset Ltd Ramset Ltd

!! Incorporated in 1993Incorporated in 1993

!! SRL Plasma business mission:SRL Plasma business mission:"" “SRL Plasma is in the business of developing, manufacturing and“SRL Plasma is in the business of developing, manufacturing and

marketing the PLASCON™ process to companies in themarketing the PLASCON™ process to companies in thehazardous waste destruction business or to companies which inhazardous waste destruction business or to companies which inthe course of producing useful products generate hazardousthe course of producing useful products generate hazardousorganic by-products”organic by-products”

!! The business has won 3 awards for PLASCON™The business has won 3 awards for PLASCON™"" Australian Chemical industry Council Australian Chemical industry Council Env’t Env’t Award - 1993Award - 1993

"" Engineering Excellence Award - 1994Engineering Excellence Award - 1994

"" Society of Chemical Industry - “Plant of the Year” - 1998Society of Chemical Industry - “Plant of the Year” - 1998

COLLABORATIVE R&D AGREEMENTCOLLABORATIVE R&D AGREEMENTCOLLABORATIVE R&D AGREEMENT

50:50 Funding50:50 IP

50:50 Funding50:50 Funding50:50 IP50:50 IP

Sub LicenceSub Licence

RoyaltyRoyaltyRoyaltyRoyalty

Exclusive Licence

Exclusive LicenceExclusive Licence

ELECTRIC-ARC PLASMA TECHNOLOGY ELECTRIC-ARCELECTRIC-ARC PLASMA TECHNOLOGY PLASMA TECHNOLOGY

!! What is an electric-arc plasma?What is an electric-arc plasma?"" Ionised gas capable of carrying an electric currentIonised gas capable of carrying an electric current

!! Why use plasma for waste destruction?Why use plasma for waste destruction?"" Superior destruction performance without toxic by-productsSuperior destruction performance without toxic by-products

"" Very high energy density - leads to compact processVery high energy density - leads to compact process

"" Thermal process - very versatileThermal process - very versatile

"" Safety - rapid shut down without loss to the environmentSafety - rapid shut down without loss to the environment

!! The “in-flight” plasma processThe “in-flight” plasma process"" Waste gas or liquid is injected directly into the plasma gasWaste gas or liquid is injected directly into the plasma gas

PLASCON™ TORCH & FLIGHT TUBEPLASCONPLASCON™™ TORCH & FLIGHT TUBE TORCH & FLIGHT TUBE

AnodeAnodeAnodeAnodeAnodeAnodeAnodeAnode

DC+DC+ WasteWaste

FLIGHT TUBEFLIGHT TUBE

Cooled LinerCooled Liner

DC-DC-

TempTemp(C)(C)

10,00010,000

7,5007,500

5,0005,000

2,5002,500

12,50012,500

CathodeCathodeCathodeCathodeCathodeCathodeCathodeCathodeArgonArgon

PLASMAPLASMA

TemperatureTemperature((ooCC))

Residence TimeResidence Time(Seconds)(Seconds)

1,0001,000

2,0002,000

4,0004,000

6,0006,000

>1>1

3.80 x 103.80 x 10-3-3

0.16 x 100.16 x 10-6-6

5.50 x 105.50 x 10-9-9

RESIDENCE TIME FOR THE DESTRUCTION OF TOLUENE TO ONE PART PER MILLION RESIDENCE TIME FOR THE DESTRUCTION RESIDENCE TIME FOR THE DESTRUCTION OF TOLUENE TO ONE PART PER MILLION OF TOLUENE TO ONE PART PER MILLION

IncinerationIncineration

PLASCONTMPLASCONTM

ProcessControlSystem

ProcessProcessControlControlSystemSystem

ScrubberScrubber

ArgonArgon

Waste FeedWaste Feed

OxygenOxygen

PackedPackedColumnColumn

Salts toEffluent

TorchTorch

Off GasOff Gas

FlightFlight TubeTube

CausticCausticMake-upMake-up

QuenchQuench

PLASCON™ PROCESS SCHEMATIC PLASCON PLASCON™™ PROCESS SCHEMATIC PROCESS SCHEMATIC

PowerPowerSupplySupply

NUFARM PLASCON™ FACILITY NUFARM PLASCON NUFARM PLASCON™ ™ FACILITYFACILITY

NUFARM - SECOND PLASCON™ NUFARM - SECOND PLASCON NUFARM - SECOND PLASCON™™

CASE STUDY - OZONE DEPLETION CASE STUDY - OZONE DEPLETION CASE STUDY - OZONE DEPLETION

!! Independent Panel on Intractable Waste (1991)Independent Panel on Intractable Waste (1991)

!! First Halon conversion trials at CSIRO (1992)First Halon conversion trials at CSIRO (1992)"" Destruction performance provenDestruction performance proven

"" Identified potential problemsIdentified potential problems

!! Extended Halon and CFC research trials for 3 yearsExtended Halon and CFC research trials for 3 years

"" CFCF4 4 emissions identified emissions identified

"" Inter-conversion of CFC’s identifiedInter-conversion of CFC’s identified

"" Severe corrosion evidentSevere corrosion evident

!! Focus on resolving design issuesFocus on resolving design issues

50kW ODS TEST RIG50kW ODS TEST RIG50kW ODS TEST RIG

PlasmaPlasmaSpeciesSpecies

Flight tubeFlight tubeSpeciesSpecies

DischargeDischargeProductsProducts

HALON 1211HALON 1211

COCO222 H2 H22OO

PyrolysisPyrolysis

1 C atom1 C atom2 O atoms2 O atoms4 H atoms4 H atoms2 F atoms2 F atoms11 Cl Cl atom atom1 Br atom1 Br atom

COCO22

2 HF2 HF HCl HCl HBr HBr

22 NaF NaF NaCl NaCl NaBr NaBr

QuenchQuench

44 NaOH NaOH

CFCF22BrClBrCl

Off-gasOff-gas

DESTRUCTION OF HALON 1211DESTRUCTION OF HALON 1211DESTRUCTION OF HALON 1211

ODS DESTRUCTION PLANT ODS DESTRUCTION PLANT ODS DESTRUCTION PLANT

!! Design criteriaDesign criteria"" Compliance with Compliance with Montreal Montreal Protocol - DE >99.99%Protocol - DE >99.99%

"" 1,500 tonne destruction capacity in 5 years1,500 tonne destruction capacity in 5 years

"" Regulatory compliance EPA, Water authorityRegulatory compliance EPA, Water authority

"" Must be capable of treating a variety of ODSMust be capable of treating a variety of ODS

!! Modular skid concept - developed by SRL PlasmaModular skid concept - developed by SRL Plasma

!! Research, Development & Demonstration ApprovalResearch, Development & Demonstration Approval"" PLASCON approved by Victorian EPAPLASCON approved by Victorian EPA

!! Skid construction - by Process Design & Fabrication P/LSkid construction - by Process Design & Fabrication P/L

PLASCON™ FACILITYTYPICAL SITE SCHEMATICPLASCONPLASCON™™ FACILITY FACILITYTYPICAL SITE SCHEMATICTYPICAL SITE SCHEMATIC

ArgonArgon

CoolingCoolingTowerTower

HalonHalonFeedFeed

Tanks Tanks

46% NaOH46% NaOH

Effluent Effluent

ProcessProcessControlControl

SRLSRL PlasmaPlasmaSupplySupply

PLASCON™ SKIDPLASCON™ SKIDPLASCON™ SKIDPowerSupply

MainsPowerMainsMainsPowerPower

Off-gas Off-gas

PLASCON™ INSTALLATION PLASCON™ INSTALLATION PLASCON™ INSTALLATION

!! Skid mounted 150 kWSkid mounted 150 kW PLASCON PLASCONTMTM Plant Plant

!! Size 2.1m x 6m x 3.5mSize 2.1m x 6m x 3.5m

PLASCON™

150kW ODS DESTRUCTION PLANTPLASCONPLASCON™™

150kW ODS DESTRUCTION PLANT150kW ODS DESTRUCTION PLANT

PLASCON™ PLANT - REAR VIEW PLASCON PLASCON™™ PLANT - REAR VIEW PLANT - REAR VIEW

PLASCON™ 200kW POWER SUPPLY PLASCON PLASCON™™ 200kW POWER SUPPLY 200kW POWER SUPPLY

HALON & CFC BULK STORAGE HALON & CFC BULK STORAGEHALON & CFC BULK STORAGE

PLASCON™ PLANT SERVICES PLASCONPLASCON™™ PLANT SERVICES PLANT SERVICES

PLASCON™ ODS OPERATIONS PLASCON PLASCON™™ ODS OPERATIONS ODS OPERATIONS

!! Destruction performanceDestruction performance"" Montreal Montreal Protocol target 99.99% DE, actual 99.999+%Protocol target 99.99% DE, actual 99.999+%

"" No dioxin formationNo dioxin formation

!! Plant utilisationPlant utilisation"" 24 hrs/day, 7 days/week, average 70% on-line24 hrs/day, 7 days/week, average 70% on-line

!! 1, 019 tonnes of Halon 1211 converted (between 97-99)1, 019 tonnes of Halon 1211 converted (between 97-99)

!! 84 tonnes of mixed CFC converted in 199984 tonnes of mixed CFC converted in 1999

!! Manning - two shifts/day 5 days. Weekends unmannedManning - two shifts/day 5 days. Weekends unmanned

!! Remote “on-line” monitoringRemote “on-line” monitoring

GC TRACE FOR HALON 1211 GC TRACE FOR HALON 1211 GC TRACE FOR HALON 1211

Halon 1211 Peak

HALON 1211 DREHALON 1211 DREHALON 1211 DRE

Feed Rate (kg/h)Feed Rate (kg/h) 118118 Stack Gas Temp (°C)Stack Gas Temp (°C) 3333Dry Gas Flow (m³/h)Dry Gas Flow (m³/h) 39.239.2 Discharge Velocity (m/s)Discharge Velocity (m/s) 6.16.1

Bulk Gas AnalysisBulk Gas Analysis Vol FlowVol Flow Mass FlowMass Flow

HydrogenHydrogenArgonArgonNitrogenNitrogenMethaneMethaneCarbon MonoxideCarbon MonoxideCarbon DioxideCarbon DioxideWater VapourWater VapourTotalTotal

(m³/h)(m³/h)0.00.0

24.824.80.10.10.00.01.71.79.79.71.01.0

37.337.3

(g/min)(g/min)00

6886882200

3434294294

13131,0311,031

Trace Gas AnalysisTrace Gas Analysis Vol FlowVol Flow Mass FlowMass Flow((mlml/h)/h) ((mgmg/min)/min)

Halon 1211Halon 1211UnknownUnknownTotalTotal

0.150.150.100.100.250.25

5.905.903.903.909.809.80

0.700.700.400.401.101.10

CompositionComposition

0.00.063.363.3

0.30.30.00.04.44.4

24.624.62.62.6

95.295.2

(vol%)(vol%)

CompositionComposition((vppmvppm))

ODS Destruction & Removal Efficiency = 99.99994%ODS Destruction & Removal Efficiency = 99.99994%

DIOXIN EMISSIONS (I-TEQ)DIOXIN EMISSIONS (I-TEQ)DIOXIN EMISSIONS (I-TEQ)

COST OF DESTRUCTION COST OF DESTRUCTION COST OF DESTRUCTION

Elements impacting on cost:Elements impacting on cost:

!! Plant & equipment depreciationPlant & equipment depreciation

!! Consumables, ie. electricity, argon, causticConsumables, ie. electricity, argon, caustic

!! Replacement parts, ie. certain wearing componentsReplacement parts, ie. certain wearing components

!! LabourLabour

!! MaintenanceMaintenance

!! Throughput rateThroughput rate

PLASCON™ THROUGHPUT PLASCON PLASCON™™ THROUGHPUT THROUGHPUT

Throughput varies for different waste typesThroughput varies for different waste typesand is a function of:and is a function of:

!! Molecular weight of the wasteMolecular weight of the waste

!! Number and strength of atomic bondsNumber and strength of atomic bonds

!! The allowable discharge limitsThe allowable discharge limits

!! The characteristics of the feedThe characteristics of the feed

"" liquid or gasliquid or gas

"" contaminants (water, oils etc)contaminants (water, oils etc)

"" particulates particulates (suspended solids, inorganics and metals)(suspended solids, inorganics and metals)

"" viscosityviscosity

PLASCON™ CONSUMABLES PLASCON PLASCON™™ CONSUMABLES CONSUMABLES

!! ElectricityElectricity"" 150 kW plasma torch + 50 kW for pumps etc.150 kW plasma torch + 50 kW for pumps etc.

!! ArgonArgon"" for plasma gas (bulk cryogenic liquid supply)for plasma gas (bulk cryogenic liquid supply)

!! Steam/OxygenSteam/Oxygen"" to convert C to CO (bulk cryogenic liquid supply)to convert C to CO (bulk cryogenic liquid supply)

!! Sodium hydroxide (Caustic)Sodium hydroxide (Caustic)"" to neutralise acid gases generated by pyrolysisto neutralise acid gases generated by pyrolysis

!! Wearing torch and flight tube componentsWearing torch and flight tube components"" the torch itself is very stable, some components are consumablethe torch itself is very stable, some components are consumable

PLASCON™ DIRECT COST FOR HALON 1211 PLASCON PLASCON™™ DIRECT COST DIRECT COST FOR HALON 1211 FOR HALON 1211

ElectricityElectricity14%14%

ArgonArgon19%19%

CausticCaustic44%44%

Other Consumables & Other Consumables & MaintenanceMaintenance

23%23%

Direct Cost: approx. US$570/tDirect Cost: approx. US$570/t

PLASCON™ DIRECT COST FOR R-22/R-12 MIXTURE PLASCON PLASCON™™ DIRECT COST DIRECT COST FOR R-22/R-12 MIXTURE FOR R-22/R-12 MIXTURE

ArgonArgon21%21%

CausticCaustic41%41%

ElectricityElectricity14%14%

Other Consumables & Other Consumables & MaintenanceMaintenance

24%24%

Direct Cost: approx. US$845/tDirect Cost: approx. US$845/t

PACKAGE COSTPACKAGE COSTPACKAGE COST

!! PLASCONPLASCONTMTM licence fee licence fee

!! PLASCON PLASCONTMTM royalty/kg ODS destroyed royalty/kg ODS destroyed

!! Turnkey PLASCON Turnkey PLASCONTMTM destruction plant including destruction plant including"" PLASCON skidPLASCON skid

"" PLASCON transformer/rectifierPLASCON transformer/rectifier

"" Process control hardware and softwareProcess control hardware and software

"" Total Above (ex works) Approx. Total Above (ex works) Approx. US$ 1million plusUS$ 1million plus

!! Additional items as required Additional items as required"" Waste feed tanks and feed pumpWaste feed tanks and feed pump

"" Effluent tanks, site engineering etc Effluent tanks, site engineering etc US$ POAUS$ POA

PLASCON™ LIMITATIONS PLASCON PLASCON™™ LIMITATIONS LIMITATIONS

!! Waste Physical PropertiesWaste Physical Properties"" can’t treat solids directlycan’t treat solids directly

"" soil remediation possible with ‘front-end’ extractionsoil remediation possible with ‘front-end’ extraction

"" not cost effective if waste is lightly contaminatednot cost effective if waste is lightly contaminated

!! Waste CompositionWaste Composition"" not suitable if waste contains significant heavy metalsnot suitable if waste contains significant heavy metals

"" mixed organic/arsenic pesticides probably treatablemixed organic/arsenic pesticides probably treatable

!! Scale UpScale Up"" 150 kW unit treats 1-3 tonnes/day, depending on waste type150 kW unit treats 1-3 tonnes/day, depending on waste type

"" multiple torch systems allow increased capacitymultiple torch systems allow increased capacity

PLASCON™ FEATURES PLASCON PLASCON™™ FEATURES FEATURES

!! Destruction is by pyrolysis Destruction is by pyrolysis NOTNOT COMBUSTIONCOMBUSTION!! Suitable for concentrated organic liquid or gasSuitable for concentrated organic liquid or gas!! High High destructiondestruction efficiency; 99.9999% DE efficiency; 99.9999% DE!! A compact skid mounted device; can be relocatedA compact skid mounted device; can be relocated!! Inherently safe due to low hold-up volumeInherently safe due to low hold-up volume!! Computer control allows safe and rapid shutdownComputer control allows safe and rapid shutdown!! A continuous process that can operateA continuous process that can operate un un-manned-manned!! Operates stand alone or integrated into processOperates stand alone or integrated into process!! Operating efficiency is unaffected by halogen loadOperating efficiency is unaffected by halogen load!! Proven technologyProven technology

KEY SUCCESS FACTORS TO DATEKEY SUCCESS FACTORS TO DATEKEY SUCCESS FACTORS TO DATE

!! Timing - luck? R&D matched Timing - luck? R&D matched Nufarm’sNufarm’s need need

!! CSIRO supportCSIRO support

!! Board leadership & patienceBoard leadership & patience

!! Unique market position - Australia no incinerationUnique market position - Australia no incineration

!! Independent Panel on Intractable WasteIndependent Panel on Intractable Waste

!! Priority on ODS Disposal by Australian Priority on ODS Disposal by Australian Gov’tGov’t

!! Passion and PerseverancePassion and Perseverance

PLASCON™ AWARDSPLASCONPLASCON™™ AWARDS AWARDS

!! SCI - 1998SCI - 1998Plant of the YearPlant of the Year

!! ACIC - 1993ACIC - 1993Environment AwardEnvironment Award

!! IEAustIEAust. - 1994. - 1994Engineering ExcellenceEngineering Excellence

CONCLUDING REMARKS CONCLUDING REMARKS CONCLUDING REMARKS

!! PLASCONPLASCON™™ is commercially proven is commercially proven

!! The process is technically efficientThe process is technically efficient

!! The process is cost effectiveThe process is cost effective

!! PLASCONPLASCON™™ is patented world leading technology is patented world leading technology

!! PLASCONPLASCON™™ is now internationally recognised is now internationally recognised

!! SRL Plasma is ready to supply turnkey solutionsSRL Plasma is ready to supply turnkey solutions

!! The timing is right - opportunities are emergingThe timing is right - opportunities are emerging

Leading the Way in Leading the Way in ODSODS Conversion Conversion