EcopolisEcopolisComplex SDW Complex SDW

VR EnergieVR Energie GmbHGmbH&&

Company «Vanguard Recycling Energy»

175202, Novgorod region,

Staraya Russa, No. 8, Slavic St.

+Fax: : 7 (81652) 59410

www.vrenergy.ru

info@trt-wv.com

SummarySummary

For the first time in world practice is proposed creation of the plant onthe basis of new highly effective, fuel - producing and environmentallyclean technology for processing of the waste, including solid municipalwaste or like refuse and also of mentioned refuse together with oil-industrywastes (oil sludge, acid tars, etc.), soil polluted by pesticides and oilproducts, waste products of electronics, used tires, all kinds of plastics,sewage sludge of the city waste water treatment plant , the polluted groundsediment of reservoirs, biologically polluted waste of hospitals, contents ofcattle mortuary, dumps, etc.

Efficiency of the project

The calculation of efficiency of the investment project is carried out onthe basis of the cash flow statement. Integral indexes evidently demonstratethe economic efficiency of the project and allow accepting the decisionabout the expediency of realisation of the project. The calculation value ofthe indexes is presented in table 1.1.

The presented indexes are within the limits of legitimate values

Table 1.1 Common economic indicators (in Common economic indicators (in €€))

Indicators

Necessary credit resources 12.000.000

Profitability:

- Pure profit as percentage of income 63

Discounted commercial effect 16.300.000

Internal Rate of Return, (IRR) 31.1%

Net Present Value (NPV) 37.100.000

Profitability index (PI) 1.24

Profitability, % 60

TERM of PAYBACK, months 22

TERM OF REPAYMENT OF LOAN, months 60

The analysis of existing methods for refuse processing

Now in world practice has realized more than ten technologies of processing solid household and industrial

wastes. The most widespread among them are thermal ways - burning, pyrolysis and gasification.

Burning cannot be considered as economically justified or saving resources method as many organic substances

which could be used, are burnt with additional consumption of energy. Besides existing and offered plants for

refuse insineration have a lot of lacks, the main among them is forming secondary extremely toxic waste

products (polychlorinated dibenzodioxins, -furanes, and -biphenyls), allocated together with heavy metals in an

environment with chimney gases, sewage and slag .

It is necessary to note, that chlororganic waste products frequently named "dioxins", pertain to supertoxic group,

the steadiest and extremely dangerous as destroying hormonal system of the human, that results in an

immunodeficiency, is especial to growth of female illnesses, children"s death rate and physical inability,

decrease of birth rate. On May, 25 2002 in Stockholm the Global International Convention on prohibition of

persistent organic pollutants has been accepted. The group of 12 listed highly dangerous substances includes

mentioned earlier dioxins, furans and biphenyls .

Dioxin formation components of waste products are such materials as polyvinylchloride, linoleum, plastics,

packing cardboard, newspapers, etc. Toxic metals are thrown out in the form of salts or oxides, that is in a steady

kind, and can be in an environment uncertain quantity of years, gradually collecting and with a dust getting into

human body that results in defeat of a liver and a gastroenteric path, autoimmune to diseases of joints, diseases

of nervous system and psychoneurological frustrations, genetic changes at descendants, to increase of sensitivity

to ionizing radiation, osteoporosis of tubular bones.

Concentration of heavy metals oxides in slag and ashes in 2-3 times (and sometimes more) is higher, than in

burning waste products. Therefore, though the method of burning allows to reduce considerably volume of waste

products, thus even more dangerous to an environment ash and slag demanding special recycling measures or a

burial place are formed.

Now for toxic slag processing the technology of ecoconcreting is used: mixture of slags after their neutralization

with cement, lime or silicon dioxide with the subsequent hardening of mixture. At correct mixing ratio waste

products to the bonding agent occurs an "incapsulation" toxic substances (including heavy metals and dioxins)

in the cement stone, which is not passing, in authors opinion, ecotoxicants into an environment. However, such

technology demands preliminary neutralization of waste products for what a plenty of chemical reagents is

necessary. A number of the substances making waste products, for example, sulphur-containing, can cause

degradation of a cement stone that results in penetration contaminators into an environment. Besides toxic

metals in the certain conditions can be washed away from blocks by rains, for example, at change of acidity of

rain water "on weather conditions". Now the advanced method of ecoconcreting - integrated mineral-matrix

technology (IMM-technology) is developed, which should provide ecological safety of a received material due

to chemical bonding contaminators down to their inclusion in a crystal lattice of cementing new formation (for

example, heavy metals) or blocking contaminators by colloidal-disperse and sol-gel phases in mass of a forming

material. However, as authors specify in same publication, it is possible only "at rationally picked up

components of system when potential chemical properties of components of system and their mechanical

characteristics are summarized". Commercially such condition cannot be executed, as structure of municipal

refuse and, accordingly, slag is not constant. Thus, even the advanced technologies do not provide manufacture

of non-polluting, suitable slag for the further use, municipal refuse received after burning. Thus it is necessary to

note, that cost of a burial place of dangerous waste products (ashes and slag) 10 times higher, than a burial place

of refuse. Other serious lack of incinerators is their low profitability. So, in New Jersey (USA) in 1997 seven

incinerators had total debit in 1.6 billion dollars. It speaks in the low coefficient of useful consumption of heat

energy which even on the best plants for municipal refuse incineration does not exceed 65 % and a significant

amount of used an additional liquid fuel reaching 70 gallons per ton of burning waste. To the modernized ways

of burning of solid waste it is possible to attribute replacement of air submitted to a place of burning, by oxygen.

It allows to speed up process, to lower emissions of nitrogen oxides, however emission of the most dangerous

components - dioxins, furanes, biphenyls, heavy metals - remains constant. Besides the similar technology

demands additional significant expenses for generation of oxygen.

As burning waste products produces heat, the desire to use it was natural. So movement "Waste-to-Energy" has

appeared. However, burning of solid waste with the purpose of heat reception to manufacture the electric power

results in the even greater environmental contamination. It speaks that the electric power consumption is not

constant and has daily and seasonal peaks, that, accordingly, results in fluctuations of loading of combustion

chambers of garbage incineration boilers and, as a result, to incompletely burn of waste products and to the even

greater emission of harmful substances with chimney gases, slag, ash and sewage. For only technical reasons

cost of the electric power made at municipal refuse incineration plants cannot compete to cost of the electric

power of heat power stations. The price of one kilowatt at heat power stations is 1 - 3 cents, and at refuse

incineration plants - 11 cents. However, on laws in force for stabilization of the market to consumers it is obliged

to sell energy for 2 cents per 1 kilowatt, that gives enormous losses for refuse incineration plants, and in a

combination to necessity of a burial place for slag and ash makes these plants absolutely unprofitable and

financial forecasts for their development are extremely adverse. Now authorities of New York plan to use the gas

received at burning of waste products of a megacity, for manufacture of electricity at eight recycling refuse

factories. In New York has already installed eight 200-kilowatt fuel batteries at four plants of Brooklyn. Mayor

of city Michael Blumberg has explained, that "fuel elements will transform garbage gas in electric and thermal

energy and thus do not poison air of nearby neighborhood". Really, fuel elements have some advantages. The

main thing - these elements are much more efficient in comparison with any other ways of electric energy

generation. Efficiency of already existing elements is 50%, theoretically it can be more than 85%. The electric

power in batteries is developed directly due to chemical reactions and in this case it is not required the

intermediate parts used at power stations (boiler units, turbines) which reduce efficiency of energy reception.

Non-polluting fuel elements develop the electric power due to electrochemical reaction between hydrogen and

atmospheric oxygen, and, as a by-product water is formed only. However, using methanol the process ceases to

be rather non-polluting as methanol at decomposition forms not only hydrogen but also poisonous carbon

monoxide (CO).

It is necessary for utilizing, and, the simplest way to achieve it is carbon monoxide (CO) up to carbon dioxide

(CO2) which then will be thrown out in an atmosphere. Thus, finally a problem of emission reduction of

greenhouse gases in an atmosphere in such a way to solve it is not possible . At use in fuel elements of the gas

received as a result of refuse burning, the problem of environmental contamination remains at all not solved as

the most dangerous toxic substances - dioxins, furanes, biphenyls, heavy metals, etc. cannot be detained in fuel

batteries. Besides the slags received after refuse burning also are dangerous and require a burial place. The level

of burning of household waste products in some countries is various. So, from total amounts of household refuse

the share of burning fluctuate in such countries, as Austria, Italy, France, Germany from 20 % to 40 %; Belgium,

Sweden - 48-50 %, Japan - 70 %; Denmark, Switzerland - 80 %; England and the USA - 10 %; Russia - 2 %.

Now many scientists consider, that incinerators cannot be the non-polluting plants at all. Among supporters of

this point of view are Paul Connett - the professor of chemistry from university in Canton (N.Y.), Michael

Gendron from Ontario which has entitled article on September, 8, 1999: " The Full Health Implications of Waste

Incineration are Unknown ", Neil J. Carton - former Clean Air Program Director, Austin (Texas), toxicologist

from state Maine Robert Frakes, etc. The head of the organization of independent experts of Russia Doctor of

Chemistry S.Yufit has convincingly shown not only danger of incinerate factories, but also their inefficiency,

ecology destruction and absolute economic unacceptability for any local budget. Recently many companies pass

from simple burning waste to the two-level process including a stage of pyrolysis (decomposition of organic

substances without access of oxygen at rather low temperatures 450 - 800°C). Such process appears

energetically more favorable, than simple burning. As a result of pyrolysis receive gas and solid rest of

pyrolysis. Then those and other products at once, without any additional processing, direct to the furnace to

burn. The part of gases of pyrolysis after condensation can be deduced from system and is used as liquid fuel by

other consumers. There are the same lacks, as at direct waste products burning. In the cases when gas of

pyrolysis is refining from acid gases such as hydrogen chloride (HCL), economically process becomes

expensive enough because of application of the expensive equipment and using of expensive caustic or

calcinated soda and environmental contamination by heavy metals is not eliminated.

Alternative to process of pyrolysis is the process of gasification which goes similarly, but at temperature 800 -

1300°C and at presence of a small amount of air. In this case received gas represents a mix of low-molecular

hydrocarbons which then are burning in furnace. Unfortunately, such process does not improve an ecological

situation, whereas presence of air and contained in refuse chlorine organic substances in combination to high

temperature results in intensive formation of dioxins, furanes, biphenyls, and salts of heavy metals, as well as in

other technologies, from process are not deduced and pollute an environment. Anyway in materials of the U.S.

EPA (Table 2) such comparative characteristics are presented:

Table 2

The most complete destruction of the products contained in refuse, is carried out during high-temperature

pyrolysis or gasification at temperature 1650-1930°C in melted metal with mineral additives, or at temperature

up to 1700°C in melt of salts or alkalis in a mix with additives and at the presence of catalysts. The specified

ways provide refuse processing practically of any structure as at such temperature are completely destroying all

dioxins, furanes and biphenyls. As a result it turns into synthesis gas - a mix of hydrogen, methane, carbonic

oxide, carbon dioxide, water steam, nitrogen oxides and sulfur, the solid rest - coke, pieces of inorganic

materials, lime, cement, glass and slag which are proposed to be removed from a reactor in sealed bunkers and

forms without the indication of their further use and wasted melts of salts and metal which regeneration is

extremely complex and power-consuming process demanding besides the significant consumption of various

reagents.

The name of pollutant Incinerators, kg/t waste products. Gasification plant, kg/t waste products.

Dioxins and furanes

Mercury

Lead

Dioxide of sulfur

Oxide nitrogen

Oxide carbon

0,7 х 10-7

3 х 10-3

14 х 10-4

1,57

1,12

0,21

0,6 x 10-6

3 x 10-3

13 x 10-4

1,47

1,43

0,14

Synthesis gas after enough complex clearing of impurity can be used as fuel. It is necessary to note also, that the

specified processes do not provide allocation of heavy metals and their salts from the firm rest of pyrolysis,

therefore the further utilization of slag for manufacture of building materials and designs is impossible, special

measures of their recycling or a burial place are necessary.

Now in world practice some technologies of joint thermal processing of solid municipal waste and sludge

deposits of the sewage formed at city sewage purification plants. Thus their joint burning in furnaces of various

designs with preliminary drying deposits and obligatory returning of chimney gases after drying for

deodorization in a furnace is provided. In connection with the elevated content of heavy metals in sludge

deposits of sewage all these technologies result in producing of extremely dangerous slag and ashes which

demand a burial place. Besides chlororganic compaunds contained in solid waste, leads to environmental

contamination by dioxins, furanes and biphenyls - the extremely dangerous to human health and an

environment. Thus, the problem of clearing of places of mass human dwelling for the present moment has no

satisfactory solution.

Advantages of offered technology

Disadvantages of existing methods of municipal solid waste processing, mentioned above, completely are

eliminating in offered technology which differs from above mentioned:

- the technology is based on well-known and repeatedly checked up methods in another industries. Actually the

new technological chain consist of old well-known parts which, however, entirely now still is not carried out

anywhere;

- allow to process effectively waste products of any humidity, including frozen together;

- does not require preliminary sorting of waste;

- produces fuel which in connection with deep heat recovery in productions covers self-consumption over the

odds that allows to refuse use of fuel from outside sources (except for the starting period) and provides an output

of commodity fuel to the market;

- coefficient of useful consumption of thermal energy in technological processes of the plant is equal 91.1 %;

- produces a variety of ecologically clean commodity by-products: dry calcium chloride, liquid carbon dioxide,

concentrate of salts of the heavy metals;

- requires no sewage system by utilizing waste waters in the process itself, that simultaneously reduces on 100 %

consumption of fresh technical water;

- a production waste are only smoke gases which structure fully complies with all requirements of ecological

safety norms that is achieved directly during technological processes of waste processing and reception of

commodity products without installation of any additional clearing equipment as offered technology:

- does not produce chlorine organic substances such as dioxins, furanes and biphenyls and, accordingly, excludes

their emission into an environment; - does not eject highly toxic heavy metals into an environment;

- does not eject highly toxic carbon monoxide, organic light and unwell smelling substances into an

environment;

- capacity of the plant can be varied in wide range of parameters, because it consist of separate autonomous

technological lines (modules);

- all processes are continuous, fully-automated, not toxic and not explosive.

This technology is based on the principle new methods of influence of energy on a matter - the use of energy of

a revolved electromagnetic field of high specific concentration is in unit of volume of working space of reactor

Production process

A complex consists of six blocks:

- of preparation;

- of reactor;

- of concentration, selection, granulation and packing of technical carbon;

- of receipt from sintesys of gas of petrol, methanol;

- of power;

- of warehousing of the prepared products.

The process takes place in an all-closed reactor with the use of melted andsalt liquid, in which all materials (including those radio active) separate intosynthetic gas, H2, and H20. End product of the reactor is either synthetic gaswhich can further be used to produce electricity, gasoline through gas-synthesis, bio diesel, bio gasoline A-98, methanol, technical carbon and otherenergy products.

DESCRIPTION OF PROJECTDESCRIPTION OF PROJECT

Process Flow Diagram of Domestic Solid Waste (DSW) and Sludge Utilization

• Option of constructing units with high single-unit power;

• Universal method allowing utilization of all types of organic waste and the transfer from

steam blast to air steam blast, oxygen blast and oxygen steam blast;

• Low metal consumption;

• Small number of stages for preparation of raw material;

• Insensitivity to inorganic components;

• Working with raw materials with high humidity;

Main Advantages

• Optimal temperatures: 900 - 950°С;

• Effective transfer of heat onto organic compounds by heat transfer medium (eutectic mixture of salts and alkalis);

• Effect of dispersers and specifically selected accelerators;

• Heating, drying and heat impact disposal of SDW and sludge;

• Dynamic activation of physical and chemical processes affecting the opening of the molecular links of organic compounds using gas-dynamic details of the reactor construction;

• pressurization system for removing inorganic residues from the reactor, which enables removing it without discharging all melts;

• Low melt SDW components are converted into non-toxic melt body as a result of chemical reactions.

• Gasolinee production

• Methanol production

• Dimethyl ether production

(alternative to diesel fuel)

• Power generation

• Heat generation

Technical characteristics of complexComplexes are built on module principle. Productivity of the modules 50, 100, 200 tons in dayson a dry organic material and in 2-3 time higher on initial. The unicity of technology allowed tocreate compact complexes. Due to a compactness and module construction any set productivity,for example 5 modules, can be got for 200 t/days =1 000 t/days.

Designed module by the productivity of 100 t/days are occupied by an area on an equipment(without a ware-house and auxiliary area) - 300 m2. All complex occupies an area a no more than2 hectare. The contract of delivery on the basic equipment of complex is celled.

Descriptions of complex are resulted in a table

№ Name of characteristic Unir fo measure Amount

1 Productivity on raw material (at round-the-clock CW of works with

the coefficient of the use of equipment 0,85):

- Silts

t/h

t/day

5

100

2 Office hours Shifts/day 3

3 Coefficient of the use of basic equipment 0,85

4 Temperature on the walls of chamber of decomposition

Temperature of flowing of reaction

k

k

Less than 1000

1500-1700

5 Pressure in the chamber of decomposition of the PC atm. 0,3

6 Temperature of get-away gases: - after the chamber of full cleaning k 350

7 Volume of developed synthesis-gas М3/h 1500 min

8 Set electric power of equipment of complex kWt 200

9 Maximal expense of electric power

In the mode of acceleration

In the set mode,

complex with illumination

kWt/h

kWt/h

kWt/h

140

70

12

Production and realization of products volume

Middle product output from a 1 ton of silts

Profit from a product of complex SWD-100 output by the productivity of 100 t/days,

36 000 tons during work in the combined mode

№

p/p

Product Combined

mode

Petrol

mode

Methanol

mode

Carbon

mode

1. Synthesis of gas, cub.m. 300 300 300 300

2. Petrol, t. 0,1 0,2 - -

3. Methanol, t. 0,12 - 0,25 - 0,35 0,12

4. Diesel fuel, t. 0,1 0,1 0,1 0,1

5. Technical carbon, t. 0,2 0,15 0,13 0,35

6. Electric power MWt 1,0 1,0 1,0 1,0

8. Heat power, Gkkal 1,5 1,5 1,5 1,5

№ Product Unit of

measure

Price of

unit of

product

(euro)

Annual

amount

Income

(thousands of

euro)

1 Heat power Gkkal 20.0 54.000 1.080

2 Electric power kWt/h 0.04 36.000.000 1.440

3 Technical carbon Tonns 1500 5.400 8.100

4 Petrol Litres 0.5 3.600.000 1.800

5 Diesel fuel Litres 0.4 3.600.000 1.440

6 Methanol Litres 0.5 3.600.000 1.800

Overall income: 15.700.000 euro

CONCLUSIONSCONCLUSIONS

A complex SDW-100 allows to process all types of wastes, containing organic components -

silts of cleansing buildings, hard domestic wastes, oil wastes, sour gudrons, exhaust oils,

wastes of mining, peat, slates, manure, dung, agricultural wastes, pesticides and poison

chemicals. With the receipt of the high-quality claimed products – carbon, bio petrol, building

materials, fertilizers, heat and electric energy without extrass in the atmosphere of toxic matters.

The complex processing of a few types of wastes is expedient. Complexes are able to decide the

questions of providing of energy in any places of accumulation and formation of wastes with a

high ecological and economic effect. Because of compactness, module construction, processing of

any wastes is possible a high yield with the large productivity, construction on the base of

processing of wastes of profitable business and industry of economy.

Short term of recoupment of project enables an enterprise to point an income at development of

enterprise for the receipt of additional profit. For example, the use of block on the production of

hydrogen will give additional annual earnings no less than eight (8.000.000) million Euro.

Creation of the own processing of gas soot in fibred soot will bring an additional profit more than

20 million euro in a year, at a price - 2 million euro for a ton. Fibred soot - it is unique carbon

material, a requirement in which makes 10 thousand tons and every year grows on 25%.

Building of more powerful on the productivity complex in future due to the personal funds or at

the additional investing will allow an enterprise to create the network of branches and occupy

leading positions at the market of ecological services in utilization of wastes.