Plasma Gasification: Two Approaches

1. Plasma Arc and 2. Plasma Torch

IInsmn CnsIfIcnfIon Is nbIo fo gof fho onorgy If noods from wnsfo-
sfronms such ns munIcIpu! so!Id wuste (MSW) nnd ovon hnznrdous
nnd foxIc wnsfos, wIfhouf fho nood fo bury fhoso wnsfos In n InndfIII.
%horo nro fwo mofhods usod In Insmn gnsIfIcnfIon - fho fIrsf ono Is n
"Insmn nrc" nnd socond Is cnIIod n "Insmn forch."
A "Insmn nrc" Insmn gnsIfIcnfIon Innf oornfos on rIncIIos sImIInr
fo nn nrc-woIdIng mnchIno, whoro nn oIocfrIcnI nrc Is sfruck bofwoon
fwo oIocfrodos. %ho hIgh-onorgy nrc cronfos n hIgh fomornfuro, hIghIy
IonIzod gns. %ho Insmn nrc Is oncIosod In n chnmbor. Wnsfo mnforInI Is
fod Info fho chnmbor nnd fho Infonso honf of fho Insmn bronks down
orgnnIc moIocuIos (such ns oII, soIvonfs, nnd nInf) Info fhoIr oIomonfnI
nfoms. In n cnrofuIIy confroIIod rocoss, fhoso nfoms rocombIno Info
hnrmIoss gnsos such ns cnrbon dIoxIdo. SoIIds such ns gInss nnd mofnIs
nro moIfod fo form mnforInIs, sImIInr fo hnrdonod Invn, In whIch foxIc
mofnIs nro oncnsuInfod. WIfh Insmn nrc fochnoIogy fhoro Is no
burnIng or IncInornfIon nnd no formnfIon of nsh.
"IInsmn nrc" Insmn gnsIfIcnfIon Innf hnvo n vory hIgh dosfrucfIon
offIcIoncy. %hoy nro vory robusf; fhoy cnn fronf nny wnsfo wIfh mInImnI
or no rofronfmonf; nnd fhoy roduco n sfnbIo wnsfo form. %ho nrc
moIfor usos cnrbon oIocfrodos fo sfrIko nn nrc In n bnfh of moIfon sIng.
%ho consumnbIo cnrbon oIocfrodos nro confInuousIy Insorfod Info fho
chnmbor, oIImInnfIng fho nood fo shuf down for oIocfrodo roIncomonf
or mnInfonnnco. %ho hIgh fomornfuros roducod by fho nrc convorf fho
orgnnIc wnsfo Info IIghf orgnnIcs nnd rImnry oIomonfs.
CombusfIbIo gns Is cIonnod In fho off-gns sysfom nnd oxIdIzod fo CO2
nnd H2O In cornmIc bod oxIdIzors. %ho ofonfInI for nIr oIIufIon Is Iow
duo fo fho uso of oIocfrIcnI honfIng In fho nbsonco of froo oxygon. %ho
InorgnnIc orfIon of fho wnsfo Is rofnInod In n sfnbIo, Ionch-rosIsfnnf
sIng.
In "Insmn forch" sysfoms, nn nrc Is sfruck bofwoon n coor oIocfrodo
nnd oIfhor n bnfh of moIfon sIng or nnofhor oIocfrodo of oosIfo
oInrIfy. As wIfh "Insmn nrc" sysfoms, Insmn forch sysfoms hnvo vory
hIgh dosfrucfIon offIcIoncy; fhoy nro vory robusf; nnd fhoy cnn fronf nny
wnsfo or modIum wIfh mInImnI or no ro-fronfmonf. %ho InorgnnIc
orfIon of fho wnsfo Is rofnInod In n sfnbIo, Ionch-rosIsfnnf sIng. %ho nIr
oIIufIon confroI sysfom Is Inrgor fhnn for fho Insmn nrc sysfom, duo fo
fho nood fo sfnbIIIzo forch gns.
ImItutIons und Concevns ubout P!usmu Avc TecLno!ogy
A chIof concorn nbouf Insmn nrc fochnoIogy Is onsurIng fhnf gnsoous
omIssIons nro kof fo n mInImum nnd cIonnod boforo boIng roIonsod fo
fho nfmoshoro.
ImItutIons und Concevns ubout P!usmu TovcL TecLno!ogy
Concorns hnvo boon rnIsod rognrdIng fho roIInbIIIfy of "Insmn forch"
fochnoIogy ns fho wnfor-cooIod, coor, "Insmn forch" musf bo roIncod
orIodIcnIIy fo rovonf burn-fhrough nf fho nffnchmonf oInf of fho nrc
nnd n subsoquonf sfonm oxIosIon duo fo rnId honfIng of fho roIonsod
cooIIng wnfor.
App!IcubI!Ity oI P!usmu Avc TecLno!ogy
%ho Insmn nrc cnn bo usod for orgnnIc nnd InorgnnIc wnsfos. If Is boIng
sfudIod for mIxod rndIoncfIvo wnsfo fronfmonf, bocnuso If sonrnfos fho
orgnnIc from fho InorgnnIc orfIon of fho wnsfo. If Is nIso boIng sfudIod
fo roduco oxIosIvo comounds nnd unoxIodod ordnnnco In Inco of
frndIfIonnI fochnoIogIos, such ns oon burnIng nnd oon dofonnfIon,
fhnf roducod foxIc omIssIons nnd hnznrdous nsh.
TecLno!ogy eve!opment Stutus
ofh Insmn nrc sysfoms nro dovoIood nnd commorcInI nIIcnfIons
oxIsf for bofh hnznrdous nnd rndIoncfIvo wnsfo.
Important Considerations and Advantages of
PIasma Gasification

O Plasma Gasification provides for a sustainable waste solution for all
types of waste streams, including MSW , hazardous wastes, and
even RADOACTVE waste, which delivers tangible economic and
environmental benefits .

O Plasma Gasification does not produce hazardous bottom ash and
fly ash.

O Plasma Gasification is "fueled" by the "free" waste, and is
"powered" by electricity, and can be turned off with the flip of a
switch.
O Plasma Gasification unit does not need to be brought up to
temperature over 24/36 hours burning expensive fuel oil as does
mass burn incineration .
O Plasma Gasification systems require very little maintenance and
unlike traditional power plants, do not need to be shut down for
weeks at a time for cleaning and maintenance while waste-streams
back-up .
O Plasma Gasification is just as efficient in smaller-scale systems (25
and 50 TPD units) as large-scale systems.

O Plasma Gasification can provide a high degree of flexibility over the
longer term and it can operate at less than 100% of capacity so
there is flexibility when waste-stream decline.
The Plasma-arc gasification process is a chemical reduction process that converts MSW
from its original state to a glass-like aggregate solid at the bottom, and a synthetic fuel
gas, also known as syngas, at the top.
Once gasification is over, the syngas is cleaned in a multi-step process, bringing it to levels
near natural gas cleanliness. It is then compressed before being used as fuel for a gas
turbine.
The gas turbine for this process is a modified natural gas turbine that mixes the cleaned
syngas with air from the atmosphere, combusts the mixture and sends the hot gases
through a turbine. The turbine spins an electric generator to produce electricity. The
discharged hot gases are then passed through a heat recovery steam generator to produce
more steam and to cool the hot gases. The cooler exhaust gases are then discharged into
the atmosphere via a stack.
Emissions from this process are very similar to natural gas combined cycle plants which
are considered to be 'clean and are located and permitted all over the U.S., and for that
matter the whole world.

Braz. 1. Phys. 34 (4b), Dec. 2004
Plasma Processing of Municipal Solid Waste
Edbertho Leal-Quirs
ScientiIic Research Department, Polytechnic University oI Puerto Rico,
PO Box 192017, San Juan, PR 00919-2017
Abstract
In this paper a review and assessment oI the Hot Temperature Plasma Processing oI
Waste is presented. The environmental advantage oI this method over incineration is
clearly demonstrated. The present technology oI Plasma Arcs and the Modern Plasma
Torches Applications are also shown. An Assessment oI the Heavy Duty GasiIication
Combined Cycle Turbines, GasiIication Process, Magmavication/VitriIication
process, and Environmental Engineering Protection are also described.
1. Introduction
Imagine a process in which we convert the inorganic components oI the municipal
solid waste in architectural tiles and construction bricks, at the same time we convert
all the organic contents oI the waste into Synthesis gas, (basically a mix oI H2 CO,
almost a green Iuel) and in addition we generate electrical power. Furthermore, could
we have a system that doesn't generate ashes, and doesn't pollute the air, the water nor
the soil, as incineration does? The answer is yes. The plasma torches that operate at
very high temperatures (between 5,000C and 100,000C) can process all kinds oI
waste: municipal solid, toxic, medical, biohazard, industrial and nuclear waste at
atmospheric pressure. EIIectively, the inorganic waste is vitriIied in solid-like glass
materials that are used to manuIacture aggregates Ior the construction industry
(Magmavication process) and the organic materials (plastics, paper, oil, bio-materials,
etc.) are converted into Syngas with caloric value, Iuel that is used on the Heavy-duty
advanced gas turbines Ior the generation oI electrical power (GasiIication process).
No ashes are produced because at more than 5,000C, all the organic molecules are
disintegrated and only the mix oI H2 CO remains at high temperature.
2. Plasma and it's technological evolution: from discharge tubes to torches
Plasma is the ionized state oI matter, it's conIormed by a quasi-neutral gas composed
oI charged and neutral particles, which exhibit a collective behavior; plasma is the
most abundant Iorm oI matter in the universe. It is Iormed whenever ordinary matter
is heated over 5,000 C, which results in electrically charged gases or Iluids. They are
proIoundly inIluenced by the electrical interactions oI the ions and electrons by the
presence oI a magnetic Iield.

Plasma produced with DC electrical discharge has been the precursor oI a modern and
more eIIicient Plasma Torch device1. Taken an electrical discharge tube |2,3,4| -like
the classical schematic shown in the Fig. 1 and raising the voltage V, while measuring
the current I Iollowing through the discharge, the result is a high nonlinear Voltage-
Current curve. The three major regimes oI industrially important DC low-pressure
electrical discharges tubes are:the Dark Discharge, the Glow Discharge and the Arc
Discharge (Shown in Fig. 2).
The arc regime is comprised oI three regions: the glow to arc transition, the non-
thermal arcs, and the thermal arcs. When the current density is great enough to heat
the cathode to incandescence, then a discontinuous glow-to-arc transition region
appears in the Voltage-Current characteristic curve. This glow-to-arc transition
happens Ior currents between1 and 10 Amperes at low pressures.

As we can see in Fig. 3, thermal arcs always are Iound at higher pressures and higher
gas temperature than non-thermal arcs; however, non-thermal arcs may also exist at
atmospheric pressure.
The total current oI arcs is always more than 1 ampere and the current density ranges
Irom several amperes per square centimeter to more than thousand amperes per square
centimeter. The electron density oI thermal arcs is higher than in non-thermal arcs.
In non-thermal arcs, low emission arcs usually require thermionic emission Irom
cathodes, whereas in thermal arcs, high intensity arcs usually operate in Iield
emissions.
Thermal arcs can be considered in thermodynamic equilibrium. Figs. 4, 5 and 6 show
diIIerent types oI arcs and torches: the transpiration stabilized arc, the coaxial Ilow
stabilized arc and the axe symmetric, non-transIerred, unmagnetized arc jet or plasma
torch.


3. Cascade process of ionization
In a cascade process, one incident electron (e) collides with a neutral atom to
produce a second electron and an ion. There are then two electrons and one ion. AIter
these two electrons have each collided with another neutral atom, there are produced
Iour electrons and three ions. This process continues and, aIter about 20 successive
sets oI collisions, millions oI electrons and ions will have been Iormed rapidly (the
mean Iree path between collisions is very small at atmospheric pressures).
The Debye length is a measure oI the width oI the eIIective electric Iield oI an ion and
is given approximately by the next Iormula, in which Te is the electron temperature
and ne is the number density oI electrons (per mL). lD 6.9 (Te/ne)1/2. For a plasma
temperature oI 8,000 K and ne 1014/cm
3
, lD is about 0.0006 mm, which is very
much smaller than the 1mm sampler oriIice and so ions can pass through easily. Hot
gases Irom the plasma impinge on the edges oI the sampler oriIice so that deposits
build up and reduce its diameter with time. The surroundings oI the sampler oriIice
suIIer also Irom corrosive eIIects due to bombardment by hot species Irom the plasma
Ilame. These problems necessitate replacement oI the sampler Irom time to time. As
the gas leaves the other side oI the sampler oriIice, it experiences a vacuum oI about
10-5 Torr and the expanding jet oI gas cools very rapidly and reaches supersonic
speeds.

4. Modern high power plasma torches
Westinghouse in his Plasma Center2 , has produced modern High Power Plasma
Torches |4,5|. The author visited that Iacility, inspected one torch, and noticed the
excellent perIormance. There are several manuIacturers oI plasma torches (a list oI
them is available on the web). However, to the author knowledge, only Westinghouse
manuIactures torches oI high power even in the order oI 10 MW (Fig. 8). Models
similar to this torch are commercially available even in the range oI 75 KW to 10,000
kW oI power. A thermal eIIiciency oI 90 is easily possible; the eIIiciency represents
the percentage oI arc power that exits the torch and enters the process. However, the
operational characteristics oI each torch depend oI the gas composition. The most
common gases used in plasma torches are Argon, and Helium. The quality oI the
plasma produced depends on the plasma density and the plasma temperature; at
atmospheric pressure plasma torches may produce a density oI 1014 cm
-3
. As more
power is given to the torch, there is better quality oI plasma. Due to the broad range oI
plasma temperatures and densities, plasmas have several applications in research,
technology and in the industry.
. Plasma magmavication or vitrification process
Plasma torches provide eIIicient means Ior melting solids or waste materials into
magma or a lava Iorm, aIter a short time oI interaction oI the plasma (T ~ 5000C)
with the solids. In a longer cooling time, the resulting mass Iorms a chemically and
physically durable igneous rock. Depending upon the original mineralogy and rate oI
cooling, the Iinal product consists oI either amorphous glassy material resembling
volcanic obsidian or a crystalline igneous rock similar to granite or basalt. Several
applications have been done in the construction industry (Circeo |6,7,8| et al., 2000 at
Georgia Tech). The Georgia Tech group Iound a Iormula Ior the amount oI vitriIied
mass produced, as a Iunction oI the plasma torches energies. The mass produced
obeys the relation: M (kg) 0.35 P (kW-hr), where M is the vitriIied mass-produced
in Kg, and P is the electrical energy consumed in the process. One application is Ior
remediation oI radioactive waste, where highly radioactive liquid and sludge are
mixed with glass particles and heated to very high temperatures to produce a molten
glass. This molten glass is then poured into stainless steel canisters. When the mixture
cools, it hardens into a stable glass that traps the radioactive elements and prevents
them Irom moving through the air or water into the environment. DOE is currently
operating vitriIication plants at the Savannah River Site in South Carolina and the
West Valley Demonstration Project in New York. In Japan, Kobe |9,13,14| Steel LTD
and The Kansai Electric Power Company developed a Plasma vitriIication system.
6. High temperature plasma processing of waste
Solid waste Irom municipalities can be processed using high-energy plasma torches.
Plasma can process any kind oI waste. The chemical properties and the contents oI the
average municipal waste are shown in Table 1.
Westinghouse |12| has conducted many successIul experiments, designs and
developments involving the gasiIication and/or VitriIication oI simulated MSW
(municipal solid waste), ASR (auto shredder residue), Iossil Iuels, and industrial
liquid and solid wastes in a plasma reactor.
The gasiIication test material Ieed ranged Irom low Btu MSW (1600 kcal/kg) to
medium Btu simulated auto shredder residue (4500 kcal/kg) and to high Btu coal
(8,000 kcal/kg).
Experiments were conducted where Iuels were gasiIied to produce primarily carbon
monoxide, CO and hydrogen, H2. The inorganic components oI the Ieed were
converted to molten slag that was removed as vitriIied by product. The slag passed the
EPA-mandated Toxicity Characteristic Leachate Procedure (TCLP) requirements.
Emissions are very much reduced and the slag is a glassy product with value as a
construction material base. Dioxins were measured at levels approximately 100 times
lower than Irom an incineration plant (e.g., 0.01 ng/nm3 measured in stack gas), and
predicted Iuel gas production is observed. For organic waste, the production oI power
via a combustion/turbine combined cycle at much higher eIIiciencies (approximately
40 thermal eIIiciency versus approximately 20 Ior an incineration steam boiler
plant) is an added beneIit which makes the project cost attractive compared to
incinerator/steam boiler MSW plants. Additionally, the high quality glassy material
produced can be sold as a roadbed or construction material and the need and expense
to dispose oI ash is eliminated.
. Metal-electrode-plasma furnace applications
The plasma energy corporation has investigated the use oI this plasma technology Ior
treatment oI municipal waste, used tires, polychlorobenzyl (PCB), oils and medical
wastes (Pocklington and Corox |3|, 1992; Camacho |5|, 1990) since plasma can
provide thermal decomposition oI some toxic molecules into simple benign one's. A
300-kW level power operation has been used in a range oI experiments. Hydrocarbon
waste is Ied into the Iurnace through a double door air lock system. A molten pool
was Iormed in the earth. In some experiments, steam was injected to generate
hydrogen-rich gas that could be used in Iuture applications Ior energy production. The
gases produced by the Iurnace were scrubbed to control chlorine and sulIur emissions.
The inorganic and metals in the molten pool oI the Iurnace were tapped, and vitriIied
(glass-like) slag and metal product was obtained. The electrical power requirement Ior
conversion oI one ton oI municipal solid waste into the Iinal products oI vitriIied
solids and metals, hydrogen and carbon monoxide gas was 550-790 kW h. Typically
20 oI the initial waste is converted into solid products. The remainder is converted
into gas. Combustion oI the hydrogen and carbon monoxide in the gas could be used
to oIIset the electrical power requirement.

. Plasma gasification processes of waste
GasiIication |9,11,13| is a simple and commercially well-proven technology. It
involves the conversion oI various Ieedstocks to clean syngas, through a reaction with
oxygen and steam; this reaction is spontaneous at high temperature and pressure under
reduction conditions, and consumes halI oI the oxygen required Ior total combustion.
The raw syngas product is cooled and puriIied, it is then used in one or a combination
oI many product applications: syngas Ior chemicals, gaseous Iuels, Ior liquid Iuels
burned in commercial boilers to produce steam or in heat transIer process and in
internal combustion engines to produce electrical energy. Combined cycles are also
possible leading to co-generation oI electrical energy. The energy eIIiciency oI
biomass gasiIication varies Irom 75 to 80, this depends oI the composition and heat
capacity oI the raw material; Humidity and the inorganic inert matter content reduce
the eIIiciency. The traditional market Ior syngas is Iocused in gas production as an
intermediate step during the production oI important chemicals, such as ammonia Ior
Iertilizer. However, application oI gasiIication in other processes is increasing due to
market changes associated with improved gas turbines, deregulation oI electrical
power generation, and stringent environmental mandates. GasiIication plant capacity
is reported in units oI volumetric output oI syngas (i.e., normal cubic meters per day).
However, the Department oI Energy (DOE) converted all the gasiIication input and
output capacities to MWth. (1MWth 3,413,000Btu/hr). GasiIication is an alternative
to combustion, and has an energy eIIiciency oI 50. The advantage consists on
reducing both the atmospheric emissions and the volume oI solid residues to be land
Iilled. Since the solid residues come Irom a high temperature at normal conditions,
they're inert materials that can be used as part oI the bulk material in concrete
production.

. Synthesis gas cleaning island
The purpose oI this system is to remove pollutants such as sulIur dioxide (SO2),
particulate matter, hydrochloric acid (HCl) and Hydrogen SulIide (H2S) vapors Irom
the synthesis gas. The primary design requirements are environmental protection and
saIe operation oI the gas turbine. The basic unit operations are those oI gas cooling,
particulate removal, and acid gas neutralization. First, the syngas is suIIiciently cooled
prior to gas cleanup it is passed through a partial quench. The gas leaves the chamber
at 350 C. The goal is to lower the gas temperature suIIiciently so as not to damage
the downstream equipment while maintaining the gas above saturation temperature.
The gas then passes through a Iabric Iilter bag-house to remove particulates. The
blowers are each sized at 100 to provide Iull redundancy. The gas is then in a
saturation tank, which lowers the gas temperature to 50 C, then it passes through a
packed bed aqueous scrubber Ior acid remove. Sodium hydroxide solution is used to
neutralize the acid. The gas, still ''sour'' at this point, then undergoes Iirst stage
compression Ior use in the gas turbine. It then enters the lower section oI the H2S
Absorber Vessel and Ilows countercurrent to a regenerated solution oI chelated iron
oxide (FeO2) Iluid Ior removal oI any H2S. The H2S absorbed by the solution is
removed Irom the bottom oI the H2S Absorber Vessel and circulated by the Rich
Solution Pump, through a Solution Cooler, and into the Solution Oxidizer Tank,
where Air Blower introduces air. The air blower agitation causes the elemental sulIur
to precipitate, Iorming slurry at the bottom oI the Solution Oxidizer Tank. The slurry
is removed Irom Solution Oxidizer Tank by a SulIur Slurry Pump Tag and sent to a
conveyor SulIur Filter. The Iiltrate solution drains oII and is returned to the Solution
Oxidizer Tank, while the wet inert sulIur cake is collected Ior disposal to a non-
hazardous landIill. At this point, the gas exiting the H2S Absorber Vessel is
considered 'clean' Ior use as a Iuel gas. SpeciIic Heat Capacity oI Syngas 1.488
kJ/kg. K
10. Gas turbine excess of energy and green energy
The Lower Heating Value (LHV) oI the natural gas supply is assumed to be
11,900kcal/kg. The minimum LHV acceptable to the CTG is assumed to be
3,600kcal.kg. The ability oI the Integrated Plasma GasiIication Combined Cycle
System (IPGCC) to use low caloriIic value (LCV) Ieedstock, and produce high value
co-products, along with energy, enhance the economic viability oI new projects. The
ability to successIully burn LCV Iuels like the case oI municipal solid waste required
that GE modiIied the can-annular combustion systems since 1990. GE concluded that
a Syngas Iueled combined cycle plant can have the same Reliability-Availability-
Maintenance (RAM) perIormance as a natural gas-Iueled combined cycle plant.
IPGCC shows superior environmental perIormance and viability, also the power plant
emissions are Iar below any other coal technology, Ior all the major pollutant
categories (NOx, SOx, metals, mercury, CO2, sludge, water).
11. IPGCC environmental performance
IPGCC is inherently "greener" than any other coal technology. In the process, harmIul
pollutants can be removed Irom the syngas beIore they reach the gas turbine; thus,
back-end exhaust gas clean up is not necessary. The SOx, NOx, mercury, metals, and
particle emissions Irom the plant are Iractions oI those oI a conventional pulverized
coal boiler power plant. Consequently, IPGCC plants require signiIicantly less eIIort
and time to meet air emissions regulations and to obtain local and state governmental
environmental permits. The process is approximately 5 more eIIicient than other
coal power technologies; thus, CO2 emissions per kW are also 5 lower.
Additionally, in the process, carbon can be removed Irom the syngas to create a high
hydrogen Iuel that eIIectively eliminates CO2 emissions. The advantage oI IPGCC
over conventional boiler plants Ior CO2 reduction is that the carbon can be removed
Irom the Iuel gas (pre-combustion) instead oI having to remove it Irom the exhaust
(Ilue) gas (post-combustion), which is Iar more costly because oI the larger SCR
volume required (about 10:1).
12. Conclusion and general assessment
The Plasma Torches technology is mature, reliable and a well-known method oI
producing plasma at atmospheric pressure and temperatures larger than 5,000 C; this
may disintegrate all mater, in particular solid waste, creating gasiIication because the
organic materials are converted in syngas, which is cleaned beIore being used in the
Turbine. Magmavication or VitriIication is the result oI the interaction between
plasma and inorganic materials, in presence oI a coke bed in the cupola or reactor, a
vitriIied material is produced and products are used in the manuIacture oI
architectural tiles and construction materials.
Integrated Plasma GasiIication Combined Cycle System (IPGCC) generates green
electrical power using heavy duty Turbines; the heat Irom the non-transIerred electric
plasma torch is used to gasiIy the waste, producing a synthetic Iuel gas that is then
cleaned. The cleaned syngas will then be combusted in two simple cycle combustion
turbines to produce electricity Ior internal consumption, as well as Ior export to the
electric grid. The reactor will be designed to handle some liquid waste mixed with the
solids. The plant is designed Ior continuous operation, twenty-Iour hours a day, seven
days a week and about 330 days per year. Although at Iirst look the IPGCC process
appears new, it is in Iact a repackaging oI existing, proven technologies.
To the author's knowledge, the IPGCC plasma process MSW is the only
environmentally ideal technology that we have today to process waste.
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Duty Gas Turbines,'' GE Company, Schenectady, New York, 1983.
|12| Shyam V. Dighe, et al: 2001, Private communication.
|13| S. Lavoie and J. Lachance, ''Five years oI Industrial Experience with the Plasma
Dross Treatment Process''. Proc. Third International Symposium Recycling oI Metals
and Engineering Materials. Edit by Queneau, P., and Peterson, R. (A publication oI
TMS) 1995.
|14| Mitsubishi heavy industries, LTD.5-l, Marunouchi 2-chome, Chiyoda-ku, Tokyo
100 TEL03-3212-3111, FAX03-3212-984.
Received on 03 February, 2004; revised version received on 04 June, 2004
1 Reed J. Roth |3| gives a comprehensive review oI the evolution oI the plasma
technology to the modern TransIerred and Non-TransIerred Plasma torch and it is
used Ior this review.
2 Waltz Mill Site, Madison Pennsylvania Plant.
Sociedade Brasileira de Fisica
Caixa Postal 66328
05315-970 So Paulo SP - Brazil
Tel.: 55 11 3091-6922
Fax: (55 11) 3816-2063

Iorida county pIans to vaporize IandfiII trash

FORT PERCE, Fla. (AP) A Florida county has grand plans to ditch its
dump, generate electricity and help build roads all by vaporizing garbage
at temperatures hotter than the sun.

The $425 million facility expected to be built in St. Lucie County will use
lightning-like plasma arcs to turn trash into gas and rock-like material.
t will be the first such plant in the nation operating on such a massive
scale and the largest in the world.

Integrated PIasma Gasification Combined CycIe System (IPGCC) generates
green electrical power using heavy duty Turbines; the heat from the
non-transferred electric plasma torch is used to gasify the waste,
producing a synthetic fuel gas that is then cleaned. The cleaned syngas
will then be combusted in two simple cycle combustion turbines to produce
electricity for internal consumption, as well as for export to the electric
grid. The reactor will be designed to handle some liquid waste mixed with
the solids. The plant is designed for continuous operation, twenty-four
hours a day, seven days a week and about 330 days per year. Although at
first look the PGCC process appears new, it is in fact a repackaging of
existing, proven technologies.

Plasma arc gasification
Plasma arc gasification could be considered the most
efficient gasification process. A conventional gasification
plant produces about 685 kilowatt hours (kWh) per ton of
MSW net energy to the grid, whereas a plasma arc
gasification plant produces about 816 kWh per ton of solids.
Plasma arc gasification can be used to produce a syngas,
which can be converted to liquid fuels via the Fischer-
Tropsch synthesis. A simplified schematic is shown for such
a process in Figure 1.

Plasma arc gasification is a high-temperature pyrolysis
process (7,200F to 12,600F) whereby the organics of
waste solids are converted to a synthesis gas, and the
inorganic materials and minerals of the waste solids produce
a rock-like byproduct. The synthesis gas is predominantly CO and hydrogen, and the inorganic
materials and minerals are converted to a vitrified slag, typically composed of metals and silica
glass. This vitrified slag is basically non-leaching and exceeds EPA leach test standards. Metals
can be recovered from the slag. The slag material can be used to produce other byproducts such
as rock wool, floor tiles, roof tiles, insulation and landscaping blocks, or be recycled as a road
aggregate material.

The synthesis type of gas can be used to produce electricity, steam and/or liquid fuels. The
syngas can be converted into liquid fuels such as ethanol or methanol via the Fischer-Tropsch
catalytic process. The syngas produces byproducts of HCl and sulfur via the cleanup step. The
ethanol can be blended with gasoline to produce a motor fuel, while the methanol can be used
in biodiesel manufacturing.


Plasma arc-onomics
The capital cost for using plasma arc gasification to produce
electricity and/or syngas and a vitrified slag was discussed
in the November 2006 issue of Pollution Engineering (pg.
26). Figure 2 provides a cost analysis of a plasma arc
gasification facility with a 500-ton daily MSW capacity,
showing a capital investment of about $67.7 million for the
plasma arc processing plant and almost $27 million for the
Fischer-Tropsch synthesis processing plant, including the
distillation unit for the separation of the two alcohols.

The plasma plant supplies sufficient energy for the production of about 10.4 million gallons per
year of alcohol mixture. The mixture is about 60-percent ethanol and 40-percent methanol. The
mixture yield was taken at a conservative value of about 95 gallons per ton MSW (dry material).
Capital cost of the overall plant is about $94.7 million. Capital financing for both plants was
calculated at 6-percent interest for 20 years, making two payments per year. The byproduct
rock material would be sold as a road construction material at $15 per ton. Cost considerations
for operations & maintenance, a capital budget reserve, process water, and sewer have been
considered in the economic evaluation. The estimate includes over 40 jobs created by the
combined plasma and liquid fuel facility. Energy costs for the combined plant were calculated at
zero, since the plant would produce all of its own energy.

From these initial economic analyses, one likely approach to a business plan could be a
cooperative effort between a local utility, local industry and/or local governmental entities. As
the local government participates in the MSW treatment part of the plasma arc facility, the local
utility would produce the syngas and liquid fuels. Alternately, a local industrial/business entity
could own/operate the liquid fuel facility, allowing the local government to remain in the MSW
business while the utility handles the electrical, steam and liquid fuel energy businesses.


Case study

The preliminary economics of the combined plasma arc gasification and Fischer-Tropsch
catalytic synthesis facility was considered for a Linn County/Cedar Rapids, Iowa, facility
processing about 500 tons per day of MSW. A positive cash flow was obtained for a cooperative
venture with a tipping fee for the solids of $35 per ton, and a selling price of ethanol at $2.09
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Figure 1
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Figure 2
per gallon and methanol at $0.93 per gallon. Annual net revenue - before taxes - from the
combined facility operation was just under $6.13 million per year. If the alcohol mixture yield
was taken at a value of about 113 gallons per ton MSW rather than the previous yield of 95
gallons per ton, that number would increase to almost $8.67 million per year. The alcohol
mixture produced would be about 12.4 million gallons per year.

As expected, this economic evaluation demonstrates the commercial importance of utilizing the
Fischer-Tropsch catalyst with the highest yield for the products desired. It is expected that such
catalysts with higher yields and selectivity for desired products are most likely to be just over
the horizon.


ogical approach for future progress

This economic model may not apply to every application. Industry and municipality groups
interested in pursuing a plasma arc gasification investment are encouraged to conduct and
periodically update their analyses. Cost is not the only obstacle; such an endeavor requires a
cooperative effort between governmental body(s) and industrial entity(s), and both parties will
require a fully transparent evolvement and trust in the final economic analysis.

The attractiveness of plasma arc gasification technology is the generation of renewable energy
from a widely available resource, with useful byproducts. The process uses plasma technology
to treat MSW, eliminating the need for a landfill, and can even be used to process existing
landfill MSW sites. The energy generated from the plasma plant can supply energy that is self-
sustaining, and additional syngas to be sold as liquid fuels. Other fuels can be produced using
the Fischer-Tropsch synthesis.

A utility or industrial in partnership with a local government would likely be the most economical
combination, and have the most positive benefit to the environment and financial reward to the
local area. With some diligence, a viable business plan can be developed from the consideration
of the many factors influencing the economics associated with a specific site selection, economy
of scale and the surrounding community. PE