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Biofuel and waste management: C-POWER Plant, SH Dryer (SHD)

Biofuel and waste management: C-POWER Plant, SH Dryer (SHD)

OSTRAND Corporation

C-POWER Plant: Making Strides
in Waste Management

OSTRAND Corporation is a specialist in process design and engineering for waste-to-energy (WTE). The company has developed C-POWER Plant to address these concerns.Because waste management is one of the largest issues in the developing world, there becomes a need to effectively deal with odor, water pollution and infestations that occur as a result. This negatively affects the health of the population. A new technology by OSTRAND allows factories that produce combustible waste to generate electricity from waste and cut down on disposal. This technology is easy to use, and turns wastes such as biomass and plastics into gas.

 

Major Features and Advantages

I. Easy to Use

Thanks to its streamlined design and ability to be used in a variety of areas, C-POWER Plant is easy to set up, use and maintain. There is no need for professionals with special qualification. It works by thermally decomposing organic carbon such as MSW (Municipal solid waste) and biomass to generate the fuel gas, rotate the engine, and generate electricity.

II. Thermal Decomposition Rather Than Incineration

This technology allows waste to be thermally decomposed rather than incinerated, which results in the generation of fuel gas with a high caloric value. In the past, the only option to get rid of waste was to bury it or incinerate it. With thermochemical decomposition and gasification, this is no longer necessary.

III. Unique Rotary Design

Thanks to a one of a kind rotary design, twice as much fuel gas generation can take place, when compared with standard pyrolysis technologies. This design (U-turn kiln) allows for more than 80% energy recovery ratio.

IV. Used for Power Generation

Small-scale plants can use this gas for power generation. In addition, the fuel gas and hydrogen can be utilized for batteries and chemical supplies.

V. No Harmful By-Products

This technology does not produce harmful by-products like nitrogen oxide or dioxin. As a result, there is no treatment process needed.

NEXCO East Japan is the first commercial plant in the country to use this technology. The hope for the future is that this technology can be used instead of incineration in developing countries.

Technology Data

Conceivable applications

Waste disposal and energy production
Waste: municipal solid waste (MSW), biomass, plastics, and every kind of organic carbon.
Energy: electricity, fuel-gas, and heat

Competitive advantage

Performance
More than 80% energy recovery ratio
(= Net produced gas energy / energy contained in organic carbon)
C-power plant operation with U-turn kiln can produce about 0.7 kWh/kg-df of electricity, and that with spiral-turn kiln can produce approximately 1.2 kWh/kg-df.
The residue rate is approximately 15% for U-turn kiln, and about 5% or less for spiral-turn kiln.  

Identification of competitive technology
Landfill & Incinerator
Power generation by steam turbine

Performance

1. C-Power plant
The electricity generating process based on current technologies is to incinerate MSW, generate high-pressure steam, rotate the turbine, and generate electricity.

These technologies require:
a. MSW of 100 tons/biomass of 200tons or more a day
b. Dioxine treatment process
c. Qualified persons handling high-pressure gas
d. Lower steam temperature ( leads to lower power generation efficiency below 20% for MSW of 100 tons)

 Our technology called C-POWER* thermally decomposes organic carbon such as MSW, biomass etc. generates the fuel gas, rotates the engine, and generates electricity. This technology has the following advantages over the current technologies:
a. MSW of five tons a day is enough to operate plants
b. The Dioxine treatment process is unnecessary
c. A special qualification person is unnecessary
d. Higher power generation efficiency around 30%

*One of our recent technologies includes “spiral-turn kiln” which enables thermochemical decomposition more efficient than U-turn kiln in terms of fuel gas generation and reduction of residue from the process.

2. SH Dryer (SHD)
Current dryer technologies need:
a. The hopper and the feeder besides the dryer
b. The deodorization equipment
c. Fuels such as oil and natural gas for drying

SHD has the following advantages:
a. Because hoppers, dryers, and feeders for a plant are integrated, the cost of a plant is low.
b. The deodorization equipment is unnecessary.
c. The fuel for drying is unnecessary.

Technical maturity

1. C-POWER plant
1985 – Bench scale plant of pyrolysis
2000 Invention of rotary reactor (U-turn kiln)
2004 Pilot plant (20kg/h)
2006 Test plant (200kg/h)
2010 Commercial plant ( Biomass 2,000t/y)
2014 Invention of rotary reactor (Spiral-turn kiln) Pilot plant(20kg/h)

2. SH Dryer
2009 Invention
2010 Commercial plant

Conceivable risk

Fluctuation of waste collection

Information on patent related to this technology

N/A

Company Data

Name OSTRAND Corporation
Address 1-21 Yotsuya Shinjyuku-ku Tokyo Japan
Capital 25 million yen
Contact person Akimichi Hatta
Telephone +81-90-3226-8503 
E-mail hatta@ostrand.co.jp
Number of employees 7 (1 for international operation)
Date of company foundation 9th of September 1976
The type of business Process design and engineering for waste-to-energy (WTE)

Modality of business transaction

Partnership
Arrange partnerships in WTE business & WTE process engineering

Attachments

Compendium of organic carbon conversion technologies

(Conversion into Liquid & Gas Fuel or Electricity)

Liquid Fuel Production / Pyrogas Production

Main features

Feed 1. All plastics (thermoplastics, thermosetting, halogen-containing)
2. All Biomass(dry, wet, vegetable, animal, microbe)
3. Mixture of plastics ,biomass, metal, asbestos, microbe etc.
Processes Pyrolysis & reforming
Main equipment Rotary kiln equipped with the screen and spiral for solid circulation and tar & char reforming.
Special features Continuous operation and rapid heating by internal circulating of solids.
External or internal heating by heating medium.
Main product Liquid and gaseous hydrocarbons

Image of a typical commercial plant

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Photo 1 Gasification Plant in Iwaki city (Copyright OSTRAND)

Technical description

As shown in figure 1, our system of thermal decomposition for organic wastes consists of a hopper, feeder, rotary reactor, condenser, gas refiner, oil (gas) storage tank and dual fuel engine generator.

tech_db_244_2

Figure 1 Schematic diagram of a typical plant

Specification of pyrolysis plant

Plant capacity 200 kg/h
Input (Raw materials) Mixture of plastics (30.7%), biomass (60.8%) and others (8.5%)
Bulk density 500 kg/m3
Output (Products) Gaseous products 80 – 100 Nm3/h; 20,900 – 25,100 kJ/Nm3
( Electricity 120kWh/h)
Char 20 – 30 kg/h
Kiln Dimensions Inner vessel1,000 mm outer diameter x 3,540 mm length
( Equipped with solid circulation system installed.)
Outer vessel1,382 mm outer diameter x 2,600 mm length
Feed Screw feeder200 mm outer diameter x 1,300 mm length
Water-cooled; nitrogen-gas sealed
Utility Nitrogen gas: 20 Nm3/h for sealing at dumper and screw feeder
Chilled water: 50 L/h
( Power: 5.7 kWh/h is supplied by C-POWER itself)

Typical operating results based on a pilot plant

Mixed plastics & municipal solid waste were pyrolyzed at the pilot plant shown in Photo 2.

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Photo 2 Outlook of the pilot plant

1.OperationMixed plastics (Higher calorific value 9,519kcal/kg-dry base)
The components of mixed plastics used as feedstock and the typical operating results are shown in Tables 1 and 2 respectively.
Operating conditions included a temperature of 700 degrees Celsius and feeding rate of 20 kg-plastics/h.

Table 1Contents of three elements of mixed plastics

  Moisture Ash Combustibles Total
wt% 1.04 2.19 96.77 100

Table 2Element of Combustibles (Dry base)

Ash Combustibles Elemental analysis Total
C H N O S Cl
2.21 97.79 73.8 12.9 1.11 9.86 0.03 0.09 100

Table 3Output: Gas, Oil, Char (by pilot plant 20kg/hr)

  wt% Remarks notes
Gas 87.9 Calorific value: 10.630kcal/Nm3
Heavy tar 5.8 Boiling temp: >more than150oC
Light tar 4.6(3.3*) Boiling temp: 150-50oC
Char 1.7  
Total 100.0  

*water content

2.OperationMunicipal solid waste
Dry MSW was heat resolved, and a combustible gas, the tar, and Char were obtained.

Table 4Contents of municipal solid waste (original sample)*

  Water Ash Combustible Total
wt% 45.8 5.6 48.6 100

*Higher calorific value 11,700 kJ/kg-wet base, 21,500 kJ/kg-dry base

Table 5Contents of municipal solid waste prepared as RDF (dried sample)*

  Water Ash Combustible Total
wt% 2.9 13.1 83.9 100

*Higher calorific value: 20,000 kJ/kg-dry base

Table 6Elemental composition

Analytical results of six elements, (wt%) Subtotal Other Total
C H N O S Cl
44.7 6.7 0.9 31.9 0.0 2.6 86.9 13.1 100

*Higher calorific value: 20,000 kJ/kg-dry base

Table 7Output : Gas, Oil, Char (by pilot plant 20kg/hr)

  wt% Remarks notes
Gas 52.5 23800 kJ/Nm3
Heavy tar 2.8  
Light tar 29.1(14.9*)  
Char 15.6 Organic: 3.3, Inorg.: 12.3
Total 100  

*Water content

Comparison between conventional furnace, U-turn and S-turn kiln

  Conventional type OSTRAND Corporation
Vertical furnace Type of rotation cylinder
U-turn kiln Spiral-turn kiln
Acceptable waste Piece of wood
(improper plastics)
Various combustibles
(plastics, garbage, paper, wood etc.)
Heat supply Partial combustion Heat transfer
Fuel gas electricity obtained Usual
0.5kWh/kg-df
Slightly large
0.7kWh/kg-df
Quite large
1.2kWh/kg-df
Quantity of residual 5% or less About 15% 5% or less
Case of operation Every country Japan: Highway Nasu-Kogen service area Japan: P-company commissioned from NEDO

Photo of pilot plant of Hybrid Kiln (Spiral-turn kiln)

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Diagram of S-turn kiln

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Contact Person(s) *Please mention that you saw UNIDO's website when making the first contact with the company.

Mr. Akimichi HattaE-mail: hatta@ostrand.co.jp

Registered Category

  • Low carbon & energy conservation : Renewable energy / Cogeneration
  • Waste treatment & management : Production process / Municipal solid waste