Advanced Plasma Gasification Systems

Current & Emerging Technologies

Dr. Ben Herbert - Director of Research &

Environment

Stopford Energy & Environment

The 14th Annual APGTF Workshop 13.03.14

Our Organisation
Stopford is an international energy and environment
consultancy providing innovative multidisciplinary solutions to
a global market leveraging over 30 years of experience
Stopford is an associate company of Lancaster Environment
Centre giving its staff access to the world class research and
development facilitates on the campus.

Clients

Energy from Biomass &

Waste - Our Approach

Current WtoE Climate

Increasing energy prices

High demand for renewable and clean electricity
Increasing waste disposal and landfill costs
Lack of efficient & safe waste disposal systems
Increasingly stringent environmental regulations
Increasing interest in novel energy generation technologies
e.g. Fuel Cells and Hydrogen Gas

The Technologies
Non-Thermal Technologies:

Thermal Technologies:

Anaerobic Digestion
Biodrying
Mechanical Biological Treatment

Incineration (Thermal Oxidation)

Pyrolysis
Gasification
Plasma Arc Gasification

The Technologies
Non-Thermal Technologies:

Thermal Technologies:

Anaerobic Digestion
Biodrying
Mechanical Biological Treatment

Incineration (Thermal Oxidation)

Pyrolysis
Gasification

Plasma Arc Gasification

Plasma-Arc Gasification
Gasification is defined as the partial thermal degradation of a substance
under sub-stoichiometric conditions (i.e in the presence of oxygen but
with insufficient oxygen to oxidise the fuel completely).
Plasma-Arc Gasification uses high electrical energy and high
temperatures to break down waste into its basic elemental composition,
under controlled oxygen conditions, producing a synthesis gas and an
inert vitrified slag.
A high temperature process with operating temperatures exceeding
5000oC

All organic materials in the feedstock of the gasifier are converted to a

syn-gas (comprising carbon monoxide and hydrogen)
All Inorganic materials are vitrified into an inert a glass-like slag

Plasma-Arc Gasification
The advantage of gasification process is that the production of energy
from syngas is potentially more efficient than direct combustion of the
original fuel.

The process does not convert all of the chemical energy in the fuel into
thermal energy but instead leaves some of the chemical energy in the
syn-gas and in the solid residues
Syn-gas may be burned directly for electricity production, used to
produce methanol and hydrogen, or converted via the Fischer-Tropsch
process into a second generation biofuel.
The typical NCV of the gas from gasification using oxygen is 10 to 15
MJ/Nm3
For comparison the NCV for natural gas is about 38 MJ/Nm3

Plasma

Plasma Torch

NASA Technology:
Testing Shuttle Tiles

The Process

Plasma Torch for Metal Cutting

Plasma Gasification

1. Mixed Materials
Fed Into
System

2. Organic Materials
Gasified Into
H2 &CO...

Inorganic Materials
Vitrified Into
Inert Slag

3. Gases Converted
Into Energy

Plasma-Arc Gasification

Isometric Full View

Isometric Cut Away View

Direct Current Plasma

High temperatures (~5000 C) achievable causing
improved organic-inorganic separation efficiencies
High calorific value syngas produced with multiple
applications
Hazardous/Toxic compound destruction/immobilisiation
(e.g. dioxin and furans/heavy metals)
Secondary vitrified product from inorganic content

High CAPEX & OPEX costs

High Parasitic Load
Large scale to be economically viable
Relatively few demonstration or commercial facilities

The Alternative Microwave

Induced Plasma

All benefits of direct current plasma

Improved energy efficiency
Lower CAPEX and OPEX
Economically viable at smaller scales
Lower maintenance requirement as no electrodes
required
Ability to auto-strike plasma
Proven technology (microwaves)

Microwave-Induced Plasma
for Energy from Waste
Project: Carbon Abatement Technology
Funding: Technology Strategy Board (TSB)

Phase I: 12 month project proof of concept

project to test the viability of microwaveinduced plasma for the gasification of mixed
wastes and biomass.

Phase II: 3 year project to develop a 160 tpa)

microwave-induced
plasma
gasification
demonstration system.

What is Microwave Induced

Plasma?

Waveguide Design

Waveguide Design

Waveguide Design

Phase I Reactor
1 kW 2.45 GHz magnetron
200 x 200 x 250 mm mild steel
box
100 mm removable sight glass

~40 g batch charge

Plasma gas inlet (argon at
1 L min-1)
Pressure gas inlet (nitrogen at 1
L min-1)
Stainless steel crucible

Plasma Plume Generation

Advanced Thermal
Treatment Trials
Aim:
To determine the syngas composition, evolution, and
calorific value (CV) from microwave-induced plasma
treatment of mixed waste materials

Waste Types Trialled

Commercial & Industrial Waste (C&IW)

Biomass
Screenings Waste
Sludge Cake

Thermal Trials Calorific Value

Waste Type

Waste NCV
(MJ/kg), AR

Condition

Syngas NCV
Range (MJ/m3)

C&IW

9.5

Pyrolysis

11.4 17.4

Biomass

16.3

Pyrolysis

14.5 19.2

Screenings
Waste

6.1

Gasification

8.7 11.2

Sludge Cake

1.2

Gasification

6.5 10.8

Gas Evolution
Gas Evolution (Screenings)
80

80

70

70

60

60
50
CO2

40

80
70

Left: 1.1 % O2

CO2

40

CO

30
20
10

Time (s)

92
4

85
8

79
2

72
6

66
0

59
4

52
8

46
2

39
6

33
0

26
4

19
8

13
2

Vol %

50

66

Bottom: 10.8 % O2

60

1584

1496

1408

1320

1232

1144

968

1056

11
0
22
0
33
0
44
0
55
0
66
0
77
0
88
0
99
0
11
00
12
10
13
20
14
30
15
40
16
50
17
60

Time (s)

Time (s)

Right: 5.9 % O2

880

792

704

10

616

20

10

528

20

CO

440

30

30

352

CO

264

40

176

CO2

88

Vol %

Vol %

50

Intermediate Reactor
2 kg/hr
Designed to:
Gain more representative
gas and thermal data
Test multiple plasma
operation
Reduce risks associated
with scale up to
demonstration reactor

Intermediate Reactor

Commercial Analysis &

Modelling

Digester Cake
Screenings Waste
C&I Waste

ROO
Payback (Years)
8.31
5.31
5.82

IRR (%)
14
20
18.73

CfD
Payback (Years)
8.41
5.63
6.51

IRR (%)
13.68
18.73
16.49

The Future
To design and construct a 160 tpa demonstration
facility for commissioning in 2015
To deploy the reactor at United Utilities WwTW in
Ellesmere Port, UK, for continuous operation
To optimise the process to accept a range of
different waste types
To design bespoke systems to satisfy customer
requirements for small-scale biomass/waste to
energy schemes

Acknowledgements
Stopford would like to thank its project partners:
Liverpool John Moores University
United Utilities
Finning
& project funders
Technology Strategy Board

Thank you
Stopford Energy and Environment
Providers of the complete technology development solution

For further information contact us

www.stopford.co.uk
+44 (0)1524 510 604