Post on 11-Mar-2016
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►►Destroying►Hazardous►Waste►►►Alter►NRG►and►Technip►Alliance►►A►Look►at►Biomass►Conversion►►Representative►Meeting►Highlights
In this Issue:►►Regulatory►Approval►and►a►Big►Project:►St.►Lucie►►Plasma►Torches►Applications►and►Technology►Developments►►Touring►the►Eco-Valley►Facility
DECEMBER 2010 | INAUGURAL ED I T ION
A GLOBAL OUTLOOK
™
TECHNOLOGY | REVIEW | UPDATE
In an effort to keep our customers current on
Alter NRG and partner activities, we are happy
to launch a quarterly bulletin highlighting
the most up-to-date information on
projects, regulations affecting development
of plasma gasification projects, technology
and corporate initiatives.
Wishing you and your family warm greetings this holiday season. From the team at Alter NRG
Richard Fish President
ContentsTechnip _______________3Technip: What Does Our Alliance Mean?
Plasma Gasification _______4Not Just a Waste Solution; A Look at Biomass Conversion
Highlights _____________ 7Representative Meeting
Spotlight On ____________82 Guys, Regulatory Approval and a Big Project. St. Lucie: How Did They Pull it Together?
Tech Talk _____________ 10►● Plasma Torches Applications►● Generation 4 of Plasma Gasification Technology Developments
India ________________ 17Destroying Hazardous Waste
Close up: _____________ 18A Plasma Gasification Close Up. Touring Eco-Valley, Utashinai
Cover Photo:►Plasma►Gasification►in►actionContent & Design:►Alter►NRG►Corp.►-►Corp.►Development►Team
Alter►NRG►Corp.►is►a►registered►trademarks.►All►other►company►and►product►names►may►be►trademarks►of►their►respective►owners.►The►information►contained►herein►cannot►be►re-producted►in►any►format►without►legal►permision►from►Alter►NRG►Corp.,►and►is►subject►to►change►without►notice.►►Copyright►©►2010.►All►rights►reserved.
2 ISSUE►|►DECEMBER►2010
Technip USA is Alter NRG’s preferred EPCM for complete balance of plant
After►working►with►the►technical► team►at►Alter►NRG►and►gaining► in-depth►knowledge►of► the►Westinghouse►Plasma►Gasification►technology,►Technip►USA►felt►that►Alter►NRG►is►leading►the►energy►from►waste►technology►industry.►Technip►USA►will►provide►balance►of►plant►integration►engineering►as►well► as► overall► performance►guarantees,► in► conjunction►with►Alter►NRG,► to►support►project►financing►for►plasma►facilities.►Having►Technip►on►board►as►a►strategic►partner►further►validates►the►Westinghouse►Plasma►Gasification►technology►and►brings►significant►gas►clean-up►experience►into►our►projects.
From► conventional► and► alternate► technologies;► production► of► steam► and► power;► syngas►conditioning►and►clean-up;►and►emission►abatement►technologies,►Technip►USA►has►extensive►experience►in►the►field►of►syngas►production
Alter►NRG’s►strategic►partners►can►benefit►from►Technip►USA’s►gas►processing►expertise►for►the►design►and►operation►of► their►syngas►generating►plasma►gasification►facilities.►Technip►USA’s►performance►guarantees►means►that►they►ensure►the►facility►will►operate►at►the►stated►levels,► which► helps► mitigate► the► project► developers► risk► while► also► indicating► to► financial►institutions►that►it►is►a►suitable►project►for►debt►financing.►
About TechnipTechnip► USA,► a► subsidiary► of► Technip► S.A.►(“Technip”),►is►a►recognized►leader►in►the►energy►sector► with► 23,000► people► working► in► 48►countries►globally,► and►over►6.5►billion►Euros►of►annual► revenues.►Technip►provides►engineering,►procurement► and► construction► services► to► the►energy,►refining►and►process►chemical►industries,►with► project► management► expertise► including►complex► project► integration,► risk► assessment,►conceptual► design,► preliminary► and► detailed►engineering,► global► procurement► and►construction►management.
“Technip is excited about partnering with Alter NRG and the Westinghouse Plasma Technology that we feel is the industry leading technology in the field of Waste-to-Energy. During our due diligence period we have become comfortable that this technology can be broadly applied and can make a significant difference in creating sustainable energy for the future. We believe Technip can add technical and commercial value to plasma gasification facilities through efficient execution of these projects.”
- Jeroen Snijder, General Manager of Claremont office of Technip USA, Inc.
Alter NRG & Technip USA Sign Alliance
Highlights:
• Technip will provide balance of plant and integration engineering for facilities using the Alter NRG plasma gasification technology
• Technip will offer performance guarantees on entire facilities
• Facilitates project finance
ImageSource:www.Technip.com 3 NRG►FOCUS►|►BY►►ALTER NRG
Biomass►represents►a►large►market► opportunity► that► is►growing► year► over► year.►Around► the►world,► all► types►of► biomass► are► currently►being►used►to►generate►heat►and► electricity.► In► some►cases,► coal► and► biomass►are►blended►together.►In►the►U.S.► alone,► the► estimated►total► biomass► resource► is►over► 590► million► wet► tons,►however,► access► is► limited►to►only►20►million►wet►tons1.►Due►to►its►varied►quality►(e.g.►dirt► and►moisture► content),►many► technologies► and►processes►are►ineffective►in►the►conversion►of►biomass.►
According to PowerGen World Wide, “Biomass has the potential to be a leader in renewable energy growth for two main reasons. The first reason is the location factor. Biomass generation can be developed almost anywhere. Other renewables such as wind, hydro and solar can be much more location-specific. Second, biomass power can be produced on demand. Most other renewables are susceptible to the weather or seasonal changes. Biomass—like coal, natural gas and nuclear power generation—can be run around the clock throughout the year.”2
1 U.S. EIA http://www.eia.doe.gov/oiaf/analysispaper/biomass/
2 http://www.powergenworldwide.com/index/display/articledisplay.articles.power-engineering.volume-113.issue-11.features.biomass-an-emerging-fuel-for-power-generation.html
Plasma Gasification: Not Just a Waste SolutionThe Westinghouse Plasma Gasification technology is best known for marketing its use in energy from waste applications; however, the technology also has distinct advantages in the biomass market.
Highlights:
• The Westinghouse Plasma gasification technology for biomass conversion offers:
• Feedstock flexibility: blend or change feed types
• End product versatility: syngas, electricity, ethanol, steam
• High availability and reliability
4 ISSUE►|►DECEMBER►2010
3 Juniper Commercial Assessment – Advanced Commercial Technology (Gasification) for Biomass Projects, June 2007 for Renewables East.
Plasma Gasification Fluidized Bed Combustion (Circulating and Bubbling)
Gasification
End►product Syngas►and►vitrified,►inert►slag Heat►and►ash Syngas►and►slag►or►ash
Reliability►&►Availability► The►torch►systems►can►be►used►to►process►inconsistent►or►dirty►batches►of►feedstock►without►any►down►time►and►consistently►produce►a►quality►syngas
Downtime►is►necessary►to►clean►out►the►bottom►ash,►otherwise►high►availability►
Reliable►as►long►as►feed►size►is►consistent►for►gasification►process3
Feedstock►Flexibility► A►plasma►gasifier►at►a►biomass►facility►will►provide►a►customer►with►insurance►against►market►fluctuations►and►even►shortages►of►feedstock►with►the►ability►to►process►blended►feedstocks.►►
A►Bubbling►Fluidized►Bed►can►process►wood/woodwaste►or►wood/woodwaste,►sludge►and►tires►as►fuel
A►Circulating►Fludizied►Bed►can►process►Coal►or►Coal►and►wood/wood►waste,►petroleum►coke►and►tires
Can►blend►similar►consistency►feed
Biomass is a renewable energy source consisting of plant waste material, vegetation and agricultural waste. Plasma gasification can convert biomass into a carbon neutral base load power source or other valuable products such as ethanol and steam.
The energy harnessed from biomass comes from the process of photosynthesis. As plants grow, they capture an amount of carbon dioxide (CO2) equal to that released during plasma gasification. This process creates an energy rich and carbon neutral balance.
Biomass Conversion TechnologiesBiomass►energy►systems►can►be►based►on►a►wide►range►of►feedstocks►and►use►many►different►conversion►technologies►to►produce►solid,►liquid►and►gaseous►fuels.►Commonly►used► technologies► for► processing►biomass► include► fluidized►bed► combustion► (bubbling►and► circulating)► and►gasification.► In► comparison► to►plasma►gasification,►the►main►differences►between►the►technologies►include:
Not► typically►known► for►processing►biomass,► the►Westinghouse►Plasma►gasification► technology►has►emerged► in► the►biomass►market►as►a► reliable►and► rugged►alternative.►Plasma►gasification►is►able►to►reliably►process►various►types►of►biomass►while►also►providing►the►flexibility►to►incorporate►new►sources►of►feedstocks.►Processing►biomass►with►plasma►gasification►generates►syngas►which►can►be►used►for►power,►steam►or►ethanol.►With►the►Alter►NRG►gasification►system,►facilities►can►choose►to►process►different►feedstocks►over►time.►Specifically,►lower►value►feedstocks,►or►even►negative►value►(with►tipping►fees)►could►be►processed►at►a►facility.►Alter►NRG►has►proven►biomass►processing►experience►as►seen►at►the►Westinghouse►Plasma►pilot►plant►in►Madison,►Pennsylvania►where►biomass►is►being►converted►into►clean►syngas►for►use►in►Coskata’s►cellulosic►ethanol►process.►Also,►Wuhan►Kaidi►is►currently►building►a►biomass-to-energy►demonstration►facility►in►China►using►the►Westinghouse►Plasma►technology.►Construction►will►likely►be►complete►in►the►first►quarter►of►2011.►
Why Plasma Gasification for Biomass Conversion?
The Process of PhotosynthesisPHOTOSYNTHESIS
BIO
MA
SS
CA
RB
ON
DIO
XID
E
RESIDUES & BY-PRODUCTS
5 NRG►FOCUS►|►BY►►ALTER NRG
At► the► Westinghouse► Plasma► Pilot► Centre,► Coskata► is►operating►their►first►commercial►demonstration►cellulosic►ethanol► facility► called► Project► Lighthouse.► Coskata► is►using► clean► syngas► generated► from► the► processing► of►biomass►in►the►Westinghouse►Plasma►gasification►process►to► feed► microscopic► bugs► in► the► creation► of► cellulosic►ethanol.
Providing Clean Syngas for Coskata’s Cellulosic Ethanol Facility
The Westinghouse Plasma Gasification technology is best known for marketing its use in energy from waste applications; however, the technology is also very competitive for use in biomass applications.
Dispelling Concerns About Processing Biomass with Plasma
Most►concerns►regarding►the►processing►of►biomass►with►plasma►gasification►were►with►respect►to►operating►costs,►specifically:►►
1. Cost of Bed Material: The cost of the met coke needed to form the bed in the gasifier
2. Internal Power Consumption: The cost of plasma torch power
Through►simulations►and► testing►Alter►NRG►has►eliminated► the►bed►material,► torch►power►and► the►steam► injection► into► the►gasifier► in►order► to►prove► that► the►Westinghouse►Plasma►Gasification►technology►is►a►strong►conversion►process►for►biomass.►►While►our►gasifier►requires►a►fixed►bed►and►torch►power►to►process►most►feedstocks,►it►does►not►need►either►the►bed►or►torch►power►to►process►biomass►feedstock►with►less►than►2%►ash►content.►If►necessary,►the►gasifier►can►be►operated►with►a►fixed►bed►composed►of►BRIQs.►►BRIQs►are►made►from►recycled►particulate,►are►cheaper►than►met►coke►and►do►not►require►being►purchased►on►the►open►market.
Operating►our►gasifier►without►the►bed►and►torch►power►reduces►costs►compared►to►direct►gasification►and►in►the►case►of►ethanol►►it►can►increase►the►liquid►yield.►The►ability►to►blend►feedstock►significantly►reduces►the►net►operating►costs►of►plasma►gasification.►Feedstock►prices►and►availability►will►change►over►time.►►Installing►an►Alter►NRG►gasifier►at►a►biomass►facility►will►provide►a►customer►with►insurance►against►market►fluctuations►and►even►shortages►of►feedstock.►
6 ISSUE►|►DECEMBER►2010
Kevin► Willerton,► VP► Strategic► Alliances► and► Business► Development► of► Alter► NRG► hosted► the► representatives►providing►a►well-received►educational►session.►Several►presentations►were►given►by►Alter►NRG►and►Westinghouse►Plasma►employees.►
Allison►Newman,►Westinghouse►Plasma’s►sales►engineer,►provided►insight►into►other►plasma►torch►applications►aside►from►gasification►and►provided►the►group►with►a►tour►of►the►pilot►facility.►►
Alex► Gorodestsky,► gasification► engineer► at► Alter► NRG,► presented► a► plasma► gasifier► technology► update► to► the►representatives,►including►details►on►the►latest►gasifier►design►and►the►replacement►of►Met►Coke►with►BRIQs►for►the►bed►material.►
Bruce►Leonard,►Manager►of►Corporate►Development,►informed►the►representatives►of►the►target►markets►for►plasma►gasification►based►on►feedstock►(municipal►waste,►hazardous►waste►and►biomass)►and►key►downstream►markets►(energy►and►ethanol).►
Kevin►Willerton►provided►an►overview►of►how►Alter►NRG’s►strategic►alliances►can►help►the►representatives►with►their►sales►processes►and►gave►insights►into►the►fuel►replacement►market.►
Each►representative►also►gave►an►update►on►the►activity►in►their►regions,►encompassing►opportunities,►threats►and►the►overall►marketplace►for►plasma►gasification.
Attendees►were►fortunate►to►receive►a►presentation►from►Coskata►and►a►tour►of►their►new►facility,►Project►Lighthouse,►adjacent►to►the►Westinghouse►Plasma►Corp►pilot►plant.►Project►Lighthouse►is►Coskata’s►pilot►facility►that►is►producing►cellulosic►ethanol.►Biomass►is►processed►in►the►Westinghouse►Plasma►gasifier►to►generate►syngas.►The►syngas►is►piped►to►the►Lighthouse►Facility►where►Coskata►uses►it►to►feed►the►microscopic►bugs►to►generate►cellulosic►ethanol.►
Westinghouse Plasma Corp. Hosts First Representative MeetingOver two days in early November, all of the Westinghouse Plasma sales representatives were invited to meet at the Westinghouse Plasma Corp pilot plant in Madison, Pennsylvania for a business development session regarding the Alter NRG/Westinghouse Plasma technology.
Companies Representing the
Westinghouse Plasma Technology:Australia Moltoni►Energy
Brazil RGT►International►
China Wuhan►Restech
China AC►Capital
Greece,►Bulgaria,►Macedonia,►Albania
VI.PA►S.A.
India SMSIL
Israel Vecron►Holding►Limited
Italy Italplasma
Mexico Green-Tech►Brokering►GR►Investments
Middle►East►(Saudi►Arabia,►UAE,►Oman,►Kuwait,►Iraq,►Qatar,►Jordan)
Utilities►Holdings►International,►LLC
New►Zealand Moltoni►Energy
Poland MDI►Sp.►Z►o.o.
Spain Green-Tech►Brokering►GR►Investments►
United►Kingdom►(England,►Wales,►Scotland)
Waste2Tricity►Ltd
The success of this session has led to Westinghouse Plasma committing to semi-annual representative sessions.
Attendees of the Representative Meeting at the Westinghouse Plasma Pilot Plant
7 NRG►FOCUS►|►BY►►ALTER NRG
Geoplasma► has► now► engaged► Alter► NRG► for►engineering►support►and►other►services►related►to►this► project,► which► is► expected► to► lead► to► further►engineering►and►a►plasma►gasification►equipment►order►upon►successful►development.►Many►barriers►had► to►be►overcome►to►achieve► this►permit►–►how►was►this►done?
Of►utmost►importance►is►the►acknowledgement►by►Florida► State► that► waste► management► is► a► vital►issue.►“We’ve►only►got►the►size►of►the►planet,”►said►Richard► Tedder,► program► administrator► for► the►Florida►Department► of► Environmental► Protection’s►solid► waste► division.► “Because► of► all► of► the►pressures► of► development,► people► don’t► want►
landfills.► It’s►going►to►be►harder►and►harder►to►site►new►landfills,►and►it’s►going►to►be►harder►for►existing►landfills►to►continue►to►expand.”►►Hillburn►Hillestad,►the► President► of► Geoplasma,► Robert► Martin,► a►Senior►Engineer►at►Geoplasma►and►other►members►of► the► team► at► Geoplasma► were► instrumental► in►getting► regulatory► approval► from► the► Florida►Department► of► Environmental► Protection► (DEP).►Through► dedicated► effort,► they► were► diligent► in►educating► local► residents►and► the►Florida►DEP►on►the► technology► and► the► advantages► to► the► local►area.
Once► the► need► to► find► alternative► waste► disposal►methods►was►established,►St.►Lucie►County►set►out►
specific►criteria►for►its►technology►selection:►it►had►to►be► proven,► commercialized,► economically► viable,►and► environmentally► friendly.► Several► different►technologies►were►reviewed,►including►gasification,►bioreactors,► incineration,►anaerobic►digestion►and►plasma► gasification.► Leo► Cordeiro,► director► of► the►St.►Lucie►County►Solid►Waste►Department,►traveled►with►chair►of►the►county►board►of►commissioners►to►Japan►to►see►Eco-Valley►in►Utashinai,►a►commercial►example►of► the►Westinghouse►Plasma► technology.►In►the►end,►the►county►determined►that►only►plasma►gasification►met►all►four►criteria.
2 Guys, Regulatory Approval and A Big Project St. Lucie: how did they pull it together?
Another milestone has been reached in the development of Geoplasma’s St. Lucie, Florida plasma gasification energy from waste plant. This past July, Geoplasma received its final Air Construction Permit from the Florida Department of Environmental Protection and is no longer subject to any appeal process.
4 http://www.usatoday.com/news/nation/2006-09-09-fla-county-trash_x.htm
“For the amount of energy produced, you get significantly less of certain pollutants like sulfur dioxide and particulate matter” - Rick Brandes, Chief of the Environmental Protection Agency’s Waste Minimization Division
The project site is within the boundaries of the existing
St. Lucie County landfill site
Highlights:• Located at a landfill site in St. Lucie
County, Florida• Processing 660 tonnes per day of
municipal solid waste and tires• Generating 25 MW of electricity• Florida Department of
Environmental Protection has granted the final Air Construction Permit for the facility
• The ground lease and energy sales agreements are two of the final steps, both under negotiation
8 ISSUE►|►DECEMBER►2010
A►ten►month►public►consultation►period►followed►the►technology► selection► process.► County► citizens► did►not►oppose►the►process,►however►‘non-stakeholders’►did► present► a► challenge,► insisting► that► plasma►gasification►is►the►same►as►incineration.►To►counter►this,► extensive► engineering► was► performed► by►county► engineers,► out-of-state► engineers,► and►Geoplasma► engineers► to► advance► the► system► to►meet► and► exceed► both► EPA► and► Florida► DEP►emissions►criteria.►
When► it► came► time► for► the► final► decision► on►implementing► Geoplasma’s► proposed► waste►management► technology► and► facility► for► St.► Lucie►County►in►June►2007,►all►five►commissioners►voted►in► favor.► Since► then,► both► Geoplasma► and► the►County► have► been► flexible► to► accommodate►changing► conditions.► The► planned► capacity► was►decreased►to►approximately►660►tons►per►day►due►to► economic► conditions► and► declining► waste►volumes.► Feedstock► will► consist► primarily► of►municipal► solid►waste► from►St.► Lucie►County,► plus►tires► and► other► permitted► feedstocks► and► convert►this►into►steam►and/or►25►MW►power.5
In►order► for► the► facility► to►survive►once►operations►begin,► two► critical► conditions► are► required:► a►guaranteed►fuel►supply,►and►a►contract► for►sale►of►electricity,► steam,► and/or► byproducts.► Geoplasma►has►a►20►year►agreement►with►St.►Lucie►County►to►process► the► waste► into► clean► energy► instead► of►continuing► to► bury► it► in► the► County► landfill.►Discussions►are►in►the►works►for►a►power►purchase►agreement►with►Florida►utilities.►
It►seems►promising►that►the►flexibility►demonstrated►throughout► past► stages► of► development► will►continue► into► the► future.► Alter► NRG► is► currently►advising►on►the►project►as►is►develops.►The►St.►Lucie►facility►will►have►the►potential► to►expand►to►accept►biomass► and► construction► and► demolition► waste.►Geoplasma►also►expects►to►contract/partner►with►a►recycling► company► that► will► operate► a► recovery►facility►at►the►front►end.►The►need►to►dispose►of►solid►waste► by► alternative►means► has► been► around► for►years,►Hillestad►said.►“But►the►economic►component►is►really►being►driven►by►the►fact►that►we►generate►a►lot►of►power.►That’s►green►power►from►a►renewable►source.”►6
The►ground►lease►and►energy►sales►agreements►are►two► of► the► final► steps,► both► under► negotiation.►Construction►could►begin►late►Q1►or►Q2►2011,►with►operations►beginning►March►2013►.7
5 http://www.publicpower.org/newsletters/ppmagazinedetailarchive.cfm?ItemNumber=25584
6 http://www.americanrecycler.com/dec06/b/progressive.shtml
7 http://www.tcpalm.com/news/2010/nov/09/st-lucie-county-geoplasma-could-agree-on-lease/
St. Lucie County Solid Waste Director Leo Cordeiro, left, and Assistant Director Ron Roberts,
right, pose at the St. Lucie County landfill in Fort Pierce, Fla.
Geoplasma is a subsidiary of the Jacoby Group which has business interests in Real Estate, Healthcare, Education as well as clean energy and has been advancing St. Lucie and other energy projects since 2003
9 NRG►FOCUS►|►BY►►ALTER NRG
What is Plasma?The► plasma► torch► is► an► electric► arc► gas► heater► which► can► be► utilized► in► high►temperature►industrial►processes.►As►the►process►energy►is►provided►by►direct►heat►transfer►from►an►electric►arc,►gases►of►widely►varying►chemical►composition►can►be►used.►
Plasma►torches►have►the►unique►capability►of►increasing►the►energy►of►the►process►gas►by►2►to►10►times►higher►than►that►of►conventional►combustion►equipment.►As►such,►the►plasma►torch►offers►distinct►advantages►over►traditional►methods.►These►advantages► include► control► of► process► variables,► such► as► precise► temperature►regulation,►process►gas►flexibility►and►increased►process►operating►temperature►not►typically►possible►by►conventional►means.
Westinghouse Plasma Corp. Torch Development Developed►in►the►early►1970’s,►the►Westinghouse►Plasma►torches►were►first►used►for►hydrocarbon► process► research► and► for► the► production► of► Solar► Grade► Silicon► for►NASA.► In► the► last► 40► years► Westinghouse► Plasma► has► sold► torches► to► over► 30►different►companies►with►the►majority►being►in►the►following►applications:
►● Metallurgical►Processing
►● Hazardous►Waste►Treatment
►● Boiler►Igniter►Replacement
►● Vitrification►(incinerator►ash,►etc.)
►● Chemical►Processes
►● High►Temperature►Applications
The► latest► torch►sales►were►sold► for►use► in►gasification►processes,►boiler► igniters,►metal►processing,►steel►blast►furnace,►acetylene►production,►iron►ore►pelletizing►and►ferrosilicon►powders.►
Plasma SubsystemThe►plasma►torch►system►is►comprised►of►the►following►elements,►which►allows►for►optimal►performance►of►the►plasma►torch►system:
1. The plasma torch is the center of the plasma system with several subsystems needed for torch operation.
2. A thyristor power supply is utilized to provide DC power to the torch.
3. A control system is necessary to vary process parameters and to interlock the power supply, gas and, water systems.
4. The electrodes in the torch are water cooled by a high pressure water cooling system.
5. The process gas system for the torch is supplied by a gas compressor or gas storage.
Tech Talk: Plasma Torch ApplicationsThe foundation of Westinghouse Plasma Corp. is its plasma torches. Prior to using torches in plasma gasification applications, Westinghouse Plasma was selling torches for high heat applications including metal melting.
MARC 11 Plasma Torch
Highlights:• Demand for plasma torches for use in
high temperature industrial applications is increasing as the prices of fossil fuels (coke, fuel oil) escalates
• Ideal uses for plasma torches include:• Metallurgical processes
• Blast Furnaces• Iron Ore Pelletizing
• Industrial Boiler Igniter Replacement• Hazardous waste destruction• Ash Vitrification
• The Westinghouse Plasma torches have been in use since the early 1970’s for high temperature applications
10 ISSUE►|►DECEMBER►2010
Westinghouse Plasma Torch Experience
Date Customer Application Plasma Torch Systems
2010 Undisclosed►Client►–►Metals►research MARC►11H
2010 SMS►Infrastructure,►Ltd.►►►Commercial►Vitrification►of►Common►Hazardous►Waste►
MARC►3A►
2009► SMS►Infrastructure,►Ltd.►►►►Commercial►Vitrification►of►Common►Hazardous►Waste►
MARC►3A►
2005► Georgia►Institute►of►Technology►►►►Laboratory►Application►
MARC►3A►
2002► Hitachi►Metals►Ltd.►►Commercial►Gasification►of►MSW►&►Waste►Water►Sludge►
MARC►3A►
2001► Hitachi►Metals►Ltd.►►Waste►to►Energy►Facility►Gasification►of►Auto►Shredder►Residue►&►Refuse►Derived►Fuel►
MARC►3A►
2000► Undisclosed►Client► MARC►3A►
1999► Hitachi►Metals►Ltd.►►Commercial►Gasification►of►MSW►
MARC►3A►
1995► Geneva►Steel►Corporation►►Commercial►Production►of►Molten►Iron►for►Steel►Making►
MARC►11►
1994► DuPont►Corporation►Materials►Synthesis►Development► MARC►3A►
1995► Ishkawajima-Harima►Heavy►Industries►Co.►(IHI)►►Commercial►Vitrification►of►MSW►Incinerator►Ash►
MARC►3A►
1993► Ishikawajima-Harima►Heavy►Industries►Co.►(IHI)►►Research►Lab►for►Vitrification►of►Incinerator►Ash►
MARC►3A►
1992► China►Steel►Co.►►Research►Lab►for►Metals►Production►
MARC►3A►
1992► ALCAN►(Aluminum►Canada►Ltd.)►Commercial►Aluminum►Dross►Recovery►Furnaces►
MARC►11H►
1990 ALCAN►(Aluminum►Canada►Ltd.),►►Research►Lab.►For►Aluminum►Dross►Recovery►
MARC►11H►
1989 General►Motors►Corporation►►►Commercial►Cast►Iron►Production►
MARC►11H►
1988 Consarc►Corp.►►►Research►Center►for►Refining►of►Refractory►Metals►
MARC►3A
1987 Eldorado►Resources►Ltd.►►Extraction►of►Uranium►from►Magnesium►Fluoride►Research►Center►
MARC►3A
1986 Pyrolysis►Systems►Inc.►►►Mobile►Trailer►for►Liquid►Toxic►Waste►Destruction►
MARC►3A
1985 Intermountain►Power►Co.►►►Commercial►Ignition►of►a►Pulverized►Coal►Boiler►
MARC►3A►
1985 Owens-Corning►►►Fiberglass►Research►Lab.►
MARC►3A►
1985 Studsvik►Energiteknik►►►Thermal►Simulation►of►a►Nuclear►Reactor►Core►Meltdown►
MARC►11►
1984 Pickands►-Mather►Co.►►Metal►Project►Development►of►Plasma►Iron►Reduction►and►Steelmaking►
MARC11►
1983 Westinghouse►Research►and►Development►Lab.► MARC►11►MARC►3A
1981 Cockerill►Steel►Co.►►►Commercial►super-heating►of►blast►furnace►air►to►reduce►coke►usage►
MARC►3A
1980 SKF►Steel►Co.►►Commercial►Sponge►Iron►Production►
MARC►11►
1977 Westinghouse►Research►►►Jet►Propulsion►Lab.►NASA►Production►of►Solar►Grade►Silicon►
MARC►11►
1975 Westinghouse►Research►►Arc►Heater►Project
MARC►11►
1973 International►Minerals►&►Chemicals►Corp.►►Phosphate►Defluorination►Process►
MARC►11►
1971 Dow►Chemical►Corp►►Hydrocarbon►Process►Research►
MARC►11►
Westinghouse Plasma torches have 40 years experience in a variety of high temperature applications.
11 NRG►FOCUS►|►BY►►ALTER NRG
The►Alter►NRG►owned►Westinghouse►Plasma►technology►has►a►10►year►successful►track►record►of►commercially►operating► facilities► in► Japan► and► India► along► with► a►demonstration►facility►in►the►U.S.►and►one►being►built►in►China.► Westinghouse► Plasma► has► spent► more► than►$100►million►in►R&D►funding►over►a►period►of►25►years.►Since► acquiring►Westinghouse►Plasma►Corporation► in►2007,► Alter► NRG► and► its► customers► have► spent► over►$20MM►on►technology►upgrades.►
Tech Talk: The Fourth Generation Alter NRG Plasma Gasification Design is HereSince acquiring Westinghouse Plasma Corp. in 2007, Alter NRG has been continuously improving its plasma gasification technology, now in its fourth generation. Innovative efforts have focused on reducing capital and operating costs, improving efficiency and operability, and increasing the ability to process a wide range of feedstocks. The technology has evolved through expanded product offerings, balance of plant integration, comprehensive performance assurance guarantees and proven reliability.
PHASE 1
Acquisition of
Westinghouse
Plasma
• In 2007 Westinghouse Plasma sold only plasma torches and provided basic engineering preliminary diagrams.
• Our customers wanted a more complete solution…
PHASE 2
Expanded
Product Offering
• During 2008, Westinghouse Plasma expanded the gasifier vessel design and expanded scope of the gasifier island to include:
- Quench system
- Slag system
- Refractory optimization
• As well, Westinghouse Plasma used independent third parties to perform detailed capital costing.
• Westinghouse Plasma was then able to offer a full “gasifier island” which can be integrated with other conventional equipment to create energy.
PHASE 3
Integrated
Product Offering
• During 2009, Westinghouse Plasma integrated its gasifier island into the complete energy facility performing independent engineering on the steam cycle, combined cycle power island, the syngas clean-up, and the feedstock handling systems.
• Westinghouse Plasma took all of the independent engineering and got to a +/- 10% level of costing on the gasifier island and also a full 3D model on the entire energy facility.
PHASE 4
Improved Product
Offering
• Reduced capital by approximately 30% through:
- International sourcing
- Design optimization
• Reduced operational cost by approximately 30% through:
- Metcoke bed replacement
- Reduced parasitic load
• The Westinghouse Plasma facilities are now able to get facility performance guarantees through a leading engineering company, Technip.
Evolution Supported by:
Highlights:Focus of Generation 4 plasma gasification technical development has improved design resulting in:• Reduced Operating Cost - alternative
bed material in some cases only 30% of the cost of a metallurgical coke bed
• Reduced Capital Cost - reduced by up to 30% for the Alter NRG scope from original cost estimates
• Improved Efficiency - optimize overall torch power usage
• Improved Operability – based on learnings from the Eco-Valley facility
12 ISSUE►|►DECEMBER►2010
Vessel Design OptimizationAlter►NRG’s►next► generation►design► includes►modifications► resulting► from►operating►problems►experienced►at►Eco-Valley.►Enhanced►design►tools,►such►as► flow► analysis► and► refractory,► as► well► as► strategic► partnerships► with►engineering► companies► and► material► supply► companies,► are► continually►being►used►to►improve►design.►Modifications►and►improvements►have►been►tested►and►implemented►at►pilot►plant►to►further►prove►new►design►elements.►
Eco-Valley, Utashinai Facility Operational LearningsThe►Eco-Valley► facility► in►Utashinai,► Japan►experienced► three►operating► issues►including►bottom►diameter►sizing,►refractory,►and►carry-over.►These►issues►were►rectified►through►thermal►modeling,►comparison►of►existing►plant►data,►testing►in►our►pilot►plant,►and►design►modifications.►Today,►the►Eco-Valley►gasifier►is►running►extremely►well.►Also►incorporated►into►the►gasifier►design►is►the►experience►of►Mr.►Shinichi► Osada,► who► helped► design► the► Japanese► facilities► and►who►was► the►General►Manager►for►Eco-Valley►before►he►retired►and►became►a►consultant►for►Alter►NRG.►
Generation 1 Generation 3/4
Optimization of flow reducing High velocity zones,
minimizing carryover
CFD Modeling - Gas flows, Temperatures
Generation 2
Gasifier Vessel Development The►design►of►the►gasification►vessel►has►evolved►into►an►optimized►solution►by►incorporating►operational► learnings►the►commercial► facilities,►simulations,►and►testing►at►the►pilot►facility.►Each►generation►of►the►gasification►vessel►builds►upon►learnings►and►experience►of►the►previous►design.►The►initial►gasification►vessel,►Generation► 1,► closely► resembled► a► metal► melting► cupola► which► resulted► in►several►inefficiencies►in►the►plasma►gasification►process.►Generation►2►addressed►the►operating► inefficiencies►of►Generation►1►by► increasing► the► freeboard►area►which►resulted►in►a►longer►residence►time.►This►led►►to►a►decrease►in►particulate►matter► carry-over► and► tar► formation.► Generation► 3► focused► on► optimizing► the►available► volume► in► the►gasification► vessel►by► redesigning► the► freeboard►area►based► on► the► learnings► from► the► Eco-Valley► facility.► Today,► Generation► 4►incorporates►all►learnings►from►commercially►operating►facilities►and►focuses►on►the► optimization► of► the► gasification► vessel► including► a► reduced► capital► and►operational►cost.
13 NRG►FOCUS►|►BY►►ALTER NRG
Foundry►coke►has►been►used►as►bed►material►at►all►facilities►using►the►Westinghouse►Plasma►technology,►possessing►good►attributes.►However,►it►is►a►fossil►fuel►with►the►associated► negative► perceptions,► it► is► expensive,► and► is► not► readily► available►globally.► These► shortcomings► have► been► addressed.► Residual► material► (BRIQs)►created►through►the►plasma►gasification►process►was►used►as►a►replacement►for►metallurgical►coke►as►bed►material►in►multiple►runs►at►the►pilot►plant.►Results►were►very► positive► both► operationally► and► economically.► Virtually► all► of► the► potential►waste►generated►by►the►process►is►now►recycled.
Alter►NRG►has►recently►filed►for►a►provisional►patent►for►the►use►of►these►alternative►bed► materials,► eliminating► the► need► for► fossil► fuels► in► its► plasma► gasification►process.►
Refractory Thermal Modeling Work
Finite Element Analysis for Vessel Mechanical Integrity
Residual material for use as bed material
Prediction of slag freezing plane
Increasing Refractory Performance And Improving Vessel Integrity
Optimization of Gasifier Design
“Globally, it is imperative that we reduce our need on fossil fuels for energy production. As a leader in the alternative energy sector we believe that we need to be leading these types of innovations.”
- Mark Montemurro, CEO of Alter NRG
Testing BRIQ material with a Westinghouse Plasma Torch
Replacement of metallurgical coke as a bed material improves both the economics and the environmental impact of the process
Bed Material Improvements
14 ISSUE►|►DECEMBER►2010
Seeing Plasma Gasification First Hand: Touring the Eco-Valley, Utashinai FacilityIn 2003, Eco-Valley became one of the first energy from waste facilities in the world to utilize the Westinghouse Plasma gasification technology on a commercial basis. Eco-Valley is located in Utashinai, Japan and has been successfully processing municipal solid waste (MSW) and auto shredder residue for over seven years.
The► facility► processes► up► to► 220► tonnes-per► day► of►MSW► or► up► to► 165►tonnes►per►day►of►a►50/50►mixture►of►MSW►and►auto►shredder►residue.►The►facility► was► designed► primarily► as► a► waste► destruction► facility► and►
secondarily►as►an►electricity►production►facility.►
The►technology►used►at►Eco-Valley►is►a►result►of►a►successful►collaboration►between► Westinghouse► Plasma► Corp.► and► Hitachi► Metals.► ► Alter► NRG►regularly► organizes► tours► of► the► Eco-Valley► facility► where► only► guests► of►Alter►NRG►can►visit►the►facility.►
“Our visit reinforced there is confidence in the technology promoted and that as it is the Japanese local governments that actually own and operate these plants themselves, this highlights that there do appear to be suitable mechanisms available to control these type of facilities and that this can be achieved.” - Town of Kwinana, Australia
Attendees at Eco-Valley viewing the control room
“Utashinai and Mihama Mikata (Westinghouse technology) are the only plasma gasification plants processing MSW in the world on a commercial basis at this time.” -Juniper Consulting
15 NRG►FOCUS►|►BY►►ALTER NRG
Municipal governments, including: ● City of Sacramento, California
● Taunton
● City of New Orleans, Louisiana
● Department of Environmental Affairs, Jefferson Parish, Louisiana
● St. Tammary Parish, Louisiana
● Kwinana Town Council, Australia
● Moscow Region, Russia
● INEA, Environmental State Institute, Brazil
School, including: ● COPPE ( Alberto Luiz Coimbra Institute of Post Graduate and
Research), Brazil
Clients, including: ● Air Products
● US. Science and Technology (USST)
● Wuhan Kaidi Holding Investment Co. Ltd.
● Wuhan Kaidi Electric Power Engineering Co. Ltd.
● Dalian MEC Environmental Technology & Engineering Co. Ltd.
● China Energy Conservation Investment Corporation
● Shanghai Institute of Mechanical & Electrical Engineering Co.
● GES Corp.
● Waste2Tricity
● Alliance Federated Energy
● Corvelle Ryan
● Atco Power
● Pannone Lopes Devereaux & West LLC
● Alternative Resources, Inc.
● Sun Energy Group
● MWH Americas, Inc.
● Camp Dresser & McKee Inc.
● Simon Carves
● Plasma Recycling Ltd. Israel
● Coronal
● Plasma Renewable
● GE
● Juniper Consultancy
● Firebox Energy System
● ECO Manufacturing
● Saint-Gobain Ceramic Materials
● Braskem
● Cetrel/Lumina
● Comlurb - (Waste Municipality Company of Rio de Janeiro)
● NRG Energy
● Hatch
● Taliya
● ItalPlasma
● GTS Energy Technology (Shanghai) Co., Ltd.
● Shun Green
● GTL Utility Resources
● Moltoni Energy
● Alcoa
● MGSSI
● Tangshan Xinfeng Group
● GES
● Carbonium
● TBC Innovations
Visitors to UtashinaiVisitors► are► hosted►by►Mr.► Syuichi►Mukai,►the► Utashinai► Plant► Manager► and► a►representative► from► Alter► NRG.► The►attendees► view►all► aspects► of► the► facility,►seeing► the► municipal► waste► arriving,► the►plasma► gasification► reactor,► the► control►room►and►the►slag►by-product►discharging►from►the►reactor.
Municipalities► and► government► officials►along►with►many►of►Alter►NRG’s►prospective►and►current►customers►are►among►the►list►of► attendees► to► view► the► plasma►gasification►technology►in►operation.►Since►2007,►over►10► tours►have► taken►place►at►the►facility.►
A crane hoisting the waste which will be placed in the plasma gasification reactor
Visitors to the Eco-Valley Facility:
Eco-Valley, Utashinai Facility
16 ISSUE►|►DECEMBER►2010
Pune and Nagpur On► June► 15,► 2010,► Alter► NRG► signed► a► strategic► alliance► agreement► with► SMS►Envocare►Ltd.,►a►group►company►of►SMS► Infrastructures►Limited► (“SMSIL”),► India’s►largest► civil► engineering► and► infrastructure► development► company.► Using► the►Westinghouse► Plasma► technology,► SMS►Envocare► has► constructed► two► hazardous►energy►from►waste►facilities►in►India.►The►first,►at►Ranjangaon,►Pune,►began►operations►in► 2009,► and► has►met► all► prevailing► regulatory► requirements.► Construction► of► the►Butibori,►Nagpur►facility►is►complete,►with►commissioning►expected►in►early►2011.►
These►facilities►demonstrate►the►ability►of►the►Westinghouse►Plasma►torches►to►gasify►a►multitude►and►variety►of►feedstocks.►Each►facility►has►a►capacity►of►30-75►tonnes►per►day►of►hazardous►waste,►and►exports►1.6MW►of►electricity►to►the►grid.►The►primary►by-product►of►the►gasification►process►is►an►inert►vitrified►slag►which►is►sold►and►used►for►road►aggregate.►At►each►site,►the►gasification►facility►is►part►of►a►larger►Eco-Park,►which► includes►an►analytical►and► instrument► lab,►as►well►as►a►secured►hazardous►waste►landfill►for►low►calorific►value►waste.►►
India►has►been►experiencing►rapid►industrial►and►economic►growth►in►recent►years,►producing► more► hazardous► waste► than► ever► before.► Heavy► metals► and► other►pollutants►from►hazardous►waste►can►have►a►serious►effect►on►human►health►and►the►environment.►Open,► illegal► incineration►of► these►wastes►causes►emissions►of►SOx,►NOx► and► particulate► matter.► These► toxins► can► also► leach► into► the► groundwater,►entering►the►already►limited►human►water►supply.►Managing►this►waste►at►a►common►site► allows► for► greater► possibility► of► recovery► of► material,► increased► ease► and►economic►viability,►and►more►efficient►environmental►monitoring.
India: Destroying Hazardous Waste
Pune Facility
Nagpur Facility
17 NRG►FOCUS►|►BY►►ALTER NRG
Project Updates:Alter NRG’s strategic partners are developing projects around the world using the Westinghouse Plasma gasification technology, below is a list of a few of these projects and their project status:
St. Lucie, FloridaGeoplasma► is► developing► a► 25►MW► plasma► gasification► waste►to► energy► plant► in► St.► Lucie,►Florida.► The► facility► is► expected►to► process► approximately► 660►tons► per► day► of► primarily►municipal► solid► waste► from► St.►Lucie► County,► plus► tires► and►other► permitted► feedstocks► for►conversion► into► steam► and/or►power.► Geoplasma► received► its►final► Air► Construction► Permit►from►the►Florida►Department►of►Environmental► Protection► in►July,► 2010► and► is► no► longer►subject►to►any►appeal►process.
Koochiching County, MinnesotaCoronal► LLC► is► developing► the► Renewable► Energy► Clean► Air►Project► (RECAP)►using► the►Westinghouse►Plasma►Gasification►technology► in► Koochiching► County,► Northern►Minnesota.► The►facility►is►expected►to►gasify►a►variety►of►feedstocks,►including►municipal►waste,►regional►woody►biomass►waste►and►biosolids►from► the► nearby► waste► water► treatment► facility► to► create►syngas,► then► steam► or► electricity► for► use► in► the► local► area.►Koochiching► Development► Authority► has► contracted► with► the►Minnesota►Pollution►Control►Agency►for►the►release►of►US$2.5►million►in►funding►from►the►State►of►Minnesota►for►the►project.►The► State► funding► is► expected► to► be► matched► from► the► US►Department►of►Energy.
Tees Valley, UKAir►Products►recently►announced►plans►to►build►a►new►49MW►renewable► energy► plant► in► Tees► Valley► using► Alter► NRG’s►Westinghouse►Plasma►Gasification►technology.►The►facility►will►convert► 950► tonnes► per► day► of► pre-processed► waste► into►baseload► renewable► power► through► a► combined► cycle► power►configuration.► This► facility► will► generate► electricity► for► up► to►50,000►homes►and►divert►300,000►-►350,000►tonnes►of►waste►from►landfills.
The project site is within the boundaries of the existing St. Lucie County landfill site
“The RECAP project receiving these significant grant monies is a major milestone for the project. Koochiching Development Authority and ourselves as the developer, are adequately capitalized to take the project through preliminary design and regulatory approvals.”
- John Howard, Chief Technical Officer and Stephen Korstad, Chief Financial Officer, of
Coronal LLC
Schematic of the proposed facility in the UK
18 ISSUE►|►DECEMBER►2010
“Our Apollo project is moving forward aggressively with support from state and local jurisdictions. Our relationship with Alter NRG is an important component of our strategy and we are very pleased to have access to their industry leading Westinghouse Plasma Technology”
- Christopher Maloney, Chairman and CEO of AFE
Wuhan, ChinaAlter► NRG► and► Wuhan► Kaidi► signed►an►alliance►agreement► in►May►2010►to►construct►a►demonstration►facility►and►development►of►future►biomass-to-energy► projects► in► the► Chinese►market.► The► demonstration► facility►will► complete► construction► in► Q1,►2011.► Wuhan► Kaidi,► the► leading►green► energy► company► in► China,►plans► to► develop► more► than► 150►biomass► projects► throughout► China►using► the► Westinghouse► Plasma►Gasification►technology
Milwaukee, WisconsinAlliance► Federated► Energy► (AFE)► is► currently► developing►Project►Apollo,►25MW►plasma►gasification►based►renewable►energy► project► located► in► Milwaukee,► Wisconsin► which►plans►to►be►operational►in►late►2013.►The►first►phase►of►the►renewable► energy► facility► is► expected► to► process►approximately►1000►tons►of►municipal►and►industrial►waste►per► day.► Alter► NRG► and► AFE► signed► an► exclusive► license►agreement► for► all► feedstocks► in► the► States► of► Illinois,►Wisconsin► and► Indiana► and► hazardous► waste► for► the►continental►U.S.►in►September,►2010.
Nagpur, India SMS► Envocare► has► recently►completed►construction►of►its►second►facility► using► the► Westinghouse►Plasma►Technology►for►treatment►and►disposal► of► hazardous► waste► at►Butibori,►Nagpur►in►India.►Designed►to►destroy►30-75►metric►tonnes►per►day►of► hazardous► waste► with► the►capability► to► export► 1.6► MW► of►electricity,► the► facility► is► expected► to►be► operational► in► early► 2011.► SMS►Envocare►intends►to►construct►further►plasma►gasification►facilities►for►itself►and► other► customers► in► India► and►other►parts►of►the►world.
“We are pleased to be working with the Westinghouse plasma solution and believe it provides fuel flexibility for the more than 150 biomass projects that we plan to develop throughout China.”
- Mr. Chen Yilong, Chairman of Kaidi
19 NRG►FOCUS►|►BY►►ALTER NRG
Other Recent News and Highlights►● Signed►an►Engineering►Services►Agreement►with►Air►Products►for►$1.2M►►(October►27,►2010)
►● Announced►the►expansion►of►the►proposed►project►in►Dufferin►County►and►the►creation►of►an►Ontario►Development►Company,►Navitus►Plasma►(October►21,►2010)
►● Signed►a►collaboration►agreement►with►Technip►USA,►a►major►EPC►company,►to►market►the►Westinghouse►Plasma►Technology►and►provide►full►facility►performance►guarantees►(October►7,►2010)
►● Announced►being►recognized►as►a►finalist►in►the►Platts►Global►Energy►Awards►and►the►Ernst►and►Young►Entrepreneur►of►the►Year►(October►4,►2010)
►● Announced►a►plasma►project►in►Minnesota►that►received►US►$2.5M►of►State►funding►(September►28,►2010)
►● Signed►a►22►month►extension►agreement►with►Coskata►valued►at►a►minimum►value►of►US$4.1M►(September►22,►2010)
►● Signed►a►Technology►Site►License►Agreement►with►Air►Products►for►US$500,000►(September►20,►2010)
►● Announced►engineering►services►agreement►for►a►24►MW►energy►from►waste►project►in►St.►Lucie►County,►Florida►(September►16,►2010)
►● Announced►AFE►first►project,►Project►Apollo,►located►in►Milwaukee,►WI.►This►project►represents►approximately►$30M►to►Alter►NRG►(September►7,►2010)
►● Signed►an►exclusive►license►agreement►with►AFE►for►approximately►$11.4M►(September►7,►2010)
►● Air►Products►announced►plans►to►build►a►new►49MW►renewable►energy►plant►in►Tees►Valley►in►the►UK.►This►project►represents►approximately►$20M►to►Alter►NRG►(July►20,►2010)
►● A►►WTE►project►in►St.►Lucie►County,►FL►received►its►air►permit,►which►represents►the►first►commercial►permitting►of►a►WTE►facility►using►the►WPC►plasma►gasification►in►North►America.►This►project►represents►approximately►$25M►to►Alter►NRG►(June►17,►2010)
►● Selected►as►the►technology►provider►for►an►industrial►waste►project►in►Spain►(June,►2010)
►● Signed►a►strategic►alliance►agreement►with►SMS►EnvoCare►Ltd.►(June►15,►2010)
►● Signed►a►$1M►equipment►sale►and►strategic►alliance►agreement►with►Wuhan►Kaidi►Holding►Investment►Co.►Ltd.►(May►4,►2010)