Gasification Power Plants

EXECUTIVE SUMMARY

The plant will be comprised of modular standard 50 ton/hr dry RDF and or Biomass gasification systems which will supply around 4,000 Nm3/hr syngas to a syngas engine power generation unit per system. The expected power output of the proposed plant is 50MWe per day (2MWe per hour) plus surplus thermal heat around 60MWt per day per gasification unit. The gasification plant is prepared in modular concept and up to 250 ton per day RDF or Biomass multi-gasification units (5 gasification systems each 50 ton/day) can be built in the same site which will produce power of around 250 MWe per day (10MWe per hour). The gasification plant will also include the associated ancillary structural buildings.

Deco Jones will provide gasification systems which will take 50 ton/day RDF per gasifier module for specified RDF feedstock and the client will provide all other necessary equipment’s and site for this proposed project.

Proposed Gasification System is provided by Deco Jones will be discussed in this proposal and it mainly includes gasifier reactor with ash discharge, gas clean up system including, cyclone filters, gas coolers, water scrubber with water re-circulation tank, WESP, gas suction blower, pipe work, syngas flare stack, instruments with control system and frame structure.

Locations of installation

SN:

Located City, Country

Waste Processing Capacity

(TPD)

Date, Year of Commission & Contract Period

Energy Production per ton MSW used

(KW/Ton)

Current Status

Istanbul (TR)

70 TPD

03. 2016

500

Operating

Namwon (KR)

50 TPD

01.2015

500

Operating

Bangkok

(TH)

30 TPD

01.2013

500

Operating

Malatya

(TR)

400 TPD

01.2017

500

Operating

Nottingham

(UK)

900 TPD

08.2018

500

Under Construction

INTRODUCTION

On a worldwide scale the amount of waste and biomass is steadily growing, especially in densely populated urban areas, where today, nearly half of the world is growing population lives. So cities have to find progressive technological ways of waste treatment to handle this problem.

Reuse, Recycling, thermal treatment, Bio-Mechanical Processes and waste biomass disposal in landfills are the main strategies for waste treatment. All of them have their advantages and limitations. Reuse and Recycling are only economic for parts of the waste, esp. industrial waste. From the main amount of municipal solid waste, mainly the organic fraction can be composted and reused as soil. The rest has to be bio- mechanically or thermal treated. By these strategies, which are often used in industrial countries, the amount of waste can be significantly reduced and additional parts of the energy in the waste may be used.

The rest has to be landfilled. Land-filling is an end-of-the-pipe solution and therefore no sustainable solution. It should be avoided when possible. Nevertheless, land-filling is so far the most used strategy for waste biomass treatment, mainly because of its low technological requirements and it’s low costs at the beginning. The disadvantages are a loss of the energy in the wastes and an environmental pollution by landfill gases like methane or odorous gases and landfill leachate. An environmental pollution through landfills can only be avoided by an appropriate landfill design with base liner, leachate and gas collection system and a cost intensive aftercare for several decades.

Thermal treatment plants have the advantage of reducing the amount of waste to about one third and use the energy in the waste to produce, useable syngas, heat and electricity. The residues are inorganic ashes, which can be landfilled or utilized in the construction industry. Thermal treatment has become the most used technique in USA and in Europe. The technology of thermal waste treatment is still improvable for the following aspects:

Converting the energy in the waste not only to heat of syngas but also to electricity with high efficiency
Gaining hydrocarbons out of appropriate wastes
Producing a higher inert residue, by smelting the inorganic components to vitreous slag
Reducing the costs of flue gas cleaning
Lowering the corrosive impact of the flue gas

Deco Jones has found a clean solution which shows a general concept of an Advanced Thermal Treatment Process by which the above mentioned improvements are included. Especially all kinds of waste can be processed from biomass up to all kinds of industrial waste.

Existing Biomass Waste Treatment Technologies / Comparison

Land filling

On average, every country disposes 50% of its arising waste and biomass in landfills including industrial waste. The resulting environmental pollution through this behavior cannot be fully foreseen yet. Ground water pollution and the formation of toxic residues are only two of the known risks. Especially uncontrolled landfills represent one of the most harmful and uneconomic ways of waste disposal.

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Waste Incineration

The fundamental idea of incineration is to reduce the biomass waste volume to about one third and then to dispose the residual ashes. However, the classical waste incineration produces dioxins which can only be removed at a huge financial expense for flue gas cleaning. The energy efficiency of incineration plants is very low, since they often produce only heat, and is disproportional to the investment costs. Doubts about the sustainability and cost effectiveness of conventional waste incineration plants are discussed worldwide. Further processing of these residual ashes is so far not possible. Furthermore, incineration plants are the most expensive way to dispose waste – the building costs alone are staggering. When compared to the existing waste incineration, the Deco Jones Technology can gain a significant higher amount of useful energy. Part of the energy in the produced syngas can be transferred into electricity and heat. The dioxins and furan molecules occurring during the smouldering of waste material are completely destroyed. The inorganic residues are completely solidified slag and are much more inert than partially sintered ashes of conventional waste incineration.

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Pyrolysis Technology

The production of Pyrolysis-gas takes place in a special pyrolysis furnace/reactor without oxygen addition. Only 0.1% of aerial oxygen is allowed for the pyrolysis of biomass waste under medium temperatures (400°C to 600°C). A risk of explosion exists if additional oxygen flows into the furnace. The waste has to be compressed and should be homogenous in its calorific value. Due to the operating temperature of the pyrolyser, the energetic short chained gases are transformed to heat and can no longer be used for the subsequent production of electricity. While the energy efficiency is much better than with oxygenic waste incineration, it still falls short of what is actually possible. Deco Jones Technology allows sub-stociometric oxygen for gasification. That guarantees a safe operation of the plant for the production of syngas. The gasification takes place within the temperature range of 900°C to 1200°C (and up to 1500°C). By an extraction of syngas the energetic valuable gases remain stable for later use in the gas motor or turbine (production of electricity and heat).

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Biomass Waste Gasification Technology

Deco Jones biomass waste gasification technology works well with input contaminated biomass and waste or mixture of waste materials. Energy efficiency is very high (88%) and the machines allow (due to their design) great syngas flow rate. The Technology is based on moving bed modified gasification technology and reaches significantly higher temperatures than the furnaces. The ultimate result is a higher throughput performance in a small area.

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Conclusion

Deco Jones gasification and gas clean up technology…:

is not based on combustion/incineration but rather on gasification.
operates economically even at a low operational capacity.
can dispose biomass waste as well as industrial waste in a sustainable and ecological way.
attains energy production levels many times higher than conventional waste incineration technology.
produces highly efficient renewable electricity and heat.
produces slag with a low leachability that is suitable for road, building construction or cement industry.
does not leave any residue fractions with detachable pollutant fractions.
Causes almost no emissions. has minimal space requirements; plant size can be customized.

Crucial Advantages of Deco Jones Gasification Gas Clean-up Technology:

affordable construction and operation costs
sorting or combination of biomass waste not required up to certain extend
effective use of contained raw materials
stable, robust technique (long terms)
complies with environmental regulations

DECO JONES GASIFICATION TECHNOLOGY

By means of the applied Deco Jones Technology for the first time ever, all kinds of biomass waste material, including problematic industrial wastes and household wastes, can be processed in an environmentally friendly and sustainable manner. The secret of the proven success lies in the coactions of several processing technologies for energy recovery and biomass waste disposal. In comparison to existing incineration plants, the energy efficiency of Deco Jones Gasification Technology is significantly higher. The Gasification Plant produces syngas and highly efficient electricity and heat. The Gasification Technology is completely self-sustained requires no external energy; nearly all processes are fed by energy produced during the process. No residues remain for land filling. Ground water, air and soil are protected. The thereby applied gasifier is based on the reliable moving bed technology with a conveying- and feed technology specializing in the gasification of biomass waste materials.

Plant sizes / Modular method of construction

The modular construction enables individualized adaptation of tasks. Deco Jones Gasification Plants as well as the gas clean up modules and WESP - Plants are basically built in a modular way. This enables a successive expansion via convenient single components when the demand is growing and cost effectiveness when the plant is not operating at full capacity. Therefore, the plant conception of Deco Jones can be expanded at any time and, likewise, unused capacities which can be turned off.

The standard gasification module is designed for continuous operation and has availability of more than 8000 hrs per year (>91%). It has a single module capacity of 50 ton/day (16,000 ton/year) which will produce 4000 Nm3/hr syngas. According to the requirements the modules can be expanded by combining modules up to plant capacity of 250 ton/day (83,000 ton/year).

Size of proposed one gasifier module: 15m (L) x 4.5m (W) x 10m (H)

Total site footprint required for one gasifier module with power generator area is 20m x 10m.

Operation Facilities

The demand for operation facilities for running the operation of Deco Jones Gasification Plant is, in comparison to existing incineration technologies, very low. The Deco Jones Technology requires only a small amount of external energy; nearly all processes are fed by energy produced during the process. Only small amounts of consumable material (e.g. propane/butane gas for conventional ignition and flare pilot torch, make up water for WESP) is necessary.

List of Process able Biomass and Wastes

The processing technology of Deco Jones for thermal biomass waste disposal and syngas generation, including electricity and thermal energy is applicable to a wide range of biomass waste material, including:

Wood and woody materials
Contaminated wood waste
Agricultural wastes such as nutshells etc.
Combustibles from Municipal and industrial wastes (RDF)
Dry sewage sludge of wastewater treatment plants
Rubber and plastics waste including tyre waste
Chemical and oily waste
Waste of electronic industry
Other combustible solid materials

Environmental Protection

The Deco Jones Gasification Technology for biomass waste disposal and energy generation with production of syngas for electricity and heat fulfils the requirements of integrated prevention and reduction of environmental pollution. All of engine exhaust air and wastewater is completely purified by the integrated exhaust air- and wastewater modules and thus can be released back to the environment. Produced wastewater reaches processing water quality.

In comparison to existing incineration plants no residues with detachable pollutant components remain - even during the treatment of hazardous waste. This is an entirely novel aspect. Thus common problems such as land filling of toxic residues and resultant unpleasant odor for residents do not occur. Moreover, the process works with slight low negative pressure, thus preventing gas leakage and unpleasant odor even during the actual process. The process releases back to the environment a far lower amount of harmful substances than permitted. These results have never been achieved before by any other existing technology.

CONCEPT OF DECO JONES GASIFICATION PLANT

Gas Production Module

Gasification is the thermal decomposition of feedstock in the presence of sub- stoichiometric oxygen to produce combustible gas (syngas) which is rich in carbon monoxide and hydrogen. With an insufficient amount of oxidant, oxidation is limited and the thermodynamics and chemical equilibria of the system shift reactions and vapor species are in a reduced rather than an oxidized state. Consequently the elements commonly found in fuels and other organic materials (C,H,O,N,S) end up in the gas stream as CO, H2, CH4, H2O, CO2, N2 and lesser amounts of H2S, SO2, HCI elemental carbon and trace quantities of other hydrocarbons depending on the biomass waste input.

Gasifier Reactor

The Gasifier system uses a modified moving bed gasifier which is designed to produce a combustible syngas from a variety of combustible solid materials which can be supplied to chemical synthesis processes or a boiler or used directly in an internal combustion gas engine or dual fueled engine to produce electricity and heat.

The each gasifier system is designed to process 2 tons per hour of biomass and or waste RDF and a range of other industrial and domestic waste products per gasifier module with the resulting syngas being converted into heat/electricity by a spark ignition or duel fuel compression standard engine generators. Alternatively the syngas produced from the gasifier can be utilized for the synthesis of chemicals.

The Deco Jones system concept embodies a number of features which are potentially attractive. The system is designed to be economically feasible at a modest scale and is capable of using a variety of low-grade fuels and contributes not only to energy production but also to the achievement of renewable energy and biomass industrial waste management goals. The reactor vessel has the advantages of requiring no external energy supplies and of containing no moving parts in the high temperature areas of the process which serves to the ambition of increasing the life and reliability of the system.

The system consists of moving bed modified gasifier reactor and a gas clean- up train, which contains the dust cyclones, gas coolers, wet scrubber, wet electrostatic precipitator (WESP), demister filter, water circulation tank, gas blower and flare stack. The whole system works under vacuum (negative pressure) which is developed by the gas suction blower at the required system pressures.

Ash Discharge

Ash discharge from the gasifier bottom is affected by a single roller crusher provided for each reactor. The ash drops onto the enclosed ash conveying system which is cooled by a water bath and is transported to the ash skids.

Igniters

Twin igniters are fitted to the gasifier. The torch construction consists of a length of stainless steel tube to one end of which is screwed a stainless steel burner head. A high tension (HT) pulse coil is housed at the other end of the torch.

A conductor rod, supported by insulator assemblies, runs concentric with the bore of the tube. The rod is screwed into the H.T.Coil and terminated at the burner head with a heat resisting spark-flame electrode.

A low tension pulse is fed into the ignition coil via an approved four pin connector and the resultant H.T. spark is created across the gap between the spark electrode and the burner head. Either natural gas or propane may be used to ignite the feedstock in the gasifier.

Dust Cyclones

A pair of identical hot gas coarse dust cyclones, designed to take 10 micron and above gas dust particles, is installed in the gas clean-up train where it exists from the gasifier.

Their purpose is to collect fly ash, dust and particulates from the gas stream prior to further clean-up and are fitted. The contaminants captured by the cyclones are delivered by augers to the ash collection hopper at the base of the gasifier to achieve continuous removal of impurities from the system as they are collected.

Gas Coolers

The product syngas temperature is reduced via shell and tube heat exchangers with utilizing ambient air and or water. Syngas enters the gas cooler around 600°C and leaves around 100°C. Waste heat collected in gas coolers returned back to the gasifier to prevent heat loses.

Water Scrubber

The syngas enters the wet scrubber where it is first saturated with water by the action of sprays in a venturi section. The cooled saturated gas then passes upwards thorough WESP where it is scrubbed by water fogging system.

From the venture water scrubber the liquor gravitates via return pipe to the integralrecycle tank at the base of the scrubber. The scrubbing liquor from the recycle tank is pumped by the duty recycle pump to the humidifying sprays and to the WESP. Temperature of the syngas is reduced to 40°C from 100°C after the water scrubber. The scrubber condenses water from the gas stream resulting in a dilute effluent stream containing solids and acid components of the gas stream.

The blow down of effluent passes to the water treatment plant, this serves to control the level of particulates in the scrubbing liquor. A ball float valve maintains the water level within the scrubber.

Wet Electrostatic Precipitator (WESP)

The Deco Jones WESP equipment is located just after the venture scrubber and specifically designed by Deco Jones for biomass waste gasification syngas cleanup. Deco Jones will install a new single module WESP system to achieve an overall removal efficiency of above 98%. The proposed system will comprise of a vertical flow tubular WESP system.

Deco Jones wet electrostatic precipitators are in use throughout the world in more than 3,000 installations. Wet Precipitators are of rigid frame design with fixed point suspension for the high voltage discharge electrode system and have been installed for collecting different types of dusts, such as fly ash, glass melting furnaces, forming stations, tar droplets, cement, lime, sodium sulfate and dust containing ferrous and non-ferrous metal oxides.

The Deco Jones electrostatic precipitator embodies many unique design features that ensure high collecting efficiencies over an extended lifetime with a minimum of preventative maintenance. A WESP can either have horizontal or vertical gas flow.

The Deco Jones Wet Tubular Electrostatic Precipitator uses a multi-stage action to collect fine particles and tar with mist. Prior to entering the precipitator collector, the process gas will pass through a fogging quench system to cool and saturate the gases. As the gases enter the up flow ionizing stages, the particles and the mists are charged in a corona generated by points extending from disks on the ionizing rods. The charged particles go to the collecting stage, where they are attracted to a collection plate (inside surfaces of tube walls). Subsequently, they are washed down the plate by a film of water or mists which is formed by the use of fogging nozzles upstream of the collector section or by the acid mists itself. These events are repeated many times in each tube, with each tube containing one ionizing rod.

Water Treatment

The water treatment system comprises a Dissolved Air Flotation (DAF) designed to remove oils and particulates and a heavy metals. Filter is also installed in the recirculation line after the DAF system. The filter vessel contains sand which removals emulsified oil as well. The sludge produced from the water treatment will be pumped back to the gasifier.

Coalescent Cyclone Separator

After the gas cooler is a 300mm coalescent type cyclone separator to effect the removal of the condensed water and remaining tars from the gas. The cyclone has an EN1092-2: 1997 PN16 RF flanged inlet, outlet and 1½” BSPT (F) tapped vertically downward drain connection of fabricated steel construction. The collected liquids will drain back to wet scrubber tank for eventual treatment by the water treatment system.

Gas Suction Blower

The Blower is a compact, rotary lobe type axial flow blower. The meshing of two screw type rotors synchronised by timing gears provides controlled compression of the air for maximum efficiency and pulsation free of discharge.

Compression is affected by the main (2 lobe) and gate (4 flute) rotors meshing within an enclosed housing. The timing gears maintain close rotor clearances. The rotors do not touch each other, the housing, or the bearing carriers. Although clearances are small, lubrication in the compression chamber is not required, ensuring oil - free gas delivery.

The compression cycle begins as the rotors un-mesh at the inlet port. Gas is drown into the rotor cavities, trapped and compressed by the reducing cavities as rotation continues. When proper compression is made, the cavities cross the discharge port, completing the cycle. The cycle occurs twice for each revolution of the main rotor. The housing is a one-piece casting with flanged inlet and discharge openings.

The rotors are ductile iron with integral shaft. Rotors are dynamically balanced for vibration-free operation. Helical timing gears are of alloy steel, hobbed and shaved for quiet operation.

Two heavy-duty angular-contact ball bearings are used on each rotor shaft, at the discharge end, as fixed bearings to maintain rotor and clearance. A redial bearing is on each rotor shaft at the gear end as a floating bearing. All gears and bearings are oil splash lubricated.

Gasifier and WESP Control Panel Suite

The gasifier control panel suite will comprise stainless steel floor standing wardrobe style enclosures, suitably braced to form a composite unit, mounted upon 100mm H plinth affording ingress protection to IP55, complete with standard double bit camlock door locks.

The enclosures will be equipped as follows:

• Incomer Section comprising a 400A TP&N molded case circuit breaker, complete with:

• Electronic protection unit

• Terminal protection shields

• Door interlocked pad-lockable handle

• 415V ac/110V ac 2000VA transformer, protection miniature circuit breakers on 415V ac primary and secondary 110V ac output distribution circuits and links

• “Power On” LED indication lamp

Motor Starter Sections comprising suitably rated TP isolating device, each section complete with:

• Terminal protection shields

• Door interlocked pad-lockable handle

• Variable Speed Motor Starters

Each of the above includes a motor application circuit breaker auxiliary contact block AC3 duty block type contactor, auxiliary contact block Variable Speed Drive module, keypad and Profibus communication card module/ Wiring to the required field terminations is run neatly within cable containment trunking.

Wet Electrostatic Precipitator (WESP)

Water Treatment

Coalescent Cyclone Separator

Gas Suction Blower

The rotors are ductile iron with integral shaft. Rotors are dynamically balanced for vibration-free operation. Helical timing gears are of alloy steel, hobbed and shaved for quiet operation.

Gasifier and WESP Control Panel Suite

The enclosures will be equipped as follows:

• Incomer Section comprising a 400A TP&N molded case circuit breaker, complete with:

• Electronic protection unit

• Terminal protection shields

• Door interlocked pad-lockable handle

• 415V ac/110V ac 2000VA transformer, protection miniature circuit breakers on 415V ac primary and secondary 110V ac output distribution circuits and links

• “Power On” LED indication lamp

Motor Starter Sections comprising suitably rated TP isolating device, each section complete with:

• Terminal protection shields

• Door interlocked pad-lockable handle

• Variable Speed Motor Starters

PLC Section comprising suitably rated DP isolating device, complete with:

Terminal protection shields

Direct mounted handle.

110V ac/24V dc 10A power supply unit, protection miniature circuit breakers on 110V ac input and 24V dc output connections and links

PNOZ X3 Category 4 safety relay

Twin RCD protected metal clad 240V socket outlet

Internal panel lighting

Ethernet 5 port unmanaged Switch

HMI mounted on door

Siemens S& PLC equipment, comprising:.

SN: QTY Product / Materials / Parts

1 PLC base plate for up to 11 40mm modules approx. 500mm card space but 530 mm wide

1 PLC rack / base PSU 110/240V input 5A for 1 rack

1 PLC CPU Size 3 128KB with PROFIBUS DP built in (safety enabled)

1 EEPROM / NVRAM Module for above PLC – 4MB

1 PLC Ethernet interface 8 connections cards CP343-1 ETHERNET LEAN COMMS CARD

1 MP277 10 “TFT display touch PROFIBUS STRAIGHT CONN

2 BUS CONN+IF 12 MB FAST CONN

Reactor area is i/o panels in a Stainless Steel wall mounting wardrobe style enclosure measuring 760mm H x 760mm L x 300mm D affording ingress protection to IP66, complete with standard double bit camlock door lock.

Equipped with:

Protection miniature circuit breakers and links

PNOZ 11 Category 4 safety relay

Siemens S7 PLC equipment, comprising :

SN QTY Product / Materials / Parts

2 ET200ISP PSU

1 IM152-1 interface for ET200ISP

3 ET200ISP Module 8D1 NAMUR

1 ET2004DO 23.1 V/20MA H disable

5 ET200ISP 4AI 2 WIRE HART MODULE

1 ET200ISP 4AO HART MODULE 4-20 MA

1 S7-300RAIL 585MM FOR ET200ISP

2 ET200ISP PSU terminal module

2 ET200ISP terminal module screw

6 ET200ISP terminal module screw

1 ET200S Fail Safe DO Module 4 DO

The above wired to the required EEx field terminations with cable run neatly within cable containment trunking.

Gas Clean-up Area IS I/O panels are located in a stainless steel wall mounting wardrobe style enclosure measuring 760mmH x 760mm L x 300mm D, affording ingress protection to IP66, complete with standard double bit camlock door lock Equipped with:

Protection miniature circuit breakers and links

PNOZ 11 Category 4 safety relay

Siemens S7 PLC equipment, comprising :

SN QTY Product / Materials / Parts

1. 2 ET200ISP PSU

2. 1 IM152-1 interface for ET200ISP

3. 3 ET200ISP Module 8D1 NAMUR

4. 2 ET2004DO 23.1 V/20MA H disable

5. 5 ET200ISP 4AI 2 WIRE HART MODULE

6. 1 ET200ISP 4AO HART MODULE 4-20 MA

7. 1 S7-300RAIL 585MM FOR ET200ISP

8. 2 ET200ISP PSU terminal module

9. 4 ET200ISP terminal module screw

10. 8 ET200ISP terminal module screw

11. 1 ET200S Fail Safe DO Module 4 DO

The above wired to the required EEx field terminations with cable run neatly within cable containment trunking.

Syngas Flare Stack

The flare stack will be approximately 3000mm in height with the following characteristics:

A 5mm thick stainless steel stack, from approximately 9000mm above ground level. The stack is designed for easy removal / refit without disturbing the ceramic liner.

A galvanized flare-stack base section containing the stainless steel combustion system and airflow control louvers.

150mm thick ceramic wool liner, rated to 1260ºC. The liner is in modular form with a concealed stainless steel attachment system which is not exposed to the combustion process.

Syngas ignition and pilot assembly with UV flame detection and automatic ignition and flame failure control.

Flame arrester.

4x5” flanged particulate stack sample ports

Operating range for a typical syngas: 20 % to 100% of max. flow.

Combustion temp.: >1000ºC operating range.

PLANT SUPERVISORY CONTROL PANEL SUITE & SCADA

This will be mounted in the same site main control room to allow the operator to manage the plant from a single point.

The Supervisory PLC is a dual redundant failsafe type.

The system offered comprises a single desktop SCADA PC running Siemens WinCC connected to the supervisory PLC and the individual gasifier PLCs using industrial Ethernet over CAT5 copper connections. To allow for a modular configuration and scalability for differing site environments all of the PLCs are S7300 Fail Safe Type. This allows safety interlocking functionality to be integrated within the PLC system.

The supervisory PLC connects to the individual engines via Fieldbus (preferable -connection to be finalized) and to the individual Gasifier PLCs via industrial Ethernet. Any common services will be connected at this PLC. This PLC is the master system controller for automatic operation. However, each gasifier and engine can be operated individually via human machine interfaces (HMIs) located on the gasifier control panels (local to plant).

Supervisory PLC Panels are stainless steel wall mounting wardrobe style enclosures, affording ingress protection to IP66, complete with standard double bit camlock door lock and contain:

Non-door interlocked TP isolating device
Terminal protection shields
Direct mounted handle
415V ac/110V ac 500VA transformer, complete with protection miniature circuit breakers on 415V ac primary and secondary 110V ac output distribution circuits and links
110V ac/24V dc 5A power supply unit, complete with protection miniature
circuit breakers on 110V ac input and 24V dc output connections and
PNOZ 11 category 4 safety relay “Power On” LED indication lamp Internal panel lighting
Ethernet unmanaged switch
Siemens S7 PC equipment, comprising:

Continued...

SN QTY Product / Materials / Parts

2 CPU414H – 768K

2 UR2 CENT/ EXP RACK 9 SLOT

2 PWR supply 120/230VAC 10A

2 S7 – 400 MC952 4MB Memory

2 CP443- 1 TCP H1 Processor

4 400H SYNCmodule up to 10km

2 400H FO cable for synch module 2M

1 Y-link package IM, BMs coupler, repeater

1 SIMATIC NET IE CP1613 A2 PCI CARD

1 S7 REDCONNECT S/W VERS 6.3

1 ET200M redundant bundle, 2XIM153 = 1

3 ET200M 2X4MM BUS unit

The above wired to the required EEx field terminations with cable run neatly within

SCADA System Hardware

The SCADA hardware is as follows:

Desktop PC complete with 27” flat screen monitor
A4 laserjet black/white printer
Win CC SCADA Configuration

UPS

The UPS System is to maintain the following for 15 mins in order to allow controlled shutdown:

SCADA PC
Supervisory PLC I/O
Gasifier PLC Processors
Gasifier PLC I/O including IS I/O panels
Engine controls

The UPSs have volt free contacts wired to PLC inputs with status of battery, supply and bypass mode displayed on the SCADA.

PLANT PHILOSOPHY

The Deco Jones approach to the construction of its energy solutions is the application of simply standard modular approach, broken into three functional units:

. Fuel biomass-waste and ash handling
Gasifier syngas reactor and syngas cleanup with WESP
Clean syngas production for power generation

Fuel & Ash Handling

This element of the plant will handle the off load feedstock, transporting to the storage silos and the transporting this on to the gasifiers on demand. It also removes the ash on demand from the discharge end of the gasifier to sealed ash skids. The feedstock silos act as buffer store for this system.

The Plant operating regime will be, to operate 24 hours a day, seven days a week, with much of the plant being already automated in order to minimise the operators on site at any given time. For ease of operation, minimise construction time and fit with standard modular approach each of the above units will have individual local control suites controlling their elements of process within the plant and interface via the overall plant via the plant control system.

Gasifier and Gas Cleanup

This will consist of a standard gasification module consuming feedstock at the rate of approximately 2 tonnes/hr per gasifier delivered into a common syngas main to supply 4000 Nm3/hr syngas for client’s own use. The units are supported by common water treatment plant and gas cooling systems. Matching the outputs from the gasifiers to the gas demand from the power plant is via the main gas header; the control is achieved by gasifiers maintaining the gas header pressure at 250mBara through adjusting the speed of the blowers to maintain the required delivery pressure.

In turn the gasifiers will demand feedstock from the fuel handling system, as the fuel is consumed within the gasifiers, this is achieved by the level of control of the feedstock in the gasifier.

Clean syngas production

The low level of tars and particulates in the final product syngas is crucial for the reliable operation of the up stream gas separation process.

The seven stage gas clean up system includes cyclones for particulate control, gas coolers and air pre-heaters, a high efficiency water scrubber to cool the product gas and wet electrostatic precipitator (WESP) for control the fine sub-micron particulates in the syngas stream.

The typical expected syngas composition from RDF gasification is given in the following table.

Table 1: Typical Expected Syngas composition

Syngas (with Air supply)

% Volume (Dry)

H 2

17.5

C O

20.8

CH 4

3.3

N 2

45.8

CO 2

11.4

C 2 H 4

0.7

C 3 H 6

0.4

Syngas Volume (m3/hr)

4000

COMMERCIAL

Complete Gasification System

This option provides complete gasification system with syngas clean up system application as explained in the above sections of this proposal. Deco Jones assumes that produced syngas will be utilized for the power production in this project.

Deco Jones will design, fabricate, and supply each 50 ton/day; 5 off gasifier modules to achieve 250 ton/day RDF (combustible waste mixture produced from MSW) gasification system made of high grade stainless steel (SS310 and SS304) throughout the gasifier system and steel structure as described in the following section:

SN: QTY Material / Products / Parts

1. 1 off complete Gasifier reactor vessel with monitoring elements necessary valves, level detector, ignition systems.

2. 1 off Ash discharge auger and receiver complete with pneumatic isolating gate and rotary valves.

3. 2 off hot syngas dust cyclones with augers

4. 1 off gas cooler heat exchanger

5. 1 off venturi vortex water scrubber

6. 1 off water re-circulation tank and water pumps

7. * Wet Electrostatic Precipitator rated at 4000 Nm3/hr syngas

8. * Coalescent cyclone separator

9. * Separator and Demister Filter

10. 1 off product syngas suction blower and motor

11. 2 off syngas flare stacks

12. * Necessary pipe work and motors

13. * Monitoring equipment’s (thermocouples, pressure transducers and flow meters)

14. * Automatic PLC system and electrical control panel

15. * SCADA control remote link

16. * Skid mounted steel structure for the gasifier and gas clean up plant

17. * Delivery to the S. Korea custom’s port and 2 man advisors for the installation.

18. * Advisor for the training of the client’s personnel (2 weeks).

Price Schedule

Option 1-A

Basic

Gasification

50 ton/day RDF gasification and gas clean up plant.
50 ton/day proposed complete 1 off gasification system

Option 1-B

Basic Gasification with Engine Generator

250 ton/day RDF gasification, gas clean up and gas engine generator plant.
250 ton/day proposed complete 5 off modular gasification power production (10 MWeh) systems (rated 2 ton/hr each)

Option 2-A

Gasification

only

250 ton/day RDF gasification and gas clean up plant.
250 ton/day proposed complete 5 off modular gasification systems (rated 2 ton/hr each)

Option 2-B

Gasification

with Engines

250 ton/day RDF gasification and gas clean up plant.
250 ton/day proposed complete 5 off modular gasification systems (rated 2 ton/hr each)

Comments and Clarifications

The following comments and clarifications relate to our quote:

No civil engineering works or building is included and all health and safety requirements are the client’s sole responsibility.
The Gasification plant operational capability may be tested during the commissioning trials at the client site within 90 days.
After completion of commissioning trials for the gasifier, an operator’s manuals will be provided at the time of delivery to site.
The connection and commissioning schedules will be agreed during the detailed design stage.
The client will supply necessary wastes needed during the commissioning trials to be carried out at the site. The client’s operators will be trained during be carried out at the site. The commissioning trials at site.
Necessary interlocks will be provided for integrated gasifier and engine/boiler/turbine operation, safety critical operations will be hardwired, and software monitored.
All controls suitable for non-hazardous areas only.
The plant supply comes with 12 months manufacturer’s warranty against faulty manufacturing or electrical equipment failure.
The gasifier will be installed with the necessary safety equipment however, any additional equipment needed to meet the demands of specific industrial waste will be charged in addition to the original contract price.
Above quotas are valid for 12 weeks from the date of issue.

Delivery Program

Estimated delivery time is 40 weeks (+/- 6 weeks) for both options from the award of contract. However, this is subject to any adjustment on the production of the final contract program.

Terms and Conditions

This proposal will be subject to our standard terms and conditions, which will be available on request. This proposal is an initial discussion proposal only and cannot be treated as a final binding contract.