WASTE-TO-ENERGY & HEAT RECOVERY SYSTEMS


WASTE-TO-ENERGY SYSTEMS

High-efficiency fuel & energy production

Efficient reduction of waste feedstocks into liquid and gaseous fuels for storage, onward processing or direct generation of electrical energy from waste.

FuturEnergy waste to energy plants provide recycling of wastes into highly valuable liquid, gaseous and solid fuels using pyrolysis or gasification or recovery and use of heat lost from other processes. Wastes as diverse as end-of-life tyres, mixed plastics, sewage sludge, AD digestate or other organics can be turned into valuable alternative energy solutions.
TECHNOLOGY INTRODUCTION
All systems comprise of a series of discrete modules integrated into a whole designed to manage a variety of raw feedstock materials into base compounds. Wherever possible multiple flow paths are adopted to prevent pinch-points and single points of failure.
Pyrolyser

Waste feedstock:
end-of-life tyres; waste plastics; Solid Recovered Fuel (SRF)

Temperature: subject to feedstock, 450°C to 600°C

System objective:
Reduction and disposal of waste (end of life certification)
Production of high quality stable fuel oils and combustible gases
Direct use of oil in IC generator sets with electricity export
Direct use of combustible gases in gas IC generator sets with electricity export
Recovery and reuse of heat
Storage of oils for onward processing (option)
Production of high quality carbon char

Sizes: 2.5MW(e) modules based on rubber waste at ~1t/hr

Typical equipment:

• Materials handling systems comprising pumps, feed-screws, conveyors, storage hoppers
• Input hopper feed system (with weight loss monitoring to manage throughput)
• Nitrogen inerting system comprising generator, storage and delivery
• Materials compounder (subject to waste type)
• Pyrolysis chambers
• Heat exchangers, heat recovery and recirculation systems
• Char extraction and cooling systems

• Vapour condensers, gas filters, gas scrubbers, and gas pressure buffer
• Flare system
• Overarching control system
• Cooling modules with air blast cooler
• Oil storage units
• Oil or gas IC engines
• Grid connection facilities

Gasification (Advanced Thermal Treatment)
Waste feedstock: sewage sludge or cake; AD digestate

Temperature:  circa 1250°C

System objective:
Reduction and disposal of waste (end of life certification)
Production of combustible gases
Direct use of combustible gases in gas IC generator sets with electricity export
Recovery and reuse of heat
Production of high quality carbon char

Sizes: 
Small scale – from 25kW(e) to 250kW(e) using ~1.5kg/1kW(e) organic waste
Large scale – from 1.5MW(e) to 20MW(e) using ~1.7kg/1kW(e) sewage sludge

Typical equipment:
• Materials handling systems comprising pumps, feed-screws, conveyors, storage hoppers
• Materials dewatering and drying systems
• Briquetting system
• Nitrogen inerting system comprising generator, storage and delivery
• Gasification units
• Heat exchangers, heat recovery, and recirculation systems
• Char extraction and cooling systems
• Gas cooler, filters and scrubbers
• Flare system
• Overarching control system
• Cooling modules with air blast cooler
• Gas IC engines
• Grid connection facilities

WASTE-TO-HEAT RECOVERY SYSTEMS

Waste heat energy recovery systems

Generate electrical energy from waste heat using Stirling Power Pack Systems

 

Heat is often generated as a by-product of a core process that is then vented to atmosphere. FuturEnergy Stirling Power Pack Systems (SPPS) convert waste heat, for example flue or exhaust gas, into useful electrical energy. A highly efficient method of generating energy from waste and converting an existing process into an alternative energy source.
TECHNOLOGY INTRODUCTION
The SPPS is a series of Stirling engines installed in banks in a standard ISO container, a 20’ unit will typically produce 500kW(e), subject to the gas flow and temperature of the hot gas feed to the hot cylinder. Gas is fed through a refractory-lined steel duct to a manifold system directing gas to each engine. Engines can be individually removed for maintenance without affecting the remainder of the system. Best performance is achieved with inlet temperatures greater than 1,000°C but recovery is possible with temperatures above 600°C. A 300°C temperature drop occurs as the energy is extracted from gas with a second-stage generation possible in a further bank of engines..
Waste feedstock:                  Any waste that has created heat in the process, e.g. incineration systems
Temperature:                         1000°C +
Gas type:                                   Any gas, (clean gas preferred to avoid soot build up)
Generation:                             565V DC (inverter supplied as standard to meet local requirements)
System objective:                 Recovery and reuse of heat for electrical generation
Typical equipment:
Stirling power pack unit comprising banks of 15kW(e) or 22kW(e) engine/generators.
Manifold assembly for heat transfer
• Cooling system for Stirling engine cold cylinder
• Grid connection inverters
  • +44 (0) 1789 450280
  • Ettington Park | Stratford upon Avon | CV37 8BT
  • +44 (0) 1789 450280
  • Ettington Park | Stratford upon Avon | CV37 8BT