To summarize, the system works very effectively, produces very clean high quality gas for the production of energy, is very protective of the environment and generates a form of carbon that can revolutionize the composite lumber industry. Some of the features of the gasification system are:
- reducing the nation’s dependence on foreign energy
- utilizing coal, municipal and animal waste to generate clean burning gas
- production of a carbon by-product that can greatly reduce the nation’s reliance on natural trees to produce lumber
- reducing greenhouse gas emissions
- generating large number of jobs
The Waste to Energy Process Technology system was designed, tested and built to be a wholly new pyrolysis gasification system that transforms coal, municipal solid waste (msw) or other biomass (poultry litter, wood chips, corn stalks, etc.) into natural gas and useful carbon products.
The process sequesters 100% of the mercury, sulphur and other noxious materials in the carbon matrix so little or no scrubbing of the resultant gas or byproduct is required. The gasifier can meet a variety of energy requirements. Because of its compact size, it is readily transportable and scalable. Also, it reduces the amount of energy imported from foreign sources while significantly reducing energy-related emissions, including greenhouse gases.
The process represents a transformational shift in the state of gasification technologies known in the world today. Unlike present day gasifiers that extract every erg of latent energy from organic feed stocks and thereby create undesirable stack emissions, the process extracts only energy that can be extracted cleanly and thus avoids harmful stack emissions altogether. The process accomplishes this by separating the gaseous energy of the organic material from the organic carbon. Even so, each of the 20 ton/day process units can produce 1.5 MW of power.
If the process is used to gasify organic materials from landfills, the methane gas normally created by degradation of the waste materials and emitted into the atmosphere is eliminated. The carbon byproducts resulting from this process are commercially valuable and can be used for several purposes. Two of these are the cleansing of the gas produced by the system and the manufacture of unique carbon reinforced lumber (crl).
The manufacture and sale of carbon reinforced lumber and energy producing gas from the process assures its sustainability. More importantly, the energy produced by the process from coal fields and landfills nationwide can reduce significantly the amount of energy imported from foreign sources, and generate new jobs.
In addition to the overall green aspects of the technology, it lends itself to improving the local economy for communities and cities that choose to install our process. For example, 250 tons per day of MSW, which is a typical installation, will include MSW sorting, recycling, shredding, drying, pelletizing of RDF pellets, and four gasifiers, to produce methane for the production of electricity, as well as activated carbon that will be used to perform the final scrub of the methane of all gasifiers.
The recycled HDPE plastic will be sent to the CRL manufacturing area. Two coal gasifiers will generate non-wetting carbon. In addition, a tire vacuum distillation unit will be installed, also utilizing waste heat from the coal gasifiers, to reduce tires to syngas, diesel fuel and carbon black. Larger or smaller landfill sites can be scaled easily by adding or subtracting the number of units installed.
This typical operation would employ approximately 150 people. In the current national job crisis the process would be good for every community, not only by reducing our landfills in a clean, responsible manner and making green, useful products, but in putting people to work when so many desperately need it.
The process is a superior, patented gasification technology that sequesters sulphur, mercury and other heavy metals. It also sequesters other noxious compounds that previously plagued the gasification industry. This provides for an economically viable and ecologically correct alternative to existing coal-to-energy facilities.
We have the ability to produce a high quality and quantity of gas and carbon. Professional laboratory testing to date has already proven the quality of the products of the process and further refinement will only enhance sustainability.
We utilize carbon and reclaimed landfill polyethylene to manufacture a superior composite lumber product known as Carbon Reinforced Lumber (CRL). Potential additional uses for carbon include extruded fencing, siding, railroad ties, waterproof/pothole-free asphalt, stronger lightweight concrete, lightweight car parts, and emission cleaning systems for plants, military aircraft parts, aerospace applications, and medical uses.
The Laboratory Analysis Reports support our findings that the methane created by the process is an excellent gas devoid of undesirable elements and has a Btu value similar to natural gas. These reports show that compounds of Mercury, Sulfur, Silicon, Aluminum, Iron, Calcium, etc. are captured by the carbon and therefore not retained in the gas.
A product consisting of carbon is Carbon Reinforced Lumber (CRL). CRL is similar to Composite Plastic Lumber in that it combines carbon filler with scrap polyethylene to create a “green”, long lasting alternative to cutting down trees for wood lumber. However, CRL is superior to Composite lumber in two respects: Composite lumber utilizes wood “flour” or rice husks as a filler. However, each of these are faced with soaking up moisture, mold retention and boards expansion.
Manufacturers of composite lumber attempt to solve the mold problem by injecting fungicides in the board itself, but there still are many complaints of mold. They attempt to solve the expansion problem by selling special fasteners and providing specific installation instructions, but many customers continue to complain of boards buckling and warping and of excessive spaces between decking.
Our CRL will utilize a waterproof, closed-cell carbon as the filler material. This will eliminate both mold and swelling problems because the boards will not absorb water or moisture of any kind. CRL is also impervious to dry rot and has greater strength and dimensional stability. A fundamental vision of our team is that of making superior products from Municipal Solid Waste (MSW) streams with innovative technologies, beyond the waste stream of plastics and resultant carbon to manufacture carbon reinforced lumber.
Advantages of Typical Composite Lumber vs. Traditional Wood
Over the years’ wood has been the material of choice for the building of outdoor decks as it was plentiful and manufacturers were able to render it very durable by adding weather resistant coatings and/or creosote impregnation. However, the EPA banned the use of CCA (copper, chromium, arsenic) pressure treated lumber materials in playground and residential applications effective December, 2003.
The park and recreation market was the first major market to convert to the use of composite lumber in all furniture and playground equipment. In addition to the removal of pressure treated chemicals which are hazardous and can leach into the ground and water sources, composite lumber has the added benefits of being non-splintering, has a longer life span, and requires no periodic staining or sealing. Other benefits of composite lumber include a reduction in solid waste materials in landfills, a reduction in the deforestation of the world’s trees, and the value to the economy by recycling plastic materials.
Our product, Carbon Reinforced Lumber (CRL), will solve the mold and rotting problems due to the inherent design and manufacture of the CRL decking board. This is possibly due to the use of the non-wetting carbon resultant that is naturally made during the production of the syn-gas. This patented CRL decking board is completely waterproof because the carbon will not absorb moisture or water which eliminates the mold and rotting problem discussed above.
Also, the CRL is impervious to termites and other wood-hungry insects. In addition when a CRL structure is torn down the lumber can be recycled by regrinding and then extruded into CRL lumber again instead of land filling.
The “green” aspect of our products – with the primary material of CRL being recycled polyethylene – will include:
- filler material being non-wetting carbon
- non-noxious waterproof element
- CRL recyclable
- education of distributors and customers
- environmentally friendly process
Waste to Energy Process Technology
EIF has the right to purchase on a location basis and use four broad licensed patent applications from the Coal gasification system with “Non-wetting” carbon resultant and products.
- Coal gasification as combined cycle operation with vacuum distillation, utilizing the waste heat from temp coal gasifier.
- MSW (Municipal Solid Waste) high temp gasification – a combined cycle operation low temp coal liquefaction utilizing the waste heat from the high MSW gasifier.
- Automobile tire vacuum distillation as combined cycle operation, utilizing the waste heat from the high temp MSW gasifier.
- Enviro-Logic Processors (Process Description)
- LJ’s Blue Crab Farm (Organic Crabs)
- No Name Ranch (Organic Cattles)
- The Pitt Family Organic Prawn Farm (Shrimp Jet Harvest Solution)
*Note: Other partnering programs will be listed at a later date.
Mr. & Mrs. Gary Cochran
This process description combined with the diagram on the following page will assist you in understanding how our process works and will provide you with a step by step written explanation combined with a visual example for you to follow.
Step I) Feed Stock (whole tires, split tires or shredded rubber) is loaded onto trays that are put onto racks and then these racks are loaded into the processor.
Step 2) Once the processor is completely loaded with our feed stock, the door is closed and sealed and we turn on the vacuum pumps in order to pull out all air inside of the unit.
Step 3) While the internal air is being extracted we turn on the burner unit to begin the process of internally heating the processor. The burner is fired through the use of propane initially and then run with methane that is produced from our process. This burner flame will run through burner tubes located inside the processor, therefore there is not any direct flame in contact with our feedstock. The emissions from this burner will be vented through the back of the unit and run through a stack. The only air emitted to the environment is that of a 1.2 million BTU burner fired with propane. It will have no other particulates and will not produce emissions any higher than a large furnace.
Step 4) Once the optimum temperature is achieved, the feedstock will begin to discharge an oil-laden gas. The vacuum pulls this discharge through a condenser where the oil is converted back into a liquid and flows through into the oil collectors. Once the oil collectors are near capacity, we will pump this product to our larger storage tanks. The methane gas that is produced flows through the vacuum pumps and goes into the methane storage tanks. These tanks once full will be utilized to operate the processor.
Step 5) Once the process is complete and the unit has been cooled down, we remove the racks from the processor and unload the solids from the trays onto a conveyor system. (At this time, a second set of racks will be ready to be loaded into the processor for another run). Once the solids are placed onto the conveyor system it will go through a stage to remove the steel from the remaining product and the carbon black that is still on the conveyor will continue on to a bagging system that will package this product for shipping.
There are four basic products that are produced as a result of this process. Listed below are the average product percentages yielded through the use of waste rubber.
The percentages of the above products can be adjusted slightly utilizing the processors control system. Quantities of gas will change also with the age of a tire.
The fuel oil has a heating value of 19,000 to 20,000 BTU/ lb. and can be used in a number of applications. This fuel can be burned directly or blended for a variety of uses such as electrical generation, and direct energy, or for producing steam. Our fuel also has a higher BTU value than #2 diesels, thus making it a cleaner burning fuel for diesel engines. It will produce 10,000 gallons of oil per day. This fuel will also be an excellent additive material for use in the asphalt industry.
The carbon black is a combination of carbon and trace elements found in all manufactured rubber products. A typical sample of the carbon black will contain certain percentages of carbon and trace elements as found in the original production of the rubber product. On average, the percentage that is found in waste tires is 87% carbon and 13% trace elements. These percentages will vary slightly dependent upon the quality of the waste rubber.
The steel that is recovered from the process is primarily the beads and belts used in the construction of radial tires. The steel is recovered by crushing the carbon black after it is removed from the processor and running it through a series of magnets.
The gas produced is of a quality equal to Natural Gas. The gas produced is used to operate our processor. Any excess gas can be used to supplement a local natural gas pipeline or utilized for the production of electricity or steam.
Projected Uses of Our Products
Our fuel has a higher BTU value than # 2 diesel; therefore it must be mixed 50/50 to be run in a combustion engine. Local markets include local farmers, trucking companies, textile industry, tire manufactures, asphalt industry, state departments of transportation, shingle manufacturing, bio-diesel and companies that use oil to produce steam.
The carbon black produce will be a mid-range re-enforcement black. There are local markets in the brake shoe industry, asphalt industry, new tire manufacturers, recap rubber industry, asphalt shingles, plastic piping industry and coatings (asphalt and paint). Also with a small amount of additional processing, it can be used in inks, dyes, and when activated, it can be used for air and water filtration. However, if activated, it will sell for a higher price.
Our steel is a high carbon steel. The major market for this is a scrap metal dealer. There are six within 40 miles of our plant location.
We use approximately 10% of the gas we make. The excess can be used to run an engine generator to produce power for our company. Moreover, the local power company must buy any excess power we produce. It is of such quality, that it can be added to a natural gas pipeline. There is one located within .2 miles from our plant location. They would pay us to have it added to their pipeline. Currently, our pro-forma shows no monetary value for our gas.
Community and Environmental Impact
Rubber is one of the largest waste problems on the earth today. It will never degenerate; scraps tires are breeding grounds for rodents, diseases carrying mosquitos’s and are very unsightly. They cannot be buried whole because they will work their way back to the top where they were buried. The Army Corp of Engineers have tried making reefs out of them only to have the binding devises break and get in commercial fishing nets or washed ashore. Our process TOTALLY ELIMINATES the tire and is environmentally clean.
The community that we locate our process site in will have approximately 100 jobs added to their employment picture. We intend on becoming a part of the community by supporting the local Schools and Churches.
We have the knowledge and ability to produce a “non-wetting “carbon. It is produced in a proprietary, patented process during the production of our syn-gas.
We are proud to have the proprietary rights to this process which provides the basis for producing a superior composite lumber, as well as other yet to be named products. We will exploit this technological niche and the CRL products to become the premier supplier of composite lumber.
The process has been incorporated into a full scale demonstration unit, already built and tested (over 75 tests with chemical analysis). It has proven the feasibility of this unique gasification process through extensive testing and laboratory analysis. The technological paradigm shift was made possible because the process takes advantage of a high temperature chemical phenomenon known as the “Lewis Acid Site Sequestration”.
When the organic feedstock, coal, msw, biomass or animal waste is conveyed into the unit, high temperature sequestration takes a select number of undesirable compounds and elements into chemisorption bonding, thereby preventing leaching from occurring. In the process, only an extremely small amount of oxidation takes place. Therefore, there is no SO2 or NO2 (NOX) produced.
Further oxidation and reaction of any residual SO2 to form H2SO4 does not occur in the process. With practically zero sulfuric acid, carbon reaction site poisoning is minimal in the chemisorption function. The chlorine contained in organic feedstock reacts during the high temperature stage by bonding with the activated carbon. It promotes the reactivity of the activated carbon in regard to the Lewis Acid Sites.
Only the stable Hg2+ compounds such as HgS are captured at the high temperature stage. The free HgS compound molecules are captured via chemisorption. HgC12 forms in the cooler stage of the process and is also captured via chemisorptions.
The physisorption sequestration process acquires numerous compound molecules and free elements not already acquired by the Lewis Acid Site chemical bonding that occurs in the high temperature gasification region of the process. The gasification process lends itself to not only gasification of the organic materials into methane and some methane gases, but also to cleaning and sequestration of the gas that is produced.
Typically, today’s gasification systems utilize incomplete combustion that includes the latent heat of the fixed carbon. As a result, carbon monoxide (co) is produced, and combusted in turbines or steam generators. The undesirable compounds and elements of the feed stocks are not sequestered during these traditional processes and must be captured via subsequent electrostatic precipitation or other chemical means.
The Process transforms the volatile fraction of the feedstock into gas which is cleaned within the process. It can also produce a unique non-wetting carbon product which can be used in a number of commercial applications. More importantly, nothing is released into the atmosphere during the gasification process because it is completely closed looped.
The elimination of methane gas and other “Greenhouse” gases emitted from fermenting matter placed in landfills is an important factor in evaluating the process. When the process is utilized in landfill operation, the incoming MSW is converted into methane gas and activated or non-wetting carbon in a closed loop system. The MSW does not have a chance to degrade or leak harmful greenhouse gases into the atmosphere. Thus, in addition to its energy-producing attributes, the process can substantially reduce environmental damage by eliminating harmful gases.
While today’s gasification systems use the entire latent heat of the organic feedstock, the process finds favorable economic reasons not to do so. The non-wetting carbon produced by the process combined with landfill HDPE can be used to manufacture a very strong and waterproof lumber of superior quality. Currently, the synthetic lumber industry faces serious problems due mainly to the moisture absorption qualities of its products. This causes significant mildew, mold, swelling and warping, thereby degrading the products and limiting their durability.
The CRL by-product of the process is completely waterproof and impervious to termites and moisture problems. The economic return generated by non-wetting carbon is a significant factor that supports the viability and marketability of gasification systems. CRL manufacturing will itself produce a significant number of jobs, separate and apart from gasification system operation.
The gasification unit has been built to commercial size that can process approximately 20 – 30 tons per day, producing approximately 1.5 MW (depending upon energy density) of feedstock. To facilitate widespread deployment and use of the system, modularity and mobility features have been incorporated.
The basic commercial unit is 16’ long and 8’ wide, and can be easily transported on a flat bed trailer. Also, depending on project size, such modularity is easily staged with multiples of 20 tons/day units.
The process is distinctive of the syngas technologies of today. The gas produced by the system is not CO, but is organic gas-based. As noted above, the system’s economic viability is not dependant solely upon the energy it produces. Rather, the system is economically viable because of the revenues that will be generated by both the gas that is produced as well as the activated carbon and non-wetting carbon by-products.
The process is the ultimate transformational technology. Converting dirty coal and MSW into energy-producing gas has been accomplished in the past but never so cleanly and without emitting hazardous pollutants into the environment. The process sequestration of noxious compounds during its gasification process is a breakthrough achievement in the energy industry that will create a paradigm shift in the perception of energy production.
The U.S. will no longer be constrained in its use of “traditional” fossil fuels to produce energy. The nation can now enjoy the very cleanest method for converting all of its fossil fuels into usable energy and eliminate environmental hazards being put in the ground (landfills).
Greenhouse gases (GHG’s) and other emissions will be drastically reduced using our gasification systems. U.S. coal fired power plants discharge the majority of sulphur, nitrous oxide and carbon dioxide into the air each year, as well as mercury and other toxins. The burning of gas produced by our systems will emit only a fraction of nitrogen oxide and carbon dioxide emissions of coal and oil, resulting in essentially no particulate matter, sulphur or mercury emissions.
Also, by preventing hundreds of thousands of tons of garbage from being land-filled each day, the process effectively “intercepts” methane and permits it to be burned cleanly. This is a highly cost-effective way of preventing the decomposition of garbage in landfills and the resulting release of methane into the atmosphere.