About Research & Manufacture Company "Eco-Technology-Group"

      Company started with establishing Manufacture & Trade Company 'TeploElectronServis' in 1994, Nikolaev, Ukraine. Babiy Victor Petrovich is a founder and owner of the company. 'TeploElectronServis' designs, manufactures gas-consuming equipment and provides its installation and adjustment.

      At the same time the company carried out perspective scientific research of a method of low-temperature dry pyrolysis, which allows to utilize polymer and mechanical rubber products with extraction of alternative fuels.

      Company staff together with a deviser of invention developed unique technology of environmentally safe utilization of organic waste products (dephlegmatic stepwise pyrolysis - DSP). DSP technology has been discussed at five international conferences and has received positive references. Technology is protected by Ukrainian patents. It has been applied for similar patents in the USA.

      To test effectiveness of DSP technology, we designed and manufactured a pilot infected waste utilization plant (IWUP-10).

      Research & Manufacture Company 'Eco-Tech Solutions' New Jersey, USA. Company target is to work out documentation, to manufacture and implement plants and modular factories of new generation based on DSP technology. Working areas, researchers and highly qualified maintenance staff are available.

      As per international contract the company manufactured an export version of IWUP-10 by request of 'FIA' USA. According to American legislative rules the plant is taking the tests to receive all permissive documents and apply the present technology on the territory of America.

Technology of dephlegmatic stepwise pyrolysis

      The offered method of dephlegmatic stepwise pyrolysis (DSP) allows to create modern technology, which provides not only environmentally safe recycling of waste products, but also extraction of high-energy gaseous, liquid and solid fuels from them. Given process of recycling, in comparison with traditional incineration, is completely isolated from outer environment, i.e. occurs in a hermetic reactor, without access of oxygen and provides effective decomposition of the whole mix of various by chemical and physical properties waste types (rubber, worn automobile tires (WAT), polymers and copolymers, paper, cardboard, leather, textiles, liquid petrochemicals, etc.). The given set of mix of waste products has a wide range of molecular weights (from 10 up to 10 6), and it is not obviously possible to process them by existing pyrolysis technologies, with an output extraction of liquid light fraction resins. All known processes require an individual technological mode for each kind of waste products, which is not possible to create in reactors of existing designs. DSP technology is universal and provides selective impact on each kind of the waste products, which is taking place in the stream-and-gas reactor's mix. Uniqueness of this implies limitless structures and variety of utilized waste products. It is possible to recycle equally effectively both one of a waste's kind and multiple kinds of products in various percentage parities. Destruction depth adjustment by DSP technology is provided as a result of stage-by-stage decomposition of the intermediate heavy products formed during pyrolysis with emanation of an output pyrolysis gas, a liquid composed of light fractions with molecular weights of 100-160 unit/sec with low solidification temperature and firm dry residue - pyrocarbon. The method of automatic control of thermal destruction depth for various organic waste products and their combinations has been developed. Utilization of this know how allows securing ecological safety of the manufacturing, flexibly operating by pyrolysis processes and receiving target products with the present characteristics.

      Technology was tested by Medved Institute of Ecohygiene and Toxicology, Kiev, Ukraine. We have received enthusiastically positive expert ecological conclusions on the offered technology from Scientific and Production Enterprise "Mashproekt" and Institute of Gas of National Academy of Sciences of Ukraine.

Output products under the method of DSP:
• Pyrolysis gas extracted from various mixes of waste products is comparable to natural gas and can be used for internal technological needs. Since technological process does not require external power sources, a plant operates at independent mode.
• Liquid fuel (crude mix) is comparable to diesel fuel. It was tested on diesel and gas-turbine power station.
• Pyrocarbon is a pure carbon residue (purified from carcinogenic substances), which can be applied as an absorbent for filters on sewer pumps.

Technological line of DSP:
• Preliminary preparation of waste products for recycling (crushing up to fraction in the sizes (min 5x5ii, max 10x10ii), with drying up to humidity of 7 %;
• Transportation of crushed waste products to the technological unit of a reactor;
• Thermal destruction of waste products in the isolated hermetic compartment of special reactor;
• System of disintegration of target products onto liquid, gaseous and solid components;
• Automated control system and the control technological process;
• Complex filtration system for smoke gases deriving from NOx, SO2 and CO;
• Utilization of smoke gases' heat;
• Automated system of explosion hazard and fire extinguishing;
• System of storage and distribution of target products.

     Important advantage of offered technological process is its electric power autonomy (pyrolysis gas is used). Technological process does not require current consumption from external power sources. Liquid fuel is used for electric power production at turbogenerator power station. As an example, when utilizing high-energy waste products (polyethylene and copolymers, worn autotires, petrochemicals etc.) a factory with 500 t/day of capacity can additionally generate approximately 400 mil KW-h/years of electric power for the needs of national economy.

Implementation of pyrolysis factories

      As a result of testing the method of dephlegmatic stepwise pyrolysis (DSP) and getting expert conclusions, we received permissive documents on industrial manufacturing of plants based on DSP technology. Plants are designed according to TS S 23044537.001.99 - "Pyrolysis plants". Technical specifications are approved by Ministry of Health Protection of Ukraine, no. 5.05.07. - 279/58/527 of 07.30.99. Output products manufactured according to technical specification are included in the list of goods made in Ukraine. Company manufactures and implements plants and modular factories for utilization of organic waste products based on DSP technology and TS. Key specialists of the company not only install and adjust equipment, but also train the staff. The company gives warranty assurance on manufactured output products. As per auxiliary contracts, the company provides after-sales service, current repair and major overhaul.

Ecological safety

      Ecological safety is defined by pyro- (explosive) and fire safety of the manufacturing in emergencies, and atmospheric emissions in operation at normal mode. Ecological safety is preemptively met by constructive solutions of a pyrolysis line:

1. Close-circle low-temperature work cycle has been created for pyrolysis in a reactor without access of oxygen that reduces amount of formed dioxins and furans;
2. All additional technological lines with allocation of pungent smells are placed in the closed volume container with exhaust ventilation and with the subsequent 2 step smoke gases filtration:
   • Afterburning with forced blowing air in a reactor's furnace equipment torches at temperatures 1100-1400 oC (2000-2500 F), which leads to neutralization of a wide spectrum of toxic gaseous emissions, decomposition and additional oxidation of harmful dioxides and furan elements;
   • Catalytic way of neutralization of gas emissions by flameless method at temperatures 350-400 oC (660-750 F) which is the most effective method of multicomponent mixes filtration composed of various harmful substances. However, it is worth to note, that since universal catalysts do not exist, in each particular situation it is necessary to select them based on optimal conditions of their application.

     For purpose of pyro- and fire safety factories have four protection levels:

• Control system regulates limited temperatures of reactor's heating at an operation cycle;
• Control system provides adjustment of pressure inside a reactor and limits its increase above allowable threshold;
• In case of emergency, the reactor is supplied with two safety lock valves, with dumping of formed gases in the afterburning chamber;
• The system of precise devices measuring reactor's heating of a smoke gases is supplied with control system guaranteeing its safe operation according to the West European standards.

Competitiveness

     Today many companies deal with technologies extracting alternative fuels from organic waste products. 'Torrax' method devised by Andco Company and Carborundum Company, and 'Purox' method worked out by Union Carblue Company in America, are good examples of putting such technologies into practice. Urban Research Company (USA) and Nippon Stell Company (Japan) tested waste pyrolysis in vertical shaft reactors with slag drip. In the USA dry-ash removal in vertical shaft reactors was also tested by 'Batelle - Northwest' process. Motala Verkstad Company (Sweden) worked out 'Pyrogas' process. 'Pyrogas' used pyrolysis of organic waste products in mix with coal. Mon Santo Enviro-Chemical Company (USA) developed 'Longard' process with a revolving reactor. Devco Management Company is working on the same type of reactor. 2-step process 'Goldshofe' is created for fuel gas receiving. Occidental Research Company (USA), the affiliated branch of Occidental Petrolium Corporation, worked out 'Occidental Flash Pyrolysis' process with boiler liquid fuel receiving. Ebara Company (Japan) worked out 'Pyrox Process'. As a result they extracted pure gas with high combustion value. There are other processes that use pyrolysis method: 'Kemp Converter', 'Lanz Converter', 'Warren Spring Laboratory', 'Hercules', 'Pyrotek', etc.

     All mentioned above companies and their technologies are incapable to control pyrolysis of multicomponent waste products with wide range of molecular weights. Moreover, they do not provide necessary destruction depth that is an indispensable condition for receiving stable fuel with thickness comparable to thickness of average and light fuel. Technology we introduce is unique. It guarantees the emanation of stable liquid fuel. Control system of multistage pyrolysis allows utilizing waste products with wide range of original molecular weights. Output product is liquid fuel with molecular weight of approximately 160.

     Cost of equipment manufactured for a factory in Ukraine is much lower than cost of factories offered by overseas companies.

Infected waste utilization

Solid municipal waste utilization

      Solid municipal waste utilization (SMW) is a solution of a problem of city dumps and municipal waste products. Well-known technologies of SMW processing are environmentally harmful and too expensive because of high power consumption.

      In comparison with traditional incineration, SMW utilization based on the method of dephlegmatic stepwise pyrolysis allows to create modern manufacturing, which provides not only environmentally safe recycling of waste products, but also extraction of high-energy gaseous, liquid and solid fuels from them.

      Technology simplifies sorting of municipal waste products. It is important to separate glass, metal, construction waste products and foodstuffs. Other substances of municipal waste products can be easily utilized to emanate output high-energy fuels of great commercial value.

According to average statistical data the mix of waste products after sorting is as follows:
• ~ 50% - worn automobile tires (WAT), rubber, paper, cardboard, leather, textiles, petrochemicals;
• ~ 50% - polymers and copolymers.

An output per one ton of waste products:
• ~ 600 kg - liquid fuel;
• ~ 250 kub.m (50 kg)- gas
• ~ 350 kg - pyrocarbon

      Construction of modular factories is very convenient to gain necessary productivity. Depending on capacity of utilization, it is possible to create the required number of modules with 10 ton/day of capacity for each one. Modules guarantee real-time equipment removing to the places of waste accumulation. Factories have electric power autonomy and do not require external power sources (electricity, fuel). They can be installed anywhere.

Unit for solid municipal waste utilization with 300 ton/day of capacity

1. Deliver
2. Raw material feeder
3. Dehydration basket
4. Line of sorting
5. Crusher
6. Feeder for raw material delivery to reactor
7. Reactor where occurs destruction of rubber waste products (autotires), polyethylene and its copolymers, leather, paper, petrochemicals, pesticides, overdue medicaments, etc.

      Technological line of pyrolysis gas:

      Technological line of liquid fuel:

      Technological line of pyrocarbon:

      Technological line of exhaust gases:

Utilization of worn automobile tires, polymers and copolymers (polyethylene film, plastic packs, bottles, etc.)

      The problem of utilization of worn automobile tires, polymers and copolymers becomes more topical with every passing year. According to statistical data only 30 % of worn tires and partially polymers and copolymers are recycled. Storage of waste products of this kind requires not only additional expenditures, but leads to air and soil pollution as a result of chemical, thermal and radiation destruction.

An output per one ton of worn autotires:
• ~ 450-500 kg - liquid fuel (it is possible to use it as oil-dilutant in manufacture of mechanical rubber goods);
• ~ 250 kub.m (50 kg) - gas;
• ~ 380 kg - pyrocarbon;
• ~ 120 kg - metal cord.

An output per one ton of polymers and copolymers:
• ~ 800 kg - liquid fuel;
• ~ 950 kub.m (190 kg) - gas;
• ~ 10 kg - pyrocarbon;

      Factories on utilization of worn autotires have a modular design. Depending on capacity of utilization, it is possible to create the required number of modules with reactors' capacity of 10 ton/day. To be economically sound factory's productivity has to be 100, 300 and more ton/day. Factories do not depend on power sources, and can be installed in any place of waste accumulation.

Module for utilization of polymer waste products and autotires with 10 ton/day of capacity

1. Hangars for preparation of raw material
2. Transporter
3. Feeder
4. Reactor

      Technological line of pyrolysis gas:

      Technological line of liquid fuel:

      Technological line of pyrocarbon:

      Technological line of exhaust gases utilization:

Petrochemicals utilization

      Great deals of liquid and solid petrochemicals are accumulated on the fields of petroleum extraction and processing and at the stations where tanks are cleaned from petroleum and petrochemicals. Petrochemicals leak down, penetrate through soil and evaporate on the surface. This process leads to environmental pollution. DSP technology allows utilizing both liquid and solid petrochemicals.

      It is possible to apply pyrolysis plant to technological line of oil refinery that can allow to reach practically wastefree manufacturing.

      At the filling stations, parking places and maintenance stations soil is soaked with waste oils/greases and cannot be used. After processing of polluted soil in a transportable pyrolysis plant we receive clean soil suitable for farming.

Fecal sewers utilization

      Our company has projects on utilization of ship waste products in combination of pyrolysis plant with foreign equipment for dehydration of fecal sewers.

      We can apply our technology to river and sea transport. Sea and river vessels are to utilize ship waste products in ports. It is very expensive for shipowners. Utilization of organic waste products on a board of a ship during navigation is much more profitable.

      Space-saving pyrolysis plant provides utilization of food waste products, fecal sewers and SMW products.

Perspective streamlines of application of low-temperature pyrolysis technology

      We are aware that DSP is the technology of the future.

      Company proceeds with scientific and practical work for using technology in utilization of various kinds of waste products. We carried out investigations with main waste products. The wide spectrum of technology application is not studied yet.

      Based on our research we experimented on waste products never utilized before by pyrolysis method.

      1. Harmful waste products

      Pesticides

      In the world people refuse to use agricultural products grown on pesticides. These harmful waste products with overdue expiration date are kept in warehouses and agricultural enterprises. In many cases storage conditions do not match ecological safety requirements. Therefore utilization of these harmful waste products is a problem for many countries.

      Results of experiments prove that DSP technology can be applied to solid and liquid kinds of pesticides. Output products are environmentally safe and harmless.

      To deliver harmful waste products to the place of processing within the norms of ecological safety, the company developed a project with use of autonomous mobile processing plant. It has equipment placed in two 40-feet containers installed on semitrailer of a truck that gives an opportunity to process waste products directly in places of their accumulation.

      Chlorinated waste products

      A problem of utilization of worn transformer oils, chlorinated polymers, copolymers and so on is not less important. Chlorinated waste products are not processable by known methods of utilization therefore they are stored. Experiments with processing of given polyvinylchlorides by DSP method positive results.

      For receiving all permissive documents on harmful waste products utilization by DSP technology it is necessary to do all required tests together with Medved Institute of Ecohygiene and Toxicology, Kiev, Ukraine.

      2. Biomass

      Cremation is a process of incineration. Filters do not prevent atmospheric pollution. Construction of crematorium in the town is ethically impossible because of installation of a chimney. On demand of FIA, USA, our company experimented on biomass processing by DSP technology and received positive results, including reduction of time spent on the process.

      According to these results and the results of infected medical waste utilization, we can speak on perspective utilization of burial ground of cattle.

      For complete confidence perspective streamlines of low-temperature pyrolysis technology need further research.

      For more info: fiausa@mail.ru