PyroPlas®

Plasma Arc Destruction of toxic wastes like POP, ODS, SGG, PFAS and more

Working Principle

PyroPlas® is a Plasma Arc Destruction process, which destroys any organic compound via high temperature pyrolysis. The intense, flameless conditions degrade all molecules into their atomic constituents. PyroPlas® incorporates the PyroInject Waste injection system. This is an enhanced ‘in flight’ injection technique where wastes are optimally injected into the plasma stream. This feature ensures the PyroPlas® is always able to meet required Destruction Removal Efficiencies (DRE) greater than 99.99.%. A DRE of 99.9999% is commonly achieved.

Benefits of PyroPlas®

  • Lower emissions compared to other technologies and better than international standards
  • The PyroPlas® can be shut down, re-started and run in less than half an hour
  • The formation of undesirable organic molecules such as dioxins and furans are avoided
  • Low capital cost compared to other technologies
  • Plant is compact and servicing is simple, clean and inexpensive
  • Higher temperatures
  • Offers extremely safe operation

Elements of PyroPlas®

  • Feeding System
  • PyroInject Injection Manifold
  • Rapid Quench
  • Scrubber
  • Off-gas treatment
  • Control Unit
Plasma torch
1. Plasma torch

Argon Plasma at 12,500°C is created by a 150kW non-transferred DC arc within a vortex stabilised multi-segment plasma torch. This design provides a reliable plasma torch with a long operating life.

Waste feed
2. Waste feed

Waste, as a liquid or gas, is injected into the plasma along with any reactants (such as steam or oxygen) that are required. The wastes and reactants are instantaneously pyrolyzed into their constituent atoms, resulting in a gas at over 2,500°C.

Reaction zone
3. Reaction zone

Passing through the reaction zone, the pyrolysis gas cools to around 1,200°C, allowing the formation of simple molecules such as HCl, CO2 and H2O. The gas is then rapidly quenched to below 100°C which prevents the reformation of any complex molecules such as Dioxins or Furans.

Off-gas treatment
4. Off-gas treatment

The gas then passes through a series of scrubbing processes where the acidic vapours and any other contaminants are removed, before finally being discharged to the atmosphere. The level of contaminants in the emitted off-gas is extremely low, and well under the standards applied to such emissions around the globe. Additionally, as there is no combustion process, the volume of discharged gas is substantially lower than most competing technologies, allowing the plant to be located in close proximity to residential areas.

Ancillary equipment
5. Ancillary equipment

Caustic for neutralisation of the reaction products, cooling water, air and process reactants are required for the operation of the plant. Typically, the reaction products, once neutralised, can be disposed of to the sewer as inert salts.

Control unit
6. Control unit

The plant is operated and controlled from a control room via a computer interface. All important operating parameters such as plasma power, operating temperatures, flowrates, pressures etc are continuously recorded and displayed. The plant can be operated in Automatic mode, with manual operations of individual devices also provided from the computer. The control system includes all necessary power, measurement and electrical devices, as well as safety interlocking and emergency stops.

PyroPlas® Technical Details

PyroPlas® technology utilises pyrolysis to degrade wastes to its atomic constituents. There is no combustion process involved. The PyroPlas® torch passes a high energy direct current into an argon gas stream which creates a plasma zone. This high energy plasma zone reaches a temperature in excess of 10,000°C. Waste is injected into this plasma zone where the waste is pyrolysed into its constituent atoms.
For this reason, the PyroPlas® technology destroys high concentration, pure and complex waste streams with minimal risk of hazardous by-product (such as dioxins or furans) formation.
Due to the continuous injection of waste directly into the plasma zone, the process is inherently protected against any chance of environmental release, even in the case of situations such as power failure.
Designed to operate continuously and with a high level of automation, the PyroPlas® delivers safe and consistent destruction efficiencies.
With this quality of destruction and simple consistent operation, the PyroPlas® meets the standards of Best Available Techniques (BAT) and Best Environmental Practise as required by the Stockholm Convention, Montreal Protocol and Basel Convention for the destruction of Persistent Organic Pollutant (POPs) and Ozone Depleting Substances (ODSs).

Charts

Automated Operation

PyroPlas® plants are controlled by a fully integrated Programmable Logic Control (PLC) and Human Machine Interface (HMI) system which automatically controls the start-up, continuous operation and shut-down of the process. The PLC provides active monitoring and immediate automated responses in the event of a process parameter deviating from its operating limits.
Being a modern system the PyroPlas® operating interface is able to be linked to remote interfaces allowing operators and management to continuously monitor PyroPlas® status.

PyroPlas® Sizes

The torch configuration and the PyroInject Waste Injection system is the heart of the PyroPlas® technology. In circumstances where greater throughput capacity is required, we have the option of using PyroPlas® II and PyroPlas® III. These systems contain multiple torch and waste injection modules. The PyroPlas® versions have significantly higher throughput capacities without compromising Destruction Efficiency.

Waste Streams

PyroPlas® has the capability of safely destroying a wide range of waste and hazardous materials. It is especially adept in the destruction on Persistent Organic Pollutant (POPs), Ozone Depleting Substances (ODSs), Synthetic Greenhouse Gases (SGGs) and other chlorinated and/or brominated substances. Waste streams include but not limited to:

ODSs and SGGs
Chlorofluorocarbons (CFCs) like R11, R12, R13 etc.
Hydrofluorocarbons (HFCs) like R21, R22, R134a etc.
Halons and Haloalkanes
Sulphur Hexafluoride (SF6)
Methyl Bromide
Sulfuryl Fluoride
Halogenated Wastes
Brominated flame retardants (BFRs) like HBCD
Chlorinated Wastes (Chlorobenzene, Tri and Tetrachloroethylene)
Perfluorinated Compounds (PFCs)
Chloroalkanes
Brominated Wastes (TBBA)
Fluorinated Wastes
Persistent Organic Pollutants (POPs)
Polychlorinated Biphenyls (PCBs)
Organochlorine Chemicals (Aldrin, DDT, Dieldrin, Mirex, Endrin, Toxaphene, Chlordane, Lindane, Heptachlor)
Dioxins and Furans (PCDD and PCDF)
Hexachlorobenzene (HCBs), Pentachlorobenzene (PeCB)
Per- and Poly-fluoroalkyls Substances (PFAS) such as PFOS and PFOA
Polychlorinated naphthalenes and Short Chain Chlorinated Paraffins