Plant Concept

General information

Conceptually, TCP Energies offers to utilize high-calorific residual materials by means of our patented innovative technology in an ecologically and economically highly efficient way in order to generate electricity for the company's own use and/or to feed it into the public grid.

Technical implementation

The basic technical implementation is as follows: Material reception and material processing (conditioning), thermal area with a WGL 2-50 (two Waste Gasification Lines) with gas treatment and electricity generation area. Conveyors are used to transport the accumulated and collected residual materials to the material preparation area of the plant, where they are pre-conditioned in accordance with the process requirements. This is followed by thermochemical treatment in the two gas lines. The combustible and engine-compatible fuel gas produced is then converted into electricity in gas Otto engines and ORC systems. The plant concept includes all main and auxiliary units required for proper operation as well as all storage tanks for operating and auxiliary materials. The design and installation are carried out in accordance with the applicable regulations and standards for the construction and operation of such a plant. The interfaces are:

Main components

Material control / material preparation

Acceptance of residual materials
→ Fine separation of iron and non-ferrous metals
→ Screening into 2 fractions (coarse >> 30 mm edge length and < 30 mm edge length)
→ Coarse fraction in fine comminution
→ Combining the screening fractions
→ Drying and intermediate buffering
→ Transfer of thermal area

Thermal range

Gas production in the pre-reactor and main reactor
→ Gas treatment in the heat exchanger cyclone
→ Waste heat boiler
→ Hot gas filter – Gas Quench
→ Gas storage
→ Handover of electricity generation
→ Exhaust gas treatment

Electricity generation

Gas use by combustion in special gas engines with generator
→ Use of the heat potential by Organic Ranking Circle to generate electricity/steam
→ Feed into the power grid/operating grid

Auxiliary components

1. Fuel supply, in particular lime from lime silos directly to the unit
2. Supply of 50% caustic soda from the existing network at the site into an intermediate buffer tank
3. Fuel supply: Natural gas or liquid gas for start-up and shut-down process
4. Vapor evaporator to avoid waste water and recycling of process water → Separation of salty sludge for disposal
5. Flare system as a safety function in the event of an incident
6. Indoor crane for maintenance and repair work in the hall area
7. Residual material silo for slag/ash

System parameters

Characteristic	! values
Material	homogeneous, high calorific, shreddable or miscible
Input flow (0-25 Ma% water)	6.0 - 9.2 t/h → 49.5 - 75.9 kt/a
Chemical energy of the fuel gas	28.3 - 34.2 MWh/h
Electricity generation per line	7.33 - 8.88 MWh/h
Total electricity supply	15.53 - 17.78 MWh/h
Process-related residual materials (ash/slag)	approx. 5 - 14%
Available area	2.1 ha - 2.5 ha

Plant analysis/plant classification

• No process-related emissions; only during start-up and shut-down via flare
• Engine emission behavior according to environmental standards
• Explosion protection: ATEX guidelines (Atmosphere Explosible) of the European Union
• Lightning protection: DIN EN 62305 lightning protection class I and II with online monitoring
• Hazard detection systems (GMA)
• Thermochemical process conditions: no interference from heavy and light metals
• Process control technology: Siemens PCS7 process control and safety system
• Maintenance behavior/maintenance cycles: operating hours per line 8,200 h/a to 8,400 h/a