Duplex-TEC-Process®

Description

From a process and plant engineering point of view, the Duplex-TEC-Process® (Duplex-Turbulent-Expansive-Carbonbed-Process) is a multi-stage closed thermal waste treatment for high-calorific carbonaceous waste for product gas generation with subsequent electricity and heat generation. The plant consists of drying, degassing / carbonisation (referred to as thermolysis in this process) and gasification. The three processes are coupled in terms of flow and heat technology, among other things, but are separated from each other not only spatially but also in terms of equipment.

Main characteristics

Feedstock and property

→ high calorific homogeneous-selective waste/residues

Technique/technology

→ conditioning of the waste /EBS

• Shredding
• Separation of foreign matter
• Pre-drying to 10 - 15 Ma% water content

→ Pre-gasifier (thermolysis rotation reactor - stationary)

• Conversion to carbon coke by means of hot gasification agent

→ Main gasifier (direct current / entrained flow gasifier ascending) with moving bed / TEC (turbulent expansive carbonbed)

• Multiple oxidation and reduction stages

→ Recuperative gasification medium preheating

→ CHP power generation

• Gas engines coupled with ORC technology

→ Modular design in lines

• Waste gasification line (3.3 t/h thermal)

Special features

• Utilisation of selective high-calorific waste (RDF): The process is characterised by the targeted use of selective high-calorific, non-homogeneous, shreddable or mixable waste. RDF (refuse derived fuel) and/or RDF (Refuse Derived Fuel) with a calorific value of around 18.5 to 35.0 MJ/kg are used.

• Continuous and closed multi-stage pure carbon gasification process: The realisation of a continuous, closed multi-stage pure carbon gasification process without flue gas formation is an outstanding feature of this process. This enables extremely efficient and environmentally friendly energy generation.

• Technical separation into pre-gasification and main gasification: A precise technical separation into the pre-gasification (degasification/ carbonisation without active mixing) and main gasification (complete conversion, multi-stage, 3T rule) phases enables optimum control of the overall process. This ensures targeted treatment of different material phases.

• Main gasifier as multi-stage co-current/ entrained-flow gasifier with moving bed (TEC): The main gasifier is designed as a multi-stage co-current/entrained-flow gasifier and uses an ascending moving bed, known as TEC (Turbulent Expansive Carbonbed). This innovative design optimises carbon conversion efficiency.

• Recuperative air preheating by utilising the process heat: The integration of recuperative air preheating, based on the utilisation of the process heat generated in the gasification process, enables autothermal process control. This feature leads to stable process control without external energy and contributes to the overall efficiency of the process.

• Gasification agent as a preheated air/O2 mixture: The gasification agent consists of a preheated mixture of air and oxygen (O2). This configuration ensures effective reaction control and creates optimum conditions for the gasification process.

• No material separation in the thermal process: There is no material separation in the thermal process, but a continuous gas and solids flow. This enables efficient and uninterrupted conversion of the starting materials into the desired carbon state.

• Modular design with up to 12 gasification lines - WGL (Waste Gasification Line): The modularity of the system enables the construction of up to 12 gasification lines, referred to as WGL (Waste Gasifications Line). This structure supports flexible and scalable adaptation to different requirements and quantities of high-calorific waste.

Goals

→ CO2-neutral gasification

→ Production of a high calorific value, dust and tar-free gasification/fuel gas for electricity generation in the gas engine

→ No flue gases caused by gasification technology

→ no dioxins and furans

→ no pollutant emissions

→ electricity production costs ≤ 2 euro cent/kWh