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SEPTEMBER 2013

™

TECHNOLOGY | REVIEW | UPDATE

A GLOBAL OUTLOOK Westinghouse Plasma Gasifier Auxiliary Equipment and Control Modules

Tees Valley Project 1 Update Tees Valley Project 2 Update Westinghouse Plasma Torch Applications

SPOTLIGHT ON: GTS Shanghai Facility, China


8th Edition CONTENTS

Tees Valley Project 1_______3-5 Photos and Updates for the Auxiliary Equipment and Control Modules

Tees Valley Project 2_________ 6 Update on Planning Permission and Power Purchase Agreement

Spotlight On

GTS Shanghai________________ 7 Medical Waste / Incinerator Fly Ash Demonstration Facility

Open House________________8-9 Hosted by Alter NRG, June 2013

Plasma Torch Applications____________ 10-14 Foundry and Iron Making

Conference Updates________ 15

Cover Photo: Auxiliary Equipment and Control Modules for the Tees Valley 1 Project (TV1), UK Content & Design: Alter NRG Corp. - Corporate Development Team Past Issues: http://www.alternrg.com/media/publications/ Alter NRG Corp. is a registered trademark. All other company and product names may be trademarks of their respective owners. The information contained herein cannot be reproduced in any format without legal permission from Alter NRG Corp., and is subject to change without notice. Copyright Š 2013. All rights reserved.

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ISSUE | SEPTEMBER 2013

www.alternrg.com


Bearing witness at the Tees Valley (TV1) Site From ideas to designs, designs to manufacturing through construction, the Alter NRG team has always believed but there is something to be said about seeing what you believe in. Danny Hay, CFO of Alter NRG shared that “We all know that Recently, some of the management team took just this

the Alter NRG technology is at the heart of this $400MM

kind of opportunity and toured the TV1 site in Northern

breakthrough facility expected to begin commissioning in

England. Our team was joined by representatives from

early, 2014. It is rewarding to see this large scale 50 MW power

Millhouse Capital Services and hosted by the Air

facility which is significant enough to garner the attention from

Products Plant Manager, who gave a comprehensive

any large industrial company.”

overview of the progress to date and upcoming scheduled events.

(L-R: Alter NRG) Alex Gorodetsky, Kevin Willerton, Danny Hay, Walter Howard, Kent Hicks and MHC’s Stephen Harris, Gennady Sukhanov and Percy Hayball.

nrg Focus | by

ALTER NRG

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TV1 Project Update Alter NRG’s breakthrough technology – the Westinghouse Plasma gasification technology - is showcased in the world’s largest plasma gasifier reactor which was manufactured under our auspices in Malaysia and arrived at TV1 in May 2013. Construction of the auxiliary modules is almost finished as shown in photos 1 through 3. The facility, scheduled to enter commercial operation in 2014, is expected to produce 50MW of electricity capable of powering 50,000 homes safely and reliably. Tory Government Minister for Business and Energy, Michael Fallon stated that “It has been very encouraging to witness first-hand the economic progress within Tees Valley and how companies in the area are at the forefront of emerging technologies and markets,” he added, “What I have seen is a clear sign that when Government and business work in partnership, Tees Valley firms have the ambition, talent and ability to succeed.”

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ISSUE | SEPTEMBER 2013

1

3


2

Tees Valley project under construction in Teesside, UK

Engineering and construction of the auxiliary modules for the first Tees Valley project in their finishing stages.

nrg Focus | by

ALTER NRG

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Tees Valley 2 (TV2) Project Update Plans are underway for a second advanced energy from waste project using the Westinghouse Plasma Gasification Technology. In July, 2013, Air products received planning permission and approval notice for the TV2 project situated adjacent to TV1. This project is consistent with the UK’s vision to encourage renewable sources of energy. Air Products has plans for up to 5 advanced gasification facilities using plasma gasification technology which would result in over £1 billion of potential new investment. To enhance the economics of the project, the UK government and Air Products signed a new 20 year Power Purchase Agreement that is, according to the UK government’s web site, “expected to deliver £84 million in savings over the life of the contract through an innovative fixed price agreement that will provide stability in what the public sector pays for energy”. With regulatory approval and a long-term off-take agreement, the TV2 facility has achieved two significant milestones.

TV1 TV2

The TV2 project will be a replica of TV1

Blowout: Westinghouse Plasma Gasifier at TV1 6

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SPOTLIGHT

GTS Demonstration Facility Alter NRG delivered the gasifier design and plasma torches for a demonstration facility currently being constructed in Shanghai, China and is expected to start up in Q3 2013. The facility will process a combination of medical waste and incinerator fly ash and is focused on the effective and efficient disposal management of medical waste and its potential environmental hazards and public health risks. As incinerator fly ash is an increasing disposal issue in China, it has become a high priority environmental concern for the Chinese Government. The facility is being constructed by GTS Shanghai and is located at the Shanghai Chengtou (Shanghai Environmental) Hazardous waste facility in Jiangding. The facility is built to integrate with existing incinerators to process medical waste, incinerator ash and other difficult, hazardous feedstocks. The facility will produce steam for use throughout the balance of the process facility. The integrated system is flexible and will engage in several waste control, treatment and disposal methods such as reuse, recycling, sterilization and land filling to minimize the environmental and health impacts of waste.

IMPACT for Alter NRG - yet another reference facility with long term strategic benefits. This facility opens new markets by highlighting the Westinghouse Plasma gasification technology’s ability to complement existing incinerator plants. THE WIN for all of us - more hazardous incinerator ash is going to be turned into environmentally neutral slag instead of being land-filled. nrg Focus | by

ALTER NRG

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Alter NRG: Open House 2013 Alter NRG held its 5th open House in Pittsburgh, PA on June 11, 2013. The purpose of the open house was to gather industry experts who share technological developments and discuss their project developments. Alter NRG welcomed 71 guests including project developers, EPC partners and financial institutions who visited our world class demonstration facility in Madison, PA for this unique networking event. A site tour and live torch demonstration were enjoyed by all guests.

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ISSUE | SEPTEMBER 2013


Walter Howard, CEO, addressing guests at the Alter NRG’s 5th Open House event held on June 11, 2013. nrg Focus | by

ALTER NRG

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Westinghouse Plasma Torches Driving production efficiency in steel making Westinghouse Plasma Corporation’s (WPC) plasma technology has been developed for over 30 years with an estimated $100 million invested in research and development. The WPC technology was initially developed in collaboration with NASA for use in the Apollo space program to simulate space vehicle re-entry conditions. Alter NRG acquired WPC in 2007 and has further developed the plasma torches. WPC torches provide a clean source of heat that can improve efficiencies and improve environmental performance in many different industrial applications. Since 1980, WPC torches have been commercially deployed in over 34 different industrial applications for a wide variety of uses such as metals recycling, catalyst re-forming, heating of cupolas, and cleaning industrial gases. With rising costs of foundry coke and fuel oil, the WPC torch can effectively reduce energy consumption and cost by precisely managing heat input to the furnace.

Furnace Applications As early as the 1980’s, WPC plasma torches have been deployed in industrial furnaces in various metals applications. Our customers include General Motors, SKF Steel, ALCAN, China Steel Co., Picklands-

Commercial deployment of Westinghouse Plasma Torches in Metals Applications ●● SKF Steel used MARC 11 – Plasma torches for commercial sponge iron production (1980)

Mather Co., Cockerill Steel and Eldorado Resources Ltd. The largest, and longest running application was the GM cupola in Defiance, Ohio,

●● Cockerill Steel Co. used MARC 3A – Plasma torches for superheating of blast air to reduce coke consumption (1981)

which successfully utilized six (6) MARC-11 plasma torches in a plasma assisted foundry cupola to make steel from scrap material for engine block castings. The plasma assisted cupola ran successfully for 22 years using the same plasma torches that were originally installed. This makes the WPC plasma torch and torch system the most industrially rugged and commercially acceptable offering on the market.

●● Pickands-Mather Co. used MARC 11 - Torches for iron reduction and steelmaking (1984) ●● General Motors Corporation – MARC 11 - Torches for the production of cast iron in a commercial cupola (1989) ●● ALCAN – MARC 11 – Aluminum dross recovery (research furnace) (1990) ●● ALCAN - MARC 11 – Aluminum dross recovery (commercial furnace) (1992)

The integration of our plasma torches in furnace applications have allowed

●● China Steel Co. – MARC 3A – Metals production research lab (1992)

our customers to benefit from higher blast temperatures lower coke

●● Undisclosed Metals Recycler – MARC 11H – Metals melting (2010)

utilization rates, higher furnace productivity, higher alternative fuel utilization

●● Beijing Huanyu Guanchuan Plasma Technology Ltd. – Steel and iron ore

and better control over furnace temperature and process chemistry.

industry (2013)

Plasma Melting Furnace, General Motors (GM), Defiance, Ohio, USA

The unit was installed in 1989 at the General Motors’ Powertrain car plant in Ohio, USA as part of the foundry operation for the production of grey iron for the manufacture of engine blocks and other automotive castings. This was the first commercial scale plasma cupola built in the world, employing 6 MARC 11 WPC plasma torch systems, operating at 1,750 kW each. The plasma cupola processed a feed charge that consisted of sprue, steel turnings, iron borings and fragmented steel scrap.

Plasma Melting Furnace, Aluminum Canada Ltd. (ALCAN), Jonquière, Canada The plant was built in 1992 as an aluminium dross recovery furnace at ALCAN’s plant at Jonquière, Canada. It uses 2 MARC 11 plasma torch systems each operating at 850 kW. As an alternative to the conventional Rotary Salt Furnace (RSF) dross processing technology, the plasma dross processing technique reported an increase in material quality, reduced waste for disposal and excellent electrode life. Source: Juniper Consulting Services Ltd.

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ISSUE | SEPTEMBER 2013

GM reported that “... over ten years of operating experience demonstrated that the plasma technology is economically suitable for Iron melting. No major changes of traditional industry practices are required to operate plasma cupola systems. The plasma equipment can be operated and maintained by routine plant personnel”


Plasma Torch Ratings High efficiency - low maintenance design MARC 3A Plasma Torch WPC’s standard MARC 3A configuration operates in a range from 80kW to approximately 300kW. The current to the field coils in the MARC 3A is in series with the arc current. The

Westinghouse Plasma Torches The WPC MARC 3A or MARC 11 plasma torches operate over electrical ranges based on the configurations below.

MARC 3A does not feature independent control of the field coil current and arc current.

MARC 11 Plasma Torch The MARC 11 torch power is controlled by changing either the arc current, field current or the process gas flow. Torch connections include quick disconnects for the air supply, cooling water and electrical connections to facilitate torch removal for inspection and maintenance. WPC has two standard MARC 11 configurations, a low power torch, the MARC 11L and a high power torch, MARC 11H. The low power MARC 11L plasma torch operates in the range from approximately 350 kW to approximately 800 kW. The high power torch operates in the range from approximately 860 kW to 2400 kW. The maximum arc

Torch Type

MARC 3A

MARC 11L

MARC 11H

Rated Min Power (kW)

80

350

860

Rated Max Power (kW)

300

800

2400

Air Flow (scfm)

20

95

200

Air Flow (kg/hr)

42

197

415

Thermal Efficiency

70%

85%

85%

400 ADC

1000 ADC

2000 ADC

860 VDC

950 VDC

1200 VDC

Maximum Operating Current Maximum Operating Arc Voltage

Model

Diameter

Typical Length

Weight

inches

mm

inches

mm

Pounds

11 torch uses two separate power supplies: one for the field

MARC 3A

3.5

89

32.5

826

45

coil and one for the arc. The arc current and the field coil

MARC 11

18

457

35

889

450

current of the MARC 11 plasma torch is 2000A. The MARC

current can be independently controlled.

“WPC is a proven leader in its field in plasma gasification and the plasma torch system. Their systems have been proven commercially and represent significant market potential for the industrial furnace retrofits in China. China is the world’s largest steel producer and this application of Westinghouse Plasma torches will be used to reduce the overall emissions profile and operating costs in the steel facilities.” - Mr. Huang Geng, MARC 11 Plasma Torch

Chief Technology Officer,

Guanchuan

nrg Focus | by

ALTER NRG

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Furnace Integration of Plasma Torches Robust returns from increased furnace capacity and reduced coke usage Using the blast furnace as an example, WPC plasma torches can improve the profitability of the facility in two physical areas of the process scheme.

Blast Furnace WESTINGHOUSE PLASMA TORCHES

BLOW PIPE PLASMA TUYERE INJECTION WESTINGHOUSE PLASMA TORCHES

PLASMA HOT BLAST

STOVES

WESTINGHOUSE PLASMA TORCHES

WESTINGHOUSE PLASMA TORCH

BLOW PIPE

COAL INJECTION WESTINGHOUSE PLASMA TORCHES

Plasma Tuyere Injection

Hot Blast Superheating

With plasma torches located at the tuyeres, the refractory lining of the blast main is not a limiting

Hot blast superheating can occur at the stove outlet where hot blast (wind) is sent to the

factor for increased wind temperature, allowing the operator to precisely control and increase

tuyeres. With wind superheating, the hot blast is superheated in the hot blast main through

the temperature of the furnace by several hundred degrees centigrade. This enables the

mixing with high temperature plasma-heated air. This method increases wind temperature

raceway to reach higher productivity while improving the utilization of coal, natural gas or other alternate fuels. Pulverized coal injection rates can be increased by as much as 100 kg per tonne of hot metal, offsetting almost an equivalent amount of foundry coke and furnace productivity

the facility.

improvements of 4% or more can be realized.

Benefits

Benefits ●● Enables rapid conversion of pulverized coal within the limited raceway volume ●● Pulverized coal injected blast furnaces can be further optimized by offsetting an additional 100 kg/THM of coke with pulverized coal ●● Productivity increases of 4% or more can be realized ●● 2 to 5 year payback is typical

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without shortening stove life or requiring the rebuilding of stoves to operate at higher WESTINGHOUSE temperature. The increased hot blast temperature decreases the foundry coke consumption of PLASMA TORCH

ISSUE | SEPTEMBER 2013

●● 50°C - 200°C increase in blast temperature can be achieved COALreduction: INJECTION ●● Coke rate 10 to 40 kg/ tonne of hot metal, more than

offsetting the operating cost of the plasma torches ●● Consistent control over blast temperature allowing further optimization of the blast furnace ●● 2 to 5 year payback is typical


Redefining the Economics of Steel Making Plasma Tuyere Injection Original Design

Plasma-Tuyere

4000 t/day

4150 t/day

1225˚C

1450˚C

N/A

18 MW

Coke Usage

378 kg/THM

265 kg/THM

Coal Usage

100 kg/THM

200 kg/THM

Production Rate Temperature Plasma Torch Power

Typical Payback

1-2 Years

Hot Blast Superheating Production Rate Temperature Plasma Torch Power Coke Usage Typical Payback

Original Design

Plasma-Heated Blast

4000 t/day

4050 t/day

1100˚C

1150˚C

N/A

5 MW

491 kg/THM

485 kg/THM 1-3 Years

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Plasma Torch Experience Commercially proven applications Date 2013

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Customer Application Beijing Huanyu Guanchuan Plasma Technology Ltd. (GuanChuan) Industrial Furnace Applications related to Steel and Iron Industry

Plasma Torch Systems MARC 3A

2010

Undisclosed Metals Recycler – Metals Melting

2010

SMS Infrastructure, Ltd. Commercial Vitrification of Common Hazardous Waste

MARC 3A

2009

SMS Infrastructure, Ltd. Commercial Vitrification of Common Hazardous Waste

MARC 3A

2005

Georgia Institute of Technology Laboratory Application

MARC 3A

2002

Hitachi Metals Ltd. Commercial Gasification of MSW & Waste Water Sludge

MARC 3A

2001

Hitachi Metals Ltd. Waste to Energy Facility Gasification of Auto Shredder Residue & Refuse Derived Fuel

MARC 3A

2000

Undisclosed Client

MARC 3A

1999

Hitachi Metals Ltd. Commercial Gasification of MSW

MARC 3A

1995

Geneva Steel Corporation Commercial Production of Molten Iron for Steel Making

MARC 11

1994

DuPont Corporation Materials Synthesis Development

MARC 3A

1995

Ishkawajima-Harima Heavy Industries Co. (IHI) Commercial Vitrification of MSW Incinerator Ash

MARC 3A

1993

Ishikawajima-Harima Heavy Industries Co. (IHI) Research Lab for Vitrification of Incinerator Ash

MARC 3A

1992

China Steel Co. Research Lab for Metals Production

MARC 3A

1992

ALCAN (Aluminum Canada Ltd.) Commercial Aluminum Dross Recovery Furnaces

MARC 11H

1990

ALCAN (Aluminum Canada Ltd.), Research Lab. For Aluminum Dross Recovery

MARC 11H

1989

General Motors Corporation Commercial Cast Iron Production

MARC 11H

1988

Consarc Corp. Research Center for Refining of Refractory Metals

MARC 3A

1987

Eldorado Resources Ltd. Extraction of Uranium from Magnesium Fluoride Research Center

MARC 3A

1986

Pyrolysis Systems Inc. Mobile Trailer for Liquid Toxic Waste Destruction

MARC 3A

1985

Intermountain Power Co. Commercial Ignition of a Pulverized Coal Boiler

MARC 3A

1985

Owens-Corning Fiberglass Research Lab.

MARC 3A

1985

Studsvik Energiteknik Thermal Simulation of a Nuclear Reactor Core Meltdown

MARC 11

1984

Pickands -Mather Co. Metal Project Development of Plasma Iron Reduction and Steelmaking

MARC11

1983

Westinghouse Research and Development Lab.

1981

Cockerill Steel Co. Commercial super-heating of blast furnace air to reduce coke usage

MARC 3A

1980

SKF Steel Co. Commercial Sponge Iron Production

MARC 11

1977

Westinghouse Research Jet Propulsion Lab. NASA Production of Solar Grade Silicon

MARC 11

1975

Westinghouse Research Arc Heater Project

MARC 11

1973

International Minerals & Chemicals Corp. Phosphate Defluorination Process

MARC 11

1971

Dow Chemical Corp. Hydrocarbon Process Research

MARC 11

ISSUE | SEPTEMBER 2013

MARC 11H

MARC 11, MARC 3A


Conference Updates ALTER NRG AND GENERAL ELECTRIC (GE) CO-HOSTED THE GASIFICATION TECHNOLOGIES COUNCIL (GTC) INDIA TRADE MISSION The GTC, working with the US India Business Council, hosted a successful gasification trade mission to India September 7-12, 2013. Mission leaders, Alter NRG and GE, were joined by other GTC member companies in meeting with key Indian government officials, bureaucrats from the US Embassy, and representatives of various Indian oil, gas, chemical, power and fertilizer companies. The purpose of the mission was for industry leaders to share knowledge related to how gasification can help India meet its fast- growing energy needs.

Walter Howard (CEO) of Alter NRG, conducting a presentation at the GTC India Trade Mission in September 2013

Alter NRG attended and presented at the following conferences as well: April 16-18: EfW Expo – Sustainability Live, Birmingham, UK ●● Meeting

with over 300 leading suppliers of products for advanced thermal treatment processes.

April 21-25: 9th European Congress of Chemical Engineering – The Hague, Netherlands ●● Theme:

Shaping a sustainable future: A Partnership of Academia, Industry and Society.

May 8-9: Waste to Energy City Summit – London, UK ●● A

gathering of policy-makers, project developers, technology companies and investors from throughout Europe to discuss the opportunities and challenges in developing advanced waste-to-energy facilities in today’s cities and industrial parks.

July 23-26: 13th China International Environmental Protection Exhibition & Conference – Beijing China ●● Richard

Fish, President, Alter NRG, co-presented with GTS on the integration of our technology at the current hazardous waste facility of Shanghai Chengtou.

September 19: EKOS Plus Conference E+ (Efficiency+Ecology+Energetics) - Bratislava, Slovakia ●● Kevin

Willerton, VP, Business Development and Strategic Alliances, Alter NRG, presented three projects incorporating Westinghouse Plasma gasification technology which are under construction.

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Westinghouse Plasma gasifier auxiliary equipment and control modules for the world’s largest plasma gasifier

Alter NRG provides clean energy solutions that are economically viable and environmentally sustainable. Westinghouse Plasma is the industry leading plasma gasification technology that provides clean and renewable energy solutions by converting all types of waste and biomass into high value energy - like electricity, ethanol or syngas. With plasma systems in operation for 20 years and converting waste into energy since 2002, the technology is commercially proven and produces lower emissions than other conventional energy technologies.

www.alternrg.com

NRG Focus September 2013  

Contents: - Tees Valley Project 1 - Tees Valley Project 2 - Spotlight on: GTS Shanghai - Plasma Torch Applications for Foundry and Iron Mak...

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