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THERMO CATALYTIC

CONVERTER PLANTS

TCC-4000 GII

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INTRODUCTION OF THE COMPANY

FUKON Aktiengesellschaft, established in Liechtenstein in 2007, has shifted ifs focus

over the past years and recently it operates as a venture capital enterprise, focusing on

investment opportunities in the renewable energy sector. These days, Fukon A.G.

addresses processing of waste and materials for recycling by using state of the art

industrial research and development elements in the technology it applies.

The company invests into waste utilization plants using patented waste management

solutions and know-how through its subsidiaries in Hungary and Poland.

An important recent milestone was the commissioning of a TCC-4000 GII Thermo

Catalytic Converter Plant (Generation II), producing oil from segregated plastic, rubber

or even carpet, as row materials. The pilot project was built in Fehérvárcsurgó -

Hungary in 2012.

TECHNOLOGY DESCRIPTION

U TILIZATION OF PLASTIC AND RUBBER WASTE

Rubber and plastic materials are special parts of the

organic waste as these are practically non-

destructible. Eliminating them by simple means or byincineration is not a good solution, as the free

carbon particles (in the form of thick smoke) heavily

pollute the environment, together with the toxic

particulars sticking to these particles.

The production of rubber is based on the chemical technology called polymerization.

By reversing this process, with the simultaneous input of heat energy the large

molecules breakdown to smaller molecules.

The depolymerization process – provided it is achieved by using heat energy – is called

thermo catalytic transformation as long as the reaction sphere is sealed airtight.

FUKON AKTIENGESELLSCHAFT 2

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Part of the plastic waste might be recycled by

traditional methods, but there are some plastics,

due to production or other reasons (polluted, etc.)

which cannot be recycled. In case of those

plastics which cannot be recycled, the reversed

polymerization technology can be also used asthese are oil by-products as well.

Our technology is based on thermo catalytic

depolymerization.

The essence of the process is - see 1 illustration – that the slowly decomposing organic

wastes (rubber, plastic)are shredded to 20-25 mm pieces, then delivered by a screw-

driven device into an oxygen free, heated, airtight sealed reactor, where the waste is

transformed to hydrocarbon-steam and gas-phase. At the end of the procedure a slag

by-product is separated.

The produced carbon steam-phase is leaving the

equipment and enters a multiple condenser

system, where suitable liquid-phases are

formed(similar to the fractional distillation process,

but compared to the traditional distillation

procedure, operated under conditions which are

much more simple and economic).

The thermo catalytic system is designed as a block system meaning that it has modular

characteristics, i.e. smaller and larger capacity units may be constructed, step by step

capacity increase can be easily achieved in a modular way.

1. OPERATION FLOW (CONTROL PANEL OF THE TCC-4000 GII)


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END-PRODUCT / PROCESS

Out of the process the following products are produced:

Product oil liquid phase)

Characteristics:

Density: 0,8266 g/cm³

Cetane index: 53

Sulphur content: 110 mg/kg

Kinetic viscosity: at 40 degree C. : 2,23 mm²/s

Product-gas gas phase)

Characteristics:

Heating value: 54 MJ/Nm3


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Slag/Pyro-coke soot)

Characteristics:

Heating value: 15-16 MJ/kg

Steel – in case of tires

Stringy scrap metal

PROCESS FLOW OF THERMO CATALYTIC CONVERSION

Plastic/Rubberr

Reactor Condensor and

oil-treating

cleaning system

slag Oil

Turbine

Gas

buffer

Chemical

industryOil industry

Gas


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ADVANTAGES OF TECHNOLOGY

External energy (propane-butane or natural

gas) is needed only until the reactor reaches

the operating temperature, afterwards it will

produce the necessary product-gas forcaptive use. From here on the

thermocatalytic system becomes self-

fuelling, as the ful gas is produced by

processing of the waste materials.

The thermo catalytic technology and the

complex thermo catalytic – electricity

producing block system has a small footprint,

and can be easily be located in an average

Regional Waste Processing Center, fitting into an optimum production structure.

The thermo catalytic system is automatically operated from the feeding till the final

outputs, off-time of production is minimized.

The process is controlled and monitored in each production phase by an adjustable

controlling unit that plans and controls the given heating data of each process step. The

automatic shut-down of the operating line is also controlled by a sophisticated safety

mechanism.

EACH PRODUCTS CAN BE UTILIZED

S ALES OF PRODUCED ELECTRICITY

The main product of the thermo catalytic power station is electricity. The electricity may

be sold as follows:

o Open sales on the electric market

o Directly to consumers (i.e. to industrial plants, local municipalities)

o In regulated feed-in systems for alternative energy (like in the EU countries).

S ALES OF OIL

An economic solution would be the use of the oil in internal combustion engines

generating „green electricity”. Supposing that this activity is subsidized the result would

be a quicker return of the cost of technology.

Provided that the produced oil of the thermo catalytic power plant is not fully utilized to

produce electric energy, the remains balance may also be sold. If the oil price level is

favorable, it is profitable to sell the oil to oil companies for further refining. N.B: A

distillation unit can also be added to the thermo catalytic process, ensuring a higher

quality distillate with higher added value.

RAW MATERIAL INPUT


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S ALES OF THE PRODUCT -GAS

The produced gas is primarily used for operating

the plant.

The produced gas may also be used by gas

operating generators to produce electricity which

is may also be sold.

The produced gas - after being treated according

to directives of various regulations – may be

stored in tanks and later be utilized at a suitable

location.

The produced gas after suitable filtering may be used as renewed energy - mainly for

operating public transport.

S ALES OF PRODUCED THERMAL ENERGY

The produced thermal energy is suitable to provide heat to the nearby settlements using

district heating systems (therefore when choosing the site of the investment it can be a

decisive factor could be the distance to a city using district heating.)

The produced thermal energy is also suitable for cooling, therefore even in summer the

utilization of the thermal energy is solved. The thermal energy can be consumed in

cooling houses, near the power station.

S ALES OF SLAG / PYRO-COKE

The heating value of pyro-coke is equal to the heating value of brown-coal.

The advantages of investing in a thermo catalytic power station.

The return of the invested capital is 6,5 – 7,5 years.

With the sales of thermal energy sub-projects and sales of by-products the ROI can be

less than 6 years.

Calculating the negative cost of land filling the ROI can be less than 4 years.

GAS TURBINE


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DATASHEET OF THE TCC-4000 GII UNIT

1.

GENERAL INFORMATION

1.1. Processable materials:

- Polyethylene (PE, HDPE, LDPE, LLDPE)

- Polypropylene (PP)

- Polystyrene (PS)

- Shredded rubber waste

Size of the processable material :10mmx10mmx10mm

1.2. NON-PROCESSABLE MATERIALS:

Types of plastics containing halogens are undesirable for use in this technology. The

system can only process max. 0-3% of the materials containing Fluorine, chlorine (PVC)

bromine. Basically, these types of materials can be mixed into the waste material atrandom, this can be due to inaccurate selections. The contamination of raw materials.

Moisture is limited to max. 10% in value (by weight). Solid impurities can be in the

technology around 5% max. Entering of pollutants must be avoided, for example, paper

(not oily), metal waste (obstructs the feeding in), etc.. intake of radioactive substances is

strictly prohibited. Introduction of pollutants into the machine greatly reduces the

efficiency of the process. The purity of raw material thus determines the secure

operation of the equipment.

1.3. QUANTITY OF PROCESSABLE MATERIALS:

Optimal raw material input: 600kg / h (± 10%)

1.4. RESULTING PRODUCTS

Resulting products usually contain (depending on raw material input):

In case of plastic: - 70-75% product oil

- 15-20% product gas

- 5-10% solid residues (slag)

In case of waste rubber: - 35-40% product oil

- 15-20% product gas

- 40-45% solid residues (slag),

- 5-10% metal

2. T HE MAIN ELEMENTS OF THE DEVICE:

i.

Raw material conveying system

ii. Feed-in, fusion equipment

iii.

Reactor

iv.

Pre-combustion chamber, burner


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v.

Flue gas systems, mixing chamber

vi.

Condenser

vii. Oil Cleaning Product

viii.

Product oil with discharging system and storage tank

ix. Product gas cleaning equipment, process gas system

x.

Gas Torchxi. LPG system

xii. Slag Removal System

xiii.

Inerting system

xiv. Auxiliary systems ( cooling- heating system, ventilation, Water lock)

xv.

Control System

3. T HE OPERATION OF THE EQUIPMENT :

The responsibility of the raw material conveying system is to deliver the shredded

material from the ground level, to the system located on the upper level. The material

placed in the feeding and fusing equipment will be melted and preheated for the thermal

decomposition process. The material coming into the reactor will be dissolve by the

influence of thermal treatment and hydrocarbon vapors and gases are generated. The

slag will depart at the lower point of the continuous operating reactor, while the

hydrocarbon vapors and gases will depart from the top point of the reactor towards the

direction of the condensator. During the continuous operation, the slag is being

removed into container in the open air through the slag removal system. The

temperature of the slag should not exceed 80 ° C continuously. The hydrocarbon

vapors and gases are cooled down with the condensate and the resulting liquid mixture

is then passed into product oil purification equipment by pump. The treated and purifiedproduct oil is delivered to the storage tank. After purification and treatment, the gaseous

hydrocarbons being in a normal state are pumped into a temporary storage tank. Under

normal operating conditions, the supply of fuel in to the burner takes place from here,

so the system becomes energy self-sufficient. In the case of a cold starting, we use the

LPG system, so the built-in gas burner is suitable for burning the two types of gases.

The technological potential surplus product gas generated during the operation can be

burnt out in the safety gas torch.

4. SPECIFICATIONS:

4.1. BUILDING SIZE REQUIRED FOR THE COMPLETE TECHNOLOGY :

- Length: 35m

- Width: 20m

- Height: 10 m

A portion of the auxiliary equipments should be placed outside the building, parallel to

the longitudinal axis of the building. These area:

- Length: 35m

- Width: 8m


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4.2. ENERGY REQUIREMENT OF THE COMPLETE TECHNOLOGICAL PROCESS:

- Built-in electrical power: 160 kW

- Built-in burner output : 1,000 kW

- Cooling air requirement : up to 60,000 m3 / h

- LPG consumption : 28-40 kg / h

4.3. T ECHNICAL DATA OF THE MAIN COMPONENTS OF THE SYSTEM:

4.4. R AW MATERIAL CONVEYING SYSTEM

- May be bucket or air coveyer

- Lifting height: 8-10 m

- Capacity: 800 kg / h

- Equiped with balance

4.5. FEED-IN-FUSION DEVICE:

- 2 pieces of heated fusion device connected in series

- Heat input capacity approx. 110 kW

- 2x30 kW electric drive

- Weight: kg 2x2.500

- required space : 5mx6m

4.6. REACTOR:

- 3 units connected in series, vertical reactor.

- Size: D = 500, L = 6 m (each reactor)

- 3 pieces of gear, P = 3 kW, n = 4 rev / min

- Torque: 8000 Nm

- Thermal power input of 750 kW

- Reactor temperature: 500 ° C

- Reactor pressure up to 100 mbar

- Weight: 23,000 kg

4.7. PRE-COMBUSTION CHAMBER, WITH BURNER

- Dimensions: D = 2.5 m, L = 7 m- Weight: 30,000 kg

- Electricity consumption: 2.5 kW

- Gas pressure: 150-200 mbar

- Air Consumption: 1.700 kg / h

- Temperature of chamber: 1.200 ° C.

4.8. FLUE GAS SYSTEM MIXING CHAMBER

- Dimensions: d = 450 mm

- Dilution Air Requirements: 1700 m3 / h

- Heating Air Temperature: 750 ° C


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- Flue dimensions: d = 600 mm, H = 12 m,

- Flue gas outlet temperature T = 330 ° C

- Mixing chamber: vertical design, d = 1.600mm, H = 3 m

4.9. CONDENSER

- Size: L = 2.2m, W: 2.2 m, H = 3.5 m- Capacity: 500 kg / h

- Cooling air: 10.000 m3 / h

- Container volume: 2 m3

4.10. PRODUCT OIL CLEANING EQUIPMENT

- Size : L = 4.5 m, W: 2.2 m, H = 3.5 m

- Vacuum distiller, number of poles: 3 pieces

- Thermal power consumption: 100 kW,

- Heat transfer pressure drop of 0.4 bar- Heat transfer inlet temperature: 280 ° C

4.11. PRODUCT OIL WITH DISCHARGING SYSTEM AND STORAGE TANK

Not included in the production contract or delivery volume)

- Discharging pump: flow rate of 1 m3 / h, dp = 1 bar

- Tubular heat exchanger 40 kW, dp = 0.2 bar

- Product oil tank: 2x60 m3 on the discharging side with certified gauge.

4.12. PRODUCT GAS CLEANING EQUIPMENT , PRODUCT GAS SYSTEM

- Size: L = 3m, W: 2.2 m, H = 3 m

- Washing Liquid 30% diluted alkali

- Flow rate: 2 m3 / h

- Product gas compressor: V = 90 m3 / h, dp = 300 mbar, with liquid ring

- Product gas tank: V = 5 m3

4.13. G AS T ORCH

- Power output: 1000 kW

- Dimensions: d = 600 mm, H = 5 m

- Torch: flame ionization controller - PB-gas flame support – with a combustion air fan.

4.14. LPG SYSTEM

Not included in the production contract or delivery volume)

- LPG tank: V = 5 m3, Pmax 10 bar

- Exit gas pressure: 150 mbar

- Pipe diameter: DN 65

- With electrical pre-heater


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4.15. SLAG REMOVAL SYSTEM

- Dimensions: L = 10m, W: 1 m, H = 2.5 m

- Weight: 600 kg

- Capacity: 60 kg / h

- with water cooling, nitrogen inerting, knife slide valve. –

- Electrical power: 2.2 kW

4.16. INERTING SYSTEM

-Dimensions: L = 6m, W: 1 m, L = 2 m

- Inert gas: nitrogen, pressure 100 mbar /:

- Inerting place: reactor space and slag removal system.

- Bottle groups: 200 bar

4.17. A UXILIARY SYSTEMS (COOLING AND HEATING SYSTEM, VENTILATION, W ATER LOCK

- Thermal oil cooler: - power 215 kW

- Inlet temperature: 300 ° C

- Flow rate - up to 10 m3 / h, dp = 0.3 bar

- Max pressure 4 bar

- Fan - Motor Power: 1.2 kW

- Speed (revolutions per minute): 670 r / min

- Water cooler: Power: 53 kW

- Water cooling: reactor shaft, slag removal system, and feed-in-fusion equipment gear

- Water temperature 55/50 ° C, dp = 0.5 bar- Space Ventilator: 2x30.000 Flow m3 / h, 2x2, 2 kW

- Dilution Air Blower: Flow:1750 m3 / h 1,5 kW

- Water lock capacity :2m3 volume

- Blowing pressure: 100 mbar

- Flue gas / thermal oil heat exchanger 215 kW

- Flue gas mass flow: 3492 kg / h

- Inlet temperature: 525 ° C

- Thermal oil flow: 5.3 m3 / h

- Thermal oil inlet temperature: 250 ° C

- Thermal oil outlet temperature: 300 ° C- Emergency aggregators power: 35 kVA

4.18. CONTROL S YSTEM

- Own control system which provides the control of the reactor and the entire periphery.

Displayed in 15" touch panel. The control system also carries out the security

functions. The full security systems is solved with the development of “RB” system and

the in cooperation of external emergency power generator systems. During the

operation all data recorded and stored by an external computer, which can be checked

on-line.


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