Westinghouse Plasma Corp. Gasification Technology is used in three commercial operating facilities. It is being installed at two further facilities. A more detailed explanation of each plant is given below.
Projects under Construction
TEESSIDE, UK: TEES VALLEY RENEWABLE ENERGY FACILITY
Location: Tees Valley, UK
Owner: Air Products
Capacity: 1,000 tpd
Feedstock: Sorted MSW
Output & Configuration: Power – Combined Cycle
Air Products has commenced the construction of the Tees Valley Renewable Energy Facility and will be starting construction in the near future. Air Products has purchased the gasifier for the plant, a G65, from Westinghouse Plasma Corp. and commissioning is planned for 2014. Westinghouse Plasma Corp. will deliver the gasifier to the site in early 2013.
The facility will process 1000 tpd of pre-sorted MSW and produce electricity through a combined cycle power island configuration. A combined cycle power island is the combination of a gas turbine(s), a heat recovery steam generator and a steam turbine and is considered the most efficient technology for converting gas to power.
The facility will employ sophisticated syngas clean-up technology to ensure the syngas meets the demanding specifications of the gas turbines.
The emissions from the power island will be very similar to those from a traditional natural gas fired combined cycle power plant. Air Products has received its environmental approval from the UK government.
Air Products’ business plan includes the development of at least four more facilities similar to the Tees Valley plant.
WUHAN, HUBEI, CHINA
Location: Wuhan, Hubei, China
Owner: Wuhan Kaidi
Capacity: 150 tpd
Output & Configuration: Fischer-Tropsch (FT) Liquids
In December of 2011, Wuhan Kaidi, a very large Chinese energy company, began construction of a new technology park in Wuhan, China. Westinghouse Plasma Gasifier was commissioned in Q1, 2013.
The facility includes a 150 tpd plasma gasification demonstration facility purchased from Westinghouse Plasma Corp.. Kaidi anticipates that the facility will commission in late 2012 and will process biomass for conversion to power and liquid fuels.
Kaidi’s business plan includes building numerous facilities of capacities greater than 800 tpd of biomass.
Location: Shanghai, China
Feedstock: Municipal Solid Waste & Incinerator Fly-ash Vitrification
Output & Configuration: Slag
A demonstration plant is currently being built in Shanghai, China by GTS. The demo plant will be integrated with an existing incinerator to take the incinerator ash as well as other difficult feedstocks.
Westinghouse Plasma Corp. delivered the gasifier design and plasma torches. GTS anticipated that the commissioning will take place in 2013.
Commercial Operating Facilities
MEPL, PUNE, INDIA
Location: Pune, India
Capacity: 72 tpd
Feedstock: Hazardous Waste
Output & Configuration: Power – Boiler
The Maharashtra Enviro Power Ltd. (“MEPL”) plant processes hazardous wastes from over 30 industries in India. The owner of the plant, SMSIL, is a partner of Westinghouse Plasma Corp. and together the companies offer plasma gasification into the Indian market. WPC has access to the operational data and the operating staff at the plant. SMSIL also makes the plant available to certain Westinghouse Plasma Corp. customers for pilot tests and optimization tests.
It is access to this type of information that allows Westinghouse Plasma Corp. to accelerate the optimization of its technology – another advantage Westinghouse Plasma Corp. has over its competitors.
ECOVALLEY - UTASHINAI, JAPAN
Location: Utashinai, Hokkaido, Japan
Owner: Hitachi Metals, Hitachi Ltd.
Capacity: 220 tpd
Feedstock: Municipal Solid Waste and Auto Shredder Residue
Output & Configuration: Power – Boiler
The EcoValley plant, which is located near the small town of Utashinai in a rural area on the island of Hokkaido, can process up to 220 tpd of pre-sorted MSW. The plant has two gasifier trains each capable of processing 110 tpd.
The plant was closed due to lack of feedstock (loss of long term feed contracts).
Westinghouse Plasma Corp. has been fortunate to have access to the operational data and operating staff of the plant. Hitachi Metals, the operators of the plant, modified and optimized the gasifier over the first several years of its operation.
This commercial experience has been incorporated into the next generation gasifier design begin offered by Westinghouse Plasma Corp. and purchased by Air Products. By comparison, Westinghouse Plasma Corp.’s competitors are struggling to build their first reference plants.
The plant consistently met its emissions requirements.
Location: Mihama-Mikata, Japan
Owner: Hitachi Metals, Hitachi Ltd.
Capacity: 24 tpd
Feedstock: Municipal Solid Waste and Waste Water Sludge
Output & Configuration: Heat – Boiler
The Mihama-Mikata plant processes 20 tpd of MSW from the towns of Mihama and Mikata. It also processes four tpd of sewage sludge. The syngas is used to produce heat which is then used to dry the sewage sludge so it can be gasified.
All of the slag from the Mihama-Mikata plant is used beneficially as aggregate for concrete or paving stones.
The plant consistently meets it emissions requirements.
WESTINGHOUSE PLASMA CENTER, MADISON, PENNSYLVANIA, USA
Location: Madison, Pennsylvania, USA
Owner: Alter NRG
Capacity: 48 tpd
Feedstock: Over 100 tested
Output & Configuration: Synthesis gas (Syngas)
Westinghouse Plasma Corp. owns and operates a demonstration facility located near Madison, Pennsylvania, USA. The demonstration reactor was built in 1984 and has been the home for countless gasification tests.
Our demonstration plant is a critical element for the successful completion of projects for customers and provides Westinghouse Plasma Corp. another advantage over its competitors. We have the capability to gasify the feedstocks that our customers plan to process at their projects.
The gasification tests provide valuable information about syngas and slag composition that help customers make decisions about the balance of plant design. The tests also provide information necessary for customers to obtain environmental permits. Air Products conducted a series of tests at our Madison demonstration plant in support of their Tees Valley Renewable Energy Facility.
Another customer, Coskata, the owner of a technology that converts syngas to ethanol, completed two years of successful testing at our demonstration plant. Westinghouse Plasma Corp. gasified both wood waste and municipal solid waste to create syngas which Coskata subsequently converted to ethanol.
Our demonstration plant includes downstream gas cleaning equipment and state of the art, real-time gas composition monitoring. There are three distinct feeding systems through which almost any solid or liquid can be fed into the gasifier. Westinghouse Plasma Corp. has predictive modeling capability, which includes the balance of plant, through VMG simulation software.
Westinghouse Plasma Corp. has gasified a wide range of feedstocks at its demonstration plant including:
- Municipal solid waste
- Refuse derived fuel
- Construction and demolition waste
- Hazardous waste, including PCB contaminated waste and harbour sediment sludge
- Waste water sludge
- Waste wood and clean wood chips
- Auto Shredder Residue (also know as auto fluff)
- Heavy oil
- Incinerator ash
Westinghouse Plasma Corp. continues to refine its core plasma torch and gasification technology based on the results obtained at its demonstration plant and the experience at operating facilities.