Waste Pyrolysis Plant

GEMCO waste pyrolysis plant not only represents a sustainable solution for waste disposal but also offers an opportunity for both energy production and environmental conservation in cities and communities. We are dedicated to improving the waste management industry, safeguarding our environment, and paving the way for a more sustainable approach to resource utilization in the future.

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Municipal Solid Waste (MSW) Pyrolysis

The waste pyrolysis gasification technology is a process in which waste is heated at high temperatures in an oxygen-depleted or oxygen-deficient environment to facilitate its decomposition. This technology is effective in treating municipal solid waste (MSW), organic waste, plastic waste, discarded rubber, and other types of waste, converting them into gases containing H2, CO, CO2, CH4, C2H4, and other short-chain hydrocarbons, as well as solid residues and liquid tar.

waste management facility

Sustainable Waste Management Solution

GEMCO pyrolysis gasification technology reduces waste volume up to 80% to 90% and waste weight up to 70% to 80%. It recovers energy from the waste, which can be converted into hot water or steam for residential use. Additionally, the thermal treatment process can eliminate bacteria in the waste, achieving the goal of controlling disease transmission. This technology enables the harmless, reduced, and resourceful treatment of waste while effectively addressing the air pollution issues associated with waste incineration.

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Waste gasification facility

Transform Waste to Energy

Waste containing organic combustibles undergoes bond cleavage through thermal energy under anaerobic conditions, transforming from macromolecular organic matter to small molecular weight combustible gases such as CO, CH4, H2, etc. After pyrolysis and purification, each ton of waste can generate 1000m3 of industrial gas with a heating value greater than 1500Kcal, which can be used for power generation or integrated into the local power grid. A daily treatment of 1000 tons of municipal waste can generate 365 million cubic meters of industrial gas annually, equivalent to approximately 70 million cubic meters of natural gas.

carbon black

Joint Production of Multiple Products

GEMCO waste pyrolysis plant is a poly-generation system that produces various valuable by-products in additional to energy. The waste pyrolysis process generates tar and carbon black. Tar can be used to make fuel or extract chemical raw materials based on its properties, while carbon black can be used in the production of ink, plastic, and rubber products.

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GEMCO Waste Pyrolysis Plant Advantages

Eco-Friendly Waste Management

GEMCO waste pyrolysis plant demonstrates outstanding environmental advantages in multiple aspects. One critical aspect is the combustion process in the combustion chamber. It burns small-molecule combustible gases, resulting in minimal emissions of pollutants such as SOx, NOx, dioxins, and heavy metals. It’s worth noting that the production of fly ash is less than 1% of the total waste volume, which is significantly lower than the fly ash produced by traditional grate furnaces and fluidized bed technologies, and significantly reduces secondary pollution from waste disposal and lowers the cost of exhaust gas treatment.

High Level of Automated Operation

GEMCO waste pyrolysis plant employs a Distributed Control System (DCS) for automatic control, ensuring highly automated operation. It can achieve multi-point control and 24-hour real-time online monitoring of exhaust gas emission data, ensuring precision and efficiency in operation. The system has a powerful interconnection interlocking function and adopts micro negative pressure operation to improve safety. One-touch start-stop functionality and excellent stability make the system easy to operate and maintain.

Customized Solutions for Each Client

We understand that each customer has unique requirements, and that’s why we offer customized design services. Whether it’s the type of waste, production targets, or energy needs, we can tailor production lines and select appropriate equipment specifically for our customers based on their specific conditions. This personalized design ensures that the system perfectly aligns with the customer’s needs and enhances its overall efficiency.

Fast Installation with the Modular Design

GEMCO waste pyrolysis system is designed with a modular approach, which means that various components of the system are designed as independent modular units. This not only significantly reduces the on-site installation workload but also addresses land cost issues and improves space utilization. Furthermore, modular design makes each piece of equipment easier to maintain and replace, ensuring the long-term stability and operation of the system.

GEMCO Waste Pyrolysis Plant Design

The design of Waste Pyrolysis Plant
1. Grab Crane
2. Pyrolysis Reactor
3. Secondary Combustion Room
4. Waste Heat Boiler System
5. Deacidification System
6. Activated Carbon Adsorption System
7. Bag Filter
8. Induced Draft Fan
9. Chimney

1. Waste Material Handling System

The first step in the GEMCO waste processing system is the reception and storage of various types of waste. This system ensures efficient handling and storage of materials and conveys them to the gasification reactor for pyrolysis.

2. Pyrolysis Gasification System

The pyrolysis gasification system is the core of the entire process. Here, waste is exposed to a high-temperature, oxygen-deficient environment, converting its organic components into usable energy. This step is crucial for environmental protection and resource recovery.

3. Waste Heat Recovery System

GEMCO’s system not only processes waste but also converts thermal energy into electricity. Through waste heat utilization and power generation systems, the generated electricity can be used within the system or supplied to nearby facilities, improving the system’s energy efficiency.

4. Flue Gas Purification System

To ensure that the exhaust gas emissions meet strict environmental standards, GEMCO waste pyrolysis plant is equipped with an advanced flue gas purification system, including processes such as acid removal, activated carbon adsorption, and baghouse dust removal.

5. Residue Handling System

The pyrolysis gasification process generates residue, which requires proper handling. The residue handling system is responsible for separating, storing, or further utilizing the residue to reduce waste volume and comply with environmental regulations.

6. Automation Control System

GEMCO utilizes an advanced Distributed Control System (DCS) to ensure the efficient and stable operation of the entire system. Utilizing 5G intelligent management technology to minimize manual labor costs.

Waste to Energy Process

the working flow of GEMCO waste pyrolysis system

Waste Reception and Storage: Garbage is delivered by collection trucks and unloaded into a waste storage pit. Air required for gasification is extracted from the pit, creating a negative pressure to prevent the escape of odors.

Gasification Process: Inside the updraft fixed-bed pyrolysis reactor, the waste undergoes four stages, from top to bottom: drying, pyrolysis, combustion, and burnout, completing the gasification process. The combustible components, such as hydrogen, carbon monoxide, methane, and gaseous hydrocarbons produced, enter the secondary combustion chamber for oxygen-enriched combustion. The combustion temperature is controlled between 950°C and 1100°C, with a residence time of approximately 2 seconds, promoting the rapid decomposition of dioxins.

Energy Recovery: The combustible materials generated during waste pyrolysis and gasification, such as charcoal and tar, can reach temperatures of up to 1000°C in the pyrolysis reactor, providing the necessary energy for continuous waste pyrolysis and gasification.

Residue Handling: The residual waste, after complete combustion, undergoes primary air cooling and then is crushed by a grate crusher before being discharged into a water-sealed tank at the bottom of the furnace. It is finally removed through a slag machine. The discharged residue can be directly used as auxiliary building materials.

Heat Recovery: The high-temperature flue gas produced during the combustion process in the secondary combustion chamber is directed to a waste heat boiler for heat recovery. The high-temperature steam generated by the boiler can be used for power generation or heating. It can also be combined with small-scale high-speed steam turbines and screw-expander power generation technologies to create small-scale energy stations.

Flue Gas Purification: After heat recovery, the flue gas undergoes acid removal and dust removal through a baghouse dust collector. The emitted flue gas meets the latest EU 2000 standards for emissions, ensuring compliance with environmental regulations.

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GEMCO Waste Pyrolysis Plant Parameters

SpecificationUnitDifferent Tonnage Series Parameters
MSW Process Capacityt/d50100125150
Gasifier ModelGELR-SC seriesGELR-SC2200GELR-SC3200GELR-SC3600GELR-SC4000
Combustion Layer Temperature950-1050
System Installed Powerkw65115120140
System Power Consumptionkw≈ 52≈ 92≈ 100≈ 110
Second Combustion Chamber Temperature900-1100
Waste Heat Boiler TonnageSteam Tons/h3.57911
Steam ParametersMPa/℃1.25/1911.6/2042.5/4004.1/400
Turbine CapacityMW1.21.5
Urea Consumption
kg/h≈ 6.4-8≈ 12.8-16≈ 16-20≈ 19.2-24
Quicklime Consumption
kg/h≈ 15-25≈ 30-50≈ 37-62≈ 50-75
Activated Carbon Consumption
(heavy metal 30mg/Nm³-0.5mg/Nm³)
Bag Filter Capacitym³/h21000420005250063000
Slag Outputkg/h≈ 415≈ 830≈ 1040≈ 1245
Reduction Ratio (Volume)%≥85
Heat Reduction Rate%≤3
Municipal solid waste pile

The Importance of Municipal Waste Management

Municipal waste can lead to pollution of the atmospheric environment, groundwater, soil, and agricultural crops. The decomposition of organic matter in waste generates a significant amount of harmful gases that can severely pollute the environment when released into the atmosphere. Harmful substances from waste can also dissolve into groundwater and seep into the soil, causing contamination of groundwater sources and soil, with the long-term effects of such pollution being difficult to mitigate. Additionally, waste contains factors such as pathogenic bacteria and parasite eggs that can harm human health, so improper handling can lead to the spread of diseases and impact the human living environment.

Using gasification technology to manage urban household waste not only helps eliminate the various hazards mentioned above and reduce environmental pollution but also allows for energy production and serves society. This approach enables the environmentally friendly and resource-efficient treatment of waste, contributing to the sustainable development of human society.

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