InRim Technology
The technology we use should not be confused with other technologies more loosely labelled pyrolysis, which are essentially incinerators. At InRim, pyrolysis is the true process of thermal decomposition of organic material at high temperatures in the relative absence of oxygen. Whilst there are other technologies that use the principles of pyrolytic decomposition, most are simply high temperature incinerators that restrict combustion oxygen in order to minimise the generation of harmful dioxins and furans. Although these processes can remove the need for landfill, they do not efficiently utilise the energy released from MSW or alternate feedstock.
Our pyrolysis process decomposes feedstock into its simplest molecular components, forming a synthesised gas. However, unlike other forms of pyrolysis, it does not produce significant greenhouse emissions due to the very low levels of oxidation in the process. Additionally, this process is entirely self-contained — other than the initial heating cycle to commence the process, the plant provides all the fuel and heat required for its own operation, while simultaneously delivering diesel and electricity.
Our pyrolysis technology typically operates at temperatures between 500 – 700ºC. It produces low levels of char, high-quality synthetic diesel (EN590), and clean burning syngas.
The lack of availability of landfill space in metropolitan areas, as well as the social and environmental concerns, have led some states and territories to formulate policies to reduce waste volume, or even aim to eliminate waste. As a part of that waste reduction, and to alleviate landfill pressures, a number of waste streams can be used as feedstock in our plants.
Most local governments dispose of MSW in landfill, which is a short-term answer, and the cost of MSW management is climbing (20 – 40% of municipal revenues). Not only is this problematic for the economy, but the environment as well, with landfills emitting vast quantities of toxic climate change gases. Now, MSW can be used in pyrolysis technology. A single hybrid line using MSW as feedstock will save more than 20,000 tons of GHG entering the atmosphere — equivalent to removing 4,300 cars from the road.
InRim seeks to empower poultry waste producers in removing the by-products that they generate. Research undertaken by Monash University found that manure, litter, mortalities, hatchery, and processing plant offal can be processed via pyrolysis technology so that they are environmentally sound, socially acceptable, and economically feasible. Also, sewerage has been tested and found to be a suitable feedstock.
Sorting MSW to increase the fuel value of the waste produces RDF by removing incombustible materials such as dirt, glass, metals, and wet organics. The resulting RDF material is more consistent in size than raw MSW. RDF material comprises many components including rubber, plastics, timber, cardboard, green waste, and so on.
ELV contains a variety of plastics and vinyl, known as “shredder flock”, which is currently sent to landfill and contribute to the volume of harmful chemicals released into the environment. This shredder residue, which constitutes approximately 25 – 35% of the weight of the vehicle and up to 60% of its volume, carries a significant financial cost to recyclers, but has been identified as a suitable feedstock.
Annually, over 23 million waste tyres are created in Australia. In an effort to rectify this, new legislation and guidelines have recently been developed. However, although waste tyres are now chipped, sent to landfill or used as fuel replacement for coal-fired furnaces, the emissions still exist and are considered to be worse than the coal it is replacing. To assist in emission reduction, InRim are able to use car and truck tyres as feedstock.
Incineration is a common method of medical waste disposal as it eradicates germs and limits the spread of disease. However, in recent years, positive public perception of incineration has been declining, and environmental regulations of incineration have (rightly) become more stringent. Thus, medical waste is suitable for pyrolysis, which in turn unlocks the energy from the plastics in a clean, secure, and environmentally friendly way.
Although many waste streams are available for feedstock, there are restrictions. For the safety and longevity of the plant, pyrolysis technology demands that all materials processed must be combustible. Materials such as, but not limited to, builders’ rubble and or demolition wastes consisting of concrete, bricks, and soil are not appropriate for pyrolysis.
In light of this, InRim reserves the right to refuse any material we deem unsuitable for the pyrolysis facility.
It is designed with the principles of good manufacturing practice in mind and manufacturing processes clearly defined and controlled. All critical processes are validated to ensure consistency and compliance with specifications.
In a covered and walled area for deliveries via unloading bays, waste is moved by machinery onto raised conveyors. Non-combustible items are removed using a combination of automatic and manual systems. The conveyor then deposits feedstock into The Shredder.
This unit consists of an iron core-pulling machine and cuts large material into smaller material. A hydraulically-driven closed-loop system possesses a crushing head, which in turn consists of a shredding type unit capable of shredding up to five tons of material per hour. The system works at very high pressure, and with small displacement, develops exceptional torque.
From the Primary Shredder, feedstock is broken down into manageable sizes via the Secondary Shredding Mill — a unit comprised of metal cutters and drums specifically designed to cut and mulch waste. The fine output feed is stored in the Hopper, which can be pre-loaded and contains up to ten tons of MSW and other waste. It uses a gravity fed system; a screw mechanism feeds the main pyrolysis unit automatically.
Our pyrolysis system utilises an initial endothermic, followed by exothermic, reaction processes. Decomposition is achieved in the Pyrolysis Chamber, producing solid, liquid, and gas, by heating at moderately high temperatures under a no-oxygen or low-oxygen atmosphere.
Parameters governing this process include temperature, heating rate, solid residence time, particle size, and density of particles. Our plant furnace operates between 500 – 700ºC with a residence time of approximately thirty minutes, depending on the feedstock used.
The pyrolysis mechanisms release hardly any greenhouse gases. However, acidic gases are likely to result and require removal. The Wet Scrubbing unit removes these gases with minimum chemicals by filtering the syngas using a bag filter, and then cooling the exhaust to about 60ºC in a heat exchanger. The exhaust gas then passes through an Acidic Scrubber to remove hydrogen chloride, and an Alkali Scrubber to remove any traces of sulphur dioxide.
Most gasification processes cool syngas to below 500ºC for conventional gas scrubbing. However, this cooling results in significant energy losses. Using our technologies, there is an efficiency advantage in cleaning hot gas and then burning it in a syngas turbine.
The syngas is filtered at an average of 600ºC using sintered metal filters and then burnt in a turbine. By keeping the temperature between 600 – 700ºC, tar condensation is eradicated and the temperature is sufficient to remove alkali metal chlorides.
A number of economical by-products are obtained through InRim’s Continuous Pyrolysis Technology — a process that is typically carried out at temperatures of 500 – 700ºC. The products obtained include low levels of char (approximately 10% of feed volume), high-quality synthetic diesel, and cleaner burning syngas, along with significant levels of usable heat energy.
Syn-oil is a high density, non-viscous fluid, having several different chemicals with a wide-ranging molecular weight distribution. After the final refining process, it can be used as a standard diesel replacement for energy generation or for general transport use. Uniquely, this technology creates approximately 10,000 litres of green diesel, to EN590 standards, every day through a single hybrid line — from just 20 tons of feedstock per day.
Syngas, or synthesis gas, is the name given to volatile gas that is created in the pyrolysis chamber and is a mixture that contains varying amounts of carbon monoxide and hydrogen. As syngas is combustible, it can be used for running power generation turbines. It can also supply all the plant’s power or be used in the diesel refining process.
Electricity generated from an all-electricity plant, from 20 tons of waste per day, will supply up to 3.6MW of green renewable energy directly to the local electricity grid. Using the latest advances in power generation technology, both hybrid plants and all-electricity plants utilise waste-heat and pyrolysis gases to power a generator. As a result, we can maximise resources to create an excellent return on waste-to-power ratio.
A pyrolysis plant creates a small amount of biochar — a significant co-product of the pyrolysis process which has properties similar to coke. At 23 – 32 GJ per ton, pyrolysis biochar has a higher heating value than many grades of coal and is a CO2 neutral green fuel.
Biochar can be used as a substitute for other industrial fuels to produce the heat required for drying feedstock, and also to supply heat to the pyrolysis reactor. Alternatively, it can be fed into the boiler in pelletised form to generate further energy for electricity production.
- Nutrient retention and capture exchange capacity.
- Efficient nutrient use.
- Decreased soil acidity.
- Decreased uptake of soil toxins.
- Decreased release of non-CO2 greenhouse gases.
- Improved soil structure.
- Increased water-holding capacity.