Technology
1. K² Core-Unit
The system has a planned output capacity of 500 litres of light oil per operating hour. Therefore the K² Core-Unit is named K² 500. The K² 500 is an aggregate built to transform input materials containinghydrocarbons – such as oils, plastics, animal waste or biomass etc. – into mineral light oil. The core of the unit is a liquid circuit working with temperatures below 400°C. The application of a specialised catalyst causes a shortening of the hydrocarbon molecular chains. Central main elements of the aggregate are the Alphakat reaction unit, in which the input materials are transformed applying a catalytic process, a separator, where steam and liquids are split and the distillation column, where the oil steam is condensed after passing through, caught and led to a product storage tank. The Alphakat reaction unit is electrically powered with approximately 300 kW. All parts of the aggregate running with process-temperature are isolated.
Input material is applied to the process either in solid or in liquid condition. Solids are applied by an input-spiral as an anhydrous mass with minimum grain size. The input of liquids is designed as a special combined pumpand tank-system. Catalyst and other surcharge materials (e.g. neutralisator) are put into the system using automatic dosing units. Condensed water coming from the process is caught in a tank and has to be disposed by the customer. All material which cannot be transformed into light oil as well as used catalyst is discharged by a sedimentation system using a particular discharging spiral. These high concentrated residuals are evacuated using a sluice system. They are to be disposed by the customer. All apparatus, tanks and piping is made of stainless steel. All connections are flanged or screwed. To clean the aggregate a flushing system is installed.
Controlling and monitoring is secured by a variety of sensors, measurement devices and actuators interacting as a state of the art control unit. All electrical equipment is integrated modularly into the K² 500. For safety reasons, mechanical as well as electrical control and monitoring devices are also installed. All Engineering, Construction and manufacturing of the K² 500 match the actual technical regulations valid in Germany and the European Union. Safety features and equipment installed is state of the art. Final required inspections will be done by certified German advisers (TÜV). For safety reasons, the K² 500 core unit is to be erected in an oil retention pan made of concrete and covered with an oil proof coating matching all statutory provisions. The aggregate is designed to be connected to a block-heat and power plant (BHKW) that runs with light oil produced by the K² 500. It provides the required electrical and thermal energy to the K² 500 core system. To secure continuous operation when the BHKW unit is down, there has to be a separate power feed installation (300 kW / 400 V) to be provided by the customer. Without preparation, BHKW and storage tanks the floor space dimensions of the K² 500 core unit are app. 15 x 12 m. The height is app. 13.5 m. Its modular design allows quick and safe erection. The base-modules will be connected to a foundation specified by Alphakat.
2. PREPARATION
All preparation technology needed depends on the attributes of input materials delivered. Before putting the materials into the K² 500, all metals, stones, ceramics, and glass have to be separated. The maximum grain size of the remaining input is 3mm. The maximum humidity is 15%. Using oils as input material, the preparation consists of systems to unload and store the liquids as well as some pumping equipment to feed the K² 500 core unit. According to statutory provisions, safety installations such as oil retention pans and oil separators have to be added. When working with bitumen, there must be installations adapted to its attributes for the unloading and storage of this input material. A High-Sheer-Mixer assures controlled crushing of the bitumen. The material crushed is stored in a heated tank and fed by special pumps to the K² 500 core unit. Car fluff is not really defined and shows very different compositions. Next to an appropriate system to unload and store the input material there is a system to secure separation of metals. Following the material flow a first cutting-mill using a wider perforated screen is arranged. After passing a production buffer a second cutting-mill assures the minimum grain size. In case the humidity is > 15% the shredded material is dried in a rotary furnace. From another production buffer the K² 500 core unit is fed using e.g. a belt conveyor. Using rubber and plastics the preparation is very similar to the handling of car fluff. It has to be checked that metal separation may not be necessary. In general, cutting mills have to be provided with appropriate cartridges to ensure minimum changing time e.g. in case of maintenance or break. The application of Domestic-Waste makes great demands on preparation technologies. When smell nuisance is expected (applies also for car fluff, rubber and plastic), the equipment needed for unloading and storage has to be executed in an appropriate way. To separate the stone- and glass-fractions, a gravitation-counterflow-sizer or a floatation plant has to be installed, before separating metals in a second step. In a two step shredding process the material will first be treated in a mazerator and after a production buffer the minimum grain size will be secured by a cutting mill. In case the humidity is >15% the material is dried in a rotary furnace. From another production buffer the K² 500 is fed using e.g. a belt conveyor.
The equipment needed to unload and store Organic Sludge depends on humidity. After dehydration, the sludge will be dried in a rotary furnace that is installed prior to a production buffer. A belt conveyor secures the feedingof the K² 500. All preparation technique is controlled and monitored with sensors, measuring devices, and actuators. The control is fully automatic. Operators can follow the process in a central pulpit by cameras and are alarmed by visual and acoustic warnings in case of hazards. For safety reasons, mechanical as well as electrical control- and monitoring devices are installed. All Engineering and Construction of the preparation equipment match the actual technical regulations valid in the European Union. Safety features and equipment installed is state of the art.
3. PRODUCT STORAGE
The light oil produced in the K² 500 is stored in double-wall tanks. These are fit with safety features and equipment to prevent overflow and leakage. According to local requirements and statutory provisions e.g. oil retention pans and oil separators will be added. This is valid also for all road tanker filling systems.
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