SEMINAR REPORT ON

PLASMA TORCH TECHNOLOGY FOR WASTE

MANAGEMENT
2019-2020

Done by
MOHAMMED SHAMSEER E

(17012179)

Submitted to

DEPARTMENT OF CIVIL ENGINEERING

MALABAR POLYTECHNIC COLLEGE

Kottakkal, Kerala,
676553
 SEMINAR REPORT ON
PLASMA TORCH TECHNOLOGY FOR WASTE
MANAGEMENT
2019-2020

Submitted to

DEPARTMENT OF CIVIL ENGINEERING

MALABAR POLYTECHNIC COLLEGE

Kottakkal, Kerala,
676553
 DEPARTMENT OF CIVIL ENGINEERING
MALABAR POLYTECHNIC COLLEGE
MALAPPURAM, KERALA STATE, PIN 676 553

CERTIFICATE

This is to certify that this report is a bonafide record of the Seminar Report done
by MOHAMMED SHAMSEER E, Reg. No 17012179, during the academic
year in partial fulfilment of the requirement for the award of Diploma in Civil
Engineering from Malabar Polytechnic College, Kottakkal under the Board of
Technical Education.

Head of the Section Lecturer in Charge

Internal Examiner External Exam

 TABLE OF CONTENTS

TITLE PAGE NO.

Abstract i
Acknowledgement ii
List of Figures iii
List of Tables iv
1. Introduction 1
1.1. Plasma 2
1.2. Plasma gasification – A energy solution 2
1.3. Plasma gasification v/s Incineration 3
1.3.1.Fundamental differences 3
2. Important considerations and advantages of plasma gasification 5
2.1. Limitations and concerns about plasma technology 6
2.2. How plasma converters works? 6
2.2.1.Components of plasma converter 7
3. Plasma converter by products 12
4. Conclusion 15
5. References 16
 ABSTRACT

The use of plasma technology for chemical reactions in controlled atmosphere of both organic
and inorganic compounds is presented. The principle behind the plasma technology is also
being discussed. The difference between conventional incineration and plasma technology is
briefly discussed. The advantages of plasma technology over incineration are tremendously
environment friendly. The components and working of this system are also being looked into.
Plasma technology is the future technique of solid waste treatment.

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 ACKNOWLEDGEMENT

Firstly, I thank God ALMIGHTY for blessing me in completing this report.

I take this opportunity to express our deep sense of gratitude and respect towards my
guide Miss.Neethu K.P, Department of Civil Engineering,MPTC, Kottakkal. I am very
indebted to her for the generosity, expertise and guidance; I have received from her while
collecting data on this seminar and throughout our studies. Without her support and timely
guidance, the completion of my seminar would not have been possible. She has guided me not
only with the subject matter, but also taught us the proper style and technique of working and
presentation.
It is great pleasure for me to express my gratitude towards those who are involved in
the completion of my seminar report. I whole heartedly thank to our Head Of Department,
Mr.Usman.M.K, for his guidance.
I would like to take this opportunity to thank all of my family members, teachers and
friends for their sincere cooperation and timely help.

MOHAMMED SHAMSEER.E

ii
 LIST OF FIGURES

Sl No. Figure No. Name Page No.

i. 2.2.1 Conveyer Systems 7

ii. 2.2.2 Furnaces 8

iii. 2.2.3 After Burner 9

iv. 2.2.4 Steam Turbine 10

v. 2.2.5 Emission Scrubbers 11

vi. 3.1 Air- cooled Slag 13

vii. 3.2 Rock-wool 13

iii
 LIST OF TABLES

Sl No. Table No. Name Page No.

i. 1.3.1 Differences between Plasma Gasification and 4

Incineration

iv
 CHAPTER 1
INTRODUCTION
Safe disposal of plastics waste is a serious concern all over the world. Plastic waste
management is done by reducing consumption, recycling, using bio-degradable plastics, land
filling, incineration, pyrolysis and energy recovery. Land filling is an important means of
managing the plastic waste. The requirement of large size land for land filling makes this
process costly.

Incineration is another technology that is currently used to destroy plastic, municipal and
hospital waste especially biomedical waste and hazardous chemical waste by reducing volume
and destroying some harmful constituents. Incineration utilizes combustion to reduce waste
materials to non-combustible residue or ash and exhaust gases. Modern incinerator has burner
(oil or gas fired), primary and secondary chambers, scrubber, cyclone separator, bag filter and
induced draft fan. However, the demand for excess air-flow limits the temperature that is
required in incineration. Due to insufficient temperature generated in the process chamber,
incinerator produces extremely toxic products like furans and dioxins. Chlorinated dioxins and
furans cause air pollution and dreaded disease like cancer, abnormalities etc. The toxic
pollutants can remain in the bottom ash of incinerators, eventually finding their way into
landfills. Incineration technique is facing much criticism in recent days because of the
formation of toxic compounds.

In early 1990’s, plasma pyrolysis emerged as a technology in the world, which provides
a complete solution to destroy medical and other hazardous waste safely. The intense and
versatile heat generation capabilities of plasma torches used in this technique enable it to
dispose all type of waste including polymer waste, municipal solid waste, medical waste and
hazardous waste in a safe and reliable manner. The technology has demonstrated that the
quantity of

extremely toxic compounds such as dioxins and furans in the emission were far below the
accepted limit. This technology is superior to traditional technologies like land filling,
incineration, combustion etc due to its cost effectiveness, high temperatures & complete
destruction of hazardous wastes. Plasma technology is an eco-friendly technique which
converts organic waste into commercially useful by-products.

1
1.1 PLASMA

Plasma is an ionized gas; in other words, it's a gas with free-roaming electrons that
carries a current and generates a magnetic field. It is the fourth state of matter. On Earth, we
can see natural displays of plasma fields in lightning. The temperatures generated by a plasma
torch can be hotter than the surface of the sun (more than 6,000 degrees Celsius).

1.2 PLASMA GASIFICATION - A CLEAN ENERGY SOLUTION

Plasma Gasification Process (PGP) is a thermal process that involves the application of
intense heat to waste materials in a completely closed, controlled, and oxygen-starved
environment. This process converts waste materials into a clean synthetic gas and heat that can
be used to generate electricity. It provides a clean & safe disposal of Municipal Solid Waste,
Hazardous waste, and eliminates the need of landfills, while making clean, green electricity
and energy.

Plasma Gasification is the solution to a number of problems, which include municipal

solid waste, hazardous waste, and the need for renewable, need for landfills – and their
problems by converting the free fuel that would have been placed in the landfill, in the form of
municipal solid waste, and hazardous waste. The plasma gasification plant converts
carbonaceous (carbon containing) materials such as municipal solid waste and even hazardous
waste such as bio-waste from hospitals, into two useful and beneficial by products.

i. An energy-rich fuel called synthetic gas, which is used to generate green electricity
from a sustainable and renewable resource.
ii. A commercially useful, inert solid, referred to as slag. The slag can be used for road
aggregate and building materials.

2
1.3 PLASMA GASIFICATION V/S INCINERATION

1.3.1 FUNDAMENTAL DIFFERENCES

There is a perception in some quarters that plasma gasification is essentially

incineration, since in both incineration and plasma gasification, wastes are reduced to much
smaller volumes, But whereas incineration is focused on reduction of waste to ash, gasification
involves conversion of waste to synthetic gas and inert slag with recovery of energy and
valuable metals. In its purest form, incineration involves burning of organics in the
presence of excess oxygen converting them to heat, particulates, and a variety of combustion
gases, with all of these vented to the atmosphere. Modern incinerators seek to achieve complete
combustion employing temperatures in the 1,000 to 2,000ºF range, to capture heat generated,
and to manage emissions through pollution controls.

Ash is generally land filled , with the content of ash often requiring treatment as
hazardous waste. Fundamentally different from incineration are a number of thermal
conversion (sometimes referred to as thermal-chemical conversion) technologies. All of these
processes employ high temperatures (1,200-2,800ºF) in combination with little or no oxygen
to decompose wastes. The lack of oxygen in waste decomposition prohibits combustion and
clearly separates these technologies from incineration. Many thermal conversion processes are
designed to achieve maximum gasification of wastes for subsequent use as fuel or recoverable
heat/power generation, while some often referred to as pyrolysis systems are designed for
incomplete gasification for the purpose of obtaining a variety of gaseous, liquid, and solid
products, including fuels, metals, and chemicals.

One form of thermal decomposition is plasma gasification. Plasma gasification

employs extreme temperatures (7,200-12,600ºF) in the absence or near-absence of oxygen,
with organics and other materials dissociated into constituent chemical elements that are then
either collected (in the case of valuable metals), vitrified to produce an inert glass-like slag, or
reformed into synthetic gas that can be used as an industrial feedstock or converted to energy.
Burning does not occur in a plasma gasification unit, and so as with other thermal conversion
processes, gasification is completely different than incineration (Table 1.3.1).

3
 Differences between Plasma Gasification and Incineration

Plasma Gasification Incineration

Occurs in the absence or near absence of oxygen, Excess air is induced to ensure complete
prohibiting combustion. combustion.

Gases resulting from degradation of organics are

collected and used for production of various All potential energy converted to heat.
forms of energy and/or industrial

Products of degradation largely converted to inert Combustion results in ash (as much as
(non-hazardous) glass-like slag of a volume 6% 30% of original solids volume) that must
to 15% of the original solids volume. often be treated as hazardous waste.

Emissions substantially lower than those Far greater emissions of GHG and other
resulting from incineration. pollutants than with thermal gasification
systems.

Table 1.3.1

4
 CHAPTER 2

IMPORTANT CONSIDERATIONS AND ADVANTAGES OF PLASMA

GASIFICATION

i. Plasma Gasification provides for a sustainable waste solution for all types of waste
streams, including municipal solid waste (M.S.W), hazardous wastes, and even
radioactive waste, which delivers tangible economic and environmental benefits.
ii. Plasma Gasification does not produce hazardous bottom ash and fly ash.
iii. Plasma Gasification is fuelled by the free waste, and is powered by electricity, and
can be turned off with the flip of a switch.
iv. Plasma Gasification unit does not need to be brought up to temperature over 24/36
hours burning expensive fuel oil as does mass burn incinerator.
v. Plasma Gasification systems require very little maintenance and unlike traditional
power plants, do not need to be shut down for weeks at a time for cleaning and
maintenance while waste-streams back-up.

Plasma Gasification is able to get the energy it needs from waste-streams such as municipal
solid waste (M.S.W) and even hazardous and toxic wastes, without the need to bury these
wastes in a landfill. There are two methods used in plasma gasification - the first one is a plasma
arc and second is called a plasma torch.

In Plasma-torch systems, an arc is struck between a copper electrode and either a bath of
molten slag or another electrode of opposite polarity.As with plasma arc systems, plasma torch
systems have very high destruction efficiency; they are very robust; and they can treat any
waste or medium with minimal or no pre-treatment. The inorganic portion of the waste is
retained in a stable, leach-resistant slag. The air pollution control system is larger than for the
plasma arc system, due to the need to stabilize torch gas.

5
2.1 LIMITATIONS AND CONCERNS ABOUT PLASMA TORCH TECHNOLOGY

Concerns have been raised regarding the reliability of Plasma-torch technology as the water
cooled, copper; plasma torch must be replaced periodically to prevent burn-through at the
attachment point of the arc and a subsequent steam explosion due to rapid heating of the
released cooling water.

2.2 HOW PLASMA CONVERTERS WORK?

At the most basic level, a plasma waste converter is a plasma torch applied to garbage.
A plasma torch uses a gas and powerful electrodes to create plasma, sometimes called the fourth
state of matter. Plasma is an ionized gas; in other words, it's a gas with free-roaming electrons
that carries a current and generates a magnetic field. On Earth, we can see natural displays of
plasma fields in lightning. The temperatures generated by a plasma torch can be hotter than the
surface of the sun (more than 6,000 degrees Celsius).

At these temperatures, garbage doesn't stand a chance. Molecules break down in a

process called molecular dissociation. When molecules are exposed to intense energy (like the
heat generated by a plasma torch), the molecular bonds holding them together become excited
and break apart, leaving elemental components of the molecules. With cyanide, for example,
you'll end up with atoms of carbon and nitrogen.

Organic molecules (those that are carbon-based) become volatilized, or turn into gases.
This synthetic gas (syngas) can be used as a fuel source if properly cleaned. Inorganic
compounds melt down and become vitrified, or converted into a hard, glassy substance similar
in appearance and weight to obsidian. Metals melt down as well, combining with the rest of
the inorganic matter (called slag).

Unlike incinerators, which use combustion to break down garbage, there is no burning,
or oxidation, in this process. The heat from plasma converters causes pyrolysis, a process in
which organic matter breaks down and decomposes. Plasma torches can operate in airtight
vessels.Combustion requires oxidization, pyrolysis does not.

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 Plasma waste converters can treat almost any kind of waste, including some
traditionally difficult waste materials. It can treat medical waste or chemically-contaminated
waste and leave nothing but gases and slag. Because it breaks down these dangerous wastes
into their basic elements, they can be disposed of safely. The only waste that a plasma converter
can't break down is heavy radioactive material, such as the rods used in a nuclear reactor. If
you put such material in a plasma furnace, it would probably catch on fire or even explode.

2.2.1 COMPONENTS OF A PLASMA COVERTER

i. Conveyor system

In order to feed garbage into the converter, almost all plasma facilities have a conveyor
system. Garbage is loaded on the conveyor and is pushed into the furnace (or pre-treatment
system if the plasma facility uses one) by a plunger (figure 2.2.1).

Fig: 2.2.1 Conveyor Systems

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 ii. Pre-treatment mechanism

Although a plasma torch can break down waste without any special pre-treatment, most
plasma facilities employ some sort of pre-treatment process to make the entire system more
efficient. Some designs use grinders or crushers to reduce the size of the individual pieces of
garbage before moving in to the furnace. The plasma torch can break down the smaller pieces
faster.

iii. Furnaces
Here's where the magic happens. Furnaces have an airlock system to allow garbage to
come in while preventing the hot gases in the furnace from escaping into the atmosphere. The
furnace houses at least one plasma torch; many furnaces have multiple torches to break down
all the matter. These torches are usually placed a little lower than halfway down the furnace.
The furnace also features a drainage system to tap off the slag as it accumulates and a vent
system to vent out the gases. In order to withstand the intense heat, furnaces are lined with
refractory material and often have a water-cooling system as well (figure 2.2.2)

Fig: 2.2.2 Furnaces

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iv. Plasma torch

The Plasma torches used in these facilities is custom-built. The amount of energy they
consume, the lifespan of the electrodes it uses, the gas used for ionization (most torches just
use ordinary air),the downtime it takes to replace an offline torch and the size of the plasma
field it generates all depend on the specific manufacturer. Plasma torches are water-cooled.

Molten slag pools at the bottom of the furnace and helps maintain the high
temperature inside the gasification chamber. Occasionally slag must be drained from the
furnace. Some furnaces have drains positioned at a certain height, others use a tap system.
Either way, slag drains away from the furnace and cools in a separate chamber.

v. Gas ventilation

The Furnace also has a vent system to allow gasified components to pass into another
part of the system (either an afterburner or a gas cleaning chamber).

vi. Afterburner
Gases can pass through a secondary chamber (figure 2.2.3) where natural gas flames
combust any remaining organic material in the gases. These extremely hot gases then pass
through a Heat Recovery Steam Generator (HRSG) system, where they heat water to form
steam. This steam then turns a steam turbine (figure 2.2.4) to create electricity.

Fig: 2.2.3 After Burner

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 Fig: 2.2.4 Steam turbine

vii. Syngas cleaning

Alternatively, the gases from the furnace enter a chamber where they are cooled and
scrubbed, usually by water. The gases pass through a spray of water, which scrubs the gases of
pollutants and particulates. A filter system containing a base filter neutralizes acid gases. The
acids in the gases and the bases in the filter combine to form inert salts. The cooled and clean
gases continue through the system, which in most cases involves a gas turbine connected to an
electricity generator. Some systems also harness the heat from these gases to generate steam,
similar to the afterburner method mentioned above.

If the plant uses an afterburner, the remaining gases must be cleaned thoroughly to get
rid of any hazardous material. Many designs include a dry scrubber system (figure 2.2.5).

10
 In this system, powdered carbon is injected into the gases to strip away mercury, a
poisonous element. Gases also pass through a fabric or bag filter to remove any other dangerous
particulates, like lead. Once the gases have been cleaned they are moved to the stack from
where they are released into the atmosphere.

Fig: 2.2.5 Emission scrubbers

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 CHAPTER 3

PLASMA CONVERTER BYPRODUCTS

There are three main by products that are a result of the plasma gasification process:
synthetic gas (syngas), slag and heat. Syngas is a mixture

of several gases but mainly comprises hydrogen and carbon monoxide. It can be used as a fuel
source, and some plants use it to both provide power for the plant and sell excess electricity to
the power grid. Garbage contains a great deal of potential energy; the gasification process
enables engineers to convert the potential energy into electrical energy.

Gas generated by a plasma converter depends on what you put into the furnace. If the
garbage contains a lot of carbon-based material (in other words, organic waste), then you'll get
more gas. Waste with a lot of inorganic material won't yield as much gas. Because of this, some
plasma facilities sort through garbage before feeding it into the system. The solid byproduct
from the gasification process is called slag. The weight and volume of the original waste
material is dramatically reduced. According to Dr.Circeo of Georgia Tech's Plasma
Department:

i. The weight of the slag is about 20 percent of the weight of the original waste
ii. The volume of the slag is about 5 percent that of the original waste's volume

The slag can take different forms depending on how you cool it. If slag is Air-cooled (Fig:
3.1), it forms black, glassy rocks that look and feel like obsidian, which can be used in concrete
or asphalt. Molten slag can be funnelled into brick or paving stone moulds and then air cool
into ready-to-use construction material.

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 Fig: 3.1 Air-cooled slag

If you were to blow compressed air through a stream of this molten material, you'd end
up with Rock wool (Fig: 3.2). Rock wool has the appearance of grey cotton candy. It's light
and wispy, and according to Dr. Circeo, it has the potential to revolutionize the plasma waste
treatment industry. Rock wool is a very efficient insulation material, twice as effective as
fiberglass. It's also lighter than water, but is a very good absorbent. Because of this, it could
potentially be used to help contain and clean oil spills in the ocean. Clean up crews could spread
rock wool over and around an oil spill. The rock wool would float on the water while soaking
up the oil, making collection a relatively easy process.

Fig: 3.2 Rock-wool

13
 Hydroponics growing systems can also use rock wool; farmers can plant seeds in slabs or
blocks of it. Currently rock wool is produced by mining rocks, melting them down and then
streaming the molten material onto spinning machines.

The spinning machines fling strands of molten material in the air. Today, the price of rock
wool is over a dollar a pound. Since rock wool would be a by-product of the plasma gasification
process, it could be sold for as little as 10 cents a pound. The price of insulation would decrease,
efficiencies in energy-saving techniques would increase and plasma gasification plants would
have another substantial source of income apart from selling electricity back to the grid.

Plasma technology experts, including Dr. Circeo, assert that the slag is virtually
unleachable, meaning that any hazardous materials are inert and will not dissolve out of the
slag. The heat created by plasma facilities is considerable, measured in thousands of degrees
Centigrade. Heat from the molten slag helps maintain the temperature within the furnace. Some
of the heat from gases can be used to convert water into steam, which in turn can turn steam
turbines to generate electricity. Waste treatment through gasification is unique in that it not
only gets rid of garbage and generates electricity; it also produces by products that are valuable
commodities themselves.

14
 CONCLUSION

Plasma technology which converts the non-recyclable and combustible portion of the waste
to electricity, reduces the amount of materials sent to landfills, prevents air/water
contamination, improves recycling rates and lessens the dependence on fossil fuels for power
generation, it also eliminates the waste problems confronted by municipalities.

Plasma technology for the treatment of municipal solid waste has the potential to be more
flexible than incineration because it can be modular, cost-effective and it also ensures the
complete destruction of wastes at high temperatures. It takes very less time to dispose waste
materials. This technology can be utilized to run large scale waste treatment plants with less
running cost. This technology can bring prosperity to a country both by waste cleaning and by
generation of electricity.

By-product of this process has varying applications in civil engineering. Plasma technology is
indeed a green, clean, effective and efficient alternative to the conventional practices being
used in the treatment of municipal solid wastes.

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 REFERENCES

 Nema, S.K.; Ganeshprasad, K.S., ”Plasma Pyrolysis of Medical waste”, Current Science,
V.83, No:3, 10 Aug 2002, pp 1-8
 Venkatramani,N., “Industrial plasma torches and applications”, Current Science,Vol. 83,
No.3, 10 Aug 2002,pp 254-262
 M. J. Copsey, "Plasma Technology for the Destruction of Hazardous Wastes', Plasma for
Industry and Environment, BNCEconference, Oxford, 25-27 September, 1990, paper 6.1.
 J. ThCrnblom, B. Gustafsson and B. Johansson, "Industrial Plasma Applications”,
Workshop on Industrial Plasma Applications, ISPC-9, Pugnochiuso, Italy, September 48, 1989.
 B. Johansson and U. Ufgren, "Operation of the Scandust Plant on Stainless Steel Dust”,
Plasma for Industry and Environment, BNCE-conference, Oxford, 25-27 September, 1990,
paper 2.5.

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