Plasma Special Waste Treatment Tetronics Star Power Italia

Plasma Special Waste Treatment Tetronics / Star. Power Italia experience Technology for a cleaner environment © Star. Power Italia - 2005

Overview • Who we are MMG/CDC • The Markets CDC • Environmental Drivers CDC • Tetronics Environmental Plasma System (TEPS) CDC • Cost Analysis MMG • Waste Management in the production cycle MMG • Conclusion MMG © Star. Power Italia - 2005

Starpower Italia s. r. l. - who we are • Star. Power Italia s. r. l. is a limited liability company actively engaged in promoting and marketing innovative waste management technology in Italy since 2002. • Star. Power Italia is the Tetronics ltd agent in Italy. © Star. Power Italia - 2005

Tetronics Limited – who we are • World Leader in thermal plasma applications • >30 years experience • Proven, established technology • International and credible customer base • 33 environmental solutions engineered to date (upto 35, 000 tonnes per year, 9 MW) • Key Environmental Sectors • • Inorganic waste treatment (Haz waste) • Organic waste treatment (Haz + Non Haz) Advanced Rand D facilities >1 MW Power, 6 operating stations Commercial operations and plant supply © Star. Power Italia - 2005

Tetronics: The Markets 1 • Clean Heat • Market leader in heating of steel in continuous casting process, • • • 25 systems predominantly in the far East Customers include Posco, NSC, NKK, Sumitomo, Kobe Advanced Materials • • Prime opportunity is in the synthesis of powders Strategic alliance with Qineti. Q for nanotechnology • • Most advanced processing facility in UK for thermal production of nanopowders Opportunities in micron powders and glass melting © Star. Power Italia - 2005

Tetronics: The Markets 2 • Environmental Market • Inorganic wastes • Extensive commercial experience: • • Recovery of precious metals from autocats (US, South Korea) • Treatment of steel plant dusts (Italy, US) • Vitrification of incinerator ashes (Japan) Organic wastes • Major opportunity in treatment of hazardous organic and mixed wastes • Oily sludges and solvents • Food, meat and other agro-wastes • Clinical and pharmaceutical wastes • LLRW © Star. Power Italia - 2005

Environmental Drivers: Hazardous Wastes ENVIRONMENTAL FACTORS PLASMA TREATMENT OF WASTES -More severe regulations -Landfill of certain wastes restricted ENVIRONMENTAL BENEFITS -Avoidance of leaching of toxins - Efficient destruction of organics -Prevention of dioxins and toxic gases - Vitrification of wastes POLITICAL FACTORS -Targets for reduction in landfill -Recycling/utilization -Energy recovery -Sustainable, clean solutions -Support of clean technologies - Meets most severe standards - Non-toxic slag ECONOMIC & SOCIAL BENEFITS - Revenues from electrical generation - Cost savings from avoidance of landfill - Saleable by-product TECHNICAL BENEFITS ECONOMIC AND SOCIAL - High energy efficiency -Limited landfill and landfill tax - Robust, reliable, simple and flexible -Increased cost of disposal - Easy to automate -Tax incentive schemes - Proven in wide range of applications -Recovery of energy by CHP - Clean -Poor perception of incineration © Star. Power Italia - 2005

TEPS: Solution to Hazardous wastes • Strong regulatory and economic drivers • Clean process solution • Robust and proven DC Plasma arc technology • Simple to operate and maintain • High destruction efficiency of persistent organics • Stable vitrified slag, with good utilization potential • Minimisation of waste by-products • Recycling of valuable metals • Economic • Strong position within the waste management hierarchy © Star. Power Italia - 2005

TEPS: Typical Plasma Reactor Furnace Off Gas Combustible Gases and Volatile Species PLASMA ZONE > 10, 000 K High Temperature Destruction of Organics High Intensity UV Catalysis of Photo-Chemical Reaction Metallic Phase Recovery of Metal Value Environmentally Stable Slag Repository for Heavy Metals © Star. Power Italia - 2005

TEPS: Inorganic / Organic Haz Waste Treatment ORGANIC (gasification) INORGANIC (vitrification/smelting) Raw material > 5% carbon. Furnace off gas has calorific value (CO and H 2) Raw material < 5% carbon. Furnace off gas has no significant calorific value Air, water or oxygen added to furnace No oxidant added to furnace LLRW, contaminated meat, oil sludges, solvents, POPS, clinical, Metallurgical residues, contaminated soils, incinerator ashes, asbestos © Star. Power Italia - 2005

TEPS: Process Mechanism INPUTS OUTPUTS FEED GAS CO, H 2, CO 2, H 2 O, HCL, Zn, Pb, Hg etc Cn. Hm …. . Me. O, Me, O, S, Cl, P etc SLAG OXIDANT Me. O (e. g. Si. O 2, Ca. O, Al 2 O 3, P 2 O 5, Cr 2 O 3, Fe. O etc) H 2 O, O 2, Air METAL PYROLYSIS Me (Fe, Cu, etc) FEATURES • High destruction efficiency Cn Hm + O 2 ® n. CO + m. H 2 • High UV and temperature C + H 2 O ® CO + H 2 • Metal recovery 1 C + O 2 ® CO 2 GASIFICATION • Non leachable slag © Star. Power Italia - 2005

TEPS: Key Stages PLASMA POWER OXIDANT (AIR, WATER) SECONDARY OXIDATION, COMBUSTION HEAT RECOVERY GAS CLEANING PROCESS PREHEATING PLASMA WASTE MATERIALS HOT WATER / STEAM CONVERTOR ELECTRICITY GENERATION FLUXES SLAG PRODUCT METAL PRODUCT SECONDARY USES, RECYCLING, SAFE DISPOSAL Organic waste only © Star. Power Italia - 2005

TEPS: Process Flow Sheet © Star. Power Italia - 2005

TEPS: Layout of a Plasma Waste Treatment Plant GAS DISCHARGE FEED RECEIVER GAS CLEANING SHREDDER THERMAL OXIDISER PRODUCT DELIVERY PLASMA REACTOR © Star. Power Italia - 2005

TEPS Product Utilization Cycle STEAM/ ELECTRICAL CHP WASTE PLASMA MATERIAL TREATMENT Export of electricity PLANT Production of chemicals, hydrogen Vitrified Product © Star. Power Italia - 2005

TEPS: Typical composition and impurities of Syn-gas quality Syn-gas Pollutants Gas Species Volume % Pollutant mg/Nm 3 H 2 20 -40 SOx <10 CO 20 -30 HCl <5 CO 2 <5 CO <20 N 2 <20 NOx <20 Cn Hm <1 Heavy Metals <1 © Star. Power Italia - 2005

TEPS: Plasma Destruction of Dioxins PRIMARY ASH ~ 50 ng TEQ/g Plasma Convertor SLAG<0. 001 ng TEQ/g GAS EMMISSION < 0. 05 ng TEQ/M 3 Gas Handling SECONDARY FLY ASH <0. 005 ng TEQ/g © Star. Power Italia - 2005

TEPS: Leachate Test results (steel dust) © Star. Power Italia - 2005

Cost Analysis • • • Tetronics can provide custom-made solutions optimized to address specific waste problems Capital costs are dependant on the type and quantity of waste to be treated When the waste chemical composition is known Star. Power Italia can employ its financial analysis model to forecast costs of disposal and Return of Investment rates © Star. Power Italia - 2005

Cost Analysis • Case study – 50 tpd plant / pharmaceutical waste / 348 dx 24 h / tipping fee 0. 41 €/kg • • • 1. 6 Mw. H torch 0. 09 €/k. Wh power costs Labour rates per year: • Plant Manager • Shift Supervisor • System Operator • Assistant x 3 • Other (secretary) 88, 000 euro 26, 000 euro 23, 000 euro © Star. Power Italia - 2005

Cost Analysis • Break even point for plant in operation after 9 months from start of project without considering revenues from system by-products © Star. Power Italia - 2005

Cost Analysis © Star. Power Italia - 2005

Waste Management in the Production Cycle • • • The TEPSTM can be easily integrated into companies existing production cycle to treat their waste streams Reduce waste management costs in the balance sheet Generates by-products and energy that could be fed in the production cycle Guarantees the compliance with all current and future environmental regulations Produce valuable products from “GARBAGE” © Star. Power Italia - 2005

Conclusion • TEPSTM is as an effective and versatile solution for the treatment of hazardous waste streams • The products arising are readily recycled, reused or disposed of in a safe manner • The slag products are stable and non-leachable • Potential savings by diverting vitrified slag product away from landfill • Technical risk minimised by industrial track record • Economic risk stabilised against future regulatory drivers © Star. Power Italia - 2005

For more information: Star. Power Italia s. r. l. www. star-power. it Tetronics Ltd: www. tetronics. com © Star. Power Italia - 2005