We offer many technologies for all your waste management and resource recovery needs. The below information is technical overview of the base model ECOLUS SK System.
An Example Technology: The ECOLUS™ SK Pyrolysis Recycling Systems
The SK System is a system like no other in the industry and looks surprisingly low tech. It is composed of a dry distillation furnace, first and second stage coolers and a containment unit for overflowing gas. The system is very reasonable in size occupying approximately 3200 square feet. The complete system is modular, it can be fitted on three trailers and can be set up anywhere, thereby enabling recycling wherever the waste is being stored. The SK contains an oil processing system that produces quality diesel fuel, much like marine fuel, off road diesel and burner fuel.
There are 2 reactors and 6 silos (or cartridges) in each complete system. Each silo holds approximately 1 ton of rubber, plastic, vinyl or tires etc. Kouei Industries has tested and made silos up to the 10-ton level. Kouei has also developed the World's smallest pyrolysis machines ever built at the tiny size of 0.5 cubic meters. The ECOLUS™ SK base model system can process approximately 16 tonnes of recyclables a day.
Once the machine is turned on, it takes 3 hours to complete the first cycle. The first ½ hour the SK uses kerosene to ignite the reactors and warm up. Only once in the SK’s life does it require start up fuel and once warmed up the machine then stops using kerosene and completes the rest of the process by using its own energy derived from the supply of oil from the recyclables it is melting down (with the exception of the electrical fans). This means that as long as the system stays turned on and stays operational, it requires very little external energy. The ECOLUS technology breaks materials at the molecular level, making it the perfect process for destroying pathogens. This process changes the whole industrial equation.
Outside water is used in the cooling system of the centrifugal separator and condensing towers as a cooling agent. The outside water (water not derived from this process) has no direct chemical contact to anything that takes place within this patented system. During this process, water is circulated in and out of its own storage facility acting like a large radiator. Temperature must remain constant in order to get the best quality products. Experimentation revealed that different waste streams require different cooking and coking times and yield different finished products. The oil-to-mineral ratios vary also; plastics, for example, yield large amounts of oil, while tires yield more minerals and other solids. The only feedstock the SK process cannot process is nuclear waste and metals. If it contains petroleum and organics, the ECOLUS™ can do it.
Once the waste materials are heated and partially broken down inside the silo, phase two begins. Next. In vertical distillation columns, hot vapor flows up, condenses, and flows out from different levels: gases from the top of the column, light oils from the upper middle, heavier oils from the middle, water from the lower middle. Once this process is finished the carbon black and steel wires are all that remain inside the cartridge. Essentially dehydrated tires are all that remain inside the cartridge. The recovered remaining oil is sent to storage. Depending on the configuration of the system (with or without activation) the carbon and steel products are removed from the silo and are magnetically separated from each other. The steel wires are washed in a closed loop system to further remove carbon. The carbon leaves the magnetic separator and is conveyed to a sealed tank and then into a storage silo via a screw conveyor.
The heat and low pressure reaction strips off carboxyl groups (a carbon atom, two oxygen atoms, and a hydrogen atom) and breaks the remaining hydrocarbon chains into smaller fragments, yielding JIS Grade A oil. This oil can be used as is, or further distilled (using a larger version of the bench-top distiller) into lighter fuels such as naphtha, gasoline, and kerosene. Environmentally, this machine produces no uncontrollable emissions and produces no secondary hazardous waste streams. This system can be married to other technologies to produce energy thus making the SK system perfect for off-grid operations.
The SK uses an internal low pressure system to rapidly depressurize and release about 90 percent of the free water. Dehydration via depressurization is far cheaper in terms of energy consumed than heating and boiling off the water, particularly because no heat is wasted. Any and all gases such as chlorides and hydrogen are separated from benzene, propane, ethane, and propylene. These gases are then processed in the patented Platinum Deodorizer Apparatus. With respect to the break down of PVC and the chlorine gas that is generated, we use a chlorine gas remover which operates much like a scrubber and neutralizes the chlorine gas rendering it harmless by turning it into salt. The channel to the deodorizer is also oxygen-free (no carbon monoxide) and thus no oxidization takes place. Under these conditions, separated gaseous vapors of chlorides and hydrogen are instantly burnt out in a chamber of the deodorizer at a temperature higher than 800 degrees Celsius. As complete oxidation takes place in the chamber, no carbon monoxide is produced, nor are there any burnt ashes to act as a catalyst for the formation of dioxins.
Our Technology Advantages:
Unlike other recycling systems in use today, our pyrolysis recycling systems do not involve any preprocessing of feedstock. We produce high quality carbon and oil at a lower cost than any other recycling system. Almost all of the ECOLUS™ lines are fully self-sustaining and are themselves recyclable. Our system can be made from recycled materials that are so cost effective that they not only undercut the cost of existing recycling machines, but also cut the costs of municipal waste management all together. The ECOLUS systems are designed to be not only environmental friendly but also extremely profitable. The closed-loop ECOLUS™ systems are modular and can be scaled to fit both small and large-scale applications with complete plant construction assembled in less than 6 months.
The ECOLUS™ SK Dry Distillation Pyrolysis process is the only technology of its kind to operate purely on the fuel oil produced by the system as it does not utilize the syn-gas to fire the pyrolysis process. Our unique design makes the ECOLUS™ technology the safest and most stable technology available. Other systems are inefficient, energy hungry and produce low grade by-products. Traditional pyrolysis systems and competitors of the ECOLUS™ SK system employ dangerous chemical component separation. Kouei designed the ECOLUS™ system with people and the environment in mind. Safety first! The SK`s technology is based on chemistry, not alchemy, which turns waste materials into a variety of useful products. The SK system is extremely energy efficient and generates its own energy. The system uses streams naturally generated by feedstock, thereby recapturing the expended energy. The SK has a life expectancy of over 15 years meaning it can process over 90,000 tons in its life time.
All our systems represent a pro-environment alternative to traditional methods of processing waste. The Company’s patented technology is internationally proven, and exceeds the most stringent environmental standards in place in Canada, U.S.A. (California included) and the Ministry of Environment in Japan.
Over 20 years of research and development has been conducted to produce a solution that exceeds any pyrolysis recycling technology currently available from other Pyrolysis vendors.