Update on Refinery Sludge and Petrochemical Waste Project and Syngas Utilization

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As mentioned earlier in this blog, PEAT advancing a project for a client in China to treat refinery sludge and petrochemical waste. The system construction is finished and the system is currently en route to China. This plasma gasification system is expected to be commissioned during the later part of July.

Unlike incineration, where combustion gases are treated at atmospheric pressure, the volume of syngas that is generated in a plasma gasification system is significantly reduced. The smaller flue gas volumes also bring benefits in terms of the scale of downstream air pollution control equipment.

Here is a representative syngas composition, composition and heat value for processing 500 lbs/hr of petroleum sludge and fluxing agents with the following chemical composition (Carbon: 30.85%, Hydrogen: 3.18%, Chlorine: 0.65%, Oxygen: 0.41%, Sulfur 0.31%, water 23.82%, metals 0.17%, inorganics 40.54%) in a plasma thermal destruction and recovery system.

Upstream of APC System Downstream of APC System
Element Nm3/HR SCF/HR % VOL in Nm3/Hr in SCF/Hr % VOL
CO 110.204 3,889.091 34.281% 110.139 3,886.807 30.247%
CO2 17.864 630.432 5.557% 17.854 630.062 4.903%
H2 146.153 5,157.741 45.464% 146.067 5,154.712 40.114%
N2 39.756 1,402.973 12.367% 55.817 1,969.792 15.329%
H2S 0.485 17.123 0.151% 0.005 0.171 0.001%
HCl 0.935 33.001 0.291% 0.009 0.330 0.003%
Particulates and Metal Oxides 6.062 213.944 1.886% 0.052 1.817 0.014%
H20 0.008 0.297 0.003% 34.191 1,206.616 9.390%
Total 321.468 11,344.603 100.000% 364.135 12,850.307 100.000%
Heat Value (kj/Nm3)
Heat Value (kj/Nm3) 8752.595138
Heat Value (Btu/SCF) 235.076746
Density of Syngas (kg/Nm3) 0.778
Note: APC system consisting of spray Dryer/Gas Quencher, Activated Carbon Injection, Baghouse Filter, Packed Bed Tower/Polishing Scrubber

The syngas generated from a plasma gasification system could be converted into a variety of different fuels such as ethanol, natural gas (methane) and hydrogen or can be used to generate electricity directly similar to gasification. Some companies are trialing systems for upgrading syngas from their plasma gasification processes to be used as a chemical feedstock for products such as hydrogen recovery. However, the commercial status of such projects indicates that these are still in the development stage.

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