The Thermal Decomposition Plant (TDP) is a set of equipment that provides processing by thermal destruction (decomposition into low molecular weight compounds without oxygen access) of automobile tires, plastic waste, acid sludge, oil sludge, active sludge (hereinafter – waste). Thermal processing of waste by the pyrolysis process allows to obtain valuable products:
- pyrolysis gas
- liquid pyrolysis fuel
- dry residue (carbon residue)
- Steel (from waste tires)
During the processing of waste, liquid and gaseous pyrolysis products are used directly in the technological cycle of the pyrolysis process. The TDP is controlled from the operator’s control panel and remotely through the Internet. To control the technological parameters of the TDP, the installation provides an automated process control system.
Acid sludge is one of the major wastes of the oil refining industry. It is formed during the purification of technological equipment and the regeneration of catalysts. They are highly toxic, viscous, resinous masses that contain heavy hydrocarbons, sulfuric acid, and water. Acid sludges belong to hazard class II. They are accumulated in special ponds, near large oil refineries.
Acid-sludge ponds are only for the temporary storage of hazardous waste, but it was delayed for decades. Their continued existence can lead to an environmental catastrophe, so the world is actively seeking effective solutions to neutralize acid sludge and restore disturbed lands.
Oil sludge is a hazardous substance polluting the environment due to its properties and scale of formation. This is a complex of substances, which consists of many ingredients, including toxic. Sludge is formed during the construction of oil and gas wells, transportation of oil, it's processing, during tank cleaning, treatment of wastewater containing oil, during equipment repair, etc.
The general environmental consequences of oil spills, sludge storage, and other things are:
- changes in soil properties and soil cover;
- pollution of surface and groundwater, bottom sediments;
- air pollution;
- changes in the chemical composition of plants and the transformation of plant cover;
- general landscape degradation.
Of the substances that make up the sludge, the most dangerous are oil and petroleum products, which include light fractions (most of which are methane hydrocarbons – alkanes), cyclic hydrocarbons, resins and asphaltenes, sulfur compounds. Resins and asphaltenes determine the physical properties and chemical activity of petroleum. Resins and asphaltenes contain carcinogenic polycyclic aromatic structures containing sulfur, oxygen, nitrogen, and trace elements.
All methods of processing sludge can be divided into non-destructive and destructive.
Non-destructive methods: – disposal, requiring careful dehydration, after which the costs of aerobic treatment are necessary from time to time;
Destructive methods: – incineration, which requires very large expenditure on gas-emission structures to prevent air pollution. The thermal sludge decontamination method is considered the most effective and cost-effective. Sludge treatment at high temperatures (up to 500 ° С), without oxygen access, which allows to completely neutralize the oil sludge and get commercial products at the exit ( oil, pyrolysis gas, mineral residue, which is used for road filling and construction, and is 4-5 hazardous class). This process provides by the Thermal Decomposition Plant model TDP-2. Thermal Decomposition Plant showed stable and positive results in operating companies.
The impact of drilling cuttings on the soil, flora, and fauna is the pollution of petroleum products. When soil is contaminated with oil products, there is a violation of the air regime and water properties of the soil. As a result of the impact on the soil cover with petroleum products, a change in the living microorganisms inhabiting the soil is observed: the number of cellulose decaying microorganisms and bacteria that assimilate nitrogen compounds decreases. Redox enzyme processes are inhibited, which ultimately reduces the biological activity and fertility of the soil.
In most cases, drill cuttings are alkaline, which contributes to the formation of readily soluble humates, which are washed out from the surface layer of the soil, reducing the total content of humus. The vegetation in areas contaminated with drilling cuttings dies completely. When the thickness of the sludge layer is 5–10 cm, the damage caused to the soil is comparable to a high degree of oil pollution.
PTG has proposed a continuous type TDP-2 Thermal Decomposition Plant, which reduces environmental damage from the deterioration and destruction of soil and land under the influence of anthropogenic (man-made) loads and produces products such as boiler fuel and pyrolysis gas, which are used to operate the installation itself. The dry residue is used for arranging fields and as an addition to building mixtures. Water is used to make new drilling mud. This technology allows the simplest drilling, which is not only cost-effective but also environmentally friendly.
Waste oil is technical oil, which has worked for a period of time or has lost the quality established in the regulatory and technical documentation and is drained from the working system. Liquid petroleum product or synthetic product.
Industrial rubber goods, used tires, rubber wastes formed before the vulcanization stage differ a little in properties from the original rubber compounds and can be returned to production without significant processing. This waste is a valuable raw material and is processed directly in those facilities where it is created.
Plastics are materials obtained on the basis of natural or synthetic polymers, capable of acquiring a given shape when heated under pressure and stably preserved after cooling. Such a product often obtained from municipal waste and is very potent to create derived by-products of very high quality.
Currently, most of the wastewater is processed by the method of biological treatment. As a result, a large amount of sludge is formed. The utilization of sludge is a very pressing problem. Their disposal at present is costly and involves environmental problems since the sludge residue from the treatment of urban wastewater contains pathogenic microflora, parasitic agents, painful viruses, E. coli, and Koch sticks, as well as foul-smelling substances. All this creates the threat of penetration into the soil, groundwater and surface water, toxic organic compounds, and heavy metal compounds.
All these problems are solved by the Thermal Decomposition Plant (TDP) since during pyrolysis thermal sterilization occurs and derived products are formed (gas, liquid fuel, and carbon residue). Gas and liquid fuels are used to operate the plant itself. Heavy metals, such as mercury and cadmium, are removed from the flue gas due to the provided flue gas filtration system. Carbon residue after heat treatment can be used as fertilizer.
Atakam Pyrolysis Technology Group (operating in Europe and Asia as "PTG Company") is a team of highly qualified specialists with at least 15 years’ experience in the area of thermal decomposition. The idea of creating an industrial pyrolysis group was developed in 2005. We have united a team of the best engineers from different countries and got the ability to create unique installations TDP-1 and TDP-2.
The main idea of the company is the creation and development of new installations, assistance in the creation of individual projects, consulting, and expertise of objects that need modernization and reconstruction.
Our specialists will help to create custom-made equipment and a set of drawings and will train specialists to work with the equipment. And of course, we will share our experience in creating a competitive process for the processing of hydrocarbons and organic waste.
We work with such types of raw materials as sludge, oily soil (oil send), spent drilling mud, rubber-technical products, plastic, active sludge. We have developed exclusive technologies for processing of electronic scrap, acid sludge, oversized tires without cutting. All equipment produced by the “Pyrolysis Technology Group” is provided with all documentation, EU certificates, personnel training, as well as warranty and post-warranty service.