THERMO CATALYTIC

CONVERTER PLANTS
TCC-4000 GII

INTRODUCTION OF THE COMPANY

FUKON Aktiengesellschaft, established in Liechtenstein in 2007, has shifted ifs focus
over the past years and recently it operates as a venture capital enterprise, focusing on
investment opportunities in the renewable energy sector. These days, Fukon A.G.
addresses processing of waste and materials for recycling by using state of the art
industrial research and development elements in the technology it applies.
The company invests into waste utilization plants using patented waste management
solutions and know-how through its subsidiaries in Hungary and Poland.
An important recent milestone was the commissioning of a TCC-4000 GII Thermo
Catalytic Converter Plant (Generation II), producing oil from segregated plastic, rubber
or even carpet, as row materials. The pilot project was built in Fehrvrcsurg Hungary in 2012.

TECHNOLOGY DESCRIPTION
UTILIZATION OF PLASTIC AND RUBBER WASTE
Rubber and plastic materials are special parts of the
organic waste as these are practically nondestructible. Eliminating them by simple means or by
incineration is not a good solution, as the free
carbon particles (in the form of thick smoke) heavily
pollute the environment, together with the toxic
particulars sticking to these particles.
The production of rubber is based on the chemical technology called polymerization.

By reversing this process, with the simultaneous input of heat energy the large
molecules breakdown to smaller molecules.
The depolymerization process provided it is achieved by using heat energy is called
thermo catalytic transformation as long as the reaction sphere is sealed airtight.

FUKON AKTIENGESELLSCHAFT

Part of the plastic waste might be recycled by

traditional methods, but there are some plastics,
due to production or other reasons (polluted, etc.)
which cannot be recycled. In case of those
plastics which cannot be recycled, the reversed
polymerization technology can be also used as
these are oil by-products as well.
Our technology is based on thermo catalytic
depolymerization.
The essence of the process is - see 1 illustration that the slowly decomposing organic
wastes (rubber, plastic)are shredded to 20-25 mm pieces, then delivered by a screwdriven device into an oxygen free, heated, airtight sealed reactor, where the waste is
transformed to hydrocarbon-steam and gas-phase. At the end of the procedure a slag
by-product is separated.
The produced carbon steam-phase is leaving the
equipment and enters a multiple condenser
system, where suitable liquid-phases are
formed(similar to the fractional distillation process,
but compared to the traditional distillation
procedure, operated under conditions which are
much more simple and economic).

1. OPERATION FLOW (CONTROL PANEL OF THE TCC-4000 GII)

The thermo catalytic system is designed as a block system meaning that it has modular
characteristics, i.e. smaller and larger capacity units may be constructed, step by step
capacity increase can be easily achieved in a modular way.

FUKON AKTIENGESELLSCHAFT

END-PRODUCT / PROCESS
Out of the process the following products are produced:

Product oil (liquid phase)

Characteristics:
Density: 0,8266 g/cm
Cetane index: 53
Sulphur content: 110 mg/kg
Kinetic viscosity: at 40 degree C. : 2,23 mm/s

Product-gas (gas phase)

Characteristics:
Heating value: 54 MJ/Nm3

FUKON AKTIENGESELLSCHAFT

Slag/Pyro-coke (soot)
Characteristics:
Heating value: 15-16 MJ/kg

Steel in case of tires

Stringy scrap metal

PROCESS FLOW OF THERMO CATALYTIC CONVERSION

Gas
buffer

Plastic/Rubberr

Reactor

Condensor and
oil-treating
cleaning system

Gas

Turbine
slag

Oil

Oil industry

FUKON AKTIENGESELLSCHAFT

Chemical
industry

ENERGY PRODUCED FROM OIL

The end-product of the technology may be utilized as follows: the produced byproducts of the product-oil may be sold, as there is a market demand for these, or the
oil produced may also be used by high capacity, low revolution diesel engines to
produce electricity. In case of the latter method, the emission of the waste gases are
filtered to prevent any pollution to the environment.

OIL STORAGE

Beside the production of electricity, there is a

possibility provided there is a demand for it of
thermal energy heating. The heat of the thermal
energy is ~90/70 Degree Celsius. This can be used
in heating systems or in such heating system
technologies, which are capable to be operated by
this heat energy. From the emission of the motors
waste gas of the internal combustion at 6 bars
pressure, over-heated steam may also be
produced.

ENVIRONMENTAL PROTECTION ASPECTS

Taking into consideration the requirements of the most up-todate process technology for the described activity the
equipments deployed meet the most demanding technical
expectations. When designing this technology the main goal
was the low emission of waste materials and the high energy
efficiency.
The process is the final stage of a waste management system
where the collected, mixed, comingled and contaminated waste is transferred to
harmless stage, and the energy deriving from the waste is utilized.
When defining the emission limits of the polluting materials processed by the
technology, it turned out that the main characteristics were compounds of chlorine and
fluorine. Because of the low content of chlorine and fluorine of the treated feedstock
these are not typical for the waste-gas of the designed technology.
The water requirement of the technology is minimal, therefore there is no water outlet,
thus the surface and under-surface water are not effected. Noise pollution is minimal,
and by selecting the most suitable site, the noise effect can be limited to industrial
areas.
The thermo catalytic technology is a closed system. The processing units are designed
to provide the lowest emissions under normal circumstances. Under normal production
circumstances, the toxic emission of the technological line does not exceed the
internationally accepted and permitted limits.

FUKON AKTIENGESELLSCHAFT

ADVANTAGES OF TECHNOLOGY
External energy (propane-butane or natural
gas) is needed only until the reactor reaches
the operating temperature, afterwards it will
produce the necessary product-gas for
captive
use.
From
here
on
the
thermocatalytic system becomes
selffuelling, as the ful gas is produced by
processing of the waste materials.
The thermo catalytic technology and the
complex thermo catalytic electricity
producing block system has a small footprint,
RAW MATERIAL INPUT
and can be easily be located in an average
Regional Waste Processing Center, fitting into an optimum production structure.
The thermo catalytic system is automatically operated from the feeding till the final
outputs, off-time of production is minimized.
The process is controlled and monitored in each production phase by an adjustable
controlling unit that plans and controls the given heating data of each process step. The
automatic shut-down of the operating line is also controlled by a sophisticated safety
mechanism.

EACH PRODUCTS CAN BE UTILIZED

SALES OF PRODUCED ELECTRICITY
The main product of the thermo catalytic power station is electricity. The electricity may
be sold as follows:
o Open sales on the electric market
o Directly to consumers (i.e. to industrial plants, local municipalities)
o In regulated feed-in systems for alternative energy (like in the EU countries).

SALES OF OIL
An economic solution would be the use of the oil in internal combustion engines
generating green electricity. Supposing that this activity is subsidized the result would
be a quicker return of the cost of technology.
Provided that the produced oil of the thermo catalytic power plant is not fully utilized to
produce electric energy, the remains balance may also be sold. If the oil price level is
favorable, it is profitable to sell the oil to oil companies for further refining. N.B: A
distillation unit can also be added to the thermo catalytic process, ensuring a higher
quality distillate with higher added value.

FUKON AKTIENGESELLSCHAFT

SALES OF THE PRODUCT-GAS

The produced gas is primarily used for operating
the plant.
The produced gas may also be used by gas
operating generators to produce electricity which
is may also be sold.
The produced gas - after being treated according
to directives of various regulations may be
stored in tanks and later be utilized at a suitable
location.

GAS TURBINE

The produced gas after suitable filtering may be used as renewed energy - mainly for
operating public transport.

SALES OF PRODUCED THERMAL ENERGY

The produced thermal energy is suitable to provide heat to the nearby settlements using
district heating systems (therefore when choosing the site of the investment it can be a
decisive factor could be the distance to a city using district heating.)
The produced thermal energy is also suitable for cooling, therefore even in summer the
utilization of the thermal energy is solved. The thermal energy can be consumed in
cooling houses, near the power station.

SALES OF SLAG/PYRO-COKE
The heating value of pyro-coke is equal to the heating value of brown-coal.
The advantages of investing in a thermo catalytic power station.
The return of the invested capital is 6,5 7,5 years.
With the sales of thermal energy sub-projects and sales of by-products the ROI can be
less than 6 years.
Calculating the negative cost of land filling the ROI can be less than 4 years.

FUKON AKTIENGESELLSCHAFT

DATASHEET OF THE TCC-4000 GII UNIT

1.

GENERAL INFORMATION

1.1. Processable materials:

- Polyethylene (PE, HDPE, LDPE, LLDPE)

- Polypropylene (PP)
- Polystyrene (PS)
- Shredded rubber waste

Size of the processable material :10mmx10mmx10mm

1.2. NON-PROCESSABLE MATERIALS:

Types of plastics containing halogens are undesirable for use in this technology. The
system can only process max. 0-3% of the materials containing Fluorine, chlorine (PVC)
bromine. Basically, these types of materials can be mixed into the waste material at
random, this can be due to inaccurate selections. The contamination of raw materials.
Moisture is limited to max. 10% in value (by weight). Solid impurities can be in the
technology around 5% max. Entering of pollutants must be avoided, for example, paper
(not oily), metal waste (obstructs the feeding in), etc.. intake of radioactive substances is
strictly prohibited. Introduction of pollutants into the machine greatly reduces the
efficiency of the process. The purity of raw material thus determines the secure
operation of the equipment.

1.3. QUANTITY OF PROCESSABLE MATERIALS:

Optimal raw material input: 600kg / h ( 10%)

1.4. RESULTING PRODUCTS

Resulting products usually contain (depending on raw material input):
In case of plastic:

- 70-75% product oil

- 15-20% product gas
- 5-10% solid residues (slag)

In case of waste rubber:

- 35-40% product oil

- 15-20% product gas
- 40-45% solid residues (slag),
- 5-10% metal

2.

THE MAIN ELEMENTS OF THE DEVICE:

i.
ii.
iii.
iv.

Raw material conveying system

Feed-in, fusion equipment
Reactor
Pre-combustion chamber, burner
FUKON AKTIENGESELLSCHAFT

v.
vi.
vii.
viii.
ix.
x.
xi.
xii.
xiii.
xiv.
xv.

3.

Flue gas systems, mixing chamber

Condenser
Oil Cleaning Product
Product oil with discharging system and storage tank
Product gas cleaning equipment, process gas system
Gas Torch
LPG system
Slag Removal System
Inerting system
Auxiliary systems ( cooling- heating system, ventilation, Water lock)
Control System

THE OPERATION OF THE EQUIPMENT:

The responsibility of the raw material conveying system is to deliver the shredded
material from the ground level, to the system located on the upper level. The material
placed in the feeding and fusing equipment will be melted and preheated for the thermal
decomposition process. The material coming into the reactor will be dissolve by the
influence of thermal treatment and hydrocarbon vapors and gases are generated. The
slag will depart at the lower point of the continuous operating reactor, while the
hydrocarbon vapors and gases will depart from the top point of the reactor towards the
direction of the condensator. During the continuous operation, the slag is being
removed into container in the open air through the slag removal system. The
temperature of the slag should not exceed 80 C continuously. The hydrocarbon
vapors and gases are cooled down with the condensate and the resulting liquid mixture
is then passed into product oil purification equipment by pump. The treated and purified
product oil is delivered to the storage tank. After purification and treatment, the gaseous
hydrocarbons being in a normal state are pumped into a temporary storage tank. Under
normal operating conditions, the supply of fuel in to the burner takes place from here,
so the system becomes energy self-sufficient. In the case of a cold starting, we use the
LPG system, so the built-in gas burner is suitable for burning the two types of gases.
The technological potential surplus product gas generated during the operation can be
burnt out in the safety gas torch.

4.
4.1.

SPECIFICATIONS:
BUILDING SIZE REQUIRED FOR THE COMPLETE TECHNOLOGY:
- Length: 35m
- Width: 20m
- Height: 10 m

A portion of the auxiliary equipments should be placed outside the building, parallel to
the longitudinal axis of the building. These area:
- Length: 35m
- Width: 8m

FUKON AKTIENGESELLSCHAFT

10

4.2.

ENERGY REQUIREMENT OF THE COMPLETE TECHNOLOGICAL PROCESS:

- Built-in electrical power: 160 kW

- Built-in burner output : 1,000 kW
- Cooling air requirement : up to 60,000 m3 / h
- LPG consumption : 28-40 kg / h

4.3.

TECHNICAL DATA OF THE MAIN COMPONENTS OF THE SYSTEM:

4.4.

RAW MATERIAL CONVEYING SYSTEM

- May be bucket or air coveyer

- Lifting height: 8-10 m
- Capacity: 800 kg / h
- Equiped with balance

4.5.

FEED-IN-FUSION DEVICE:

- 2 pieces of heated fusion device connected in series

- Heat input capacity approx. 110 kW
- 2x30 kW electric drive
- Weight: kg 2x2.500
- required space : 5mx6m

4.6.

REACTOR:

- 3 units connected in series, vertical reactor.

- Size: D = 500, L = 6 m (each reactor)
- 3 pieces of gear, P = 3 kW, n = 4 rev / min
- Torque: 8000 Nm
- Thermal power input of 750 kW
- Reactor temperature: 500 C
- Reactor pressure up to 100 mbar
- Weight: 23,000 kg

4.7.

PRE-COMBUSTION CHAMBER, WITH BURNER

- Dimensions: D = 2.5 m, L = 7 m
- Weight: 30,000 kg
- Electricity consumption: 2.5 kW
- Gas pressure: 150-200 mbar
- Air Consumption: 1.700 kg / h
- Temperature of chamber: 1.200 C.

4.8.

FLUE GAS SYSTEM MIXING CHAMBER

- Dimensions: d = 450 mm
- Dilution Air Requirements: 1700 m3 / h
- Heating Air Temperature: 750 C
FUKON AKTIENGESELLSCHAFT

11

- Flue dimensions: d = 600 mm, H = 12 m,

- Flue gas outlet temperature T = 330 C
- Mixing chamber: vertical design, d = 1.600mm, H = 3 m

4.9.

CONDENSER

- Size: L = 2.2m, W: 2.2 m, H = 3.5 m

- Capacity: 500 kg / h
- Cooling air: 10.000 m3 / h
- Container volume: 2 m3

4.10.

PRODUCT OIL CLEANING EQUIPMENT

- Size : L = 4.5 m, W: 2.2 m, H = 3.5 m

- Vacuum distiller, number of poles: 3 pieces
- Thermal power consumption: 100 kW,
- Heat transfer pressure drop of 0.4 bar
- Heat transfer inlet temperature: 280 C

4.11.

PRODUCT OIL WITH DISCHARGING SYSTEM AND STORAGE TANK

(Not included in the production contract or delivery volume)

- Discharging pump: flow rate of 1 m3 / h, dp = 1 bar
- Tubular heat exchanger 40 kW, dp = 0.2 bar
- Product oil tank: 2x60 m3 on the discharging side with certified gauge.

4.12.

PRODUCT GAS CLEANING EQUIPMENT, PRODUCT GAS SYSTEM

- Size: L = 3m, W: 2.2 m, H = 3 m

- Washing Liquid 30% diluted alkali
- Flow rate: 2 m3 / h
- Product gas compressor: V = 90 m3 / h, dp = 300 mbar, with liquid ring
- Product gas tank: V = 5 m3

4.13.

GAS TORCH

- Power output: 1000 kW

- Dimensions: d = 600 mm, H = 5 m
- Torch: flame ionization controller - PB-gas flame support with a combustion air fan.

4.14.

LPG SYSTEM

(Not included in the production contract or delivery volume)

- LPG tank: V = 5 m3, Pmax 10 bar
- Exit gas pressure: 150 mbar
- Pipe diameter: DN 65
- With electrical pre-heater

FUKON AKTIENGESELLSCHAFT

12

4.15. SLAG REMOVAL SYSTEM

- Dimensions: L = 10m, W: 1 m, H = 2.5 m
- Weight: 600 kg
- Capacity: 60 kg / h
- with water cooling, nitrogen inerting, knife slide valve.
- Electrical power: 2.2 kW

4.16.

INERTING SYSTEM

-Dimensions: L = 6m, W: 1 m, L = 2 m
- Inert gas: nitrogen, pressure 100 mbar /:
- Inerting place: reactor space and slag removal system.
- Bottle groups: 200 bar

4.17.

AUXILIARY SYSTEMS (COOLING AND HEATING SYSTEM, VENTILATION, WATER LOCK

- Thermal oil cooler: - power 215 kW

- Inlet temperature: 300 C
- Flow rate - up to 10 m3 / h, dp = 0.3 bar
- Max pressure 4 bar
- Fan - Motor Power: 1.2 kW
- Speed (revolutions per minute): 670 r / min
- Water cooler: Power: 53 kW
- Water cooling: reactor shaft, slag removal system, and feed-in-fusion equipment gear
- Water temperature 55/50 C, dp = 0.5 bar
- Space Ventilator: 2x30.000 Flow m3 / h, 2x2, 2 kW
- Dilution Air Blower: Flow:1750 m3 / h 1,5 kW
- Water lock capacity :2m3 volume
- Blowing pressure: 100 mbar
- Flue gas / thermal oil heat exchanger 215 kW
- Flue gas mass flow: 3492 kg / h
- Inlet temperature: 525 C
- Thermal oil flow: 5.3 m3 / h
- Thermal oil inlet temperature: 250 C
- Thermal oil outlet temperature: 300 C
- Emergency aggregators power: 35 kVA

4.18.

CONTROL SYSTEM

- Own control system which provides the control of the reactor and the entire periphery.
Displayed in 15" touch panel. The control system also carries out the security
functions. The full security systems is solved with the development of RB system and
the in cooperation of external emergency power generator systems. During the
operation all data recorded and stored by an external computer, which can be checked
on-line.

FUKON AKTIENGESELLSCHAFT

13